JP3949142B2 - Aqueous binder for inorganic fiber and heat insulating sound absorbing material for inorganic fiber - Google Patents

Description

  The present invention relates to a water-based binder for inorganic fibers used for heat insulating materials and sound-absorbing materials, for example, for detached houses and building buildings. More specifically, the present invention relates to a water-based binder for inorganic fibers that provides excellent water repellency over a long period of time. The present invention relates to an inorganic fiber heat insulating sound absorbing material using the same.

  Conventionally, an aggregate of inorganic fibers has a high porosity and is further divided into fine spaces by the single fibers, making it difficult for the air contained in the aggregate to move, so houses, buildings, soundproof walls, cooling towers. It is widely used as a heat insulating material or a sound absorbing material in outdoor installation equipment and the like.

  However, if water from rainwater or condensation is absorbed into the aggregate of inorganic fibers, not only the heat insulation and sound absorption performance will deteriorate, but also the corrosion of metal parts that come into contact with the aggregate of inorganic fibers will occur. May be invited. Therefore, an aggregate of inorganic fibers that may come into contact with water is required to have as low a water absorption as possible and a high water repellency.

  In order to increase the water repellency of inorganic fibers, a lot of mineral oil emulsions have been used so far. However, as the above requirements are increased, materials having higher water repellency have been proposed.

  For example, Patent Document 1 below discloses the use of various organopolysiloxanes as a treatment agent that improves the water repellency of inorganic fibers.

Moreover, the following patent document 2 discloses a hydrophobized resin composition of glass fiber for heat insulating material containing metal soap as an active ingredient.
Japanese Patent No. 2863585 Japanese Patent Laid-Open No. 5-330861

  However, in order to add the water repellent used in the above prior art to the binder for inorganic fibers, it is necessary to disperse in water in advance. For this reason, nonionic or anionic surfactants are used in combination with water repellents to disperse and emulsify in water, but these surfactants remain in the cured inorganic fiber binder. In addition, it has a drawback that it is easy to absorb water. Therefore, even when a water repellent is added, there is a case where the water absorption of the surfactant is offset and there is a limit in improving the water repellency of the inorganic fiber heat-absorbing sound absorbing material.

  In addition, water repellents using mineral oil or organopolysiloxanes are liquid at room temperature, and some of the water repellents may be washed away from the surface of the inorganic fibers over time, thereby Has a problem that the water repellency is lowered.

  Furthermore, in order to improve the water repellency of the inorganic fiber heat-absorbing sound-absorbing material, if it contains a large amount of mineral oil or organopolysiloxane, stickiness tends to occur, resulting in poor workability during construction and cost. However, it is not preferable because it is expensive.

  Therefore, the objective of this invention is providing the binder for inorganic fibers which can provide the outstanding water repellency over a long period of time, and the inorganic fiber heat insulation sound-absorbing material using the same.

In order to achieve the above object, the aqueous binder for inorganic fibers of the present invention is an aqueous binder for inorganic fibers containing a thermosetting resin precursor dissolved or dispersed in water and a water repellent emulsion, water repellent emulsion, characterized by containing a dispersant comprising a water-soluble polycarboxylic acid resin, a water-repellent agent comprising at least one selected from wax.

According to the above invention, since a nonionic or anionic surfactant is not used, a sufficient water repellent effect can be obtained even with a small addition amount without offsetting the effect of the water repellent. Further, wax, yet solid at room temperature, during the heating for curing the thermosetting resin precursor, so a relatively low viscosity liquids, wax during the binder curing the inorganic fiber surface to flow Is coated and solidified when cooled, and adheres to the surface of the inorganic fiber, so that it is possible to maintain long-term water repellency.

In the aqueous binder for inorganic fibers of the present invention, the water repellent is preferably a mixture of at least one selected from waxes and one selected from heavy oils.

According to this, when the binder is applied to the inorganic fiber and cured by heating, the wax melts and covers the surface of the inorganic fiber, but when a relatively high melting point wax is used, the surface of the inorganic fiber of the wax Inconsistency of the coating state of the inorganic fiber may result in variations in the water repellency of the inorganic fiber heat-absorbing sound-absorbing material. By using heavy oil as the wax plasticizer, variations in the coating state of the inorganic fiber surface can be reduced. In addition, stable water repellency can be obtained.

  In the water-based binder for inorganic fibers of the present invention, the thermosetting resin precursor and the water repellent are used in the water repellent 0 with respect to 100 parts by mass of the thermosetting resin precursor in terms of solid content. It is preferable to contain so that it may become 1-10 mass parts.

