WO2012132469A1 - 硬化定形物 - Google Patents

硬化定形物 Download PDF

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Publication number
WO2012132469A1
WO2012132469A1 PCT/JP2012/002241 JP2012002241W WO2012132469A1 WO 2012132469 A1 WO2012132469 A1 WO 2012132469A1 JP 2012002241 W JP2012002241 W JP 2012002241W WO 2012132469 A1 WO2012132469 A1 WO 2012132469A1
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Prior art keywords
weight
shaped product
acid
colloidal silica
product according
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PCT/JP2012/002241
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English (en)
French (fr)
Inventor
智彦 岸木
徹也 三原
賢 米内山
鉄也 石原
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ニチアス株式会社
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Priority to CN201280016232.5A priority Critical patent/CN103459353B/zh
Priority to EP12763683.5A priority patent/EP2692712B1/en
Priority to KR1020137025192A priority patent/KR101390509B1/ko
Priority to AU2012235264A priority patent/AU2012235264B2/en
Publication of WO2012132469A1 publication Critical patent/WO2012132469A1/ja

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Definitions

  • the present invention relates to a shaped product made of a cured inorganic fiber.
  • Inorganic fibers are lightweight, easy to handle, and excellent in heat resistance. For example, they are used as heat-resistant sealing materials.
  • problems have recently been pointed out that inorganic fibers are inhaled into the human body and enter the lungs. Therefore, biosoluble inorganic fibers have been developed that do not cause problems even when inhaled by the human body, or hardly cause them.
  • the shaped product manufactured using the biosoluble fiber has a drawback of low absolute strength.
  • Patent Document 1 discloses a plaster containing a biosoluble alkali earth silicate metal salt fiber and colloidal silica, and exhibits excellent storage stability by using colloidal silica as a binder. Further, it is said that the storage stability can be further improved by containing a chelating agent such as EDTA (ethylenediaminetetraacetic acid).
  • EDTA ethylenediaminetetraacetic acid
  • Patent Document 2 discloses that a zonotlite-based calcium silicate board is impregnated with an inorganic binder in order to suppress the generation of dust.
  • the present invention has been made in view of the above-mentioned problems, and an object thereof is to provide a high-strength shaped product made of inorganic fibers.
  • the present inventors have found that the strength can be increased by treating the shaped product with a curing agent, and have completed the present invention.
  • the following cured fixed form and the curing method thereof are provided. 1.
  • a shaped product composed of 20 to 99% by weight of biosoluble inorganic fiber containing SiO 2 and alkaline earth metal, and a curing agent made of colloidal silica soaks from the surface of the shaped product, and the surface is cured. Fixed form.
  • 2. The shaped product according to 1, wherein a chelating agent not containing metal ions is infiltrated with the curing agent. 3. 3. 3.
  • the shaped product according to 2 wherein the chelating agent is EDTA ⁇ H ⁇ 3 (NH 4 ) or EDTA ⁇ 2H ⁇ 2 (NH 4 ). 4). 2. The shaped product according to 1, wherein an acid is infiltrated with the curing agent. 5. 5. The shaped product according to 4, wherein the acid is a hydroxy acid. 6). 5. The shaped product according to 4, wherein the acid is at least one selected from citric acid, malic acid, tartaric acid, and salicylic acid. 7. 2. The shaped product according to 1, wherein the curing agent is acidic type colloidal silica or cationic type colloidal silica. 8). 8.
  • the shaped product according to any one of 1 to 8, wherein the inorganic fiber has the following composition. SiO 2 50 to 82% by weight Total 10 to 43% by weight of CaO and MgO 11.
  • a method for curing a shaped product which comprises dipping a curing treatment liquid containing colloidal silica into a shaped product composed of 20 to 99% by weight of biosoluble inorganic fibers containing SiO 2 and an alkaline earth metal, and drying. 13. 13.
  • a high-strength shaped product made of inorganic fibers can be provided.
  • the cured product of the present invention is obtained by treating a shaped product formed using inorganic fibers containing SiO 2 and an alkaline earth metal with a curing agent.
  • Colloidal silica can be used as the curing agent.
  • examples of colloidal silica include alkali type colloidal silica (pH 8 to 10), acidic type colloidal silica (pH 2 to 6), and cationic type colloidal silica.
  • the curing process is performed by, for example, immersing a fixed-form product in a curing process liquid, or applying the curing process liquid (brushing, rolling, etc.) or spraying (showering, spraying, etc.) and curing. Dry after treatment. Since the solvent evaporates from the surface during drying, the solvent moves to the surface, and the colloidal silica also moves to the surface. Since the colloidal silica remains even if the solvent evaporates, the colloidal silica is unevenly distributed near the surface, and as a result, the surface is cured.
  • the solvent water, monovalent alcohols such as ethanol and propanol, divalent alcohols such as ethylene glycol, and the like can be used.
  • the amount of colloidal silica contained in the shaped product by the curing treatment is an amount that increases the density of the shaped product by, for example, 10% to 150%, preferably 10% to 100%, more preferably 10% to 50%.
  • the shaped product is immersed in colloidal silica having a fixed fraction of 10 to 30% for 1 second to several minutes, but this is not limited. You may process once or twice or more.
  • the moisture content of the cured shaped product is usually about 5% by weight or less. Confirm the moisture content by the weight before and after drying.
  • the above-mentioned curing treatment improves hardness and improves strength and handling (problems such as traces of hands when gripped, peeling during processing, no corners when cut, powder falling, etc.) To do.
  • alkaline earth metal ions particularly Ca ions and Mg ions are eluted in the curing solution.
  • these ions react with the curing agent on the surface of the shaped product and are heated to 800 ° C. or higher, cracks are generated. This is probably because silica reacts with Ca ions to cause a volume change.
