JP2003213557A - Binder for inorganic fiber and inorganic fiber heat insulating sound absorbing material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a binder for inorganic fibers having sufficient water repellency and causing slight deterioration with time and an inorganic fiber heat insulating sound absorbing material. <P>SOLUTION: This binder for the inorganic fibers comprises an aldehyde condensing thermosetting resin precursor and at least one kind of fatty acid ammonium salt and/or amine salt selected from 10-30C saturated fatty acids and 10-30C unsaturated fatty acids. The inorganic fiber heat insulating sound absorbing material is obtained by applying the binder for the inorganic fibers to the inorganic fibers just after fiberizing, collecting the resultant loose fibers, then thermosetting the resultant loose fibers and forming the fibers. <P>COPYRIGHT: (C)2003,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a binder for an inorganic fiber used as a heat insulating material or a sound absorbing material for a house, a soundproof wall, etc. The present invention relates to a binder for heat insulation and an inorganic fiber heat insulating sound absorbing material using the same.

[0002]

2. Description of the Related Art Conventionally, an aggregate of inorganic fibers has a high porosity and is divided into fine voids by its single fiber, which makes it difficult for the air contained in the aggregate to move.
It is widely used as a heat insulating material or sound absorbing material in homes, buildings, soundproof walls, cooling towers and outdoor equipment.

However, when water such as rainwater or dew condensation is absorbed by the aggregate of inorganic fibers, not only the performance of heat insulation and sound absorption is significantly deteriorated, but also the generation of mold and the contact of metal with the aggregate of inorganic fibers. It may cause corrosion of parts. Therefore, an aggregate of inorganic fibers that may come into contact with water is required to have low water absorption and high water repellency.

To meet these demands, for example, it has been disclosed to use various organopolysiloxanes as a treating agent for improving the water repellency of inorganic fibers (Patent Document 1).
reference).

Also disclosed is a resin composition for hydrophobizing glass fibers for a heat insulating material, which contains metal soap as an active ingredient (see Patent Document 2).

Further, there has been disclosed an anti-scattering agent, which is capable of imparting high water repellency to a glass wool molding material, by blending mineral oil and / or synthetic oil with an amine salt of a higher fatty acid (see Patent Document 3).

[0007]

[Patent Document 1] Japanese Patent No. 2863585

[Patent Document 2] Japanese Unexamined Patent Publication No. 5-330861

[Patent Document 3] Japanese Patent Laid-Open No. 7-10611

[0008]

However, among the above-mentioned conventional techniques, the organopolysiloxanes disclosed in Japanese Patent No. 2863585 are liquids at room temperature, and therefore, from the surface of the inorganic fiber over time. Part of the water may be washed away and water repellency may be gradually deteriorated. In addition, organopolysiloxanes cause stickiness of the surface of the inorganic fiber heat insulating and sound absorbing material, which may cause contamination and discoloration of the wood in contact with the inorganic fiber heat insulating and sound absorbing material, and impair workability during construction. However, it is not preferable because it is expensive.

When organopolysiloxanes or metal soaps are used as the water repellent, they are all hydrophobic and therefore, in order to mix them uniformly with the water-based binder, they are first emulsified with a surfactant or the like. Water dispersion system. Therefore, in the binder, a highly hydrophobic water repellent component and a hydrophilic surfactant coexist, but organopolysiloxanes or metal soaps having poor water repellency compared to fluorine compounds are The surfactant may impair the water repellent effect of the water repellent component. On the contrary, when the amount of the surfactant is too small, the stability of the water repellent in the water-based binder is deteriorated, the miscibility with the water-based binder is poor, and the desired water repellent performance may not be obtained. is there.

A binder containing an anti-scattering agent as disclosed in Japanese Patent Laid-Open No. 7-10611 can provide anti-scattering effect but may not have sufficient water repellency.

On the other hand, as a method of solving the above problems, a method of applying a binder for inorganic fibers other than the water-based material after forming the heat insulating and sound absorbing material for inorganic fibers can be considered. But,
With this method, it is difficult to uniformly apply the binder to the bulky inorganic fiber heat-insulating sound absorbing material, and more than the necessary amount of binder is required to apply the binder to the center of the inorganic fiber heat-insulating sound absorbing material. However, it is not preferable in terms of economy.

Therefore, an object of the present invention is to provide an inorganic fiber binder which can impart excellent water repellency for a long period of time and is excellent in stability while being water-based, and an inorganic fiber heat insulating and sound absorbing material using the same. To provide.

