JP2006037066A - Molded product with small environmental load and production process of the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a molded product giving a less load on environments compared to conventional products and with excellent safety and sanitary performances. <P>SOLUTION: The molded product is characterized by using a selected reinforcing material having a small environmental load and a binding material composition containing an entirely new binding agent produced by incorporating sucrose, a metal phosphate and further a lime powder. The product can be produced cheaply as a material without asbestos-problems, sick house disease and carcinogenic problems. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  INDUSTRIAL APPLICABILITY The present invention is a molded product having a small environmental load and excellent mechanical strength and heat insulation, and can be used as a heat insulating material, a heat insulating material and a general structural material.

Conventionally, as a heat insulating material and a heat insulating material, rock wool (inorganic fiber) is used alone or as a thermosetting resin (phenolic resin is used as described in the product catalog of Japan Rock Wool Co., Ltd. The artificial mineral fiber molded body in the form of solid plates or cylinders is used in the industry as boilers, air-conditioning heat insulating materials and heat insulation materials, etc. It is also used as a thermal insulation and sound absorbing effect. In addition, a molded body using a phenol resin as a binder uses paper, cloth, glass fiber or the like as a reinforcing material, and is commercially available as an electrical insulating material or a general structural material.
"Nippon Rock Wool Co., Ltd. General Catalog 03.03.3N"

Further, as described in patents (for example, see Patent Document 1), a molded body in which asbestos fibers (inorganic fibers) are solidified with borate is used as an arc extinguishing material or heat insulating material that requires heat resistance and arc resistance. . However, the use of asbestos fiber has been limited since it was designated as a specific chemical substance in terms of environment and safety and health.
"Patent Document Japanese Patent Publication No.54-7359"

In these conventional molded bodies, a phenolic resin is used as a reinforcing material for a specific chemical substance such as asbestos and a binder. Asbestos has been recognized for environmental hygiene and its use has been limited. On the other hand, the phenol resin contains a formaldehyde component and is considered to cause sick house disease. Recently, there is information that it is a carcinogenic substance, and it has become a hot topic in terms of environmental impact. In the case of synthesizing a phenol resin, formaldehyde is used in a large amount as a raw material, so that it exists in a free form in the resin. In order to remove formaldehyde, a method of burning exhaust gas at the time of forming a molded body, removal by absorption or decomposition with ammonia or a photocatalyst, and the like are performed. Furthermore, each product has a formaldehyde emission category, which is selected according to the application. (For example, see Non-Patent Document 2)
"Japan Standards Association JISA9521 Residential Artificial Mineral Fiber Heat Insulation Molded Product Revised March 20, 2003"

  However, it is almost impossible to completely exclude formaldehyde generated at the time of producing a phenol resin or a molded body using the phenol resin, which is a big problem in terms of the environmental load.

  The present invention selects a reinforcing material with a small environmental load, develops and uses a completely new sucrose as a binder for binding it, and obtains a molded article excellent in health and safety. It is intended to reduce the impact on the environmental load that is a problem of conventional products.

  The invention according to claim 1 has developed and used a binder mainly composed of sucrose, which has an extremely low environmental load. Sucrose has a melting point of 185 ° C. and exhibits thermosetting properties at 230 ° C. or higher. However, since a high molding temperature is required, the production equipment is expensive, and the compact is expensive, which is not preferable. Therefore, it is necessary to lower the curing temperature of sucrose, and as a result of intensive studies, by finding a binder composition (I) in which a metal phosphate is added to sucrose, the curing temperature is significantly lowered, It was confirmed that a strong bonding effect was exhibited even at a low molding temperature. Therefore, it is possible to lower the molding temperature when producing the molded body, and it becomes easy to produce a molded body with low environmental impact and low manufacturing cost. In addition, the effect of improving the heat resistance of the molded product also appeared compared to the case of sucrose alone. The binder composition (I) has a composition ratio in the range of 80 to 95% by weight of sucrose and 5 to 20% by weight of metal phosphate (both are solid content converted values).

