JP2004330589A - Charcoal mat material, method for producing charcoal mat material, and method for using charcoal mat material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To improve adsorption properties, thermal insulation properties, humidity adjustment properties, lightweight properties, and flame retardant properties. <P>SOLUTION: The charcoal mat material 1 is mainly composed of a mat substrate 4 produced by molding coconut fibers C obtained from a natural palm tree into a mat by using a liquid binder component 3 and a carbon layer 8 which contains fine carbon powder 6 and is formed on the surface 5 of the mat substrate 4 by spraying a carbon coating prepared by dispersing/mixing the carbon powder 6 in/with the binder component 3 etc., on the surface 5 of the mat substrate 4 and drying the coating. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

【００４３】
表１に示されるように、デシケータ内に設置されたそれぞれの試料により、Ｃ）ブランクに比して、Ａ）炭マット材、Ｂ）無処理ボード材のいずれにおいても、デシケータ内のホルムアルデヒド濃度が低下する結果が得られた。特に、Ａ）炭マット材の場合は、Ｂ）無処理ボード材に比べて、係る減少の傾向が強く見られた。これにより、ホルムアルデヒドが、Ａ）炭マット材、及びＢ）無処理ボード材のいずれによってもボード内（ココナッツファイバーＣの内部）に吸着されるとともに特に、表面に形成された炭素層８によってより多くのホルムアルデヒドの吸着が行われることを示している。すなわち、炭素層８を基材表面５に形成することにより、ホルムアルデヒド等の化学物質の吸着量を著しく増加させることができ、炭マット材１による吸着性を示すことができた。
【００４４】
＜断熱性＞
次に、炭マット材１の断熱性能について示す。ここで、断熱性能を示すものとして、一般に素材の熱伝導率（ｗ／ｍ・Ｋ）が測定される。なお、熱伝導率の測定は、二枚の炭マット材１を試料として用意し、それぞれについて測定した結果の平均を取ることにより、熱伝導率の値を求めている。ここで、熱伝導率は、熱流計法に基づいた熱伝導率測定装置（英弘精機株式会社製 ＨＣ−０７４型）を用いている。
【００４５】
始めに、サンプル１（試料厚さ：０．０２７１８ｍ）及びサンプル２（試料厚さ：０．０２８９４ｍ）を、２０℃−６０％の恒温・恒湿室内で、恒量に達するまで５日間静置する。その後、熱伝導率測定装置を用い、周囲環境温度を１８℃に設定した状態で測定を行う。このとき、熱伝導率測定装置の高温側の位置は、水平、かつ下側に設定されている。その測定結果を、下記の表２に示す。
【００４６】
【表２】

【００４７】
上記に示したように、本実施形態の炭マット材１は、サンプル１及びサンプル２の平均値で０．０５０７ｗ／ｍ・Ｋの熱伝導率を有していることが示された。係る値は、断熱性素材として使用できる範囲のものであり、これにより、炭マット材１の断熱性が示された。
【００４８】
以上、本発明について好適な実施形態を挙げて説明したが、本発明はこれらの実施形態に限定されるものではなく、以下に示すように、本発明の要旨を逸脱しない範囲において、種々の改良及び設計の変更が可能である。
【００４９】
すなわち、本実施形態の炭マット材１及び製造方法２において、炭素塗料７の配合比率の一例を示したが、これに限定されるものではない。噴霧し、形成する炭素層８の厚さやスプレー塗布する際に適した粘度に応じて配合比率を適宜変更することが可能である。さらに、難燃性を付与するために、メタルシリコン等を含む耐火液９を炭素塗料７に含有させるものを示したが、これに限定されるものではなく、難燃性をあまり必要としない用途に使用する場合等は、耐火液９に替えて水などで、バインダ成分３を希釈するものであってもよい。
【００５０】
さらに、製造方法２において、ココナッツファイバーＣ及びバインダ成分３によってマット基材４を成形するものと、炭素塗料７の調製を並行して行うものを示したが、これに限定されるものではなく、これらを一連の流れで行うものであっても構わない。ここで、炭素塗料７は、時間が経過すると、分散された炭素微粉末６が沈殿する可能性があるため、係る場合には再度撹拌したり、少量の水等（耐火液９を含む）で希釈することにより、噴霧に適した状態とすることが可能である。
【００５１】
【発明の効果】
以上のように、本発明の炭マット材は、マット基材の表面に炭素微粉末からなる炭素層が形成されるため、ホルムアルデヒド等の有害なガスや悪臭等を容易に吸着することができる。また、マット状に成形加工するためのバインダに水性のものが使用されることにより、特に住宅等の建築用の資材の一部として使用することに適している。加えて、建築用資材として使用する場合、耐火液によって難燃性が付与されるため、万が一、火災などが発生した状況にあっても延焼を防ぎ、被害の拡大を抑えることができる。また、マット基材の表面に粘度を調製した炭素塗料を噴霧することによって製造することができるため、製造工程が複雑化せず、簡易に、かつ製造コストを抑えたものとすることができる。
【図面の簡単な説明】
【図１】本実施形態の炭マット材の構成を示す一部を切欠いた切欠斜視図である。
【図２】製造方法における各工程の流れを示すフローチャートである。
【図３】製造方法の工程の一部を模式化して示した説明図である。
【符号の説明】
１ 炭マット材
２ 製造方法（炭マット材の製造方法）
３ バインダ成分
４ マット基材
５ 基材表面（表面）
６ 炭素微粉末
７ 炭素塗料
８ 炭素層
９ 耐火液（希釈液）
Ｃ ココナッツファイバー
Ｓ１ 浸漬工程
Ｓ２ 成形工程
Ｓ４ 配合計測工程（炭素塗料調製工程）
Ｓ５ 撹拌工程（炭素塗料調製工程）
Ｓ６ 噴霧工程
Ｓ７ 乾燥工程[0001]
TECHNICAL FIELD OF THE INVENTION