  • the shaped product is treated with a chelating agent not containing metal ions and a curing agent. It is considered that the chelating agent captures the eluted alkaline earth metal and simultaneously forms a protective layer, thereby suppressing the reaction between the alkaline earth metal and the curing agent and preventing the occurrence of cracks. Since the chelating agent has two or more electron donating groups, a metal chelate compound can be produced. Examples of the electron donating group include a carboxy group and a hydroxyl group.
  • the chelating agent used in the present invention does not contain alkaline earth metals or alkali metals.
  • the chelating agent examples include a chelating agent having a composition of EDTA (ethylenediaminetetraacetic acid) ⁇ H ⁇ 3 (NH 4 ), a chelating agent having a composition of EDTA ⁇ 2H ⁇ 2 (NH 4 ), and the like.
  • colloidal silica As the curing agent used in combination with the chelating agent, colloidal silica can be used, and alkali type colloidal silica, acidic type colloidal silica, cationic type colloidal silica and the like can be used.
  • concentration of the chelating agent can be appropriately set, but when alkali type colloidal silica is used as the curing agent, it is preferably 0.5% by weight or more with respect to the solid content 10% by weight curing treatment liquid.
  • the shaped product may be treated with a curing treatment solution having a pH of 6 or less (preferably pH 1 to 6, more preferably 2 to 5, particularly preferably pH 3 to 5). .
  • a curing treatment solution having a pH of 6 or less (preferably pH 1 to 6, more preferably 2 to 5, particularly preferably pH 3 to 5).
  • the shaped product is treated with an acid and a curing agent.
  • the acid may be a weak acid or a strong acid.
  • the weak acid include citric acid, malic acid, tartaric acid, salicylic acid, glycolic acid, lactic acid, mandelic acid, benzylic acid, coumaric acid, and acetic acid.
  • Strong acids include sulfuric acid, hydrochloric acid, and nitric acid. Is mentioned. Since there is no problem of generated gas, a weak acid is preferable.
  • colloidal silica of an acidic type may be used.
  • acidic type colloidal silica it is possible to use commercially available products such as silica doll 20A (manufactured by Nippon Chemical Industry Co., Ltd., solid content ratio 20%), cataloid SN (manufactured by JGC Catalysts & Chemicals Co., Ltd., solid content ratio 20%). it can.
  • Examples of those having both the chelating effect and the property of making pH acidic include hydroxy acids such as citric acid, malic acid, tartaric acid and salicylic acid.
  • Cationic colloidal silica is colloidal silica having a positive charge on the surface.
  • the surface of the colloidal silica or the inside thereof may contain a compound of a polyvalent metal ion such as an aluminum ion or an organic cationic compound so that the surface of the silica particles is cationically charged.
  • commercially available products such as Snowtex AK (manufactured by Nissan Chemical Industries, Ltd., solid content ratio 18%) can be used.
  • the shaped product of the present invention is composed of inorganic fibers.
  • it is composed of 20 to 99% by weight (preferably 30 to 95% by weight) of inorganic fibers.
  • the inorganic fiber is preferably composed mainly of SiO 2 , CaO, and MgO.
  • a main component means that 90 weight% or more or 95 weight% or more is comprised combining these.
  • the inorganic fiber may be a biosoluble fiber having the following composition. Total of SiO 2 , ZrO 2 , Al 2 O 3 and TiO 2 50 wt% to 82 wt% Total of 18% to 50% by weight of alkali metal oxide and alkaline earth metal oxide
  • the inorganic fiber may be a biosoluble fiber having the following composition. SiO 2 50 to 82% by weight Total 10 to 43% by weight of CaO and MgO
  • Biologically soluble fibers can be broadly classified into Mg silicate fibers rich in MgO and Ca silicate fibers rich in CaO.
  • the following composition can be illustrated as Mg silicate fiber. SiO 2 66-82% by weight CaO 1-9% by weight MgO 10-30% by weight Al 2 O 3 3 wt% or less Other oxides Less than 2 wt%
  • the following composition can be illustrated as Ca silicate fiber.
  • SiO 2 66-82 wt% (for example, it can be 68-80 wt%, 70-80 wt%, 71-80 wt% or 71-76 wt%)
  • CaO 10-34% by weight (for example, it can be 18-32% by weight, 20-30% by weight, 20-27% by weight or 21-26% by weight)
  • MgO 3 wt% or less eg, 1 wt% or less
  • Al 2 O 3 5% by weight or less for example, 3.5% by weight or less, 3.4% by weight or less, or 3% by weight or less.
  • Other oxides ⁇ 2% by weight
  • the total of SiO 2 , CaO, MgO and Al 2 O 3 may be more than 98 wt% or more than 99 wt%.
  • the biosoluble inorganic fiber includes alkali metal oxides (K 2 O, Na 2 O, Li 2 O, etc.), Sc, La, Ce, Pr, Nd, Sm, Eu, Gd, Tb as other components. , Dy, Ho, Er, Tm, Yb, Lu, Y, or a mixture thereof, Fe 2 O 3 , ZrO 2 , TiO 2 , P 2 O 5 , B 2 O 3 , MnO, One or more of ZnO, SrO, BaO, Cr 2 O 3 and the like may or may not be included. Other oxides may be 1.0 wt% or less, 0.2 wt% or less, or 0.1 wt% or less, respectively.
  • the alkali metal oxide may contain 1.0% by weight or less, 0.2% by weight or less, or 0.1% by weight or less of each oxide.
  • the total of the alkali metal oxides may be 1.0% by weight or less, 0.2% by weight or less, or 0.1% by weight or less.
