JP5781961B2 - Insulation - Google Patents
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- JP5781961B2 JP5781961B2 JP2012040599A JP2012040599A JP5781961B2 JP 5781961 B2 JP5781961 B2 JP 5781961B2 JP 2012040599 A JP2012040599 A JP 2012040599A JP 2012040599 A JP2012040599 A JP 2012040599A JP 5781961 B2 JP5781961 B2 JP 5781961B2
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Description
本発明は、木質繊維と、木質繊維同士を結合させるための熱溶融性バインダー繊維とを、加熱成形して得られる断熱材に関する。 The present invention relates to a heat insulating material obtained by heat-molding wood fibers and hot-melt binder fibers for bonding the wood fibers together.
近年、消費者の地球環境への意識が益々高まり、住宅等の建材においても、人体への安全性の確保が謳われると共に、環境に配慮した素材を使用する傾向が高まってきている。また、省エネ、節電対策としても、住環境等の断熱材の需要は著しく増加傾向にある。 In recent years, consumers are increasingly aware of the global environment, and in building materials such as houses, there is an increasing tendency to ensure safety to the human body and to use environmentally friendly materials. In addition, as a measure for energy saving and power saving, the demand for heat insulating materials such as living environment has been remarkably increasing.
現在、一般に広く使われている断熱材としては、グラスウール、ロックウール等の鉱物繊維系断熱材や、ビーズ法ポリスチレンフォーム、押出法ポリスチレンフォーム、硬質ウレタンフォーム、ポリエチレンフォーム、フェノールフォーム等の発泡プラスチック系断熱材、セルロースファイバー等の自然系断熱材が挙げられる。グラスウールやロックウールは、断熱性能も高く、安価で普及も進んでいる反面、結露しやすく、カビが発生しやすい。発泡プラスチック系断熱材は、断熱性能も高く、グラスウールやロックウールより結露しにくいが、製造時の環境負荷が大きい。セルロースファイバーは、製造時の環境負荷が小さく、環境や健康にも好ましく、吸放湿性能が高く、断熱性能も高いが、専門の業者による吹き込み施工を要するため高価である。 Currently, heat insulation materials that are widely used are mineral fiber heat insulation materials such as glass wool and rock wool, and foamed plastic materials such as beaded polystyrene foam, extruded polystyrene foam, rigid urethane foam, polyethylene foam, and phenol foam. Examples thereof include natural heat insulating materials such as heat insulating materials and cellulose fibers. Glass wool and rock wool have high heat insulation performance, are inexpensive and are widely used, but tend to condense and cause mold. Foamed plastic insulation has high heat insulation performance and is less likely to condense than glass wool or rock wool, but has a greater environmental impact during production. Cellulose fiber has a small environmental load during production, is favorable for the environment and health, has high moisture absorption / release performance, and high heat insulation performance, but is expensive because it requires blowing work by a specialist.
上記のような背景から、環境に配慮した様々な素材による断熱材が検討されている。例えば、特許文献1では、スギやヒノキ等の樹皮を解繊して得られた木質繊維を原料として、吸放湿特性のある、住宅用断熱材が開示されている。 In view of the above background, heat insulating materials made of various environmentally-friendly materials have been studied. For example, Patent Document 1 discloses a residential heat insulating material having moisture absorption / release characteristics using wood fibers obtained by defibration of bark such as cedar and cypress as raw materials.
特許文献2では、廃棄物である籾殻を原料として、木造住宅用の吹き込み充填外断熱構造が開示されている。 Patent Document 2 discloses a blow-fill outer heat insulating structure for a wooden house using rice husk as waste as a raw material.
特許文献3では、木材チップや竹皮、麻等から得られた木質繊維を主原料とし、二成分繊維を結合剤に用いた断熱材が開示されている。 Patent Document 3 discloses a heat insulating material using wood fibers obtained from wood chips, bamboo skin, hemp, etc. as a main raw material and using bicomponent fibers as a binder.
上記特許文献1、および2では、吹き込み、もしくは堆積による施工法を要するため、容易に施工することができない。 In the said patent documents 1 and 2, since the construction method by blowing or deposition is required, it cannot construct easily.
上記特許文献3では、環境に配慮した素材を原料としつつ、容易に施工することができるものの、結合剤として使用されている二成分繊維にはその構造に特に制限がないため、例えば、その構造が並列型である場合は、優れた成形性が得られない。また、融点の近い二成分で構成されている場合は、加熱成形により二成分とも完全に溶融する可能性があり充分に低い密度を得られない結果、優れた断熱性能を得られない、もしくは、加熱成形時の実施可能温度域を狭めてしまうといった作業性に難を要する。 In the above Patent Document 3, although it can be easily constructed while using an environmentally friendly material as a raw material, the structure of the bicomponent fiber used as a binder is not particularly limited. If is a parallel type, excellent moldability cannot be obtained. In addition, when it is composed of two components with close melting points, the two components may be completely melted by thermoforming, and as a result of not being able to obtain a sufficiently low density, excellent heat insulation performance cannot be obtained, or Difficulties are required in workability such as narrowing the feasible temperature range during heat forming.
本発明は、環境に配慮した素材を原料としたうえで、より低密度で優れた断熱性能を持ち、製造時の作業性に優れ、容易に成形でき、容易に施工することができる断熱材を提供することを目的とする。 The present invention uses an environmentally friendly material as a raw material, has a lower density and excellent heat insulation performance, is superior in workability during manufacturing, can be easily molded, and can be easily constructed. The purpose is to provide.