TECHNICAL FIELD The present invention relates to a charcoal mat material, a method for producing the charcoal mat material, and a method for using the charcoal mat material. In particular, the present invention relates to heat insulation, adsorption (including deodorizing and deodorizing properties), lightness, and difficulty. The present invention relates to a charcoal mat material excellent in flammability and applicable as a building material, a method for producing the charcoal mat material, and a method for using the charcoal mat material.
[0002]
[Prior art]
In recent years, in addition to wooden buildings (wooden houses) of conventional wooden style constructed using wood and main building materials, houses, condominiums, and high-rise buildings constructed using a large amount of concrete building materials Are constructed by the concrete method.
[0003]
By the way, in a room such as a house in recent years, an adhesive containing a volatile petroleum organic solvent is often used when a wallpaper and a cloth are attached. In addition, as a part of a fitting such as a door for a house, a plywood or a laminated material bonded with a similar adhesive or the like (for example, a “flash door”) is known. Furniture may also be manufactured using such plywood or glulam. For this reason, the petroleum organic solvent may diffuse into the room from the adhesive used for sticking or the like. As a result, the occupants of the room may inhale the petroleum-based organic solvent from the nose or mouth into respiratory organs such as the lungs, or may directly expose the skin or the like to the petroleum-based organic solvent, resulting in chemical sensitivity (so-called “substance sensitivity”). It is known to cause the symptoms of "sick house syndrome"). In particular, condominiums and the like using the above-described concrete building materials tend to be more airtight in the room and have poor air permeability compared to wooden houses. Therefore, the volatile petroleum-based organic solvent diffused in the room stays in the room for a long time, and the possibility of being taken into a resident's body or the like is further increased.
[0004]
Here, examples of the petroleum organic solvent used for the adhesive mainly include organic compounds that are frequently used industrially, such as formaldehyde, toluene, xylene, acetone, methyl ethyl ketone, and paradichlorobenzene. Most of these compounds are generally highly flammable compounds and are designated as dangerous goods (especially class 4) under the Fire Service Law, and require attention to fires and the like. In addition, excessive intake of these compounds into the body may cause headache, nausea, and dizziness, as well as various allergic symptoms to the user, especially when the intake is large, It is known to cause serious damage to the human body.
[0005]
Therefore, manufacturers of materials and the like for housing construction have stopped using petroleum-based organic solvents such as formaldehyde described above or made efforts to reduce the usage as much as possible.
