JP3008649B2 - Insulated inorganic fiber mat for metal folded plate which prevented scattering of inorganic fiber splash - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a heat-insulating inorganic fiber mat for a folded metal plate which has excellent mechanical strength and prevents scattering of inorganic fiber droplets.

[0002]

2. Description of the Related Art Conventionally, a heat insulating inorganic fiber mat, specifically, a glass fiber mat has been used as a metal plate as a metal folding roof material in a building having a fire-resistant structure because of its incombustibility and heat insulation due to the fine filling of fibers by punching. After that, it is molded into a mountain shape and used.

[0003] These heat-insulating inorganic fiber mats are specifically disclosed in, for example, JP-B-63-57228, in which a laminate of an inorganic fiber mat such as glass fiber and an endless organic fiber non-woven fabric is coated from the organic fiber non-woven fabric side. A blanket for a metal folded roof in which a glass fiber and an organic fiber are entangled by applying a dollar punching process and a flame-retardant coating made of a resin composition is formed on the surface of the organic fiber non-woven fabric has been proposed.
No. 7538 discloses a screen in which glass fibers are mixed with organic fibers and a composite fiber comprising a hot melt adhesive.
There has been proposed a heat-insulating material which is a needle-shaped material, which is subjected to needle punching in the thickness direction, and wherein the composite fiber is thermally bonded to glass fiber and organic fiber or composite fiber by heat treatment.

[0004]

[Problems to be solved by the invention]
The glass fiber heat insulating material described in Japanese Patent No. 57228 discloses a flame-retardant coating formed on the surface of a nonwoven fabric, which increases the frictional resistance, causes wrinkles at the time of folding plate forming, easily breaks a bent portion, and reduces the half of the nonwoven fabric. Since the glass fiber on the opposite side, that is, the glass surface is exposed, a large amount of glass droplets are generated, and during production, the worker feels unpleasant sensation such as flickering and is not good for health. Further, when bonding with a metal plate, a known adhesive such as neoprene or a hot-melt adhesive is used, but these adhesives are not necessarily sufficient in strength, and a problem is that the adhesive strength at high temperatures is reduced. there were.

On the other hand, a heat insulating material in which glass fibers are joined only with a composite fiber composed of an organic fiber and a hot-melt type adhesive disclosed in Japanese Patent Publication No. 63-57538 cannot be combined with the organic fiber and the glass fiber or these three members. Insufficient mechanical strength is inferior, or if the mechanical strength is to be maintained, a large amount of organic components is required, and the non-combustibility of the present mat is impaired. In addition, since this product does not have a surface coating layer such as a non-woven fabric, the surface is in a state where glass fibers are exposed, and there are many occurrences of glass droplets, and there are problems similar to those described above, and there is a problem unfavorable in environmental health. .

[0006] As a method of preventing the scattering of the inorganic fiber droplets at the time of production as in these two examples, a coating layer is formed on the surface of the inorganic fiber mat by spraying an acrylic emulsion adhesive on the inorganic fiber side of the inorganic fiber mat. Methods of preventing scattering, roll-coating a hot-melt adhesive, dispersing a thermoplastic resin powder, heating and melting, and applying pressure to form a resin coating layer have been proposed as means. However, finally, in the step of laminating this product with a galvanized sheet, and in the so-called roll forming step of forming a mountain, an external force such as compression and shear is applied to the inorganic fiber mat, and inorganic fiber droplets are generated. However, although the scattering of inorganic fiber droplets from the surface can be stopped by the above-described method, the scattering of inorganic fiber droplets generated from the cross section during packing, transport, and construction of the product after roll forming cannot be prevented in practice. It was not possible to prevent the unpleasant sensation of Kayumi and the like and the deterioration of environmental hygiene.

SUMMARY OF THE INVENTION The present invention solves the above-mentioned problems, and prevents the generation of inorganic fiber droplets in the manufacturing, processing, and construction steps of the heat-insulating inorganic fiber mat, and the heat-insulating inorganic fibers for folded metal plates, which prevent the scattering of the inorganic fiber droplets. The purpose is to provide a mat.

[0008]

The present invention relates to an inorganic fiber (2).
The organic fiber nonwoven fabric (3) is laminated with the organic fiber nonwoven fabric (3), and the organic fiber (3) is entangled with the inorganic fiber of the inorganic fiber mat (2) by needle punching from the organic fiber nonwoven fabric side to form a mat. A heat-insulated inorganic fiber mat for a folded metal plate, characterized in that a resin layer (4) is provided on a cross section at both ends of the product and a surface layer up to 30 cm from the cross section to prevent scattering of inorganic fiber droplets.