[0013]

In order to achieve the above object, the binder for inorganic fibers of the present invention comprises an aldehyde-condensable thermosetting resin precursor and saturated and unsaturated fatty acids having 10 to 30 carbon atoms. It is characterized by containing an ammonium salt and / or an amine salt of at least one fatty acid selected from the following (hereinafter, abbreviated as “fatty acid” unless otherwise specified).

According to the above invention, since the above-mentioned fatty acid which exhibits water repellency is present in the form of ammonium salt and / or amine salt, the hydrophilicity becomes strong, and the surfactant is added even when mixed with the aqueous binder. A binder with good stability is obtained without the need to use it. Note that the aqueous system includes an aqueous solution containing water as a solvent and an aqueous dispersion containing water as a dispersion medium.

Further, when the binder is applied to the inorganic fibers and cured by heating, the aldehyde condensation thermosetting resin precursor which is the main component of the binder and a part of the fatty acid cause an esterification reaction. Adhesion between the thermosetting resin, the fatty acid and the inorganic fiber is excellent. On the other hand, during the heat curing, most of the ammonium ions and / or amines contained in the ammonium salt and / or amine salt of the fatty acid are volatilized, so that the proportion remaining in the binder after curing is low, and the inorganic fiber Does not impair the water repellency performance of.

In the binder for inorganic fibers of the present invention, the aldehyde-condensable thermosetting resin precursor and the ammonium salt and / or amine salt of the fatty acid are converted into the aldehyde-condensing thermosetting resin in terms of solid content. Precursor 10
Based on 0 parts by mass, the ammonium salt of the fatty acid and / or
Alternatively, it is preferable to contain the amine salt in an amount of 0.1 to 10 parts by mass.

Sufficient water repellency can be imparted to the inorganic fiber heat-insulating sound absorbing material by adjusting the amount ratio of the ammonium salt and / or amine salt of the fatty acid to the aldehyde-condensable thermosetting resin precursor within the above preferable range. It is possible and does not impair the stability of the binder.

Further, it is preferable to contain an aldehyde-condensable thermosetting resin precursor and the ammonium salt of the above fatty acid. This is because when ammonium ions remain in the binder after curing, the water repellency of the inorganic fiber adiabatic sound absorbing material is not impaired more than when amines remain if the fatty acids are the same.

Further, it is preferable that the inorganic fiber binder contains a silane coupling agent. According to this, while enhancing the adhesiveness between the binder and the inorganic fiber,
It is possible to prevent deterioration of the water repellent effect of the inorganic fiber heat insulating and sound absorbing material with time.

On the other hand, the inorganic fiber heat-insulating sound absorbing material of the present invention is formed by applying the binder for inorganic fibers to the inorganic fibers immediately after fiberization, collecting the inorganic fibers to which the binder is attached, and then heating and curing the inorganic fibers. It is characterized by being obtained by

According to the above invention, the heat insulating and sound absorbing inorganic fiber can be obtained which has no stickiness on the surface of the inorganic fiber and can maintain good water repellency for a long period of time.

[0022]

BEST MODE FOR CARRYING OUT THE INVENTION The present invention will be described in detail below.

The binder for inorganic fibers of the present invention comprises an aldehyde condensable thermosetting resin precursor and a carbon number of 10 to 30.
And an ammonium salt and / or an amine salt of at least one fatty acid selected from saturated fatty acids and unsaturated fatty acids.

First, the aldehyde-condensable thermosetting resin precursor will be described. Examples of the aldehyde-condensable thermosetting resin precursor used in the present invention include precursors of resol-type phenol resin, melamine resin, urea resin, and furan resin. In this case, the precursor may be used alone or in combination of two or more kinds.

Here, in the present invention, the precursor means the original compound that produces a resol-type phenol resin, a melamine resin, a urea resin and a furan resin by a reaction by heating. In this case, the ratio of the monomers and dimers contained in the precursor of each resin, or the number of methylol groups added per monomer is not particularly limited.

The aldehyde-condensable thermosetting resin precursor is
Since it is a high-viscosity liquid or solid, a medium such as water or an organic solvent is required to apply it to the inorganic fibers.
In the general manufacturing process of inorganic fiber heat insulating and sound absorbing material, 2
Since the binder is often applied in an atmosphere of 00 ° C. or higher, the inclusion of a flammable solvent such as an organic solvent may cause a fire. Therefore, the aldehyde-condensable thermosetting resin precursor is preferably dissolved or dispersed in water.