[0006]
By the way, in the room of the house, the odor due to various factors may be accumulated together with the diffusion of the above-mentioned chemical substance such as formaldehyde. For example, in a home where pets such as dogs and cats (pets) are bred indoors, the animal odor of the pets or the odor due to excreted manure is diffused, and often makes the residents feel uncomfortable. Therefore, a mat having a deodorizing function, a deodorant, an aromatic, or the like is often kept in the room. Further, in the above-described condominiums that have become highly airtight and have poor air permeability, the humidity in the room may be significantly different from that outside the room due to the season or the temperature difference between day and night, and the humidity control property may be inferior to that of the timber house.
[0007]
The above prior art is naturally implemented as a person skilled in the art, and the applicant does not particularly know the literature describing the prior art at the present stage at the time of filing the present application.
[0008]
[Problems to be solved by the invention]
However, it has been difficult to stop using a petroleum organic solvent such as formaldehyde or to reduce the amount of use due to various factors. In other words, the quality (particularly, durability and adhesive strength) of wood products (plywood and glulam) manufactured by discontinuing use may be reduced, or it is difficult to find suitable (environmentally friendly) alternatives. there were. Therefore, these problems were not immediately solved.
[0009]
Therefore, attempts have already been made to physically adsorb a petroleum organic solvent or an unpleasant odor component diffused in a room. For example, attention has been paid to the adsorption effect of porous charcoal, activated carbon, zeolite, and the like, and such adsorbent substances have been placed indoors or used as a part of building materials for houses. However, in particular, when used as a building material, various characteristics other than the above-described adsorptive properties (including deodorizing and deodorizing properties) have been required.
[0010]
For example, to minimize the change in the indoor temperature with respect to the outside air, enhance the cooling and heating effect of the heating device and the cooling device, reduce the amount of energy consumption, heat insulation, and adjust the humidity of the highly airtight room. Humidity control, light weight that can reduce the burden on workers and transportation costs during construction work such as housing, and flame retardancy (flameproof) to minimize damage in case of fire in case of fire ), And combustion safety for preventing generation of toxic gases such as chlorine-based gas during combustion.
[0011]
However, most of today's building materials are hardly designed in consideration of all the above-mentioned characteristics, and in particular, people's awareness of the natural environment has increased in recent years, and there has been a high interest in health. Therefore, there has been a great demand from residents or contractors for building materials having such characteristics.
[0012]
In view of the above circumstances, the present invention provides a charcoal mat material, a charcoal mat material having excellent properties such as heat insulation, humidity control, light weight, and flame retardancy, in addition to adsorptivity capable of responding to chemical substance hypersensitivity and the like. An object of the present invention is to provide a method for manufacturing a mat material and a method for using a charcoal mat material.
[0013]
[Means for Solving the Problems]
In order to solve the above problems, the charcoal mat material according to the present invention includes a `` coconut fiber produced from natural palm, and a one-component curable aqueous binder component for forming the coconut fiber into a mat shape, A carbon layer formed by applying fine carbon powder to the surface of a mat substrate formed in a porous mat shape by the coconut fiber and the aqueous binder component, wherein the carbon layer is A carbon paint prepared by dispersing and mixing a powder with the aqueous binder component and the diluent component is sprayed on the surface of the mat base material, and further dried to form a carbon coating material. .
[0014]
Here, coconut fiber is obtained from natural palms that grow in the tropics (or a part of the subtropical region), and is mainly used for strings, etc. by spinning the extracted fiber material for a long time. Things. Furthermore, it is possible to manufacture industrial products such as automotive sheets by mainly processing into a mat-like (plate-like) shape using a latex containing a natural rubber component and the coconut fiber. It is.
[0015]
Further, the aqueous binder component is used as a substitute for the latex used when the above-mentioned conventional mat is formed, for example, by pressing immersed coconut fiber from above and below to a predetermined thickness. It is used to maintain the state of Here, as the aqueous binder component, a one-component curing type is used, and the aqueous binder component can be held in a mat shape by natural drying or forced drying by heating. The aqueous binder component has solubility in water and does not contain a petroleum organic solvent such as an alcohol solvent. Therefore, it does not fall under the category of dangerous goods under the Fire Service Law and has no flammable properties.