  The invention according to claim 2 is to neutralize by further adding lime powder to the binder composition (I) in order to expand the selection range of the reinforcing material, that is, to cope with a reinforcing material such as rock wool which is weak against acid. The binder composition (II) was found. Lime powder is a composition added at a weight ratio of 3.0 to 15% with respect to the metal phosphate (solid content conversion value) in the binder composition, so that the reinforcing material weak against acids and the like is not altered. Enabled.

  The invention according to claim 3 explains the manufacturing method of the molded body. An aqueous solution of the binder composition (I or II) is applied to the reinforcing material to prepare a prepreg. The prepreg is dried to produce a molded substrate. Next, a molded body is produced by heating and press-molding the molded base material laminated to have a desired thickness. The heating temperature is 150 ° C. or higher.

  The invention according to claim 4 describes the reinforcing material used in the present invention. The first condition is that the reinforcing material is a material having a small environmental load. As the inorganic fiber, glass fiber excellent in mechanical strength and relatively inexpensive, and rock wool used as a soil conditioner are suitable. Since organic fibers, such as paper and cotton cloth, are biodegradable and have a low environmental load, they are suitable as the reinforcing material of the present invention.

  Further, the present invention will be described in detail. First, the composition ratio of sucrose and metal phosphate in the binder composition (1) of claim 1 is desirably in the range of 80 to 95% by weight of sucrose and 5 to 20% by weight of metal phosphate. In the case of less than 80% by weight of sucrose (exceeding 20% by weight of metal phosphate), the binding force is controlled by sucrose, so that the binding force is lowered. On the other hand, if sucrose exceeds 95% by weight (less than 5% of metal phosphate), a heating temperature of 230 ° C. or higher is required as it approaches the curing temperature of sucrose alone. (The effect of low-temperature curing by adding metal phosphate is reduced.)

  As the metal phosphate used in the present invention, a first metal phosphate containing a metal such as calcium, magnesium, and aluminum is suitable, and among them, the inexpensive first aluminum phosphate is easy to use.

  In the present invention, the binder composition (II) was also developed and used. This is a composition in which 3 to 15% by weight of lime powder is added to the metal phosphate (solid content converted value) of the binder composition (I). Since the binder composition (I) contains a metal phosphate, the aqueous solution thereof is acidic. For this reason, reinforcing materials such as rock wool are vulnerable to acid, and in extreme cases, the fiber may be destroyed. Therefore, it was necessary to use properly depending on the reinforcing material, and the binder composition (II) was developed. When the content of the lime powder is less than 3% with respect to the contained metal phosphate, it approaches the acidity of the binder composition (I) and is not suitable for rock wool that is weak against acid. On the other hand, when the lime powder exceeds 15% by weight, unreacted lime is present as a precipitate and the added effect is not exhibited. By using the binder composition (II), the selection range of the reinforcing material can be expanded, and it can be used for rock wool without any abnormality.

  The binder composition (I and II) was used as a 50% strength aqueous solution. If the concentration exceeds 50%, the viscosity increases and it becomes difficult to apply to the reinforcing material. When glass fiber (glass paper) is selected as the reinforcing material, the 50% concentration can be used as it is. In the case of a reinforcing material such as rock wool, it can be made into a lightweight molded body with many air layers by diluting to a concentration of 5 to 10% and sprayed with a spray or the like, and is easy to use as a heat insulating material or a heat insulating material.

After producing a prepreg by attaching a binder to the reinforcing material, it is dried at 80 to 110 ° C. to obtain a molded substrate. Next, the molded base materials are stacked so as to have a desired thickness, inserted between hot plates, and heated and pressed to produce a molded body. Rock wool or the like is filled in a mold and heated and pressed. The molding temperature is 150 to 200 ° C., and the pressing force is determined according to the usage of the molded body. For example, when it is desired to obtain a high-strength product using glass fiber or cotton cloth as the reinforcing material, a relatively high pressure of 50 to 100 kg / cm ² is required. Meanwhile moldings such as rock wool contained many air layer, heat insulation, since it is a purpose it is necessary to exert a thermal effect, it is molded in 10g~1kg / cm ² and low pressure.