Next, the ammonium salt and / or amine salt of at least one fatty acid selected from saturated fatty acids and unsaturated fatty acids having 10 to 30 carbon atoms will be described.

In the present invention, examples of the saturated fatty acid having 10 to 30 carbon atoms include decanoic acid, undecyl acid,
Examples thereof include lauric acid, tridecylic acid, myristic acid, pentadecyl acid, palmitic acid, stearic acid, nonadecanoic acid, arachidic acid, behenic acid, lignoceric acid, cerotic acid, heptacosanoic acid, montanic acid and mericinic acid. Further, examples of the unsaturated fatty acid having 10 to 30 carbon atoms include oleic acid, elaidic acid, cetoleic acid, erucic acid, brassic acid, linoleic acid, linolenic acid and arachidonic acid. The above fatty acids may be used alone or in combination of two or more kinds.

When the fatty acid has less than 10 carbon atoms, the saturated fatty acid becomes a liquid at room temperature, so that the water repellency of the inorganic fiber heat insulating and sound absorbing material is easily lost, and the water repellency is easily deteriorated with time. It is not preferable because it may cause stickiness of the material and impair workability such as construction.

In the case of an unsaturated fatty acid having less than 10 carbon atoms, when the binder is heated and cured, the unsaturated bonds in the unsaturated fatty acid react with each other and solidify.
It does not cause the stickiness problem of the saturated fatty acids mentioned above. However, when the number of carbon atoms is less than 10, the hydrophobic linear structure portion in the unsaturated fatty acid becomes short, the number of carboxyl groups per unit weight becomes relatively large, and the unsaturated fatty acid becomes ammonium ion and / or Alternatively, the ability to capture amines becomes high. As a result, even after the binder is cured, it may remain in the form of a fatty acid ammonium salt and / or a fatty acid amine salt, impairing the water repellency of the resulting inorganic fiber heat-insulating sound absorbing material, which is not preferable.

On the other hand, when the carbon number of the fatty acid exceeds 30,
The carboxyl group of a fatty acid is neutralized with ammonia and / or amine, and it becomes difficult to dissolve or disperse them in water as a salt thereof, so that a stable water-based binder cannot be obtained, and the obtained inorganic fiber heat-insulating sound absorbing material The water repellency of 1 may not be sufficiently exhibited, which is not preferable.

The ammonium salt of fatty acid used in the inorganic fiber binder of the present invention can be obtained by neutralizing the fatty acid and ammonia. Similarly, an ammonium salt of a fatty acid can be obtained by a neutralization reaction between a fatty acid and an amine.

Examples of the ammonia include aqueous ammonia. Examples of the amine include ethylamine, diethylamine, triethylamine, isopropylamine, diisopropylamine, propylamine, t-
Butylamine, sec-butylamine, diisobutylamine, 3- (methylamino) propylamine, 3- (diethylamino) propylamine, 3- (dibutylamino) propylamine, 3- (dimethylamino) propylamine, 3- (2-ethylhexyl) Oxy) propylamine, 3,3′-iminobis (propylamine), N-
Methyl-3,3'-iminobis (propylamine), 2
-Ethylhexylamine, di-2-ethylhexylamine, 3-ethoxypropylamine, tetramethylethylenediamine, allylamine, diallylamine, triallylamine, tri-n-octylamine, 3-methoxypropylamine, N, N'-diethylethanolamine,
N, N'-dimethylethanolamine, N, N'-dibutylethanolamine, N- (2-aminoethyl) ethanolamine, N-methyldiethanolamine, N-methylethanolamine, morpholine, N-methylmorpholine, N-ethyl Examples include morpholine.

Of the above, when the inorganic fiber heat insulating and sound absorbing material is obtained by heating and curing the inorganic fiber binder, ammonium ammonium fatty acid which does not impair the water repellency of the inorganic fiber heat insulating and sound absorbing material even if it remains in the binder after curing. It is more preferable to use a salt.

The aqueous solution or dispersion of the ammonium salt of fatty acid used in the binder for inorganic fibers of the present invention is prepared by heating the fatty acid to its melting point or higher and gradually adding ammonia water while stirring to dissolve or disperse it in water. Can be obtained. By the same method, the amine salt of fatty acid can be obtained by using an aqueous solution of amine. Further, a predetermined amount of aqueous ammonia and / or amine may be added to the aqueous binder containing the aldehyde-condensable thermosetting resin precursor, and the fatty acid may be added later.

