JP2010125805A - Heat insulation for building material and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a heat insulation for building material which is almost free from sticky/scattering inorganic fibers and shows excellent acoustic absorption performance and the capability of absorbing condensed water droplets. <P>SOLUTION: A resin sheet 3 and an unwoven fabric 4 composed of a polyester fiber are piled up in that order on the surface which turns out to be a condensation side, during its use, of a mat 2 obtained by mixing 90 to 96 mass% of glass fibers and 4 to 10 mass% of polyester fiber. Further, an organic fiber 4a drawn from the unwoven fabric 4 stretches through a needle trace 3a of the resin sheet 3 and in turn, becomes entangled with the glass fiber 2a of the mat 2, as a result of needle punching process applied from the unwoven fabric 4 side following the lamination. Thus, the condensed water droplets on the unwoven fabric 4 side can be absorbed into the interior of the mat 2 by capillarity of the organic fiber 4a present in the needle trace 3a. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

The present invention relates to a heat insulating material used along with building materials such as a folded-plate roof, a wall material, and a floor material, and a manufacturing method thereof.

The following are known as conventional folded-plate roof heat insulating materials.
Patent Document 1 “Heat-insulating mat for folded plates and heat-insulated folded-plate roof using the same” laminates a thermoplastic film on at least one surface side of the inorganic fiber mat to suppress protrusion and scattering of the inorganic fibers, It is described that a resin fiber nonwoven fabric is entangled and integrated with the other side of the inorganic fiber mat or between the inorganic fiber mat and the thermoplastic film to obtain better heat insulation.
Patent Document 2 “Metal Folded Roof Blanket” includes an inorganic fiber mat and an organic fiber nonwoven fabric that are entangled and reinforced by needle punching to enable roll forming and prevent scattering of inorganic fibers. Further, it is described that a resin coating is formed on the surface of an organic fiber nonwoven fabric to fix the fiber and increase the strength.
In Patent Document 3 “Method for producing glass fiber heat insulating material for folded plate”, a glass fiber mat and an organic fiber non-woven fabric are needle punched, and heat is applied to melt the organic fiber that has jumped out to the surface to melt the opposite surface. It is described that a kind of sowing effect is used by combining with an organic fiber nonwoven fabric and simultaneously crimping through organic fibers in the inner layer portion.
Patent Document 4 “Insulating Material for Metal Roof” has a film attached to one surface of a polyolefin-based foam sheet, and an adhesive layer having a predetermined adhesive strength is provided on the film to obtain sufficient adhesive strength and handleability. It is described.

JP 2008-6695 A JP-A-57-7889 JP-A-1-246453 JP 2008-240346 A

However, the heat insulating mat having the thermoplastic film on the outermost surface as in Patent Document 1 has a high effect of preventing inorganic fibers from scattering, but water droplets condensed and condensed on the thermoplastic film fall indoors or have no holes. There has been a problem that the thermoplastic film may cover the inorganic fiber mat to reduce the sound absorbing effect of the inorganic fiber mat.
Further, as described in Patent Documents 2 and 3, the organic fiber nonwoven fabric and the inorganic fiber mat processed by needle punching may have insufficient effect of preventing protrusion and scattering of the inorganic fiber without the resin coating, and there is a resin coating. And there was a problem that condensed water drops dropped.
In addition, the polyolefin-based foam sheet having a film bonded thereto as in Patent Document 4 has no problem with the protrusion and scattering of inorganic fibers, but has a problem that condensed water drops fall and the sound absorption performance tends to be low. .

  Then, this invention aims at providing the heat insulating material for building materials which not only has few protrusion and scattering of an inorganic fiber, but is excellent in sound absorption performance and can also absorb dew condensation water droplets.