[0016]
On the other hand, carbon fine powder refers to charcoal such as Bincho charcoal or bamboo charcoal obtained by steaming bamboo, which has been handed down to Japan since ancient times. Diameter). This carbon fine powder has a very large surface area because it has a porous property having fine pores and voids on the surface. The pores and the like are capable of adsorbing a petroleum organic solvent, an odor component, and the like.
[0017]
In addition, the carbon paint is one that is applied to the surface of a mat base material obtained by molding a coconut fiber into a mat shape using an aqueous binder component, and the carbon fine powder described above and used during the molding process. It is composed of the same aqueous binder component as above, and a diluent component such as water for adjusting to a viscosity suitable for spraying. The fine carbon powder is dispersed and mixed in the aqueous binder component and diluent component.
[0018]
Therefore, according to the charcoal mat material of the present invention, a conventionally known spray coating is applied to a surface of a mat base material in which coconut fibers are formed into a mat shape by an aqueous binder component, the carbon paint having been previously adjusted to a viscosity suitable for spraying. It is sprayed using technology. Thereby, the carbon paint is applied to the surface. Then, the liquid component of the aqueous binder component and the diluent component contained in the carbon paint evaporates into the atmosphere, whereby a carbon layer of carbon fine powder is formed on the surface of the mat base material. In other words, the surface of the mat base material is covered with the carbon fine powder. As a result, the carbon mat material has the adsorptivity of the carbon fine powder.
[0019]
In addition, since the mat base material is formed in a porous state containing a large amount of air inside, the mat base material is a material that is rich in heat insulating property, humidity control property (there is also a portion caused by carbon fine powder), and lightweight. Therefore, the charcoal mat material is configured as a material having excellent adsorbing properties and heat insulating properties. Furthermore, the use of an aqueous binder component eliminates the use of petroleum-based organic solvents (eg, ethyl alcohol, etc.) as compared with the case where conventional latex is used. Absent. Therefore, flammability can be suppressed.
[0020]
Furthermore, the main raw material of the mat base material is coconut fiber obtained from the palm of a natural plant, and the carbon fine powder can use charcoal such as Bincho charcoal. For this reason, most of the charcoal mat material according to the present invention uses a material produced from nature, so it can be said that the configuration is particularly considering the natural environment.
[0021]
The charcoal mat material of the present invention, in addition to the above-described constitution, further comprises a liquid crystal component that is obtained by mixing and reacting potassium hydroxide, sodium carbonate, metal silicon, and water with each other. A refractory liquid exhibiting flammable properties is used. "
[0022]
Here, conventionally, in the case of imparting flame retardancy (fire resistance) to a substance (material), for example, asbestos (asbestos), fire-resistant water glass, and a composite material have been often used. However, asbestos may induce lung cancer when so-called “asbestos dust” is taken into the lungs and the like, and is rarely used at present. Further, the temperature at which the fire resistance of the fire-resistant water glass can be maintained may be limited to a relatively low temperature range, and it has been particularly difficult to use the water glass as a building material. Further, in the case of a composite material, since various compounds are formed as a mixture, there is a problem in that there is a high risk of generating a toxic gas when exposed to a high temperature and the weight increases. . Therefore, in recent years, a refractory liquid, which is a reaction product of potassium hydroxide, sodium carbonate, and metal silicon (metal silicon compound), is sometimes used as a flame retardant.
[0023]
Therefore, according to the carbon mat material of the present invention, a refractory liquid exhibiting flame retardancy is used as a diluent component used when applying a carbon paint to a mat substrate made of coconut fiber. Here, the refractory liquid is obtained by mixing and reacting potassium hydroxide, sodium carbonate, metal silicon, and water at a predetermined ratio. Therefore, the carbon layer on the surface of the mat base material contains the above-described metal silicon and the like, and the above-described flame retardancy is imparted. Therefore, the carbon layer formed on the surface of the mat base material includes a part of the above-described metal silicon and the like, and has fire resistance.
[0024]
As a result, for example, even in an environment where the charcoal mat material is exposed to a high temperature (for example, when a fire occurs), the fire-retardant liquid exhibits the flame retardancy and does not easily burn. Further, in this case, no toxic gas such as chlorine gas is generated unlike the related art. In addition, the refractory liquid is known to have an effect of imparting sound insulation and heat insulation to the applied material, and the charcoal mat material has such properties.