  In this invention, in order to obtain a molded body having a small environmental load and apply it to a heat insulating material or a heat insulating material, a reinforcing material having a small environmental load is selected and used. Instead of the conventional thermosetting resin (phenolic resin), a binder composition (I) composed of sucrose and metal phosphate, and a binder composition (II) combining lime powder were developed and used. As a result, it has succeeded in obtaining a molded product that is safe in handling and has a low environmental impact, and can provide a product that can be expected to be effective in removing asbestos pollution, eliminating sick house disease, and removing carcinogenic substances. It was.

  Cotton cloth, paper, glass fiber, rock wool, etc., which are safe to handle and have a low environmental impact, were selected as reinforcing materials. In addition, as a new binder that does not contain formaldehyde, such as sick house disease and carcinogenicity as a binder, it has been molded into a molded body bonded with a binder composition to which sucrose and metal phosphate are added, and lime powder. It is the best form.

  By using this molded body as a heat insulating material, a heat insulating material, and further as a cultivation floor, an attempt is made to provide a material with excellent safety that does not cause environmental destruction at a low price.

  Next, the present invention will be described in detail based on examples, but the present invention is not limited to only such examples.

Example 1
Sucrose (Taisugar Co., Ltd., sucrose) and metal phosphate (Taki Chemical Co., Ltd., 50% first aluminum phosphate aqueous solution) were used as raw materials. First, 13.5 kg of a 50% sucrose aqueous solution was prepared. (6750 g of sucrose powder was dissolved in 6750 g of water.) Next, 1500 g of a 50% aqueous solution of first aluminum phosphate was added and dissolved. This binder composition (I) is 90% by weight of sucrose and 10% by weight of metal phosphate in terms of solid content.

  Thirty pieces (48 g) of glass paper (Olivest Co., Ltd. Gravest 75E) cut into 800 mm both vertically and horizontally were prepared as reinforcing materials.

Next, a 50% aqueous solution of the binder composition (I) was applied at a ratio of 480 g to prepare a prepreg. The prepreg was dried with a hot air circulation dryer at 80 to 110 ° C. to prepare a molded substrate. 30 sheets of the molded base material were stacked, and aluminum foil was placed on the upper and lower sides for release, and was further sandwiched between 5 mm thick stainless steel plates and inserted between 160 ° C. hot plates. Immediately after that, a pressing force of 60 kg / cm ² was applied and molding was performed for 30 minutes. Next, the power of the hot platen was turned off, the hot platen was cooled by water cooling, the pressure was reduced to 80 ° C. or lower, and the compact was taken out from the press. The color tone of the molded body was black.

  A test piece was collected from the molded body, and the specific gravity, water absorption rate, and bending strength were measured. The specific gravity was calculated from the weight and dimensions using a specimen having a thickness of 50 mm and a length of 50 mm as a test piece. The bending strength was measured according to JISK6911. The thermal conductivity was measured by the unsteady hot wire method.

Table 1 shows the binder composition, binder concentration, and type of reinforcing material, and Table 2 shows molding conditions and measurement results.
Example 2
The same sucrose and metal phosphate as in Example 1 were used. 14.25 kg of sucrose 50% aqueous solution (sucrose 7125 g, water 7125 g) was prepared. Next, 750 g of 50% aqueous solution of first aluminum phosphate was added as a metal phosphate and dissolved to prepare 15 kg of a binder composition (I). This binder composition (I) is 95% by weight of sucrose and 5% by weight of metal phosphate in terms of solid content.

  Thereafter, a prepreg and a molded substrate were produced in the same manner as in Example 1. Further, a molded body was produced in the same manner as in Example 1. However, the hot platen temperature was 180 ° C. The color tone of the molded body was black.