The inorganic fiber mat (2) according to the present invention is preferably a known various glass fiber, for example, a long fiber made by a direct melt method or a marble melt method using an inorganic alkali glass (E glass) as a raw material. 3 ~
15 μm, preferably 5 to 10 μm, and the length is preferably 30 to 150 mm obtained by chopping a long fiber.
In addition, it may be a mixture of rock wool or mineral fiber, or a mixture of glass roving in addition to glass yarn.

The organic fiber nonwoven fabric (3) according to the present invention is a long fiber made of a resin such as polyester, nylon, polyethylene or polypropylene, or various copolymers or mixed resins containing these components, and has a fineness of 1-10.
Denier, preferably 3 to 7 denier, having a length of endless long fiber, the basis weight of which is 15 to 50
g / m ² , preferably 20 to 45 g / m ²
It is. Is insufficient or mechanical strength of the inorganic fiber mat in basis weight of the organic fiber nonwoven fabric is 15 g / m ² or less, since the sealing effect of the splash of the inorganic fibers is significantly reduced undesirable and if it exceeds 50 g / m ² the The provision of the resin layer for preventing the inorganic fiber from being scattered according to the present invention is not preferable because the resin component is increased and the nonflammability of the inorganic fiber mat is adversely affected.

The resin layer provided on the surface of the inorganic fiber mat of the invention according to the present invention may be a thermoplastic resin, for example, a resin such as polyester, nylon, polyethylene, polypropylene or the like or a component thereof. Various copolymers or mixed resins can be exemplified, but preferably a hot melt resin having a melting point of 65 to 110 ° C. and an MI of 10 to 20,000, or a melting point of 8
It is made of a resin having an MI of 3 to 50 and a thickness of 1 to 120 ° C.
A film of 0 to 100 μm, an emulsion resin, or the like is preferable.

In the case of a hot melt resin, the melting point is 65-1.
A difference of 10 ° C. and MI of 10 to 20,000 is preferred.
If the melting point is less than 65 ° C, it is not preferable because the resin layer may cause blocking during storage after being made into a product. On the other hand, if it exceeds 110 ° C, the melting point is high as a hot melt resin, and both ends of the inorganic fiber mat are cross-sectioned. In addition, if the product is not forcibly cooled after being applied to the surface, blocking occurs when the product is rolled up, which is not preferable. Further, since the flowability of the resin having an MI of less than 10 is poor, the coating amount cannot be reduced, and a thick resin layer is formed, which deteriorates the noncombustibility. On the other hand, if the MI exceeds 20,000, on the contrary, the flowability is so good that the retention after forming a resin layer having a uniform thickness is deteriorated and the appearance of the product is impaired. When a film is used for the resin layer, the resin forming the film must have a melting point of 80 to 110 ° C. and an MI of 3 to 50. If the melting point is lower than 80 ° C., it is difficult to produce a thin film. However, when the film is blocked, the flatness is impaired and the end sections and the surface of the inorganic fiber mat are coated, which makes it difficult to form the film uniformly. Unless the temperature is high, it is difficult to adhere when coating and bonding to the surface, which is not preferable. On the other hand, if the MI is less than 3, the flowability of the resin forming the film is poor, so that it is difficult to adhere to the fiber portion of the inorganic fiber mat. As a result, the adhesiveness to the film resin layer is insufficient. The film layer peels off when shearing is applied in the trimming step or the like, and as a result, the scattering of inorganic fiber droplets of the inorganic fiber mat cannot be prevented, which is not preferable. When the MI exceeds 50, the flowability of the resin forming the film is good. Although it is preferable in terms of adhesion with inorganic fibers, it is difficult to maintain the flatness of the resin layer after bonding with the inorganic fibers due to too good flowability, which is not preferable because the appearance of the product is impaired. Also, if the film thickness is 1
If the thickness is less than 0 μm, the inorganic fibers may break through the film layer and the inorganic fibers may be exposed on the surface of the resin layer, which is not preferable. On the other hand, if the thickness exceeds 100 μm, the resin component of the inorganic fiber mat increases and the inorganic fiber mat increases. It is not preferable because the non-combustibility of the resin deteriorates.

When an emulsion resin is used, there is no particular limitation.
Attention must be paid to the solids concentration. If the viscosity is too low, it penetrates into the inside of the inorganic fiber mat and does not remain on the surface layer of the inorganic fiber mat. As a result, the effect of coating the inorganic fiber is lost, which is not preferable. This is not preferable because it becomes difficult to uniformly coat the inorganic fibers with the resin layer. It is appropriate that the viscosity of the emulsion is in the range of 500 to 5000 centipoise and the concentration of the solid content is in the range of about 10 to 40%. As the emulsion, an acrylic resin emulsion, a polyurethane resin emulsion, an ethylene-vinyl acetate resin emulsion and the like are often used.