[0025]
In addition to the above configuration, the charcoal mat material of the present invention may be one in which “the aqueous binder component is configured to include an acrylate copolymer”.
[0026]
Therefore, according to the carbon mat material of the present invention, the aqueous binder component for forming into a mat shape is made of an acrylate copolymer. Here, examples of the acrylate copolymer include acrylate ethyl ester, acrylate butyl ester, and acrylate monomer. In addition, as described above, conventionally, a resin such as a latex containing a natural rubber component has been used to mold coconut fiber into a mat shape. However, they have a peculiar rubber odor, and were not suitable for use as a part of building materials of houses in particular. Therefore, in the carbon mat material of the present invention, an unpleasant rubber odor is not felt by using an aqueous acrylic ester copolymer for molding the coconut fiber. In addition, since it has an aqueous property, it is less likely that a petroleum organic solvent that is harmful to the human body will diffuse into a room and that a resident will inhale.
[0027]
The method for producing a carbon mat material of the present invention is a method for producing a carbon mat material for producing the above-described carbon mat material, wherein the coconut fiber is immersed in the one-component curing type aqueous binder component. And a forming step of pressing the coconut fiber containing the aqueous binder component therein by the dipping step to produce a mat base material formed into a mat having a predetermined thickness; and the aqueous binder component. And a carbon paint preparation step of dispersing and mixing the carbon fine powder in the diluent component to prepare a sprayable viscosity carbon paint, and the carbon paint prepared by the carbon paint preparation step, wherein the mat base material A spraying step of spraying and applying to the surface of the mat, and drying the carbon paint sprayed by the spraying step and applied to the surface of the mat base material, Some comprise a "and the drying step of forming the carbon layer.
[0028]
Therefore, according to the method for producing a carbon mat material of the present invention, first, a one-component curable aqueous binder component is immersed in coconut fiber. Then, the coconut fiber in which the aqueous binder component is immersed is pressed, for example, by applying pressure from above and below to form a mat base material having a predetermined thickness. After that, a carbon paint composed of a fine carbon powder, an aqueous binder component, and a diluent component and adjusted to a sprayable viscosity at a predetermined mixing ratio is sprayed on the surface of the mat device, and further applied to the surface. The carbon paint is dried. As a result, the liquid component (mainly water) contained in the carbon coating material evaporates into the atmosphere, and a carbon layer of carbon fine powder is formed on the surface of the mat substrate. As a result, a charcoal mat material having excellent characteristics such as the above-described adsorptivity is produced.
[0029]
The method of using the charcoal mat material of the present invention is “using the above-mentioned charcoal mat material as a building material”.
[0030]
Therefore, according to the method of using the charcoal mat material of the present invention, the charcoal mat material is used, for example, for at least a part of a wall and a ceiling, or laid on a foundation portion under a floor. As a result, it absorbs harmful chemical substances and unpleasant odors due to the adsorptive properties of the charcoal mat material, and further shuts off heat exchange with the outside air temperature due to the heat insulation properties, enabling the effects of cooling and heating to be efficiently enjoyed. In addition, the indoor environment can be improved by the humidity control property of the carbon layer, and even in the event of a fire, it is possible to prevent the house from burning out due to the flame retardancy.
[0031]
BEST MODE FOR CARRYING OUT THE INVENTION
Hereinafter, a charcoal mat member 1 and a method 2 for manufacturing a charcoal mat member (hereinafter, simply referred to as “manufacturing method 2”) according to an embodiment of the present invention will be described with reference to FIGS. 1 to 3. Here, FIG. 1 is a partially cutaway perspective view showing a configuration of the charcoal mat member 1 of the present embodiment, FIG. 2 is a flowchart showing a flow of each step in a manufacturing method 2, and FIG. FIG. 4 is an explanatory diagram schematically showing a part of the steps of a method 2.
[0032]
As shown in FIG. 1, the charcoal mat material 1 of the present embodiment is made of coconut fiber C (coconut fiber), which is a fiber obtained from a natural palm that mainly grows in tropical areas, mainly from an acrylic ester copolymer. Using a water-soluble binder component 3, a mat substrate 4 formed into a mat shape and a carbon fine powder 6 dispersed on the substrate surface 5 of the mat substrate 4 are dispersed in the binder component 3 and the like (details will be described later). And a carbon layer 8 composed of carbon fine powder 6 formed on the substrate surface 5 by spraying and drying a carbon paint 7 prepared by mixing. .