  By setting the amount ratio of the water repellent to the thermosetting resin precursor within the above range, the inorganic fiber heat insulating sound absorbing material can be provided with sufficient water repellency, and the stability of the binder is not impaired. .

  Furthermore, in the aqueous binder for inorganic fibers of the present invention, the thermosetting resin precursor is an aldehyde condensable resin precursor, a mixture of a polyol and a polycarboxylic acid resin, and an epoxy resin and a polycarboxylic acid resin. It is preferably at least one selected from the group consisting of these mixtures.

  According to this, since the thermosetting resin precursor shown above undergoes a curing reaction with the water-soluble polycarboxylic acid resin that is the dispersant of the water repellent emulsion, it does not adversely affect the water repellency. .

  On the other hand, the heat insulating sound absorbing material for inorganic fibers according to the present invention provides the inorganic fiber aqueous binder to the inorganic fiber immediately after fiberization, deposits the inorganic fiber to which the inorganic fiber aqueous binder adheres, and then heat cures. It is obtained by molding.

  According to the said invention, there is no stickiness of the inorganic fiber surface and it can maintain favorable water repellency over a long period of time.

  The aqueous binder for inorganic fibers according to the present invention includes a dispersant made of a water-soluble polycarboxylic acid resin and a wax as a water repellent, thereby imparting sufficient water repellency to the inorganic fiber heat insulating sound absorbing material. Can do. Moreover, since the inorganic fiber heat insulating sound absorbing material of the present invention using the binder has excellent water repellency, even if it is exposed to rainwater or condensed water, the heat insulating and sound absorbing performance does not deteriorate over a long period of time. It can solve the problem of corrosion of metal parts in contact with wood and decay of wood, and can be suitably used as a heat insulating material or a sound absorbing material for a house, a building, a soundproof wall, a cooling tower, an outdoor installation device, or the like.

Hereinafter, the present invention will be described in detail.
The aqueous binder for inorganic fibers of the present invention contains a thermosetting resin precursor dissolved or dispersed in water and a water repellent emulsion.

First, the thermosetting resin precursor will be described.
The thermosetting resin precursor used in the present invention may be anything as long as it can be applied to the production of an inorganic fiber heat-absorbing sound-absorbing material, but what cures in a short time impairs productivity. It is preferable because it is not.

  Examples of the thermosetting resin precursor include aldehyde condensable thermosetting resin precursors such as a resol type phenol resin, a melamine resin, a urea resin, and a furan resin, or, for example, in JP-A-6-184285. Some polyols such as ethylene glycol, glycerin, pentaerythritol, trimethylolpropane, sorbitol, glycolose, 1,4-hexanediol, diethanolamine, triethanolamine, methacrylic acid, acrylic acid, crotonic acid, fumaric Ethylenic acid such as acid, maleic acid, 2-methylmaleic acid, itaconic acid, 2-methylitaconic acid, α-β-methyleneglutaric acid, monoalkyl maleate, monoalkyl fumarate, maleic anhydride, and acrylic anhydride A polymer containing any of the saturated carboxylic acids Mixtures of recarboxylic acid resins, and mixtures of epoxy resins such as bisphenol A diglycidyl ether, bisphenol F diglycidyl ether, novolak phenol polyglycidyl ether and the above polycarboxylic acid resins, as disclosed in WO 2004-085729 Is mentioned.

  Here, the precursor in the present invention means an original compound that forms a resin by a reaction by heating. In this case, the ratio of monomers, dimers, etc. contained in each resin precursor, the number of functional groups per monomer, or the molecular weight of each component is not particularly limited.

  In the manufacturing process of a general inorganic fiber heat-absorbing sound-absorbing material, a binder is often applied in an atmosphere of 200 ° C. or more immediately after melting an inorganic raw material for fibers and fiberizing by a centrifugal method, etc. Including a flammable solvent may cause a fire. Therefore, the thermosetting resin precursor used is dissolved or dispersed in water.

Next, the water repellent emulsion will be described.
The water repellent emulsion of the present invention contains at least a water repellent, a dispersant, and water , and does not contain a nonionic surfactant and a cationic surfactant.
The waxes used in the water repellent of the present invention are not strictly defined, but refer to those that are solid at room temperature but become liquid with relatively high fluidity when heated to about 40 ° C. or higher.

