JP2007197870A - 無機繊維質成形体及びその製造方法 - Google Patents
無機繊維質成形体及びその製造方法 Download PDFInfo
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Images
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- Porous Artificial Stone Or Porous Ceramic Products (AREA)
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Abstract
【解決手段】被覆層形成無機繊維(a)及びバインダーを含有し、該被覆層形成無機繊維(a)は、40℃における生理食塩水溶解率が1%以上であることを特徴とする無機繊維質成形体。溶媒に、被覆層形成剤を混合し、次いで、40℃における生理食塩水溶解率が1%以上である無機繊維(b)及びバインダーを混合し、被覆層形成無機繊維(a)を含有するスラリーを得るスラリー製造工程、及び該スラリー中の水を、吸引ろ過し、無機繊維質成形体を得る脱水成形工程を有することを特徴とする無機繊維質成形体の製造方法。
【選択図】なし
Description
C(%)={ろ液量(L)×(a1+a2+a3+a4)×100}/{溶解前の無機繊維の量(mg)×(b1+b2+b3+b4)/100} (1)
D(%)={ろ液量(L)×(e1+e2+e3+e4)×100}/{溶解前の無機繊維の量(mg)×(b1+b2+b3+b4)/100} (2)
該試料2のついても、該試料1に代えて該試料2とする以外は、該試料1と同様の方法で、蒸留水溶解率D(%)を算出する。そして、該試料1の蒸留水溶解率D(%)の値が、該試料2の蒸留水溶解率D(%)の値より小さい場合、すなわち、下記式(3):
該試料1の蒸留水溶解率D(%)<該試料2の蒸留水溶解率D(%) (3)
を満たせば、該被覆層形成無機繊維(a)の表面に該被覆層が形成されていると判断する。
(被覆層形成無機繊維(a)を含有するスラリーの製造)
先ず、水に、被覆層形成剤として、予めトリポリリン酸二水素アルミニウム1.1質量%、酸化珪素0.6質量%、酸化マグネシウム0.1質量%を混合した混合物を加え、被覆層形成剤を含有する混合液を得た。次いで、該混合液に、無機繊維(b)89.3質量%、無機バインダーとしてコロイダルシリカ4.9質量%、有機バインダーとして澱粉2.2質量%及びカチオン性紙力増強剤1.8質量%を加え、更に、スラリー濃度が3質量%となるように、水を加え、攪拌し、スラリーを得た。なお、該被覆層形成剤を含有する混合液に、該無機繊維(b)を混合しても、該スラリーのpHは高くならなかった。
・無機繊維(b):SiO2 75〜80質量%、CaO+MgO 19〜25質量%、Al2O3 1〜3質量%、平均繊維径4μm、平均繊維長5.0mm、40℃における生理食塩水溶解率5.9%
・無機バインダー:30%コロイダルシリカ、「シリカドール30」(日本化学工業社製)、固形分が30%の懸濁液、固形分の平均粒子径15nm、pH10.0
・有機バインダー:澱粉、「ペトロサイズJ」(日澱化学社製)
・有機バインダー:カチオン性紙力増強剤、「ポリストロン311」(荒川化学工業社製)、カチオン性、不揮発分10質量%、pH4.2〜4.8、粘度500〜1500cps
上記のようにして得られたスラリーを、脱水成形し110℃で乾燥することにより、密度250kg/m3の無機繊維質成形体(試料A0とする。)を得た。
上記のようにして得た無機繊維質成形体(試料A0)を、湿度90RH、40℃の室内で、所定の期間保管した後(1ヶ月保管後の試料を試料A1、3ヶ月保管後の試料を試料A3とする。)に、加熱線収縮率及び曲げ強度の測定を行った。その結果を表1に示す。
上記のようにして得られた無機繊維質成形体を、電気炉中1100℃で24時間加熱し、加熱後の無機繊維質成形体の長さを測定する。加熱線収縮率は、加熱前の無機繊維質成形体の長さをXmm、加熱後の長さをYmmとし、次式により求める。
加熱線収縮率(%)={(X−Y)/X}×100
試料A0、A1及びA3の曲げ強度を、3点曲げ強度試験機を用いて、ヘッドスピード10mm/分の速度で荷重を加え、破断荷重を測定し、次式により算出した。
曲げ強度(MPa)={3×最大荷重(N)×下部支点間距離(mm)}/{2×無機繊維質成形体の幅(mm)×(無機繊維質成形体の厚さ(mm))2}
各成分の混合量を表1に示す量とする以外は、実施例1と同様の方法で行った。その結果を表1に示す。
室温下、予め混合したトリポリリン酸二水素アルミニウム2.3質量%、酸化珪素1.3質量%及び酸化マグネシウム0.2質量%を被覆層形成剤として水に添加し攪拌して白濁液を得た。次いで、この白濁液に生体溶解性無機繊維96.2質量%を添加し、スラリー濃度が3質量%となるまで更に水を加え、生体溶解性無機繊維が均一に分散するまで攪拌した。得られたスラリーを孔径0.45μmの濾紙(「DISMIC−25cs」;ADVANTEC社製)で濾過して、濾紙上に固形物を得た。固形物は組成分析の結果、無機繊維の表面にトリポリリン酸アルミニウムが被覆されたものであった。また、トリポリリン酸アルミニウムが被覆された生体溶解性無機繊維の写真を図1に示し、トリポリリン酸アルミニウムによる被覆処理をする前の生体溶解性無機繊維の写真を図2に示すが、図1の写真から、明らかに生体溶解性無機繊維の表面が被覆されていることが判る。このトリポリリン酸アルミニウムが被覆された生体溶解性無機繊維(以下、試料1aとも記載する。)及び被覆処理をする前の生体溶解性繊維(以下試料2aとも記載する。)を前述の生理食塩水溶解率及び蒸留水溶解率の測定方法により、40℃における生理食塩水溶解率及び蒸留水溶解率を求めた。その結果を表2に示す。
Claims (5)
- 被覆層形成無機繊維(a)及びバインダーを含有し、該被覆層形成無機繊維(a)の40℃における生理食塩水溶解率が1%以上であることを特徴とする無機繊維質成形体。
- 前記被覆層形成無機繊維(a)が水に難溶であることを特徴とする請求項1記載の無機繊維質成形体。
- 前記被覆層が、リン酸塩で形成されていることを特徴とする請求項1又は2いずれか1項記載の無機繊維質成形体。
- 前記無機繊維質成形体中のリンの含有量が、酸化物換算で0.1〜10質量%であることを特徴とする請求項3記載の無機繊維質成形体。
- 溶媒に、被覆層形成剤を混合し、次いで、40℃における生理食塩水溶解率が1%以上である無機繊維(b)及びバインダーを混合し、被覆層形成無機繊維(a)を含有するスラリーを得るスラリー製造工程、及び該スラリー中の溶媒を、吸引ろ過し、無機繊維質成形体を得る脱水成形工程を有することを特徴とする無機繊維質成形体の製造方法。
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