  • the biosoluble fiber may further contain other components in addition to SiO 2 and an alkaline earth metal oxide (for example, at least one of MgO and CaO).
  • an alkaline earth metal oxide for example, at least one of MgO and CaO.
  • alumina Al 2 O 3
  • titania TiO 2
  • zirconia ZrO 2
  • iron oxide Fe 2 O 3
  • manganese oxide MnO
  • K 2 O potassium oxide
  • the biologically soluble inorganic fiber is, for example, an inorganic fiber having a physiological saline dissolution rate at 40 ° C. of 1% or more.
  • the physiological saline dissolution rate is measured, for example, as follows. That is, first, 1 g of a sample prepared by pulverizing inorganic fibers to 200 mesh or less and 150 mL of physiological saline are placed in an Erlenmeyer flask (volume: 300 mL) and placed in an incubator at 40 ° C. Next, a horizontal vibration of 120 revolutions per minute is continuously applied to the Erlenmeyer flask for 50 hours.
  • the concentration (mg / L) of each element contained in the filtrate obtained by filtration is measured with an ICP emission analyzer. Then, based on the measured concentration of each element and the content (% by mass) of each element in the inorganic fiber before dissolution, the physiological saline dissolution rate (%) is calculated. That is, for example, when the measurement element is silicon (Si), magnesium (Mg), calcium (Ca), and aluminum (Al), the physiological saline dissolution rate C (%) is calculated by the following equation.
  • C (%) [filtrate amount (L) ⁇ (a1 + a2 + a3 + a4) ⁇ 100] / [mass of inorganic fiber before dissolution (mg) ⁇ (b1 + b2 + b3 + b4) / 100].
  • a1, a2, a3 and a4 are the measured concentrations of silicon, magnesium, calcium and aluminum (mg / L), respectively, and b1, b2, b3 and b4 are respectively in the inorganic fibers before dissolution. It is content (mass%) of silicon, magnesium, calcium, and aluminum.
  • the fixed form is made of inorganic fibers, excluding indeterminate forms such as plaster (which may include inorganic and / or organic binders), such as mold, blanket, block, board, paper, felt, etc. It is done.
  • the fixed form which consists of an inorganic fiber of this invention does not contain the zonotolite type
  • the shaped product can contain an organic binder, an inorganic binder, an inorganic filler and the like in addition to the inorganic fiber. As long as the effects of the present invention are not impaired, those usually used can be used. Starch, acrylic resin, polyacrylamide, pulp, acrylic emulsion and the like are used as the organic binder, and anionic colloidal silica is used as the inorganic binder. And colloidal silica such as cationic colloidal silica, alumina sol, bentonite, clay mineral and the like.
  • the curing agent is impregnated from the surface.
  • biosoluble fiber A colloidal silica, alumina sol, bentonite (inorganic binder), inorganic powder (silica, zircon, calcium carbonate, zirconia, cordierite, wollastonite, etc.), acrylamide (organic binder)
  • An inorganic board having a length of 300 mm, a width of 300 mm, and a thickness of 50 mm (density 250 kg / m 3 ) was produced.
  • Example 1 ⁇ Curing treatment> The organic board and inorganic board (density 250 kg / m 3 ) obtained in Production Example 1 were treated (immersion for 1 to 10 seconds) with a curing solution (pH about 9, solvent: water) made of alkali-type colloidal silica, and the surface Was cured and dried. The density was 300 kg / m 3 . Strength improved after curing. A photograph of the surface of the inorganic board before and after curing is shown in FIG. Furthermore, the hardness of the cured organic and inorganic boards was measured using a hardness meter (manufactured by ASKER: Asker rubber hardness meter C type). The results are shown in Table 1.
  • ASKER Asker rubber hardness meter C type
  • Comparative Example 1 The organic and inorganic boards obtained in Production Example 1 were evaluated without being cured. Both organic and inorganic boards were brittle. Hardness was measured in the same manner as in Example 1. The results are shown in Table 1.
  • Example 2 ⁇ Curing treatment> Hardness was measured in the same manner as in Example 1 except that the organic board and inorganic board obtained in Production Example 2 were used. The results are shown in Table 2.
  • Comparative Example 2 The organic and inorganic boards obtained in Production Example 2 were evaluated without being cured. Both organic and inorganic boards were brittle. Hardness was measured in the same manner as in Example 1. The results are shown in Table 2.
  • Example 3 [Chelating agent and curing agent] ⁇ Curing treatment>
  • the organic and inorganic boards obtained in Production Example 1 were treated with a curing treatment solution (pH about 9, solvent: water) composed of EDTA diammonium salt and alkali type colloidal silica to cure and dry the surface.
  • the chelating agent was used at 1% by weight with respect to a solid content 10% by weight curing treatment liquid.
  • Example 4 [Acid and curing agent] ⁇ Curing treatment>
  • the organic and inorganic boards obtained in Production Example 1 were treated with a curing treatment liquid composed of an acid and alkali type colloidal silica (curing agent) to cure and dry the surface.
  • acids citric acid, malic acid, tartaric acid, and salicylic acid were used in an amount of about 1% by weight based on a 10% solid content curing treatment liquid, and the pH of the treatment liquid was adjusted to 3-4.
  • Example 5 [Acid and curing agent] ⁇ Curing treatment> The organic and inorganic boards obtained in Production Example 1 were treated with a curing treatment liquid composed of citric acid and alkali type colloidal silica (curing agent) to cure and dry the surface. Citric acid was used at 0.4 wt%, 0.6 wt%, 1.5 wt% and 8 wt%, and the pH of the treatment solution was adjusted to 2-5. ⁇ Heating test> The same operation as in Example 3 was performed. The results are shown in Table 6.