In order to achieve the above object, the present invention employs the following means.
(1) Needle punching process in which a resin sheet and a non-woven fabric mainly made of organic fibers are laminated in this order on the surface on the dew condensation side when a mat mainly made of inorganic fibers is used, and the nonwoven fabric side is applied after the lamination. As a result, the organic fibers drawn from the nonwoven fabric extend through the needle marks of the resin sheet and are intertwined with the inorganic fibers of the mat, and the condensed water on the nonwoven fabric side absorbs water inside the mat due to the capillary phenomenon of the organic fibers present in the needle marks. A heat insulating material for building materials, characterized in that it is possible.
(1-1) The resin sheet is a foam, and the organic fiber present in the needle mark is clamped and held by the restoring force of the needle mark of the foam.
(1-2) A bonding force between organic fibers is increased by attaching a surface sealant to the surface of at least a part of the nonwoven fabric so that the capillary phenomenon is not lost.
(1-3) Either one of the back surface sealing agent and the adhesive layer or both in that order are attached to the back surface of the mat.

(2) When a mat made of inorganic fibers is used, a non-woven fabric is obtained by laminating a resin sheet and a non-woven fabric mainly made of organic fibers in that order on the surface that becomes the dew condensation side, and performing needle punching from the non-woven fabric side after the lamination. The organic fibers drawn out from the resin sheet extend the needle marks on the resin sheet so as to be entangled with the inorganic fibers of the mat, and the condensed water on the nonwoven fabric side can be absorbed inside the mat by the capillary phenomenon of the organic fibers present in the needle marks. The manufacturing method of the heat insulating material for building materials characterized by the above-mentioned.

According to the heat insulating material for building materials of the present invention, the following actions that cannot be obtained in the conventional example can be obtained.
(A) Improvement of sound absorption performance: Through the needle marks on the resin sheet, the sound absorption effect of the mat made of inorganic fibers and the sound absorption effect of the resin sheet are synthesized to improve the sound absorption performance in a wide frequency band. Of course, the nonwoven fabric and the resin sheet can also prevent the inorganic fibers from protruding and scattering.
(B) Absorption of condensed water: Condensed water generated due to temperature difference between the inside and outside of the building and adhering to the non-woven fabric or resin sheet on the surface side is absorbed into the mat by capillary action of organic fibers present in the needle marks. . Therefore, when this building insulation material is used for folded-plate roofs, it can prevent the condensation water droplets from falling indoors, and when it is used for the wall material, it can prevent the condensation water droplets from being transmitted to the floor material. When it is used for, it is possible to prevent condensation water droplets from accumulating on the top. When the temperature difference between the inside and outside of the building decreases, the water absorbed inside the mat is leached to the non-woven fabric side and evaporates due to the same capillary phenomenon.

The aspect of the component in each said means is illustrated below.
(A) Mat The mat is mainly composed of inorganic fibers (preferably more than 90% by mass) and may contain organic components such as organic fibers and organic binders as secondary components.
The kind of the inorganic fiber is not particularly limited, and examples thereof include glass fiber, rock wool fiber, ceramic fiber, silica fiber, alumina fiber, basalt fiber, and metal fiber, but glass fiber is preferable in terms of price and safety. Although the kind of glass fiber is not specifically limited, E glass fiber with the highest versatility is preferable. The glass fiber preferably has an average fiber diameter of 8 to 10 μm and an average fiber length of 48 to 96 mm. In addition to glass yarn, glass roving or glass yarn may be mixed.
It is preferable to mix 4 to 10% by mass of the organic fiber with the inorganic fiber, since the inorganic fiber can be fixed by the organic fiber melted by the post-processing heat treatment and the scattering of the inorganic fiber can be prevented. Although it does not specifically limit as this organic fiber, Olefin type organic fibers, such as polyester, polyethylene, a polypropylene, are preferable.
The mat preferably has a bulk density of 100 kg / m ³ and a thickness of 4 to 12 mm, and more preferably a thickness of 4 to 6 mm.