  Examples of the waxes include animal waxes such as beeswax, lanolin wax and shellac wax, plant waxes such as carnauba wax, wood wax, rice wax and candelilla wax, mineral waxes such as montan wax and ozokerite, paraffin wax. And synthetic waxes such as petroleum waxes such as microcrystalline wax, Fischer-Tropsch wax, polyethylene wax, polypropylene wax, polycarbonate wax, palm oil fatty acid ester, beef tallow fatty acid ester, stearamide, dipeptadecyl ketone and hardened castor oil. Can be mentioned. In this case, the waxes may be used alone or in combination of two or more.

  Among these, paraffin wax, polyethylene wax, and polypropylene wax are more preferable in terms of economy.

Generally, the above waxes are hydrophobic materials, and when added to an aqueous binder, it is necessary to disperse or emulsify in water in advance to improve miscibility.
In the present invention, a water-soluble polycarboxylic acid resin is used as a dispersant for the above waxes in water. The water-soluble polycarboxylic acid resin in this case is a resin having an acid value of 50 mgKOH / g or more, preferably 80 mgKOH / g or more, neutralized with ammonia, amines, or alkali metals, and water-soluble at pH 7 or more. It refers to what has become. If the acid value of the water-soluble polycarboxylic acid-based resin is less than 50 mgKOH / g, the solubility of the resin in water may be reduced, and the dispersibility of the water-repellent agent such as waxes in water may be reduced. .

  Examples of the polycarboxylic acid resin used as the dispersant in the present invention include acrylic acid, methacrylic acid, crotonic acid, fumaric acid, maleic acid, 2-methylmaleic acid, itaconic acid, 2-methylitaconic acid, β A resin obtained by polymerizing an ethylenically unsaturated carboxylic acid such as (meth) acryloyloxyethyl hydrogen succinate, and the ethylenically unsaturated carboxylic acid and methyl, ethyl, propyl, butyl, pentyl, hexyl, peptyl, octyl, Examples thereof include resins obtained by polymerization using (meth) acrylic acid esters such as nonyl and decyl and one or several ethylenically unsaturated monomers of styrene.

  Further, the amount ratio of the ethylenically unsaturated carboxylic acid and the ethylenically unsaturated monomer is not particularly limited, but as described above, by neutralizing with ammonia, amines, or alkali metal, As long as it is soluble in water, it can be used as a dispersant for the water repellent of the present invention.

  As the dispersion / emulsifier for waxes, α-olefin sulfonate, alkylbenzene sulfonate, paraffin sulfonate, α-sulfo fatty acid ester salt, dioctyl sulfosuccinate ester salt, alkyl sulfate ester salt are generally used. Anionic surfactants such as polyoxyethylene alkyl sulfate salts and nonionic surfactants such as polyoxyethylene alkyl ether, polyoxyethylene alkyl phenyl ether, and polyoxyethylene polyoxypropylene block copolymers are used. Yes. However, as described above, when the surfactant remains in the cured binder, the hydrophilic portion in the surfactant makes the cured binder easy to absorb water, and the desired water repellent performance may not be obtained. is there. Therefore, in order to impart high water repellency to the inorganic fiber heat insulating sound absorbing material, it is necessary to add a large amount of water repellent emulsion to the aqueous binder for inorganic fibers, which is not preferable in terms of economy. In some cases, stability such as separation in an aqueous binder may be impaired.

  On the other hand, since the water-soluble polycarboxylic acid resin dispersant used in the present invention undergoes a curing reaction with any of the above thermosetting resin precursors, conventional anionic or nonionic surfactants are used. Does not have such an unfavorable effect as described above.

  For the above reasons, it is not necessary to limit the mass ratio of the dispersant to the water repellent in the water repellent emulsion, but preferably the polycarboxylic acid type is used with respect to 100 parts by mass of the water repellent wax. The resin dispersant is preferably 10 parts by mass or less, and more preferably 5 parts by mass or less.

  When the amount of the dispersant used exceeds 10 parts by mass, the ratio of the water repellent in the water repellent emulsion decreases, so in order to obtain the desired water repellency, the water repellent to the aqueous binder for inorganic fibers. Since addition of an emulsion increases and it may impair economic efficiency, it is not preferable.

In the present invention, as the water repellent, it is preferable to use a mixture of at least one selected from waxes and at least one selected from heavy oils.
The heavy oils have a chemical structure relatively similar to waxes and have high fluidity, and thus act as a plasticizer for waxes. When heating to cure the aqueous binder, the fluidity of the waxes can be increased, and the water repellent can be applied evenly on the surface of the inorganic fibers, reducing the variation in water repellency of the inorganic fiber heat-absorbing sound absorbing material. It becomes possible.