  • Example 6 [Acid and curing agent] ⁇ Curing treatment> The same procedure as in Example 4 was performed except that the organic board and inorganic board obtained in Production Example 2 were used. ⁇ Heating test> The same operation as in Example 4 was performed. For comparison, the cured organic and inorganic boards obtained in Example 2 were similarly heated and observed. The results are shown in Tables 7 and 8.
  • Example 7 [Acid type colloidal silica and cationic type colloidal silica] ⁇ Curing treatment> The organic board and inorganic board obtained in Production Example 1 were mixed with acidic type colloidal silica (silica doll 20A (manufactured by Nippon Chemical Industry Co., Ltd.), pH 2-4) or cationic type colloidal silica (Snowtex AK, Nissan Chemical Industries, Ltd.). ) Product) (curing agent) to cure and dry the surface. ⁇ Heating test> The same operation as in Example 3 was performed. The results are shown in Tables 9 and 10.
  • Example 8 [Acid type colloidal silica and cationic type colloidal silica] ⁇ Curing treatment> The same operation as in Example 7 was performed except that the organic board and the inorganic board obtained in Production Example 2 were used. ⁇ Heating test> The same operation as in Example 7 was performed. The results are shown in Tables 11 and 12.
  • the cured product of the present invention can be used in various applications as a general high-temperature heat insulating material, a furnace furnace ceiling, a furnace wall heat insulating material lining material, a heat insulating material, and a backup material.

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Abstract

ＳｉＯ２、アルカリ土類金属を含む生体溶解性無機繊維２０～９９重量％からなる定形物であって、コロイダルシリカである硬化剤が前記定形物の表面から浸み込み、表面が硬化されている定形物。

Description

硬化定形物
　本発明は、硬化処理がなされた無機繊維からなる定形物に関する。
　無機繊維は、軽量で扱いやすく、且つ耐熱性に優れるため、例えば、耐熱性のシール材として使用されている。一方、近年、無機繊維が人体に吸入されて肺に侵入することによる問題が指摘されている。そこで、人体に吸入されても問題を起こさない又は起こしにくい生体溶解性無機繊維が開発されている。
　しかしながら、生体溶解性繊維を用いて製造された定形物は、絶対的な強度が低いという欠点があった。
　尚、特許文献１には、生体溶解性ケイ酸アルカリ土類金属塩繊維とコロイダルシリカとを含む漆喰が開示されており、コロイダルシリカをバインダーとして使用することにより、優れた貯蔵安定性を発揮することができ、さらにＥＤＴＡ（エチレンジアミン四酢酸）等のキレート剤を含有することで貯蔵安定性をより高めることができるとされている。
特許文献２には、ゾノトライト系珪酸カルシウムボードを、粉塵の発生を抑制するために、無機バインダーで含浸することが示されている。
特開２００２－５２４３８４号公報 特開２００８－１３４０２号公報
　本発明は、上記課題に鑑みて為されたものであって、無機繊維からなる強度の高い定形物を提供することをその目的の一つとする。
　本発明者らは鋭意研究の結果、定形物を硬化剤で処理することにより強度を高めることができることを見出し本発明を完成させた。