In this case, it is preferable to add the ammonia water and / or the amine in a ratio of 0.7 to 1.2 equivalents to 1 equivalent of the carboxyl group of the fatty acid. Further, not all of the carboxyl groups in the fatty acid may react with aqueous ammonia and / or amine. Here, when the fatty acid is heated, the temperature during the reaction is 1
When the temperature is higher than 00 ° C., ammonia water and / or amine for neutralizing fatty acids are likely to volatilize, and therefore it is preferable to dissolve or disperse in water under pressure.

In the binder for inorganic fibers of the present invention, an ammonium salt and / or an amine salt of a fatty acid is preferably added in an amount of 0.1 to 10 parts by mass, based on 100 parts by mass of the aldehyde-condensable thermosetting resin precursor. More preferably 1
To 5 parts by mass, particularly preferably 2 to 4 parts by mass.

When the content of ammonium salt and / or amine salt of fatty acid is less than 0.1 parts by mass, sufficient water repellency cannot be imparted to the obtained inorganic fiber heat insulating sound absorbing material. Further, even if the content of the ammonium salt and / or amine salt of fatty acid exceeds 10 parts by mass, the water repellency does not improve in proportion to the increase in the content, which is uneconomical, which is not preferable.

Further, in the binder for inorganic fibers of the present invention, in order to enhance the adhesiveness between the binder and the inorganic fibers,
It is preferable to add a silane coupling agent to the binder.

The number, type, structure, etc. of the functional groups of the silane coupling agent used here are not particularly limited, but the reactivity or compatibility with the aldehyde-condensable thermosetting resin precursor which is the main component of the binder is not limited. It is preferable to use an aminosilane coupling agent or an epoxysilane coupling agent because of their goodness. Examples of the aminosilane coupling agent include γ- (2-aminoethyl) aminopropyltrimethoxysilane and γ- (2-aminoethyl) aminopropylmethyldimethoxysilane, and examples of the epoxysilane coupling agent include γ-glycan. Examples thereof include sidoxypropyltrimethoxysilane and γ-glycidoxypropylmethyldimethoxysilane.

The amount of the silane coupling agent used is 100 parts by mass of the aldehyde-condensable thermosetting resin precursor.
It is preferably in the range of 0.01 to 0.5 parts by mass.
When the amount of the silane coupling agent used is less than 0.01 parts by mass, the effect of enhancing the adhesiveness between the inorganic fiber and the binder is poor, and the resulting heat insulating and sound absorbing material has a high temperature of 60 ° C. or higher and a high temperature and high humidity. When exposed to the environment, the water-repellent effect may decrease over time, which is not preferable. Further, even if the amount of the silane coupling agent used exceeds 0.5 parts by mass, the adhesiveness between the inorganic fiber and the binder does not improve in proportion to the amount used, and the effect of preventing the water repellency from deteriorating over time. However, it does not improve and is uneconomical, which is not preferable.

If necessary, a dustproofing agent, a curing accelerator, a flame retardant, a coloring agent, etc. may be added to the binder for inorganic fibers of the present invention. Examples of the curing accelerator include sodium sulfate, ammonium sulfate, dodecylbenzenesulfonic acid, p-toluenesulfonic acid and the like. The dustproofing agent is mainly composed of mineral oil or synthetic oil, and is mainly used to prevent the scattering of inorganic fibers.

The above-mentioned binder for inorganic fibers is preferably diluted with a solvent containing water as a main component so that the solid content is 5 to 30% by mass. At this time, by using a tank equipped with a stirrer such as a dissolver,
The inorganic fiber binder of the present invention can be obtained.

Next, the inorganic fiber heat insulating and sound absorbing material of the present invention obtained by using the above inorganic fiber binder will be described.

In the production of the inorganic fiber heat-insulating sound absorbing material of the present invention, first, the molten inorganic raw material is made into a fiber by a fiberizing device, and immediately after that, the above inorganic fiber binder is applied to the inorganic fiber. Then, the inorganic fibers to which the binder for inorganic fibers has been added are collected on a conveyor belt to form a bulky inorganic fiber heat-insulating sound absorbing material intermediate body, and a pair of upper and lower spaces are provided so as to have a desired thickness. It is sent to a belt conveyor or the like and heated under a narrow pressure to cure the inorganic fiber binder to form an inorganic fiber heat insulating and sound absorbing material. Then, if necessary, a cover material or the like is covered, and the inorganic fiber heat insulating and sound absorbing material is cut into a desired width and length to obtain a product. Less than,
Each step will be described.