(B) Nonwoven fabric The nonwoven fabric mainly consists of organic fibers (preferably more than 90% by mass), and may contain inorganic fibers as a secondary component.
The type of organic fiber is not particularly limited, but long fibers of organic fibers made of resins such as polyester, polyethylene, polypropylene, nylon, acrylic, vinylon, rayon, or various copolymers or mixed resins containing these components are used. For example, any of aramid fibers, natural fibers, and polylactic acid fibers may be mixed. Synthetic fibers (organic fibers) mixed with inorganic powder may be used.
The fineness of the organic fiber is preferably 1 to 10 denier, and more preferably 3 to 7 denier. The length of the organic fiber is preferably a continuous long fiber.
Basis weight of the nonwoven fabric is preferably ^{15~40g / m 2, 20~30g / m} 2 is more preferable. When the basis weight is less than 15 g / m ^2, it is difficult to produce a nonwoven fabric, and there is little fiber entanglement, which is not preferable. If the basis weight exceeds 40 g / m ² , it faces the indoor side in terms of fire prevention performance, which is not preferable.

(C) Resin-made sheet The resin-made sheet may be made of non-foamed material or foamed material.
The type of the resin is not particularly limited, but in the case of a non-foamed material, polyester, polyethylene, polypropylene, silicon and the like can be exemplified, and in the case of a foamed material, polyethylene, polyurethane and the like can be exemplified. Any of them has a self-extinguishing property, and a flame-retardant resin sheet in which inorganic powder or an organic flame retardant is mixed is preferable.
The resin sheet is a foam, and the organic fiber present in the needle mark is clamped and held by the restoring force of the needle mark of the foam, so that the bonding between the nonwoven sheet and the resin sheet and the nonwoven sheet and the mat There is an advantage that the bondability becomes strong. In addition, there may be an advantage that the capillary phenomenon is strengthened by narrowing the gap between the organic fibers present in the needle trace, and an advantage that the hole diameter of the needle trace is narrowed so that the inorganic fiber does not protrude and scatter from the needle trace.
10-50 kg / m < ³ > is preferable and the bulk density of a foam is more preferable 20-30 kg / m < ³ >. When the bulk density is less than 10 kg / m ^3, it is not preferable because tearing is likely to occur during needle punching, and the gripping force of the organic fibers sandwiched between the needle marks is weakened. When the bulk density exceeds 50 kg / m ³ , the foaming rate is lowered and the sound absorbing performance is remarkably lowered, which is not preferable.
The thickness of the resin sheet made of non-foamed material is preferably 10 to 50 μm, more preferably 15 to 25 μm because of versatility.
The thickness of the resin sheet made of foam is preferably 1 to 4 mm, and more preferably 1.5 to 3 mm. If the thickness is less than 1 mm, it is difficult to manufacture, and if it exceeds 4 mm, it is not preferable in terms of fire prevention performance.

In the case of construction in a humid environment, it is preferable to use an antifungal agent mixed with a resin sheet or surface-coated.
Moreover, by adjusting the surface resistivity of the foam material to 10 8 to 10 5 Ω / □, it is possible to prevent dust from being attached due to static electricity. To adjust the surface resistivity, an appropriate amount of an inorganic conductive material such as carbon or a polymer conductive agent may be added.
In any case, it is preferable to use materials and additives that do not adversely affect environmental problems and health problems.

(D) Matching needle punching process The number of needles to be driven per unit area of the mat is preferably ³ to 80 / cm ² , and more preferably 5 to 20 / cm ² . When the number of driven-in wires is less than 3 / cm ² , the number of capillarity is reduced and the water absorption is lowered, and when it exceeds 80 / cm ² , the resin sheet is easily damaged.