The heavy oils used in the present invention refer to those composed of paraffin or naphthene, which is an aliphatic hydrocarbon having approximately 15 to 120 carbon atoms. Heavy oils are classified according to kinematic viscosity, and those having a viscosity grade (hereinafter referred to as VG) of 320 mm ² / s to 680 mm ² / s can be preferably used in the present invention. . In heavy oils having a relatively low kinematic viscosity, for example, VG of less than 320 mm ² / s, the number of carbon atoms is 30 or less, in particular, the number of carbon atoms is 20 or less, and volatilizes during heating during binder curing. It becomes easy to do. On the other hand, when the kinematic viscosity is high, for example, VG exceeds 680 mm ² / s, it takes time to mix with the dispersant when emulsifying, and productivity may be impaired. In the present invention, it is more preferable to use heavy oils having a VG of 360 mm ² / s to 430 mm ² / s.

  Although there is no restriction | limiting in particular in the mass ratio of the waxes and heavy oils in the water repellent used by this invention, It is preferable that they are waxes: heavy oils = 40: 60-95: 5.

  If the ratio of heavy oils in the water repellent exceeds 60% by mass, the fluidity of the water repellent increases at room temperature. Aqueous properties may be reduced. On the other hand, when the ratio of heavy oils is less than 5% by mass, when using high melting point waxes, the plasticizing effect of the waxes is reduced, and the water repellency of the resulting inorganic fiber heat insulating sound absorbing material varies. May occur. Therefore, it is more preferable that the use ratio of the heavy oils is appropriately adjusted in accordance with the melting point of the waxes used or the desired water repellency.

  In the aqueous binder for inorganic fibers of the present invention, the water repellent is preferably 0.1 to 10 parts by mass, more preferably 0.5 to 5 parts by mass with respect to 100 parts by mass of the thermosetting resin precursor. Especially preferably, it contains 1 to 5 parts by mass.

  If the content of the water repellent is less than 0.1 parts by mass, sufficient water repellency cannot be imparted to the resulting inorganic fiber heat-absorbing sound-absorbing material. Further, even if the content of the water repellent exceeds 10 parts by mass, it is not preferable because the water repellency is not improved in proportion to the increase in the content, which is uneconomical.

  Moreover, in the aqueous | water-based binder for inorganic fibers of this invention, you may add a silane coupling agent, a dustproof agent, a hardening accelerator, a coloring agent, etc. as needed.

  Examples of silane coupling agents include aminosilane coupling agents such as γ- (2-aminoethyl) aminopropyltrimethoxysilane and γ- (2-aminoethyl) aminopropylmethyldimethoxysilane, and γ-glycidoxypropyltrimethoxysilane. And epoxy silane coupling agents such as γ-glycidoxypropylmethyldimethoxysilane, and the like, and are mainly used for enhancing the adhesion between the binder and the inorganic fibers.

  Examples of the curing accelerator include sodium sulfate, ammonium sulfate, dodecylbenzenesulfonic acid, p-toluenesulfonic acid and the like.

  The aqueous binder for inorganic fibers is preferably adjusted so that the solid content is 5 to 40% by mass. Under the present circumstances, the aqueous | water-based binder for inorganic fibers of this invention can be obtained by mix | blending using tanks with stirrers, such as a dissolver.

  Next, the inorganic fiber heat insulating sound-absorbing material of the present invention obtained by using the above-mentioned aqueous binder for inorganic fibers will be described.

  In producing the inorganic fiber heat insulating sound absorbing material of the present invention, first, the molten inorganic raw material is fiberized with a fiberizing apparatus, and immediately after that, the above-mentioned aqueous binder for inorganic fibers is applied to the inorganic fibers. Next, the inorganic fiber to which the aqueous binder for inorganic fibers is applied is deposited on a perforated conveyor to form a bulky inorganic fiber heat insulating material intermediate, and the upper and lower sides are spaced so as to have a desired thickness. It feeds into a pair of perforated conveyors etc., it heats, narrowing, and hardens the aqueous | water-based binder for inorganic fibers, and forms an inorganic fiber heat insulation sound-absorbing material. Next, a skin material or the like is coated as necessary, and the inorganic fiber heat insulating sound absorbing material is cut into a desired width and length to obtain a product. Hereinafter, each step will be described.