First, the inorganic fiber used in the present invention is not particularly limited, and glass wool, rock wool or the like which is commonly used for heat insulating and sound absorbing materials can be used. Various methods such as a flame method, a blowing method, and a centrifugal method (also referred to as a rotary method) can be used as the method for fiberizing the inorganic fiber. Especially when the inorganic fiber is glass wool, it is preferable to use the centrifugal method. The desired density of the inorganic fiber heat-insulating sound absorbing material may be the density used for ordinary heat insulating materials and sound absorbing materials, and is preferably in the range of 5 to 300 kg / m ³ .

Next, in order to apply a binder to the inorganic fibers, it is possible to apply and spray them by using a spray device or the like. The amount of the inorganic fiber binder applied can be adjusted in the same manner as in the conventional binder containing no water repellent. The amount of the binder applied varies depending on the density and use of the inorganic fiber heat insulating and sound absorbing material, but is preferably in the range of 0.5 to 15 mass% in terms of solid content, based on the weight of the inorganic fiber heat insulating and sound absorbing material to which the binder is applied. The range of 0.5 to 9 mass% is more preferable. The binder may be added to the inorganic fiber heat-insulating sound absorbing material at any time after fiberizing, but it is preferable to add it immediately after fiberizing in order to efficiently impart it.

The inorganic fibers to which the binder has been added by the above steps are collected on a perforated conveyor to form a bulky inorganic fiber intermediate. Here, when collecting the cotton on the conveyor, it is more preferable to suck with a suction device from the opposite side of the conveyor where the inorganic fibers are collected. After that, the inorganic fiber intermediate that continuously moves on the conveyor is fed into a pair of upper and lower belt conveyors provided with an interval so as to have a desired thickness, and at the same time, the binder is contained by heated hot air. After curing the thermosetting resin precursor, after molding the inorganic fiber heat-insulating sound absorbing material into a mat,
Cut to the desired width and length.

The temperature for curing the thermosetting resin precursor contained in the binder is not particularly limited, but may be the same as that of the conventional binder containing no water repellent, and may be 200 to 350 ° C. Further, the heating time is appropriately 30 seconds to 10 minutes depending on the density and thickness of the inorganic fiber heat insulating and sound absorbing material.

The inorganic fiber heat insulating sound absorbing material of the present invention may be used as it is or may be used by being covered with a skin material. As the skin material, paper, synthetic resin film, metal foil film, non-woven fabric, woven fabric, or a combination thereof can be used. At this time, it is preferable to use a material having a low water absorption rate and water repellency as the skin material.

As described above, the binder for inorganic fibers obtained by the present invention can be mixed with a water-based binder with good stability without using a surfactant, and has sufficient water repellency to be a heat insulating and sound absorbing material for inorganic fibers. Can be given to.

In addition, the inorganic fiber heat insulating sound absorbing material of the present invention obtained by using this inorganic fiber binder does not retain water in the heat insulating sound absorbing material even when exposed to rainwater or dew condensation water. The performance of noise absorption and sound absorption does not deteriorate over a long period of time, and it is possible to solve the problems of mold generation, corrosion of metal parts in contact with wood, and decay of wood.

Furthermore, in the manufacturing process, processing process or construction site of the inorganic fiber heat insulating and sound absorbing material, the fatty acid in the binder for the inorganic fiber coats each single fiber of the inorganic fiber to make the fiber difficult to break or broken fiber. The particles are fixed so as not to fall off, so that the scattering of the inorganic fibers can be suppressed. Also,
The hydrophobic portion of the fatty acid existing on the contact surface between the inorganic fiber heat insulating and sound absorbing material and the conveyor improves the releasability of the inorganic fiber heat insulating and sound absorbing material from the conveyor, thereby reducing troubles during the manufacturing process.

[0054]

EXAMPLES The present invention will be described in more detail below with reference to examples. In the following description, “part” and “%” are based on mass unless otherwise specified. [Preparation of fatty acid ammonium salt and fatty acid amine salt] Preparation 1 60 parts of stearic acid was added to 100 parts of water, and the mixture was heated to 72 ° C., which is the melting point of stearic acid, with stirring to completely melt the stearic acid. In this state, stearic acid exists in water as oil droplets. Next, a mixture of 73.9 parts of 10% aqueous ammonia and 100 parts of water was added dropwise to the molten stearic acid / water mixture while stirring to obtain an aqueous dispersion of ammonium stearate having a solid content of 20%. It was

Formulation 2 While heating at 45 ° C. and stirring 60 parts of molten lauric acid, 115.5 parts of 10% ammonia water and 150 parts of water are added.
The resulting mixture was added dropwise to obtain an aqueous dispersion of ammonium laurate having a solid content of 22%.