(E) Surface sealing agent The surface sealing agent is adhered to the surface of at least a part of the nonwoven fabric to such an extent that the capillary action is not lost. Improves durability. When an excessive amount of the surface sealant is attached to the entire surface of the nonwoven fabric, the capillary action is lost. For example, a relatively small amount of the surface sealant is attached to the entire surface of the nonwoven fabric, or When a relatively large amount of the surface filler is attached to the surface of two or more dispersed portions, the capillary phenomenon can be prevented from being lost.
In addition, when the surface sealing agent is impregnated and adhered not only to the surface of the nonwoven fabric but also to the inside, the bonding force between the nonwoven fabric and the resin sheet is also increased.
In order to attach the surface sealant, the polymer emulsion may be applied to the surface of the mat by a roll coater or a spray method. The coating amount is preferably 3 to 10 g / m ^{2 on} one side. If it is too much, it will adversely affect the fireproofing performance, sound absorption and water absorption performance. Examples of the polymer emulsion include a resin (acrylic type) system and a synthetic rubber system.

(F) Adhesive layer and back surface sealant On the back surface of the mat (the surface opposite to the surface that is the dew condensation side when in use), the installer applies an adhesive during construction to make it a building material such as folded roof Although it can be attached, it is preferable that an adhesive layer is provided in advance by a manufacturer of the heat insulating material or the like to save labor for applying the adhesive during construction. As an adhesive layer in the case where an adhesive layer is previously provided on the back surface of the mat, a synthetic rubber-based adhesive (for example, a chloroprene rubber-based adhesive layer) is preferable, or a hot melt adhesive is applied by a roll coat or a spray method, or A mode in which an adhesive film or an adhesive film that can be adhered by heating is bonded can be exemplified. 10-40 g / m < ² > is preferable and, as for the application quantity in the case of apply | coating an adhesive agent on the back surface of a mat, 15-30 g / m < ² > is more preferable. If it is less than 10 g / m ² , when the mat absorbs water, sufficient adhesive strength cannot be obtained, and peeling may occur. If it exceeds 40 g / m ² , the fireproof performance may be adversely affected. Further, by bonding release paper to the surface of the adhesive layer, the adhesive surface can be protected until construction.

  Even if the adhesive layer is not provided, at least the back surface of the mat after needle punching is attached with a back surface sealing agent to prevent the fibers from protruding and scattering during construction, and to eliminate the tingling sensation. It is preferable. Examples of the material for the back surface sealing agent include resin (acrylic type, etc.) type and synthetic rubber type polymer emulsions, which may be applied to the back surface of the mat. Further, the adhesive layer may be provided after a back surface sealing agent is attached to the back surface of the mat.

(Other)
The organic content of the heat insulating material including the organic fiber, the sealing agent, and the adhesive is preferably 200 g / m ² or less in terms of fire prevention performance.

  According to the present invention, there is an excellent effect that it is possible to provide a heat insulating material for building materials that is excellent in sound absorption performance and in which condensed water droplets are difficult to fall into the room, in addition to the few protrusions and scattering of inorganic fibers.

  A foam resin sheet and a non-woven fabric mainly made of organic fibers are laminated in that order on the surface on the dew condensation side when a mat formed by mixing 90 to 96% by weight of glass fibers and 4 to 10% by weight of organic fibers is used. The organic fibers drawn from the nonwoven fabric by needle punching applied from the nonwoven fabric side after the lamination extend the needle marks on the resin sheet and are intertwined with the glass fibers of the mat, and the organic fibers present in the needle marks This is a heat insulating material for building materials in which condensed water on the nonwoven fabric side can be absorbed into the mat by the capillary phenomenon. The surface sealing agent is adhered to the surface of at least a part of the nonwoven fabric to such an extent that the capillary phenomenon is not lost, thereby increasing the bonding force between the organic fibers. A back surface sealing agent and an adhesive layer are adhered to the back surface of the mat in that order. Release paper is attached to the adhesive layer.

  The heat insulating materials for building materials of Examples 1 to 4 and Comparative Examples 1 to 4 shown in Table 1 below were created. Note that the materials, configurations, and numerical values described in the examples are examples and can be changed as appropriate.