First, the inorganic fiber used in the present invention is not particularly limited, and glass wool, rock wool, and the like that are used in ordinary heat-absorbing sound-absorbing materials can be used. Various methods such as a flame method, a blow-off method, and a centrifugal method (also referred to as a rotary method) can be used as a method for forming inorganic fibers. In particular, when the inorganic fiber is glass wool, the centrifugal method is preferably used. In addition, the density of the target inorganic fiber heat-insulating material may be a density used in ordinary heat-insulating materials and sound-absorbing materials, and is preferably in the range of 5 to 300 kg / m ³ .

  Next, in order to impart a binder to the inorganic fiber, it can be applied and sprayed using a spray device or the like. Adjustment of the application amount of the aqueous binder for inorganic fibers can be adjusted in the same manner as a conventional binder not containing a water repellent. The amount of the binder applied varies depending on the density and use of the inorganic fiber heat-absorbing sound absorbing material, but is preferably in the range of 0.5 to 15% by mass in terms of solid content based on the mass of the inorganic fiber heat-absorbing sound absorbing material to which the binder is applied. The range of 5-9 mass% is more preferable.

  The timing of applying the aqueous binder to the inorganic fiber sound-absorbing heat insulating material may be any time as long as it is after fiberization, but it is preferable to apply it immediately after fiberization for efficient application. The water repellent emulsion may be applied to the inorganic fiber as an aqueous binder mixed with the thermosetting resin precursor, and the water repellent emulsion is separately added before and after applying the aqueous binder not containing the water repellent emulsion. You may give to a fiber.

  Thus, sufficient water repellency can be provided to the inorganic fiber heat-absorbing sound-absorbing material by providing the inorganic fiber with the aqueous binder for inorganic fibers obtained by the present invention.

  The inorganic fiber to which the binder is applied by the above process is deposited on the perforated conveyor to form a bulky inorganic fiber intermediate. Here, when depositing on the perforated conveyor, it is more preferable to suck with a suction device from the opposite side of the perforated conveyor on which the inorganic fibers are deposited. After that, the inorganic fiber intermediate that continuously moves on the perforated conveyor is sent to a pair of upper and lower perforated conveyors and the like that are spaced so as to have a desired thickness, and at the same time, heated hot air is used as a binder. The thermosetting resin precursor contained is cured to form an inorganic fiber heat-absorbing sound-absorbing material into a mat shape, and then cut into desired widths and lengths.

  The temperature at which the thermosetting resin precursor contained in the binder is cured is not particularly limited, but can be the same as in the case of applying a binder that does not contain a conventional water repellent, at 200 to 350 ° C. Good. Moreover, heating time is suitably performed in 30 second-10 minutes according to the density and thickness of an inorganic fiber heat-insulating sound-absorbing material.

  The inorganic fiber heat-absorbing sound-absorbing material of the present invention may be used as it is, or may be used after being covered with a skin material. As the skin material, paper, synthetic resin film, metal foil film, non-woven fabric, woven fabric, or a combination thereof can be used. Note that it is preferable to use a material having a low water absorption and water repellency as the skin material.

  The thus obtained inorganic fiber heat insulating sound absorbing material of the present invention does not accumulate moisture in the heat insulating sound absorbing material even when exposed to rainwater or condensed water, so that the heat insulating and sound absorbing performance is deteriorated over a long period of time. Without problems, it is possible to solve the problems of mold generation, corrosion of metal parts in contact, and decay of wood.

  Furthermore, the hydrophobic part of the water repellent agent present on the contact surface between the inorganic fiber heat insulating sound absorbing material and the perforated conveyor improves the releasability of the inorganic fiber heat insulating sound absorbing material relative to the perforated conveyor, so troubles during manufacture can be avoided. Decrease.

  Hereinafter, the present invention will be described in more detail by way of examples. In the following description, “part” and “%” are based on mass unless otherwise specified.

[Formation of water repellent emulsion]
Formulation 1
To 100 parts of a paraffin wax having a melting point of 55 ° C. melted at 60 ° C., 20 parts of a styrene-maleic acid copolymer having a solid content of 25% and an acid value of 200 mg KOH / g, neutralized with ammonia and added to water. Mix well. Further, 150 parts of water is gradually dropped while stirring is continued. The obtained emulsion was further dispersed with a high-pressure homogenizer to obtain an emulsion having a solid content of 38.9% (wax content: 37%).

  In addition, the said paraffin wax corresponds to 130P (melting | fusing point 54.4 degreeC or more and less than 57.2 degreeC) of the paraffin wax prescribed | regulated to JISK2235.