　本発明によれば、以下の硬化定形物及びその硬化方法が提供される。
１．ＳｉＯ２、アルカリ土類金属を含む生体溶解性無機繊維２０～９９重量％からなる定形物であって、コロイダルシリカである硬化剤が前記定形物の表面から浸み込み、表面が硬化されている定形物。
２．前記硬化剤と共に、金属イオンを含まないキレート剤が浸み込んでいる１記載の定形物。
３．前記キレート剤が、ＥＤＴＡ・Ｈ・３（ＮＨ４）又はＥＤＴＡ・２Ｈ・２（ＮＨ４）である２記載の定形物。
４．前記硬化剤と共に、酸が浸み込んでいる１記載の定形物。
５．前記酸が、ヒドロキシ酸である４記載の定形物。
６．前記酸が、クエン酸、りんご酸、酒石酸、サリチル酸から選択される１種以上である４記載の定形物。
７．前記硬化剤が、酸性タイプコロイダルシリカ又はカチオンタイプコロイダルシリカである１記載の定形物。
８．前記酸性タイプコロイダルシリカのｐＨが２～５である７記載の定形物。
９．前記無機繊維が、以下の組成である１～８のいずれか記載の定形物。
　ＳｉＯ２とＺｒＯ２とＡｌ２Ｏ３とＴｉＯ２との合計　５０～８２重量％
　アルカリ金属酸化物とアルカリ土類金属酸化物との合計　１８～５０重量％
１０．前記無機繊維が、以下の組成である１～８のいずれか記載の定形物。
　ＳｉＯ２　５０～８２重量％
　ＣａＯとＭｇＯとの合計　１０～４３重量％
１１．前記無機繊維が、以下の組成を有するＭｇシリケート繊維、又は以下の組成を有するＣａシリケート繊維である１～８のいずれか記載の定形物。
［Ｍｇシリケート繊維］
　ＳｉＯ２　６６～８２重量％
　ＣａＯ　１～９重量％
　ＭｇＯ　１０～３０重量％
　Ａｌ２Ｏ３　３重量％以下
　他の酸化物　２重量％未満
［Ｃａシリケート繊維］
　ＳｉＯ２　６６～８２重量％
　ＣａＯ　１０～３４重量％
　ＭｇＯ　３重量％以下
　Ａｌ２Ｏ３　５重量％以下
　他の酸化物　２重量％未満
１２．ＳｉＯ２、アルカリ土類金属を含む生体溶解性無機繊維２０～９９重量％からなる定形物に、コロイダルシリカを含む硬化処理液を浸み込まして、乾燥する定形物の硬化方法。
１３．前記硬化処理液が、さらに、金属イオンを含まないキレート剤又は酸を含む１２記載の定形物の硬化方法。
１４．１２又は１３記載の硬化方法により硬化された定形物。
　本発明によれば、無機繊維からなる強度の高い定形物を提供することができる。
実施例１の無機ボードの硬化前後の表面の写真である。
　本発明の硬化定形物は、ＳｉＯ２、アルカリ土類金属を含む無機繊維を用いて形成された定形物を、硬化剤で処理をすることにより得られる。硬化剤は、コロイダルシリカを用いることができる。コロイダルシリカには、アルカリタイプコロイダルシリカ（ｐＨ８～１０）、酸性タイプコロイダルシリカ（ｐＨ２～６）やカチオンタイプコロイダルシリカ等がある。
　硬化処理は、例えば、定形物を、硬化処理液に浸すことにより、又は硬化処理液を塗布（はけ塗り、ロールがけ等）、吹き付け（シャワーがけ、スプレーがけ等）することにより実施し、硬化処理後は乾燥する。乾燥の際、溶媒が表面から蒸発するため、溶媒が表面に移動しそれに伴いコロイダルシリカも表面に移動する。溶媒は蒸発してもコロイダルシリカは残るため、表面付近にコロイダルシリカが偏在し、その結果、表面が硬化される。溶媒としては水、エタノール、プロパノール等の１価のアルコール類、エチレングリコール等の２価のアルコール類等を用いることができる。
　硬化処理により定形物に含まれるコロイダルシリカの量は、定形物の密度を例えば１０％～１５０％、好ましくは１０％～１００％、より好ましくは１０％～５０％高くする量である。通常、定形物を固定分比率１０～３０％のコロイダルシリカに１秒～数分浸漬するが、これは限定されない。１回又は２回以上処理してもよい。硬化処理された定形物の水分量は、通常、５重量％以下程度である。水分量の確認は乾燥前後の重量にて確認する。
　上記の硬化処理することにより、硬度が向上し、強度、ハンドリング性（握った際の手の跡、加工の際のむしれ、切断した際に角が出ない、粉落ち等の問題）が向上する。
　硬化剤としてアルカリタイプコロイダルシリカを用いて定形物を処理すると、硬化処理液中にアルカリ土類金属イオン、特にＣａイオン、Ｍｇイオンが溶出する。このイオンが硬化剤と定形物表面で反応し、８００℃以上に加熱すると、クラックが発生する原因となる。シリカとＣａイオン等が反応して体積変化を起こすためと考えられる。
　クラックの発生を抑制するためには、定形物を、金属イオンを含まないキレート剤と、硬化剤で、処理する。キレート剤が、溶出するアルカリ土類金属を捕獲し同時に保護層を形成することにより、アルカリ土類金属と硬化剤の反応を抑制して、クラックの発生を防ぐと考えられる。キレート剤は電子供与基が２以上あるので金属キレート化合物を生成できる。電子供与基には、カルボキシ基、水酸基等がある。本発明で用いるキレート剤は、アルカリ土類金属やアルカリ金属を含まない。キレート剤の例として、ＥＤＴＡ（エチレンジアミン四酢酸）・Ｈ・３（ＮＨ４）の組成のキレート剤、ＥＤＴＡ・２Ｈ・２（ＮＨ４）の組成のキレート剤等が挙げられる。
　キレート剤と併用する硬化剤はコロイダルシリカを用いることができ、アルカリタイプコロイダルシリカ、酸性タイプコロイダルシリカ、カチオンタイプコロイダルシリカ等を用いることができる。キレート剤の濃度は適宜設定できるが、アルカリタイプコロイダルシリカを硬化剤として用いた場合、固形分１０重量％硬化処理液に対し０．５重量％以上が好ましい。