Formulation 3 At room temperature, while stirring 60 parts of oleic acid, a mixture of 74.5 parts of 10% ammonia water and 200 parts of water was added dropwise to give an aqueous solution of ammonium oleate having a solid content of 20.2%. Got

Formulation 4 60 parts of montanic acid was heated to 90 ° C. above the melting point and melted. While stirring the molten montanic acid, N, N '
-12.2 parts of dimethylethanolamine were added. After the completion of mixing, 200 parts of water was added dropwise with stirring to obtain an aqueous dispersion of a montanic acid amine salt having a solid content of 26.5%.

Formulation 5 After 60 parts of stearic acid was heated to a melting point of 72 ° C. or higher to be melted, 3 parts of polyoxyethylene polyoxypropylene block polymer was added with stirring. After mixing, 200 parts of water was added dropwise with stirring to obtain a solid content of 2
An aqueous dispersion of 4% stearic acid was obtained.

Formulation 6 After 60 parts of zinc stearate was heated to a melting point of 130 ° C. and melted, 5 parts of polyoxyethylene polyoxypropylene was added with stirring. After the completion of mixing, 200 parts of water was added dropwise with stirring to obtain an aqueous dispersion of zinc stearate having a solid content of 22.6%.

Example 1 [Preparation of binder for inorganic fiber] Monomer 10% or less, dimer 80% or more, free phenol 1% dispersed in water.
The following resole-type phenolic resin precursor was added to a dissolver with 100 parts of the solid content, 3 parts of the aqueous dispersion of ammonium stearate obtained in Preparation 1 in the solid content, and 450 parts of water. The mixture was prepared in an open tank, and water was added with sufficient stirring so that the solid content was 15% to obtain a binder for inorganic fibers.

[Manufacture of Insulating Sound Absorbing Material for Inorganic Fibers] The glass fiber made by the centrifugal method is spray-coated with the binder so as to give a predetermined amount, and then a perforated conveyor while sucking with a suction device. Cotton was collected on the top to form an intermediate of an inorganic fiber heat insulating sound absorbing material. 280 the intermediate
Heat in the hot air of ℃ for 3 minutes to cure the binder,
A glass wool as the inorganic fiber heat-insulating sound absorbing material of Example 1 having a density of 35 kg / m ³ , a thickness of 50 mm and a binder application amount of 8.0% was obtained.

Examples 2 to 4 The same binder preparation method and production method as in Example 1 were used, except that the aqueous dispersion or aqueous solution of the fatty acid salt obtained in Preparations 2 to 4 was used. A glass wool as an inorganic fiber heat insulating and sound absorbing material was obtained.

Example 5 50 parts of furan resin precursor in terms of solid content, 50 parts of urea resin precursor in terms of solid content, 0.1 part of montanic acid amine salt obtained in Formulation 4 in terms of solid content, 0.1 part of γ- (2-aminoethyl) aminopropyltrimethoxysilane and 450 parts of water were mixed in an open tank equipped with a dissolver, and water was added with sufficient stirring so that the solid content became 15%. A binder for inorganic fiber was obtained.

Next, the inorganic fiber heat insulating and sound absorbing material of Example 5 is obtained by the same manufacturing method as in Example 1 except that the above binder for inorganic fiber is used to cure the binder in hot air at 300 ° C. I got glass wool.

Example 6 100 parts of the water-dispersible resol-type phenolic resin precursor used in Example 1 in terms of solid content, and the aqueous dispersion of ammonium stearate obtained in Formulation 1 in solid content of 9.
0 part, 0.1 part of γ-glycidoxypropyltrimethoxysilane, and 450 parts of water were mixed in an open tank equipped with a dissolver, and the solid content was 15% with sufficient stirring.
Was added to obtain a binder for inorganic fibers.

Next, a glass wool as an inorganic fiber heat insulating and sound absorbing material of Example 6 was obtained by the same manufacturing method as in Example 1 except that the above-mentioned inorganic fiber binder was used.

Example 7 An aqueous dispersion of ammonium stearate was calculated as 1 in terms of solid content.
A glass wool as the inorganic fiber heat-insulating sound absorbing material of Example 7 was obtained by the same mixing method and manufacturing method as in Example 6 except that the amount was 2.0 parts.

Example 8 Using the binder for inorganic fibers of Example 6, the same manufacturing method as in Example 1 was used to obtain a density of 16 kg / m ³ and a thickness of 10.
A glass wool as an inorganic fiber heat insulating and sound absorbing material of Example 8 was obtained under the conditions of 0 mm and a binder application amount of 4.0%.