Formulation 2
7 parts of methyl acrylate-styrene-maleic acid copolymer having an acid value of 350 mgKOH / g is added to 100 parts of polyethylene wax having a melting point of 110 ° C., and dissolved at 120 ° C. and mixed well. Subsequently, 3 parts of methyldiethanolamine and 165 parts of water are added and pressurized in an autoclave and stirred and mixed at 120 ° C. This mixture was treated with a high-pressure homogenizer to obtain an emulsion having a solid content of 39.8% (wax content 36.4%).

Formulation 3
To 80 parts of polyethylene wax having a melting point of 110 ° C., add 30 parts of heavy oil with a VG of 430 and 7 parts of methyl acrylate-styrene-maleic acid copolymer with an acid value of 350 mgKOH / g and dissolve at 120 ° C. Mix well. Subsequently, 3 parts of methyldiethanolamine and 165 parts of water are added and pressurized in an autoclave and stirred and mixed at 120 ° C. By treating this mixture with a high-pressure homogenizer, an emulsion having a solid content of 39.8% (water repellent component content: 36.4%) was obtained.

Formula 4
100 parts of the paraffin wax used in Formulation 1 is melted at 60 ° C., 10 parts of polyoxyethylene lauryl ether and 2 parts of dipalmityldimethylammonium chloride are added and mixed well. Further, 150 parts of water is gradually dropped while stirring is continued. The obtained emulsion was further dispersed with a high-pressure homogenizer to obtain an emulsion having a solid content of 42.7% (wax content: 38.2%).

[Preparation of aqueous dispersion of heavy oil]
Formulation 5
Add 20 parts of a styrene-maleic acid copolymer with an acid value of 200 mg KOH / g having a solid content of 25%, neutralized with ammonia and added to 100 parts of a heavy oil with a VG of 430 mm ² / s. To do. Further, 150 parts of water is gradually dropped while stirring is continued. The obtained emulsion was further dispersed with a high-pressure homogenizer to obtain an emulsion having a solid content of 38.9% (oil content: 37%).

[Preparation of aqueous dispersion of dimethylpolysiloxane]
Formulation 6
15 parts of polyoxyethylene polyoxypropylene was added to 60 parts of dimethylpolysiloxane having a molecular weight of about 5000. While stirring, 200 parts of water was added dropwise to obtain an aqueous dispersion having a solid content of 27.3% (dimethylpolysiloxane content of 21.8%).

Example 1
[Preparation of aqueous binder for inorganic fibers]
A resol-type phenol resin precursor having a monomer content of 10% or less, a dimer of 80% or more, and a free phenol content of 1% or less, dispersed in water, is 100% in terms of solid content and is obtained in Formulation 1. While mixing 1.5 parts of the liquid emulsion, 0.2 parts of γ- (2-aminoethyl) aminopropyltrimethoxysilane, and 450 parts of water in an open tank with a stirrer, while sufficiently stirring Water was added so that the solid content was 15% to obtain an aqueous binder for inorganic fibers.

[Manufacture of inorganic fiber heat insulating material]
After applying to the glass fiber fiberized by the centrifugal method by spraying to the prescribed amount using the binder, it is deposited on the perforated conveyor while sucking with a suction device, and the inorganic fiber heat insulating sound absorbing material An intermediate was formed. The intermediate is heated in hot air at 260 ° C. for 3 minutes to cure the binder, the density is 16 kg / m ³ , the thickness is 100 mm, and the binder application amount is 3.0%. The glass wool that was obtained.

Examples 2-3
Except for using the water repellent emulsion obtained in Formulations 2-3, according to the same binder blending method as in Example 1 and the method for producing an inorganic fiber thermal insulation material, the inorganic fiber thermal insulation material of Examples 2-3, respectively. The glass wool that was obtained.

Example 4
A 30% aqueous solution of a methacrylic acid-maleic acid-methyl methacrylate copolymer having an acid value of 650 mg KOH / g is converted to 100 parts in terms of solid content, 16.7 parts of glycerin, 21 parts of pentaerythritol, and 3.0 parts of sodium hypophosphite. , Γ- (2-aminoethyl) aminopropyltrimethoxysilane 0.2 parts, 2 parts of water repellent obtained in Formulation 2 and 450 parts of water were prepared in an open tank with a dissolver. And water was added so that solid content might be 15%, stirring sufficiently, and the aqueous | water-based binder for inorganic fibers was obtained.

  Next, the glass wool used as the inorganic fiber heat-insulating sound absorbing material of Example 4 was obtained by the same production method as in Example 1 except that the binder was used.