As shown in FIG. 1, the heat insulating material 1 for building material of Example 1 has a resin sheet 3 and a non-woven fabric 4 made of organic fibers on the surface that becomes the dew condensation side when the mat 2 made mainly of inorganic fibers is used. The organic fibers 4a drawn from the nonwoven fabric 4 extend through the needle marks 3a of the resin sheet 3 and are intertwined with the inorganic fibers 2a of the mat 2 by the needle punching process performed from the nonwoven fabric 4 side after the lamination. Is. The mat 2 is composed of 94% by mass of E glass fiber having an average fiber diameter of 9 μm and an average fiber length of 75 mm, and 6% by mass of polyester fiber having a fineness of 2 denier and an average fiber length of 38 mm. A wicker mat having a density of 100 kg / m ³ and a thickness of 5 mm was used. As the resin sheet 3, an antistatic film made of non-foamed polyethylene and having a basis weight of 15 g / m ² was used. The nonwoven fabric 4 was made of polyester continuous long fibers having a fineness of 3 denier and having a basis weight of 30 g / m ² .

Then, as shown in the upper side of FIG. 3, the resin sheet 3 and the nonwoven fabric 4 are laminated on the surface of the mat 2 in that order, and after the lamination, the number of driving is about 20 / cm ² by a needle punching machine. By performing needle punching from the nonwoven fabric 4 side, the organic fibers 4a drawn from the nonwoven fabric 4 extend through the needle marks 3a of the resin sheet 3 as described above, and are entangled with the inorganic fibers 2a of the mat 2 to be integrated. It was set as the heat insulating material 1 for building materials. The laminated thickness, laminated weight, and bulk density in Table 1 are values after needle punching.

In Example 2, compared to Example 1, a resin sheet 3 is used as a foam, and a small amount of a surface sealant (not shown) is added to the entire surface of the nonwoven fabric 4 so that the capillary action is not lost. The difference is that the adhesion layer 6 is adhered to the back surface of the mat 2 (indicated by a two-dot chain line in FIG. 1), and the others are common. As the foam resin sheet, a sheet made of polyethylene having a basis weight of 40 g / m ³ and a thickness of 1.5 mm was used. As shown in the lower side of FIG. 3, the surface sealing agent is provided by applying an acrylic resin emulsion to the entire surface of the nonwoven fabric 4 after the needle punching and drying and heat-treating, thereby fixing the organic fibers. It was. The adhesive layer 6 was provided by applying a chloroprene rubber adhesive on the entire back surface of the mat 2 after the needle punching process and performing a dry heat treatment. The laminated thickness, laminated weight, and bulk density in Table 1 are values after drying.

Example 3 is different from Example 2 in that no surface sealant is provided and in that the adhesive layer 6 is not provided, and the others are common.
Example 4 is different from Example 2 in that no surface filler is provided, and the others are common.

Comparative Example 1 is different from Example 1 in that needle punching is not performed, and the others are common.
Comparative Example 2 is different from Example 3 in that needle punching is not performed, and the others are common.
Comparative Example 3 is different from Example 1 in that the resin sheet 3 is omitted and the needle punching process is not performed, and the others are common.
Comparative Example 4 is different from Example 3 in that the mat 2 is omitted and the needle punching process is not performed, and the others are common.

About each heat insulating material for building materials of said Examples 1-4 and Comparative Examples 1-4, the sound absorption performance and the water absorption of the surface side were investigated.
Sound absorption performance was determined by measuring the sound absorption coefficient at each frequency in accordance with a normal incidence sound absorption coefficient measurement method by a pipe method by punching a disc-shaped test piece defined in JIS-A-1405 with a blade. As shown in Table 1, the measurement results in Examples 1 to 4 were significantly higher in normal incident sound absorption at 1000 to 2000 Hz than in Comparative Examples 1 to 4.
The water absorption on the surface side was determined by visually observing whether or not the water droplets absorb water by dropping the water droplets on the nonwoven fabric 4 with a dropper. As the determination results are shown in Table 1, Examples 1 to 4 were good in water absorption. This is because condensed water on the nonwoven fabric side is absorbed into the mat due to capillary action of organic fibers present in the needle marks. On the other hand, Comparative Examples 1, 2, and 4 did not absorb water because the water was blocked by the resin sheet. In Comparative Example 3, since there was no resin sheet, water was absorbed inside the mat.