　また、クラックの発生を抑制するためには、定形物を、ｐＨ６以下（好ましくはｐＨ１～６、より好ましくは２～５、特に好ましくはｐＨ３～５）の硬化処理液で、処理してもよい。酸性にすることにより、アルカリ土類金属の溶出を抑制することにより、アルカリ土類金属と硬化剤の反応を抑制して、クラックの発生を防ぐと考えられる。
　具体的には、定形物を、酸と硬化剤で、処理する。酸は弱酸でも強酸でもよく、弱酸として、クエン酸、りんご酸、酒石酸、サリチル酸、グリコール酸、乳酸、マンデル酸、ベンジル酸、クマル酸、酢酸等が挙げられ、強酸として、硫酸、塩酸、硝酸等が挙げられる。発生ガスの問題がないことから、弱酸が好ましい。
　また、酸性タイプ（例えばｐＨ１～６又は２～５）のコロイダルシリカを用いてもよい。酸性タイプコロイダルシリカとして、シリカドール２０Ａ（日本化学工業（株）製、固形分比率２０％）、カタロイドＳＮ（日揮触媒化成（株）製、固形分比率２０％）等の市販品を用いることができる。
　キレート効果とｐＨを酸性にする両方の性質を有するものとして、クエン酸、りんご酸、酒石酸、サリチル酸等のヒドロキシ酸が挙げられる。
　また、硬化剤として、カチオンタイプコロイダルシリカ（例えばｐＨ４～６）を用いると、アルカリ土類金属の溶出を抑制することができる。この場合は、カチオンタイプコロイダルシリカで表面に保護膜を形成して、アルカリ土類金属と硬化剤の反応を抑制すると考えられる。カチオン性のコロイダルシリカとは、表面にプラスの電荷を有するコロイダルシリカである。例えば、コロイダルシリカの表面または内部に、アルミニウムイオン等の多価金属イオンの化合物又は有機カチオン性化合物を含有させてシリカ粒子表面をカチオン性に帯電させたものを挙げることができる。カチオンタイプコロイダルシリカとして、スノーテックスＡＫ（日産化学工業（株）製、固形分比率１８％）等の市販品を用いることができる。
　本発明の定形物は無機繊維を含んで構成される。例えば、無機繊維２０～９９重量％（好ましくは３０～９５重量％）からなる。無機繊維は、好ましくは、ＳｉＯ２、ＣａＯ、ＭｇＯが主成分である。主成分とは、これらを合わせて、９０重量％以上又は９５重量％以上を構成していることをいう。
　無機繊維は、以下の組成の生体溶解性繊維であってもよい。
　ＳｉＯ２とＺｒＯ２とＡｌ２Ｏ３とＴｉＯ２の合計　５０重量％～８２重量％
　アルカリ金属酸化物とアルカリ土類金属酸化物との合計　１８重量％～５０重量％
　また、無機繊維は、以下の組成の生体溶解性繊維であってもよい。
　ＳｉＯ２　５０～８２重量％
　ＣａＯとＭｇＯとの合計　１０～４３重量％
　生体溶解性繊維は、ＭｇＯを多く含むＭｇシリケート繊維と、ＣａＯを多く含むＣａシリケート繊維に大別できる。Ｍｇシリケート繊維として以下の組成を例示できる。
　ＳｉＯ２　６６～８２重量％
　ＣａＯ　１～９重量％
　ＭｇＯ　１０～３０重量％
　Ａｌ２Ｏ３　３重量％以下
　他の酸化物　２重量％未満
　Ｃａシリケート繊維として以下の組成を例示できる。
　ＳｉＯ２　６６～８２重量％（例えば、６８～８０重量％、７０～８０重量％、７１～８０重量％又は７１～７６重量％とできる）
　ＣａＯ　１０～３４重量％（例えば、１８～３２重量％、２０～３０重量％、２０～２７重量％又は２１～２６重量％とできる）
　ＭｇＯ　３重量％以下（例えば、１重量％以下とできる）
　Ａｌ２Ｏ３　５重量％以下（例えば３．５重量％以下、３．４重量％以下又は３重量％以下とできる。また、１重量％以上、１．１重量％以上又は２重量％以上とできる）
　他の酸化物　２重量％未満
　ＳｉＯ２が上記範囲であると耐熱性に優れる。ＣａＯとＭｇＯが上記範囲であると加熱前後の生体溶解性に優れる。Ａｌ２Ｏ３が上記範囲であると耐熱性に優れる。
　また、ＳｉＯ２、ＣａＯ、ＭｇＯ、Ａｌ２Ｏ３の合計を９８重量％超又は９９重量％超としてよい。
　上記の生体溶解性無機繊維は、他の成分として、アルカリ金属酸化物（Ｋ２Ｏ、Ｎａ２Ｏ、Ｌｉ２Ｏ等）、Ｓｃ，Ｌａ，Ｃｅ，Ｐｒ，Ｎｄ，Ｓｍ，Ｅｕ，Ｇｄ，Ｔｂ，Ｄｙ，Ｈｏ，Ｅｒ，Ｔｍ，Ｙｂ，Ｌｕ，Ｙ又はこれらの混合物から選択されるそれぞれの酸化物、Ｆｅ２Ｏ３、ＺｒＯ２、ＴｉＯ２、Ｐ２Ｏ５、Ｂ２Ｏ３、ＭｎＯ、ＺｎＯ、ＳｒＯ、ＢａＯ、Ｃｒ２Ｏ３等を１以上含んでもよく、含まなくてもよい。他の酸化物は、それぞれ、１．０重量％以下、０．２重量％以下又は０．１重量％以下としてよい。アルカリ金属酸化物は各酸化物を各々１．０重量％以下、０．２重量％以下又は０．１重量％以下としてもよい。また、アルカリ金属酸化物の合計を１．０重量％以下、０．２重量％以下又は０．１重量％以下としてもよい。
　なお、生体溶解性繊維は、ＳｉＯ２と、アルカリ土類金属酸化物（例えば、ＭｇＯ及びＣａＯの少なくとも一方）と、に加えて、さらに他の成分を含有してもよい。例えば、アルミナ（Ａｌ２Ｏ３）、チタニア（ＴｉＯ２）、ジルコニア（ＺｒＯ２）、酸化鉄（Ｆｅ２Ｏ３）、酸化マンガン（ＭｎＯ）、酸化カリウム（Ｋ２Ｏ）からなる群より選択される１種又は２種以上をさらに含有してもよい。
　生体溶解性無機繊維は、例えば、４０℃における生理食塩水溶解率が１％以上の無機繊維である。