Example 9 Using the binder for inorganic fibers of Example 7, the same production method as in Example 1 was used to obtain a density of 16 kg / m ³ and a thickness of 10.
A glass wool as an inorganic fiber heat insulating and sound absorbing material of Example 9 was obtained under the conditions of 0 mm and a binder application amount of 4.0%.

Comparative Example 1 100 parts of the water-dispersible resol-type phenolic resin precursor used in Example 1 in terms of solid content, 0.1 part of γ-glycidoxypropyltrimethoxysilane, and 450 parts of water were added. The mixture was prepared in an open tank equipped with a dissolver, and water was added to the solid content of 15% with sufficient stirring to obtain a binder containing no water repellent.

Further, using this binder and in the same manufacturing method as in Example 1, a glass wool as a heat insulating and sound absorbing material for inorganic fiber of Comparative Example 1 was obtained.

Comparative Example 2 100 parts of the water-dispersed resol-type phenolic resin precursor used in Example 1 in terms of solid content and 5 parts of the aqueous dispersion of stearic acid obtained in Formulation 5 in terms of solid content. , Water 450
Parts were mixed in an open tank equipped with a dissolver, and water was added with sufficient stirring so that the solid content was 15% to obtain a binder.

Further, using this binder, glass wool as a heat insulating and sound absorbing material for inorganic fiber of Comparative Example 2 was obtained by the same manufacturing method as in Example 1.

Comparative Example 3 50 parts of furan resin precursor in terms of solid content, 50 parts of urea resin precursor in terms of solid content, 3 parts of polyoxyethylene glycol ester stearate, γ- (2-aminoethyl) aminopropyl Trimethoxysilane 0.1 part, water 4
50 parts and 50 parts were prepared in an open tank equipped with a dissolver, and water was added with sufficient stirring so that the solid content was 15% to obtain a binder.

Further, a glass wool as an inorganic fiber heat insulating and sound absorbing material of Comparative Example 3 was obtained by the same manufacturing method as in Example 1 except that this binder was used and cured in hot air at 300 ° C.

Comparative Example 4 The water-dispersed resol-type phenolic resin precursor used in Example 1 was 100 parts in terms of solid content, and the molecular weight was about 1000.
5 parts of an aqueous solution of ammonium polyacrylate of 0 in solid content and 450 parts of water were prepared in an open tank equipped with a dissolver, and water was added with sufficient stirring so that the solid content became 15%. Got

Further, using this binder, glass wool as a heat insulating and sound absorbing material for inorganic fiber of Comparative Example 4 was molded by the same manufacturing method as in Example 1.

Comparative Example 5 100 parts of the water-dispersed resol-type phenolic resin precursor used in Example 1 in terms of solid content, and 5 parts of the aqueous dispersion of zinc stearate obtained in Formulation 6 in terms of solid content. Part, γ-
0.1 part of (2-aminoethyl) aminopropyltrimethoxysilane and 450 parts of water were mixed in an open tank equipped with a dissolver, and the solid content was 15 while sufficiently stirring.
Water was added to obtain a binder.

Further, by using this binder and by the same manufacturing method as in Example 1, glass wool as a heat insulating and sound absorbing material for inorganic fiber of Comparative Example 5 was obtained.

All the binders used in Examples 1 to 9 and Comparative Examples 1 to 5 had good stability. Moreover, the fatty acid ammonium salt and amine salt used in the examples could be uniformly mixed with the aqueous binder and had good compatibility with other binder components.

Test Example [Evaluation of Water Repellency] From the glass wool obtained in Examples 1 to 9 and Comparative Examples 1 to 5, test pieces of 50 × 100 × 100 mm square were cut out, and the dimensions of the test pieces were measured and weighed. Then, it was immersed in water having a water temperature of 25 ° C. and 50 mm below the water surface. The test piece was taken out 24 hours after the start of immersion, and the temperature was kept at 25 ° C.
After being left on the wire net for 0 minutes, the test piece was weighed.

The amount of increase after the immersion is relative to the volume of the test piece,
Expressed in percentage, this was taken as the volumetric water absorption. Furthermore, the test piece whose volumetric water absorption was calculated was left on a wire mesh, and the content of water after 6 hours was expressed as a percentage with respect to the volume of the test piece.
The volumetric water content was used. All the evaluation results are summarized in Table 1.