[0033]
Here, the carbon paint 7 will be described in more detail. The carbon paint 7 is made by matting carbon fine powder 6 (particle size = about 450 mesh) made of porous Bincho charcoal having excellent adsorption performance and coconut fiber C into a mat. It is composed of a water-soluble binder component 3 made of an acrylate copolymer having the same composition as that used in molding into a shape, and a refractory liquid 9 containing potassium hydroxide, sodium carbonate, metal silicon, and water. ing. Then, the carbon fine powder 6 is charged into the liquid binder component 3 and the refractory liquid 9, respectively, and is stirred by a stirrer (not shown) or the like, so that a viscosity suitable for spray coating described below (here, from 1000). (Prepared between 3000 mPa · s). An example of the composition of each component is shown below. Here, the refractory liquid 9 corresponds to the diluent in the present invention. <Formulation example>
Carbon fine powder 6 28-32% by weight
Binder component 3 58-62% by weight
Refractory liquid 9 3-10% by weight
[0034]
Next, a manufacturing method 2 for manufacturing the charcoal mat member 1 of the present embodiment will be described with reference to FIGS. First, coconut fiber C obtained from a natural palm and constituting the mat base material 4 is immersed in the binder component 3 for a predetermined time (immersion step S1: see FIG. 3A). Thereafter, the coconut fiber C immersed in the liquid binder component 3 is pressed from above and below to form a mat substrate 4 formed into a mat having a predetermined thickness (here, 1 cm) (forming step S2: FIG. 3 (b)). Then, it is inspected whether the mat base material 4 has a preset size (here, 45 cm long × 45 cm wide) (first inspection step S3).
[0035]
On the other hand, in parallel with the immersion step S1 to the first inspection step S3, the preparation of the carbon paint 7 to be applied to the substrate surface 5 of the mat substrate 4 is performed. More specifically, the amounts of the components 3, 6, and 9 are measured in accordance with the above-described mixing example, and the measured components 3, 6, and 9 are put into a stirring tank, and a stirring device (shown in the drawing) is used. (Agitating step S5). Thereby, the carbon paint 7 having a viscosity suitable for spraying is prepared. Here, the compounding measurement step S4 and the stirring step S5 correspond to the carbon paint preparation step in the present invention.
[0036]
Then, the prepared carbon paint 7 is sprayed on the base material surface 5 of the mat base material 4 by the spray device S (see the spraying step S6: FIG. 3 (c)). Since the carbon fine powder 6 contained in the carbon paint 7 has a fine particle size of about 450 mesh as described above, the carbon fine powder 6 is in the spray port SH of the spray device S and in a tube (not shown). It is unlikely to stick to and cause clogging.
[0037]
Then, the carbon paint 7 applied by spraying to the substrate surface 5 of the mat substrate 4 is placed in a drying furnace (not shown) for 30 minutes to 1 hour and dried (drying step S7: FIG. )). Thus, a carbon layer 8 mainly composed of the carbon fine powder 6 is formed on the substrate surface 5. The carbon layer 8 contains a solid substance of the acrylate copolymer contained in the binder component 3 and a substance which does not evaporate by heating, such as metal silicon contained in the refractory liquid 9. Thereafter, a final inspection of the quality is performed to confirm that the carbon layer 8 has not formed unevenly or warped during drying (second inspection step S8), and the production of the carbon mat material 1 is completed. .