Example 5
The 650 mg KOH / g methacrylic acid-maleic acid-methyl methacrylate copolymer 30% aqueous solution used in Example 4 was added to 100 parts in terms of solid content, and bisphenol A diglycidyl ether epoxy resin 118 having an epoxy equivalent of 340 g / eq. The parts were mixed and sufficiently stirred to obtain an emulsion. 2.8 parts of the water repellent emulsion obtained in Formulation 3 with respect to 100 parts of this emulsion, 3 parts of trimethylenediamine, 0.2 part of γ-glycidoxypropyltrimethoxysilane, and 450 parts of water Were mixed in an open tank with a dissolver, and water was added so that the solid content was 15% with sufficient stirring to obtain an aqueous binder for inorganic fibers.

  Next, the glass wool used as the inorganic fiber heat-insulating sound absorbing material of Example 5 was obtained by the same production method as in Example 1 except that the binder was used.

Example 6
Inorganic fiber heat insulation of Example 6 by the same binder preparation method as Example 1 and the manufacturing method of an inorganic fiber heat-absorbing material, except that the water repellent emulsion obtained in Formulation 1 was changed to 12.5 parts in terms of content. Glass wool as a sound absorbing material was obtained.

Example 7
By using the aqueous binder for inorganic fibers prepared in Example 1, the same manufacturing method as in Example 1 was used, and the inorganic material of Example 7 was used under the conditions of a density of 10 kg / m ³ , a thickness of 100 mm, and a binder application amount of 3.0%. Glass wool used as a fiber heat insulating sound absorbing material was obtained.

Example 8
By using the aqueous binder for inorganic fibers prepared in Example 5, the same production method as in Example 1 was used, and the inorganic material of Example 8 was used under the conditions of a density of 24 kg / m ³ , a thickness of 100 mm, and a binder application amount of 4.0%. Glass wool used as a fiber heat insulating sound absorbing material was obtained.

Comparative Example 1
100 parts of the water-dispersed resol type phenol resin precursor used in Example 1 in terms of solid content, 0.1 part of γ- (2-aminoethyl) aminopropyltrimethoxysilane, and 450 parts of water were dissolved in a dissolver. The mixture was prepared in an open tank attached with water and water was added so that the solid content was 15% with sufficient stirring to obtain an aqueous binder for inorganic fibers containing no water repellent.

  Furthermore, the glass wool used as the inorganic fiber heat-insulation sound-absorbing material of the comparative example 1 was obtained by the manufacturing method similar to Example 1 using the said binder.

Comparative Example 2
A 30% aqueous solution of a methacrylic acid-maleic acid-methyl methacrylate copolymer having an acid value of 650 mgKOH / g used in Example 4 was added to 100 parts in terms of solid content, 16.7 parts glycerin, 21 parts pentaerythritol, hypophosphorous acid. 3.0 parts of sodium acid, 0.2 part of γ- (2-aminoethyl) aminopropyltrimethoxysilane and 450 parts of water were prepared in an open tank equipped with a dissolver, and the solid content was 15% with sufficient stirring. Water was added so that an aqueous binder for inorganic fibers containing no water repellent was obtained.

  Next, the glass wool used as the inorganic fiber heat-insulation material of the comparative example 2 was obtained with the manufacturing method similar to Example 1 except using the said binder.

Comparative Example 3
100 parts of the water-dispersed resol type phenolic resin precursor used in Example 1 in terms of solid content, 5 parts in terms of content of the paraffin wax emulsion obtained in Formulation 4, and 450 parts of water were dissolved in a dissolver. The mixture was prepared in an open tank with a mark, and water was added so that the solid content was 15% with sufficient stirring to obtain an aqueous binder for inorganic fibers.

  Furthermore, the glass wool which becomes an inorganic fiber heat-insulation sound-absorbing material of the comparative example 3 was obtained with the manufacturing method similar to Example 1 using the said binder.

Comparative Example 4
100 parts of the water-dispersed resol-type phenol resin precursor used in Example 1 in terms of solid content, 5 parts of the heavy oil aqueous dispersion obtained in Formulation 5, and 450 parts of water in terms of content Was prepared in an open tank with a dissolver, and water was added so that the solid content was 15% with sufficient stirring to obtain an aqueous binder for inorganic fibers.

  Furthermore, the glass wool used as the inorganic fiber heat insulation sound-absorbing material of the comparative example 4 was obtained by the manufacturing method similar to Example 1 using the said binder.

Comparative Example 5
100 parts of the water-dispersed resol type phenol resin precursor used in Example 1 in terms of solid content, 5 parts of the aqueous dispersion of dimethylpolysiloxane obtained in Formulation 6, 450 parts of water, Was prepared in an open tank with a dissolver, and water was added so that the solid content was 15% with sufficient stirring to obtain an aqueous binder for inorganic fibers.