Table 1 shows the binder composition, binder concentration, and type of reinforcing material, and Table 2 shows molding conditions and measurement results.
Example 3
The same sucrose and metal phosphate as in Example 1 were used. 12 kg of sucrose 50% aqueous solution (6000 g of sucrose, 6000 g of water) was prepared. Next, 3000 g of 50% aqueous solution of first aluminum phosphate was added as a metal phosphate and dissolved to prepare 15 kg of a binder composition (I). This binder composition is 80% by weight of sucrose and 20% by weight of metal phosphate in terms of solid content.

  Thereafter, a prepreg and a molded substrate were produced in the same manner as in Example 1. Further, a molded body was produced in the same manner as in Example 1. However, the hot platen temperature was 150 ° C. The color tone of the molded body was black.

Table 1 shows the binder composition, binder concentration, reinforcement type, and Table 2 shows the molding conditions and measurement results in Example 4.
The same sucrose and metal phosphate as in Example 1 were used. 13.5 kg of sucrose 50% aqueous solution (sucrose 6750 g, water 6750 g) was prepared. Next, 1500 g of a first aluminum phosphate 50% aqueous solution as a metal phosphate was added and dissolved to prepare 15 kg of a binder composition (I). This binder composition is 90% by weight of sucrose and 10% by weight of metal phosphate in terms of solid content. Next, 150 g of lime powder (Omi Mining Co., Ltd., alkali content 60%) was added to 15 kg of the binder composition (I) and mixed with stirring. (The addition amount of lime powder is 20% by weight with respect to the metal phosphate (solid conversion value).) Then, after standing for 12 hours or more, the precipitate is filtered out and the binder composition (II ) Was used.

  Thereafter, in the same manner as in Example 1, a prepreg and a molded substrate were produced to produce a molded body. However, the hot platen temperature was 200 ° C. The color tone of the molded body was black.

Table 1 shows the binder composition, binder concentration, and type of reinforcing material, and Table 2 shows molding conditions and measurement results.
Example 5
The binder composition (II) of Example 4 was diluted to 10% concentration and used. Rock wool (Nipponka Rockwool Co., Ltd., filled cotton) was used as the reinforcing material, and a vertical pressing mold having a width of 150 mm, a length of 150 mm, a height of 120 mm and a thickness of 10 mm was used as the mold. 535 g of rock wool was collected, spread thinly on a cloth sheet, and a 10% aqueous solution was applied by spraying. The total weight after coating was 1471 g, and the coating amount was 1.75 parts by weight with respect to 1 part by weight of rock wool.

  In that state, it is naturally dried, and further dried with a hot air circulating dryer at 80 to 110 ° C., then filled in a mold, molded at a hot platen temperature of 200 ° C. and a pressure of 0.5 kg cm 2 for 30 minutes, and a thickness of 100 mm. A molded body having a width of 150 mm and a length of 150 mm was produced. The color tone was black gray.

Table 1 shows the binder composition, binder concentration, and type of reinforcing material, and Table 2 shows molding conditions and measurement results. However, the bending strength was not measured.
Example 6
The same sucrose and metal phosphate as in Example 1 were used. Next, 15 kg of Example 4 and binder composition (I), that is, 90% by weight of sucrose and 10% by weight of metal phosphate in terms of solid content were prepared. To this, 22.5 g of lime powder (same as in Example 4) was added and stirred. The amount of lime powder added is 3% by weight relative to the metal phosphate (solid content converted value).

  Thereafter, a binder composition (II) was produced in the same manner as in Example 4. The binder composition (II) was diluted to 5% and used. A rock wool (same as in Example 4) was used as the reinforcing material, and a molded body was produced in the same manner as in Example 4 below. The total weight after coating was 1500 g, and the coating amount was 1.80 parts by weight with respect to 1 part by weight of rock wool.