  Moreover, since the heat insulating material for building materials of Examples 1-4 has two layers of the resin sheet 3 and the nonwoven fabric 4 laminated | stacked on the surface side of the mat 2, there are few protrusions and scattering of the inorganic fiber in the surface side. Furthermore, according to Example 2, since the surface sealing agent is adhered to the surface of the nonwoven fabric 4, the protrusion and scattering of the inorganic fiber on the surface side are further suppressed. Moreover, according to Examples 2 and 4, since the adhesive layer 6 is adhered to the back surface side of the mat 2, the protrusion and scattering of inorganic fibers on the back surface side are small. As a result, there is almost no tingling sensation during construction, and the ambient air is clean.

  The heat insulating materials for building materials of Examples 1 to 4 are used along with building materials such as folded plate roofs, wall materials, and floor materials (in most cases, bonded). For example, as shown in FIG. 2, Examples 2 and 4 are bonded with an adhesive layer 6 to the lower surface, which is the indoor side surface of the folded plate roof 10, and in Examples 1 and 3, the installer is attached to the back surface of the mat during construction. The nonwoven fabric 4 is adhered to the lower side, which is the indoor side and the dew condensation side in use. And the dew condensation water w condensed on the non-woven fabric 4 side during use is absorbed into the mat 2 by the water absorption. A release paper 7 (indicated by a two-dot chain line in FIG. 1) is attached to the adhesive layer 6 before construction, and the release paper 7 is removed during construction.

  The present invention is not limited to the above-described embodiments, and can be appropriately modified and embodied without departing from the spirit of the invention.

It is sectional drawing which shows the Example of the heat insulating material for building materials by this invention. It is sectional drawing when the heat insulating material for building materials is used for a folded-plate roof. It is the schematic which shows the manufacturing method of the heat insulating material for building materials.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Heat insulating material for building materials 2 Mat 2a Inorganic fiber 3 Resin sheet 3a Needle mark 4 Nonwoven fabric 4a Organic fiber 6 Adhesive layer 7 Release paper 10 Folded plate roof

Claims (5)

  When a mat mainly made of inorganic fibers is used, a non-woven fabric is formed by laminating a resin sheet and a nonwoven fabric mainly made of organic fibers in that order on the surface on the dew condensation side, and needle punching applied from the nonwoven fabric side after the lamination. The organic fibers drawn out from the needle traces of the resin sheet extend and entangle with the inorganic fibers of the mat, and the condensed water on the nonwoven fabric side can be absorbed into the mat by the capillary action of the organic fibers present in the needle traces. Thermal insulation for building materials, characterized by   2. The heat insulating material for building material according to claim 1, wherein the resin sheet is a foam, and the organic fiber present in the needle mark is clamped and held by a restoring force of the needle mark of the foam.   The bonding force between organic fibers is increased by attaching a surface sealant to such an extent that the capillary phenomenon is not lost on at least a part of the surface of the nonwoven fabric. Thermal insulation for building materials.   The heat insulating material for building materials according to claim 1, 2 or 3, wherein either one of the back surface sealing agent and the adhesive layer or both of them are adhered to the back surface of the mat.   When a mat made of inorganic fibers is used, a resin sheet and a nonwoven fabric mainly made of organic fibers are laminated in that order on the surface on the dew condensation side, and needle punching is performed from the nonwoven fabric side after the lamination, thereby pulling out the nonwoven fabric. The organic fibers extend through the needle marks of the resin sheet so as to be intertwined with the inorganic fibers of the mat, and the condensed water on the nonwoven fabric side can be absorbed inside the mat by the capillary phenomenon of the organic fibers present in the needle marks. The manufacturing method of the heat insulating material for building materials.

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