[0038]
As described above, the charcoal mat member 1 is manufactured by the above-described manufacturing method 2. Such a carbon mat material 1 has excellent adsorptive properties, humidity control properties, and flame retardancy due to the carbon layer 8 formed on the substrate surface 5. In addition, it has both the heat insulating property and the lightweight property of the mat base material 4. Therefore, in particular, by using the charcoal mat material 1 of the present embodiment for a wall material of a house, a ceiling, a foundation portion under a floor, and the like, it becomes possible to use the material as a material for a house having excellent characteristics described above. . Further, since the carbon layer 8 is formed by spraying the carbon paint 7 on the base material surface 5 of the mat base material 4, the warp is more likely to occur in the drying step S <b> 7 than when the mat base material 4 is immersed in the carbon paint 7. No deformation or deformation occurs. Further, the amount of the fine carbon powder 6 contained in the carbon paint 7 can be reduced. Here, the carbon fine powder 6 is often relatively expensive as compared with the other constituent components, and it is preferable to reduce the amount of the carbon fine powder 6 used as much as possible without deteriorating the above-mentioned characteristics. Therefore, as shown in the present embodiment, a method of spraying and applying the carbon paint 7 on the base material surface 5 is particularly preferable.
[0039]
Next, an example of the characteristics of the charcoal mat member 1 manufactured by the above-described manufacturing method 2 will be described. Here, particularly, the adsorptive property and heat insulating property of the charcoal mat material 1 will be described.
[0040]
<Adsorption>
First, three specimens of this embodiment, A) a charcoal mat material, B) an untreated board material, and C) a blank, are prepared. Here, B) the untreated board material is not sprayed with the carbon paint 7, in other words, it corresponds to the mat base material 4. The test pieces were each cut to a size of 10 cm × 10 cm. Further, C) blank indicates that nothing is put into a desiccator described later.
[0041]
Then, the formalin solution (37%) is diluted 15-fold with distilled water, and 20 μL is injected into a 12-liter desiccator. Then, the test specimens described above were placed in the respective desiccators, and the formaldehyde concentration in the desiccator after 2 hours was measured using a detector tube (91 L, manufactured by Gastec). The results are shown in Table 1 below.
[0042]
[Table 1]

[0043]
As shown in Table 1, the formaldehyde concentration in the desiccator in each of A) the charcoal mat material and B) the untreated board material was higher than that of the blank by the respective samples installed in the desiccator. Decreasing results were obtained. In particular, in the case of A) charcoal mat material, such a tendency of decrease was strongly observed as compared with B) the untreated board material. Thereby, the formaldehyde is adsorbed in the board (inside of the coconut fiber C) by any of A) the charcoal mat material and B) the untreated board material, and in particular, more formaldehyde is absorbed by the carbon layer 8 formed on the surface. Shows that the adsorption of formaldehyde is performed. That is, by forming the carbon layer 8 on the base material surface 5, the amount of adsorption of a chemical substance such as formaldehyde could be remarkably increased, and the adsorbability of the carbon mat material 1 could be exhibited.
[0044]
<Heat insulation>
Next, the heat insulation performance of the charcoal mat member 1 will be described. Here, the thermal conductivity (w / m · K) of the material is generally measured to indicate the heat insulation performance. In the measurement of the thermal conductivity, two carbon mat materials 1 were prepared as samples, and the average of the results of the measurements was obtained to determine the value of the thermal conductivity. Here, the thermal conductivity is measured by using a thermal conductivity measuring device (Model HC-074 manufactured by Eiko Seiki Co., Ltd.) based on a heat flow meter method.
[0045]
First, sample 1 (sample thickness: 0.02718 m) and sample 2 (sample thickness: 0.02894 m) are allowed to stand in a constant temperature / humidity room at 20 ° C.-60% for 5 days until a constant weight is reached. . Thereafter, the measurement is performed using an apparatus for measuring thermal conductivity with the ambient environment temperature set at 18 ° C. At this time, the position on the high temperature side of the thermal conductivity measuring device is set to be horizontal and lower. The measurement results are shown in Table 2 below.
[0046]
[Table 2]

[0047]
As described above, it was shown that the charcoal mat material 1 of the present embodiment had a thermal conductivity of 0.0507 w / m · K in the average value of the samples 1 and 2. Such a value is within a range that can be used as a heat insulating material, whereby the heat insulating property of the charcoal mat material 1 is shown.
[0048]
As described above, the present invention has been described with reference to the preferred embodiments. However, the present invention is not limited to these embodiments, and various improvements can be made without departing from the gist of the present invention as described below. And design changes are possible.