　生理食塩水溶解率は、例えば、次のようにして測定される。すなわち、先ず、無機繊維を２００メッシュ以下に粉砕して調製された試料１ｇ及び生理食塩水１５０ｍＬを三角フラスコ（容積３００ｍＬ）に入れ、４０℃のインキュベーターに設置する。次に、三角フラスコに、毎分１２０回転の水平振動を５０時間継続して加える。その後、ろ過により得られた濾液に含有されている各元素の濃度（ｍｇ／Ｌ）をＩＣＰ発光分析装置により測定する。そして、測定された各元素の濃度と、溶解前の無機繊維における各元素の含有量（質量％）と、に基づいて、生理食塩水溶解率（％）を算出する。すなわち、例えば、測定元素が、ケイ素（Ｓｉ）、マグネシウム（Ｍｇ）、カルシウム（Ｃａ）及びアルミニウム（Ａｌ）である場合には、次の式により、生理食塩水溶解率Ｃ（％）を算出する；Ｃ（％）＝［ろ液量（Ｌ）×（ａ１＋ａ２＋ａ３＋ａ４）×１００］／［溶解前の無機繊維の質量（ｍｇ）×（ｂ１＋ｂ２＋ｂ３＋ｂ４）／１００］。この式において、ａ１、ａ２、ａ３及びａ４は、それぞれ測定されたケイ素、マグネシウム、カルシウム及びアルミニウムの濃度（ｍｇ／Ｌ）であり、ｂ１、ｂ２、ｂ３及びｂ４は、それぞれ溶解前の無機繊維におけるケイ素、マグネシウム、カルシウム及びアルミニウムの含有量（質量％）である。
　定形物とは、無機繊維で作られた、漆喰等の不定形（無機及び／又は有機バインダーを含んでもよい）を除いたもの、例えば、モールド、ブランケット、ブロック、ボード、ペーパー、フェルト等が挙げられる。尚、本発明の無機繊維からなる定形物は特許文献２のようなゾノトライト系珪酸カルシウムボードを含まない。
　定形物は、無機繊維の他、有機バインダー、無機バインダー、無機充填剤等を含むことができる。これらは、本発明の効果を損なわない限り、通常使用されているものを使用できるが、有機バインダーとして澱粉、アクリル樹脂、ポリアクリルアミド、パルプ、アクリルエマルジョン等が、無機バインダーとして、アニオン性のコロイダルシリカ、カチオン性のコロイダルシリカ等のコロイダルシリカ、アルミナゾル、ベントナイト、粘土鉱物等が例示できる。
　本発明の硬化定形物は、上記の処理により得られるため、硬化剤が表面より含浸されている。
製造例１
＜有機及び無機ボード（定形物）の製造＞
　生体溶解性繊維Ａ（ＳｉＯ２含有量が７３質量％、ＣａＯ含有量が２５質量％、ＭｇＯ含有量が０．３質量％、Ａｌ２Ｏ３含有量が２質量％）９０重量％と、澱粉とポリアクリルアミド（有機バインダー）、コロイダルシリカ（無機バインダー）から、縦３００ｍｍ、横３００ｍｍ、厚み５０ｍｍ（密度２５０ｋｇ／ｍ３）の有機ボードを製造した。
　さらに、生体溶解性繊維Ａ８５重量％と、コロイダルシリカとアルミナゾルとベントナイト（無機バインダー）、無機粉体（シリカ、ジルコン、炭酸カルシウム、ジルコニア、コージライト、ワラストナイト等）、アクリルアミド（有機バインダー）から、縦３００ｍｍ、横３００ｍｍ、厚み５０ｍｍ（密度２５０ｋｇ／ｍ３）の無機ボードを製造した。
製造例２
＜有機及び無機ボード（定形物）の製造＞
　生体溶解性繊維Ａの代わりに、生体溶解性繊維Ｂ（ＳｉＯ２含有量が７６質量％、ＣａＯ含有量が４質量％、ＭｇＯ含有量が１８質量％、Ａｌ２Ｏ３含有量が２質量％）を用いた他は、製造例１と同様にして、有機及び無機ボードを製造した。
実施例１
＜硬化処理＞
　製造例１で得た有機ボード及び無機ボード（密度２５０ｋｇ／ｍ３）を、アルカリタイプコロイダルシリカからなる硬化液（ｐＨ約９、溶剤：水）で処理（１～１０秒浸漬）して、表面を硬化し乾燥した。密度は３００ｋｇ／ｍ３であった。硬化後は強度が向上した。硬化前後の無機ボードの表面の写真を図１に示す。さらに、硬化した有機及び無機ボードの硬度を硬度計（ＡＳＫＥＲ製：アスカーゴム硬度計Ｃ型）を用いて測定した。結果を表１に示す。
比較例１
　製造例１で得た有機及び無機ボードを硬化処理すること無く評価した。有機及び無機ボードは共に脆かった。実施例１と同様に硬度を測定した。結果を表１に示す。
Figure JPOXMLDOC01-appb-T000001
実施例２
＜硬化処理＞
　製造例２で得た有機ボード及び無機ボードを用いた他は、実施例１と同様に硬化し硬度を測定した。結果を表２に示す。
比較例２
　製造例２で得た有機及び無機ボードを硬化処理すること無く評価した。有機及び無機ボードは共に脆かった。実施例１と同様に硬度を測定した。結果を表２に示す。
Figure JPOXMLDOC01-appb-T000002
実施例３
［キレート剤と硬化剤］
＜硬化処理＞
　製造例１で得た有機及び無機ボードを、ＥＤＴＡ２アンモニウム塩とアルカリタイプコロイダルシリカからなる硬化処理液（ｐＨ約９、溶媒：水）で処理して、表面を硬化し乾燥した。キレート剤は、固形分１０重量％硬化処理液に対し１重量％で用いた。
＜加熱試験＞
　硬化した有機及び無機ボードを、８００℃、９００℃、１０００℃、１１００℃で２４時間加熱して、外観（クラックの有無）を目視で観察した。比較のため実施例１で得た硬化した有機及び無機ボードも同様に加熱して観察した。正常なものを◎、表面に小さなクラックが発生したものを○、大きなクラックが発生したものを▲、割れが発生したものを×とした。結果を表３に示す。
Figure JPOXMLDOC01-appb-T000003
実施例４
［酸と硬化剤］
＜硬化処理＞
　製造例１で得た有機及び無機ボードを、酸と、アルカリタイプコロイダルシリカ（硬化剤）からなる硬化処理液で処理して、表面を硬化し乾燥した。酸として、クエン酸、りんご酸、酒石酸、サリチル酸を、固形分１０重量％硬化処理液に対し約１重量％で用い、処理液のｐＨを３～４とした。
＜加熱試験＞
　実施例３と同様に実施した。結果を表４，５に示す。
Figure JPOXMLDOC01-appb-T000004