Next, the structure of the heat insulating inorganic fiber mat for a folded metal plate according to the present invention will be described with reference to the drawings.

FIG. 1 is a longitudinal sectional view of a heat-insulating inorganic fiber mat for a folded metal plate in which scattering of inorganic fibers from the cross section of the inorganic fiber mat of the present invention is prevented.

In FIG. 1, the heat-insulating inorganic fiber mat for a folded metal plate, in which the scattering of inorganic fibers from the cross section of the inorganic fiber mat is prevented, has an inorganic fiber layer 2, an organic fiber non-woven fabric layer 3, and an inorganic fiber mat at both end cross sections. And a thermoplastic resin layer 4 for preventing fiber scattering.

The organic fiber non-woven fabric layer 3 is laminated on one side of the inorganic fiber layer 2 via the resin layer 4, and a part of the fibers 6 penetrate the organic fiber non-woven fabric layer 3 by needle punching to form the inorganic fiber layer 2. The inorganic fiber mat is formed by being entangled with the constituent fibers, and the resin layer 4 is bonded to and integrated with the end cross section and both surface layers adjacent thereto.

Next, one embodiment of the production according to the present invention will be described.

First, the mixing ratio of yarn and roving is 9%.
After fibrillating the glass fiber (2) composed of 0/10 to 60/40, a glass mat having a constant thickness is formed. At this time, 10% by weight of organic fibers made of vinylon or thermoplastic resin
In the following, the glass mat (2) may be mixed and mixed to form a glass mat.

Next, a glass mat is laminated on an endlessly long polyester fiber nonwoven fabric (3) and subjected to needle punching from the polyester fiber nonwoven fabric side to form an inorganic fiber mat, and an adhesive made of an acrylic emulsion is applied to the glass fiber surface. Spraying, introducing this into a hot-air drying oven equipped with a horizontal transfer device and heated to 110 ° C to 140 ° C,
The water in the emulsion is removed and dried, and slit at a predetermined width at the outlet of the hot air drying oven. The slit semi-finished product is kept horizontal, and a hot-melt resin (4) containing an ethylene-vinyl acetate copolymer as a main component is thin-film-coated on a cross section and an adjacent surface layer, and this portion is air-cooled. As a result, a heat insulating inorganic fiber mat (1) for a folded plate, which prevents the inorganic fiber droplets from scattering from the cross section, can be obtained in the form of a continuous sheet.

In the present invention, the particle size is 40 to 500 μm instead of the emulsion adhesive on the side of the inorganic fiber.
Having an acid or carboxyl group or an amino group having a melting point of 85 to 120 ° C. and having a particle size of 40 to 500 μm.
An ethylene-based copolymer and a fine powder of an epoxy-based polymer containing a glycidyl group and having a melting point or softening point of 60 to 120 ° C are evenly dispersed, and further passed through the hot-air drying furnace described above to form an inorganic fiber. An adhesive resin layer may be formed by fusing an adhesive resin on the substrate, or a hot-melt type adhesive may be applied by a roll coating method to impart easy heat fusion. In particular, in the present invention, the same resin components are formed on both end portions or adjacent surface layers, so that the characteristics of the above-mentioned products are not hindered.

Measurement method and evaluation method The measurement method and evaluation method of the characteristic value used in the present invention are as follows.

1. Melting point Perkin-Elmer differential scanning calorimeter DSC-
5 using a 5 mg sample at a heating rate of 20 ° C./min.
After the temperature was raised to 0 ° C. and maintained for 5 minutes, a so-called second run melting curve when cooling at the same speed and raising the temperature again was taken. In the melting curve, the endothermic peak temperature is defined as the melting point. When there are two or more peaks, the melting point is the endothermic peak temperature on the high temperature side.

2. According to the MI JIS K6760 method.

3. Itching of human body due to inorganic fiber droplets a. 10x with the product cross section of the heat-insulating inorganic fiber mat as one side
A 10 cm sample was cut out, and the cross section and surface other than the product cross section were covered with a tape. This sample was beaten several times on black paper, and the weight of the fiber droplets dropped on the paper was measured, and itching was judged according to the following criteria.