[0049]
That is, in the charcoal mat material 1 and the manufacturing method 2 of the present embodiment, an example of the mixing ratio of the carbon paint 7 is shown, but the present invention is not limited to this. It is possible to appropriately change the mixing ratio according to the thickness of the carbon layer 8 to be formed by spraying and the viscosity suitable for spray coating. In addition, a fireproof liquid 9 containing metal silicon or the like is contained in the carbon paint 7 in order to impart flame retardancy. However, the present invention is not limited to this. For example, the binder component 3 may be diluted with water or the like instead of the refractory liquid 9.
[0050]
Furthermore, in the production method 2, a method in which the mat base material 4 is formed by the coconut fiber C and the binder component 3 and a method in which the preparation of the carbon paint 7 is performed in parallel are shown, but the present invention is not limited to this. These may be performed in a series of flows. Here, the carbon paint 7 may have the dispersed carbon fine powder 6 settled out over time. In such a case, the carbon paint 7 may be stirred again or with a small amount of water or the like (including the refractory liquid 9). By diluting, a state suitable for spraying can be obtained.
[0051]
【The invention's effect】
As described above, the carbon mat material of the present invention has a carbon layer made of fine carbon powder formed on the surface of the mat base material, so that harmful gases such as formaldehyde and odors can be easily adsorbed. In addition, since an aqueous binder is used for forming into a mat, it is particularly suitable for use as a part of a building material such as a house. In addition, when used as a building material, fire resistance is imparted by the refractory liquid, so that even in the event of a fire or the like, the spread of fire can be prevented and the spread of damage can be suppressed. In addition, since it can be manufactured by spraying a carbon paint whose viscosity has been adjusted on the surface of the mat base material, the manufacturing process can be simplified, and the manufacturing cost can be reduced without complicating the manufacturing process.
[Brief description of the drawings]
FIG. 1 is a partially cutaway perspective view showing a configuration of a charcoal mat member of the present embodiment.
FIG. 2 is a flowchart showing a flow of each step in the manufacturing method.
FIG. 3 is an explanatory view schematically showing a part of the steps of the manufacturing method.
[Explanation of symbols]
1 Charcoal mat material
2 Production method (Production method of charcoal mat material)
3 Binder component
4 Mat substrate
5 Base material surface (surface)
6 carbon fine powder
7 Carbon paint
8 carbon layer
9 Refractory liquid (diluent)
C Coconut fiber
S1 immersion process
S2 molding process
S4 Mixing measurement process (carbon paint preparation process)
S5 Stirring process (carbon paint preparation process)
S6 spraying process
S7 Drying process

Claims (5)

Coconut fiber produced from natural palm,
A one-component curable aqueous binder component for forming and processing the coconut fiber into a mat shape,
The coconut fiber and the aqueous binder component, comprising a carbon layer formed by applying a carbon fine powder to the surface of a mat substrate formed in a porous mat shape,
The carbon layer,
The carbon fine powder is dispersed and mixed with the aqueous binder component and the diluent component, and a carbon paint prepared to have a sprayable viscosity is sprayed on the surface of the mat base material, and is formed by drying. A charcoal mat material characterized by the following. The diluent component contained in the carbon paint,
The charcoal mat material according to claim 1, wherein a refractory liquid exhibiting flame retardancy obtained by mixing and reacting potassium hydroxide, sodium carbonate, metal silicon, and water is used. The aqueous binder component,
The charcoal mat material according to claim 1 or 2, wherein the charcoal mat material is configured to include an acrylic ester copolymer. A method for producing a charcoal mat material for producing the charcoal mat material according to any one of claims 1 to 3,
An immersion step in which the coconut fiber is immersed in the one-component aqueous binder component,
By the dipping step, the coconut fiber containing the aqueous binder component therein is press-molded to form a mat base material having a predetermined thickness, and the carbon binder is added to the aqueous binder component and the diluent component. Dispersing and mixing the powder, a carbon paint preparation step of preparing the carbon paint to a sprayable viscosity,
Spraying the carbon paint prepared by the carbon paint preparation step onto the surface of the mat base material, and applying a spray step;
Drying the carbon paint sprayed by the spraying step and applied to the surface of the mat base material to form the carbon layer on the surface of the mat base material. Manufacturing method of charcoal mat material. A method of using a charcoal mat material, comprising using the charcoal mat material according to any one of claims 1 to 3 as a building material.

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