Furthermore, the glass wool used as the inorganic fiber heat-insulation sound-absorbing material of the comparative example 5 was obtained by the manufacturing method similar to Example 1 using the said binder.

All the aqueous binders for inorganic fibers used in Examples 1 to 8 and Comparative Examples 1 to 5 had good stability. Further, the water repellent emulsion used in the examples could be uniformly mixed in the aqueous binder, and the compatibility with the components other than the thermoplastic resin precursor contained in the aqueous binder was also good.

  The following evaluation was performed about the glass wool obtained in Examples 1-8 and Comparative Examples 1-5.

[Evaluation of water repellency (water float test)]
A test piece of 50 × 100 × 100 mm square was cut out from the obtained glass wool, the test piece was floated in a water tank filled with water, and the length of the flooded portion after 7 days was measured at room temperature. In addition, when it was submerged by that time, the elapsed days were counted.

[Evaluation of long-term water repellency]
From the obtained glass wool, a test piece of 50 × 100 × 100 mm square was cut out and stored for 1 month in a thermostatic chamber at 50 ° C. atmosphere. Then, the test piece was taken out from the thermostat, and the same evaluation as the above water repellency evaluation (water floating test) was performed to evaluate long-term water repellency. In addition, long-term water-repellent evaluation was not implemented about the test piece immersed in the said water-repellent evaluation by the 7th day.

The results of the evaluation are summarized in Table 1.

  From Table 1, in the evaluation of water repellency, the test pieces of Comparative Examples 1 and 2 were completely submerged on the third and fourth days, and in Comparative Example 3, the thickness of the test piece was not submerged on the seventh day. Compared to being submerged in half or more, it can be seen that the test pieces of Examples 1 to 8 floated in water for 7 days. This indicates that the water repellency of glass wool was improved by the various water repellents used in the examples.

  Moreover, it can be seen from the comparison between Example 1 and Example 6 that even when the water repellent is added in an amount exceeding the above preferred range, the water repellent performance is not greatly improved. Further, from comparison between Example 2 and Example 3, it can be seen that uniform water repellency can be obtained by using a mixture of waxes and heavy oils as the water repellent component.

  In the evaluation of long-term water repellency, in Examples 1 to 8, no change in water repellency is observed even during long-term storage in an atmosphere at 50 ° C., indicating that high water repellency is maintained. On the other hand, in Comparative Example 4 and Comparative Example 5, although the initial water repellency is relatively high, it can be seen that the water repellency performance deteriorated during long-term storage in an atmosphere at 50 ° C.

Since the inorganic fiber heat insulating sound absorbing material obtained using the aqueous binder for inorganic fibers of the present invention has excellent water repellency, even if it is exposed to rainwater or condensed water, the heat insulating and sound absorbing performance does not deteriorate over a long period of time, It can solve the problems of mold generation, corrosion of metal parts in contact with it, and decay of wood, and can be suitably used as a heat insulating material or sound absorbing material for houses, buildings, soundproof walls, cooling towers, outdoor installation equipment and the like.

Claims (5)

An aqueous binder for inorganic fibers containing a thermosetting resin precursor dissolved or dispersed in water and a water repellent emulsion,
The water repellent emulsion, inorganic fibers aqueous binder, characterized in that it contains a dispersing agent comprising a water-soluble polycarboxylic acid resin, a water-repellent agent comprising at least one selected from wax. The aqueous binder for inorganic fibers according to claim 1, wherein the water repellent is a mixture of at least one selected from waxes and at least one selected from heavy oils .   The thermosetting resin precursor and the water repellent are contained so as to be 0.1 to 10 parts by mass of the water repellent with respect to 100 parts by mass of the thermosetting resin precursor in terms of solid content. The aqueous binder for inorganic fibers according to claim 1 or 2.   The thermosetting resin precursor is at least one selected from the group consisting of an aldehyde condensable resin precursor, a mixture of a polyol and a polycarboxylic acid resin, and a mixture of an epoxy resin and a polycarboxylic acid resin. The aqueous binder for inorganic fibers according to any one of claims 1 to 3.   The inorganic fiber aqueous binder according to any one of claims 1 to 4 is applied to the inorganic fiber immediately after fiberization, the inorganic fiber to which the inorganic fiber aqueous binder is adhered is deposited, and then heat cured to form. An inorganic fiber heat-absorbing sound-absorbing material, characterized in that it is obtained as described above.