Drop of 0.1 g or more: itchiness less than 0.1 g: no itchiness b. 10x of a laminated inorganic fiber mat and metal plate
A 10 cm sample is cut out, and the product section of this sample and the portion excluding the surface resin layer adjacent to the section are tapered.
The coated product was passed three times through a press roll in which the roll interval was adjusted to 50% of the gap of the sample, and the section was coated with tape. Beat this sample several times on black paper,
The weight of the amount of fiber droplets dropped on the paper was measured, and itching was judged according to the following criteria.

3. Dropping 0.5 g or more: There is itching. Less than 0.5 g: No itching. A non-combustible glass mat is cut into 5 × 5 cm from a heat-sealed 0.6 mm zinc-iron plate, put into an electric furnace heated to 500 ° C., and observed for 5 minutes. The flammability is determined based on the combustion state at this time.

Smoke within 5 minutes but does not ignite --- Pass Smoke within 5 minutes --- Fail

[0029]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below based on embodiments.

Example 1 Glass fiber 9 having a diameter of 10 μm and a length of 30 to 100 mm
7% (mixing ratio of yarn and roving: 70/30) and 3% polyester composite fiber (product name: S-10, manufactured by Unitika Ltd.) having a fineness of 3 denier and an average length of 70 mm are mixed. Disintegrate to make a 50mm thick glass fiber mat,
Polyester long-fiber nonwoven fabric with a fineness of 3 denier manufactured by a spunbond method (manufactured by Unitika Ltd .: 904)
05 WTO, a basis weight of 43 g / m ² ) and subjected to needling of 25 stitches / cm ² from a polyester long fiber nonwoven fabric side by a needling machine, and a nonwoven fabric constituent fiber (needle fiber) on the opposite side of the needling surface. ). Next, the melting point was 102 ° C., M
I 20000 g / 10 min, ethylene-ethyl acrylate-acrylic acid copolymer (trade name Lexpol 1 manufactured by Nippon Petrochemical Co., Ltd.) having an average particle size of 160 μm, melting point 9
Ethylene-ethyl acrylate-glycidyl methacrylate copolymer (trade name: Lexpar 6170, manufactured by Nippon Petrochemical Co., Ltd.) having an average particle diameter of 200 μm at 8 ° C., MI of 30 g / 10 min, and a 1: 1 ratio. The mixture mixed at the mixing ratio is sprayed at 20 g / m ² and introduced into a horizontal transfer device provided with a far-infrared heater and a hot-air heating furnace. This heating furnace is heated to 110 to 130 ° C. to melt the adhesive resin on the surface of the glass fiber mat. Thereafter, at the outlet of the drying oven, the adhesive resin melted by nipping with a cooling roll was uniformly spread, cooled, solidified, and slit into a predetermined width. A hot melt resin (JET-MELT # 3765 (Sumitomo 3M Co., Ltd.) was used by using a melt coater equipped with a hot melt extrusion nozzle at the top, bottom, and back in a U-shape up to 50 mm from the slit cross section and the cross section of both adjacent surface layers. (Melting point: 88 ° C, MI5000) with a thickness of 20μ
m, and the hot melt resin layer was air-cooled to be solidified and continuously wound.

The obtained heat-insulating inorganic fiber mat for a folded metal plate, in which the scattering of the inorganic fibers was prevented from scattering, was fused to a colored zinc-iron plate having a thickness of 0.6 mm and a temperature of 110 ° C. This is bent into a mountain shape by roll forming,
An inorganic fiber mat backed folded plate roof was created.

The properties of the resulting heat-insulated inorganic fiber mats for metal folded plates which prevented the scattering of the inorganic fiber splashes and the heat-fused zinc iron sheet / inorganic fiber mats and inorganic fiber mat backed folded plate roof are shown in Table 1. Was.

Comparative Example 1 Glass fiber 9 having a diameter of 10 μm and a length of 30 to 100 mm
7% (mixing ratio of yarn and roving: 70/30) and 3% polyester composite fiber (product name: S-10, manufactured by Unitika Ltd.) having a fineness of 3 denier and an average length of 70 mm are mixed. Disintegrate to make a 50mm thick glass fiber mat,
Polyester long-fiber nonwoven fabric with a fineness of 3 denier manufactured by a spunbond method (manufactured by Unitika Ltd .: 904)
05 WTO, a basis weight of 43 g / m ² ) and subjected to needling of 25 stitches / cm ² from the polyester long fiber nonwoven fabric side by a needling machine, and a nonwoven fabric constituent fiber (needle fiber) is provided on the opposite side of the needling surface. ). Next, an acrylic emulsion resin (solid content: 5%) was evenly sprayed on the glass fiber mat surface so as to have a concentration of 30 g / m ^2, and then introduced into a drying furnace heated to 110 ° C., and dried. It was wound up in a sheet form.