Figure JPOXMLDOC01-appb-T000005
実施例５
［酸と硬化剤］
＜硬化処理＞
　製造例１で得た有機及び無機ボードを、クエン酸と、アルカリタイプコロイダルシリカ（硬化剤）からなる硬化処理液で処理して、表面を硬化し乾燥した。クエン酸を、０．４重量％、０．６重量％、１．５重量％、８重量％で用い、処理液のｐＨを２～５とした。
＜加熱試験＞
　実施例３と同様に実施した。結果を表６に示す。
Figure JPOXMLDOC01-appb-T000006
実施例６
［酸と硬化剤］
＜硬化処理＞
　製造例２で得た有機ボード及び無機ボードを用いた他は、実施例４と同様に実施した。
＜加熱試験＞
　実施例４と同様に実施した。比較のため実施例２で得た硬化した有機及び無機ボードも同様に加熱して観察した。結果を表７，８に示す。
Figure JPOXMLDOC01-appb-T000007
Figure JPOXMLDOC01-appb-T000008
実施例７
［酸性タイプコロイダルシリカとカチオンタイプコロイダルシリカ］
＜硬化処理＞
　製造例１で得た有機ボード及び無機ボードを、酸性タイプコロイダルシリカ（シリカドール２０Ａ（日本化学工業（株）製）、ｐＨ２～４）又はカチオンタイプコロイダルシリカ（スノーテックスＡＫ、日産化学工業（株）製）（硬化剤）で処理して、表面を硬化し乾燥した。
＜加熱試験＞
　実施例３と同様に実施した。結果を表９，１０に示す。
Figure JPOXMLDOC01-appb-T000009
Figure JPOXMLDOC01-appb-T000010
実施例８
［酸性タイプコロイダルシリカとカチオンタイプコロイダルシリカ］
＜硬化処理＞
　製造例２で得た有機ボード及び無機ボードを用いた他は、実施例７と同様に実施した。
＜加熱試験＞
　実施例７と同様に実施した。結果を表１１，１２に示す。
Figure JPOXMLDOC01-appb-T000011
Figure JPOXMLDOC01-appb-T000012
　本発明の硬化定形物は、一般高温用断熱材、窯炉の天井、炉壁の断熱材用ライニング材、断熱材、バックアップ材として様々な用途に用いることができる。
　上記に本発明の実施形態及び／又は実施例を幾つか詳細に説明したが、当業者は、本発明の新規な教示及び効果から実質的に離れることなく、これら例示である実施形態及び／又は実施例に多くの変更を加えることが容易である。従って、これらの多くの変更は本発明の範囲に含まれる。
　この明細書に記載の文献の内容を全てここに援用する。

Claims (14)

  1. 　ＳｉＯ２、アルカリ土類金属を含む生体溶解性無機繊維２０～９９重量％からなる定形物であって、コロイダルシリカである硬化剤が前記定形物の表面から浸み込み、表面が硬化されている定形物。
  2. 　前記硬化剤と共に、金属イオンを含まないキレート剤が浸み込んでいる請求項１記載の定形物。
  3. 　前記キレート剤が、ＥＤＴＡ・Ｈ・３（ＮＨ４）又はＥＤＴＡ・２Ｈ・２（ＮＨ４）である請求項２記載の定形物。
  4. 　前記硬化剤と共に、酸が浸み込んでいる請求項１記載の定形物。
  5. 　前記酸が、ヒドロキシ酸である請求項４記載の定形物。
  6. 　前記酸が、クエン酸、りんご酸、酒石酸、サリチル酸から選択される１種以上である請求項４記載の定形物。
  7. 　前記硬化剤が、酸性タイプコロイダルシリカ又はカチオンタイプコロイダルシリカである請求項１記載の定形物。
  8. 　前記酸性タイプコロイダルシリカのｐＨが２～５である請求項７記載の定形物。
  9. 　前記無機繊維が、以下の組成である請求項１～８のいずれか記載の定形物。
    　ＳｉＯ２とＺｒＯ２とＡｌ２Ｏ３とＴｉＯ２との合計　５０～８２重量％
    　アルカリ金属酸化物とアルカリ土類金属酸化物との合計　１８～５０重量％
  10. 　前記無機繊維が、以下の組成である請求項１～８のいずれか記載の定形物。
    　ＳｉＯ２　５０～８２重量％
    　ＣａＯとＭｇＯとの合計　１０～４３重量％
  11. 　前記無機繊維が、以下の組成を有するＭｇシリケート繊維、又は以下の組成を有するＣａシリケート繊維である請求項１～８のいずれか記載の定形物。
    ［Ｍｇシリケート繊維］
    　ＳｉＯ２　６６～８２重量％
    　ＣａＯ　１～９重量％
    　ＭｇＯ　１０～３０重量％
    　Ａｌ２Ｏ３　３重量％以下
    　他の酸化物　２重量％未満
    ［Ｃａシリケート繊維］
    　ＳｉＯ２　６６～８２重量％
    　ＣａＯ　１０～３４重量％
    　ＭｇＯ　３重量％以下
    　Ａｌ２Ｏ３　５重量％以下
    　他の酸化物　２重量％未満
  12. 　ＳｉＯ２、アルカリ土類金属を含む生体溶解性無機繊維２０～９９重量％からなる定形物に、コロイダルシリカを含む硬化処理液を浸み込まして、乾燥する定形物の硬化方法。
  13. 　前記硬化処理液が、さらに、金属イオンを含まないキレート剤又は酸を含む請求項１２記載の定形物の硬化方法。
  14. 　請求項１２又は１３記載の硬化方法により硬化された定形物。
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AU2012235264B2 (en) 2015-05-07
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