[0083]

[Table 1]

It can be seen from Table 1 that the test pieces of Examples 1 to 9 have a lower volumetric water absorption rate and a lower volumetric water content after 6 hours from the immersion as compared with the test pieces of Comparative Examples 1 to 5. I understand. This indicates that the water repellency of glass wool was improved by the various saturated fatty acids and unsaturated fatty acids used in the examples.

From the comparison between Example 6 and Example 7, it can be seen that even if the fatty acid is added in an amount exceeding the preferable range, the water repellency is not significantly improved.

On the other hand, Comparative Example 1 containing no water repellent, Comparative Example 3 using polyoxyethylene glycol ester stearate in place of the amine salt of montanic acid of Example 5,
In Comparative Example 4 in which an aqueous solution of ammonium polyacrylate having a molecular weight of about 10,000 was used in place of the aqueous ammonium stearate dispersion of Example 1, both the volumetric water absorption rate and the volumetric water content after 6 hours were higher than those of the Examples. It turns out that it is significantly inferior.

Further, instead of the ammonium stearate aqueous dispersion of Example 1, stearic acid was dispersed using a polyoxyethylene polyoxypropylene block polymer as a surfactant, and Comparative Example 2 and Example 6 were used. In Comparative Example 5 in which the aqueous dispersion of zinc stearate was used instead of the aqueous dispersion of ammonium stearate, the volumetric water absorption was improved, but the volumetric water content after 6 hours was inferior. It can be seen that the water repellency is inferior in the case of using the fatty acid alone of Comparative Example 2 and the case of using the fatty acid ester of Comparative Example 3 as compared with the case of using the fatty acid ammonium salt or the fatty acid amine salt of the Examples.

[0088]

INDUSTRIAL APPLICABILITY As described above, the binder for inorganic fibers of the present invention is excellent in stability in spite of being water-based, and can impart sufficient water repellency to the heat insulating and sound absorbing inorganic fibers. Further, the inorganic fiber heat insulating sound absorbing material of the present invention using this binder for inorganic fibers, even when exposed to rainwater or dew condensation, heat insulation, sound absorbing performance does not decrease for a long period of time, the metal portion that mold or contact mold It can solve the problems of corrosion of wood and decay of wood, and can be suitably used as a heat insulating material or sound absorbing material for houses, buildings, soundproof walls, cooling towers, outdoor installation equipment and the like.

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[Procedure amendment]

[Submission date] April 21, 2003 (2003.4.2)
1)

[Procedure Amendment 1]

[Document name to be amended] Statement

[Name of item to be corrected] 0032

[Correction method] Change

[Correction content]

The ammonium salt of fatty acid used in the inorganic fiber binder of the present invention can be obtained by neutralizing the fatty acid and ammonia. Similarly, an amine salt of a fatty acid can be obtained by a neutralization reaction between a fatty acid and an amine.

─────────────────────────────────────────────────── ─── Continuation of front page (51) Int.Cl. ⁷ Identification code FI theme code (reference) G10K 11/16 G10K 11/16 A 11/162 DF term (reference) 4L033 AA09 AB01 AB07 AC03 AC11 BA16 BA19 BA96 BA98 BA99 CA34 CA69 CA70 4L047 AA04 AA05 AB02 BA17 BC14 CB03 CB06 CC10 5D061 AA02 AA09 AA11 AA22 BB21

Claims (5)

[Claims] 1. An aldehyde condensable thermosetting resin precursor, and an ammonium salt and / or an amine salt of at least one fatty acid selected from saturated fatty acids and unsaturated fatty acids having 10 to 30 carbon atoms. A binder for inorganic fibers characterized by: 2. The aldehyde-condensable thermosetting resin precursor and the ammonium salt and / or amine salt of the fatty acid relative to 100 parts by mass of the aldehyde-condensing thermosetting resin precursor in terms of solid content. The binder for inorganic fibers according to claim 1, which is contained in an amount of 0.1 to 10 parts by mass of the ammonium salt and / or amine salt of the fatty acid. 3. The inorganic fiber binder according to claim 1, which contains the aldehyde-condensable thermosetting resin precursor and an ammonium salt of the fatty acid. 4. The binder for inorganic fibers according to claim 1, wherein the binder for inorganic fibers further contains a silane coupling agent. 5. The inorganic fiber binder according to any one of claims 1 to 4 is applied to the inorganic fiber immediately after fiberization,
An inorganic fiber heat-insulating sound-absorbing material, which is obtained by collecting inorganic fibers to which the binder is attached, and then heat-curing and molding the inorganic fibers.