The obtained heat-insulating inorganic fiber mat was coated with a chloroprene-based adhesive (Diabond DC 761 manufactured by Nogawa Chemical Co., Ltd.) so as to have a solid content of 42 g / m ^2. Then, it was bent and formed into a mountain shape by roll forming in the same manner as in the example to form an inorganic fiber mat backed folded plate roof. The properties of the obtained heat-insulating inorganic fiber mat, heat-fused zinc iron sheet / inorganic fiber mat and inorganic fiber mat-backed folded plate roof are shown in Table 1.

[0035]

[Table 1] As shown in Table 1, the heat-insulated inorganic fiber mat for a folded metal plate according to the present invention, in which the scattering of inorganic fiber droplets was prevented, was provided with a resin layer for preventing the scattering of inorganic fiber droplets up to the cross section of the inorganic fiber mat. In addition to preventing the scattering of inorganic fiber droplets generated at the time, etc., the scattering of inorganic fiber droplets generated in a processing process such as bending into a mountain shape by roll forming, and the inorganic fiber droplets particularly generated from a cross section in the length direction. A remarkable effect was observed in the prevention of scattering, and workability (flicker) and environmental pollution were greatly improved.

On the other hand, the comparative example is based on a conventionally known method, and it is difficult to suppress the detachment of the glass fiber from the mat surface, and it is not possible to suppress the scattering of inorganic fiber droplets from the cross section. In addition, it is difficult to prevent the scattering of glass fiber droplets in the step of bonding with a galvanized iron sheet and the step of forming a galvanized sheet / inorganic fiber mat by roll forming in the same manner as in the embodiment. It was an unsatisfactory product that could not prevent the scattering of glass fiber droplets from the cross section at all.

[0037]

The heat-insulating inorganic fiber mat for a folded metal plate, in which the inorganic fiber mat thus obtained is prevented from scattering inorganic fiber splashes, has a cross section at both ends of the inorganic fiber mat and an adjacent surface layer 30.
cm, the resin layer to prevent the scattering of inorganic fiber droplets, the shear applied during the production of the folded sheet mountain-formed product when bonding with the metal plate or the laminated product, as well as during production, Since there is no scattering of inorganic fiber droplets from both end cross-sections generated by external force such as compression and tension, the discomfort of a tingling sensation is eliminated. Conventionally, various problems due to the scattering of inorganic fibers, which were the drawbacks of the products of this system, have been solved at once, so that the commercial value as a non-combustible heat insulating material has been greatly improved, and it is suitably used for heat-insulated metal folded plate roof applications. . Specifically, it is used for parts such as various gymnasiums, warehouses, and houses where non-combustible materials based on the Building Standard Law must be used.

[Brief description of the drawings]

FIG. 1 shows a cross section of a heat-insulating inorganic fiber mat for metal half folding of the present invention provided with an inorganic fiber layer, an organic fiber nonwoven fabric layer, and a resin layer.

[Explanation of symbols]

 1: Heat-insulating inorganic fiber mat for metal half-finish 2: Inorganic fiber layer 3: Organic fiber nonwoven fabric layer 4: Resin layer 5: Surface treatment layer or heat-fusible resin layer 6: Entangled nonwoven fabric fiber

Claims (4)

(57) [Claims] A heat insulating inorganic fiber comprising an organic fiber nonwoven fabric and an inorganic fiber, wherein an organic fiber nonwoven fabric and an inorganic fiber mat are overlapped and punched from the organic fiber nonwoven fabric side, and the inorganic fiber is entangled with the organic fiber nonwoven fabric to form a mat. On the mat
30 cm from both ends and cross section of heat-insulating inorganic fiber mat
A heat-insulated inorganic fiber mat for a folded metal plate, characterized in that scattering of inorganic fiber splashes having a resin layer on the surface layer of the above is prevented. 2. The resin layer according to claim 1, wherein the resin layer has a melting point of 65 to 65.
A heat-insulated inorganic fiber mat for a folded metal plate, which is a hot melt resin having an MI of 110 ° C and a MI of 10 to 20,000, wherein the inorganic fiber splash is prevented from scattering. 3. The method according to claim 1, wherein the resin layer has a melting point of 80 to 1.
20 ° C, made of resin with MI of 3 to 50 and thickness of 10 to 1
A heat-insulated inorganic fiber mat for a folded metal plate, which is a film having a thickness of 00 μm and which prevents scattering of inorganic fiber droplets. 4. A heat-insulating inorganic fiber mat for a folded metal plate according to claim 1, wherein the resin layer comprises a coating using an emulsion resin.