Table 1 shows the binder composition, binder concentration, and type of reinforcing material, and Table 2 shows molding conditions and measurement results. However, the bending strength was not measured.
Example 7
The same binder composition (I) as that in Example 1 was prepared and used. A commercially available bleached cloth (Leader product, 330 mm width, 10 m length, 100% cotton) sold as a reinforcing material was purchased and used. The width was cut to the original width of 1 m and used. The weight of one sheet is 41 g. 82 g of the binder composition (I) was adhered to one reinforcing material to prepare a prepreg. Next, it was dried with a hot air circulation dryer at 80 to 110 ° C. to prepare a molded substrate.

  67 sheets of molded base materials were stacked, and an aluminum foil having a thickness of 12 microns was used for mold release at the top and bottom, and was inserted between 160 ° C. hot plates and pressed. The applied pressure was 30 kgcm2, and heating and pressing were performed for 40 minutes. Thereafter, the hot platen was cooled with water to 80 ° C. or less, and the pressure was released to take out the molded body. The color tone was black.

Table 1 shows the binder composition, binder concentration, and type of reinforcing material, and Table 2 shows molding conditions and measurement results.
Example 8
The same binder composition (I) as that of Example 1 was prepared and diluted to a concentration of 30%.

  Paper (Kokuyo, A4 white file) was used as the reinforcing material. The thickness is 0.5mm, the width is 322mm, the length is 460mm, and the weight of one sheet is 52.6g. A prepreg was prepared by attaching 105 g of 30% strength binder composition (I).

  Next, it was dried with a hot air circulating dryer at 80 to 110 ° C. to prepare a molded substrate. 32 molded base materials were stacked, and a molded body was produced in the same manner as in Example 7 below. However, the applied pressure was 10 kgcm2.

Table 1 shows the binder composition, binder concentration, and type of reinforcing material, and Table 2 shows molding conditions and measurement results.
Comparative Example 1
A 50% concentration composition composed solely of sucrose was used as a binder composition. Thereafter, a molded body was produced in the same manner as in Example 1. However, the heating temperature was set at 250 ° C. because it was not cured at less than 230 ° C.

Table 1 shows the binder composition, binder concentration, and type of reinforcing material, and Table 2 shows molding conditions and measurement results.
Comparative Example 2
The same binder composition (I) as in Example 1 was diluted to 10% and used. The same rock wool as in Example 5 was used as the reinforcing material. Thereafter, a molded body was produced in the same manner as in Example 5.

  Table 1 shows the binder composition, binder concentration, and type of reinforcing material, and Table 2 shows molding conditions and measurement results.

  As is apparent from the results of Tables 1 and 2, the molded product according to the present invention can be obtained having various characteristics by selecting a reinforcing material. For example, glass fiber is suitable when mechanical strength is required, and rock wool is most suitable for heat insulation and heat retention. In addition, paper and cotton cloth may be biodegradable from the constituent materials, and since the environmental load is small, it can be used as a structural material with a low environmental load.

Claims (4)

The binder is a composition comprising sucrose and a metal phosphate, and has a composition ratio of 80 to 95% by weight of sucrose and 5 to 20% by weight of a metal phosphate (both solid values). A molded article characterized by binding a reinforcing material with the composition (I). It is characterized in that the reinforcing material is bound with the binder composition (II) in which 3 to 15% by weight of lime powder is added to the metal phosphate (converted to the solid content) in the binder composition. Molded body. Attaching the binder composition (I and II) to the reinforcing material to produce a prepreg; The process of drying a prepreg and producing a shaping | molding base material. The molded body according to claim 1, wherein the molded substrate is produced by heating and pressing at a temperature of 150 ° C. or higher. 4. The molded article according to claim 1, wherein the reinforcing material is an inorganic fiber or an organic fiber having a small environmental load, and mineral fibers such as glass fiber and rock wool are used as the inorganic fiber, and the organic fiber is paper, cotton cloth, or the like. .