本発明者は、上記課題を解決すべく研究した結果、以下のような断熱材を発明するに至った。即ち、木質繊維と、熱溶融性バインダー芯鞘複合繊維とを加熱成形して得られる断熱材であって、該複合繊維は融点の異なる少なくとも2種類以上の成分からなり、前記複合繊維の融点の最も高い芯部成分と最も低い鞘部成分の融点の差が50℃以上であって、前記芯部が融点200℃以上のポリエチレンテレフタレート且つ前記鞘部がポリエチレンからなり、該複合繊維を断熱材の絶乾固形分質量に対して10〜50質量%含む断熱材によって達成される。 As a result of researches to solve the above problems, the present inventors have invented the following heat insulating material. That is, a heat insulating material obtained by thermoforming a wood fiber and a heat-meltable binder core-sheath composite fiber, the composite fiber comprising at least two kinds of components having different melting points, and having a melting point of the composite fiber The difference between the melting points of the highest core component and the lowest sheath component is 50 ° C. or more, the core portion is made of polyethylene terephthalate having a melting point of 200 ° C. or more, and the sheath portion is made of polyethylene . This is achieved by a heat insulating material containing 10 to 50% by mass relative to the mass of the absolutely dry solid content.
本発明により、環境に配慮した素材を原料としたうえで、より低密度で優れた断熱性能を持ち、製造時の作業性に優れ、容易に成形でき、容易に施工することができる断熱材を提供することができる。 With the present invention, a heat insulating material having an excellent heat insulation performance at a lower density, excellent workability at the time of manufacture, easy to mold, and easy to construct after using an environmentally friendly material as a raw material. Can be provided.
以下、本発明の断熱材について詳細に説明する。 Hereinafter, the heat insulating material of the present invention will be described in detail.
本発明における木質繊維は、特に制限がなく、あらゆる樹種の木材チップを原料とすることができ、例えば、マツ、スギ、ヒノキなどの針葉樹、ユーカリ、ブナ、ナラ、ポプラ、カバ、アカシヤなどの広葉樹の木材チップが挙げられる。また、製紙会社のパルプ製造工程で発生する廃棄物であるチップダストや、間伐材を原料とすることもできる。これら原料に難燃・防蟻処理を施し、解繊して木質繊維が得られる。ただし、難燃・防蟻処理は、解繊後でも良く、薬剤の添加順は以下に何ら制限されるものではない。 The wood fiber in the present invention is not particularly limited, and wood chips of any tree species can be used as a raw material. For example, conifers such as pine, cedar and cypress, deciduous trees such as eucalyptus, beech, oak, poplar, hippopotamus, and acacia Wood chips. In addition, chip dust, which is a waste generated in the pulp manufacturing process of a paper company, or thinned wood can be used as a raw material. These raw materials are treated with flame retardant and ant repellency, and defibrated to obtain wood fibers. However, the flame-retardant / ant-proof treatment may be performed after defibration, and the order of addition of the chemicals is not limited to the following.
木質繊維の原料、もしくは、木質繊維を難燃化処理することには、特に制限がなく、従来公知の難燃剤を使用できる。例えば、具体的には、ホウ酸、ホウ砂、ホウ酸アンモニウム、ホウ酸亜鉛等のホウ素化合物、リン、リン酸、ポリリン酸、リン酸アンモニウム、リン酸グアニジン、リン酸グアニル尿素、リン酸メラミン、ポリリン酸アンモニウム等のリン化合物、塩化カルシウム、塩化亜鉛等の塩化物、その他、シュウ酸アンモニウム、スルホン酸アンモニウム等が挙げられる。これらは、単独、もしくは2種以上を組み合わせて使用できる。処理方法は、これらの単独、もしくは混合溶液で浸漬、塗布、加圧注入等の方法で木材チップ中に浸透させる。 There is no restriction | limiting in particular in the flame-retardant treatment of the raw material of wood fiber, or wood fiber, A conventionally well-known flame retardant can be used. For example, specifically, boron compounds such as boric acid, borax, ammonium borate, zinc borate, phosphorus, phosphoric acid, polyphosphoric acid, ammonium phosphate, guanidine phosphate, guanyl urea phosphate, melamine phosphate, Examples thereof include phosphorus compounds such as ammonium polyphosphate, chlorides such as calcium chloride and zinc chloride, ammonium oxalate, and ammonium sulfonate. These can be used alone or in combination of two or more. The treatment method is infiltrated into the wood chips by such methods as dipping, coating, or pressure injection with these or a mixed solution.
木質繊維の原料、もしくは、木質繊維を防蟻化処理することには、特に制限がなく、従来公知の防蟻剤を使用できる。例えば、具体的には、ホウ酸、ホウ砂等のホウ素化合物、カルバリル等のカーバメート化合物、その他、トリプロピルイソシアヌレート等が挙げられる。これらは、単独、もしくは2種以上を組み合わせて使用できる。処理方法は、これらの単独、もしくは混合溶液で浸漬、塗布、加圧注入等の方法で木材チップ中に浸透させる。 There is no restriction | limiting in particular in the raw material of a wood fiber, or wood fiber-proofing processing, A conventionally well-known anti-anticide can be used. Specific examples include boron compounds such as boric acid and borax, carbamate compounds such as carbaryl, and other tripropyl isocyanurates. These can be used alone or in combination of two or more. The treatment method is infiltrated into the wood chips by such methods as dipping, coating, or pressure injection with these or a mixed solution.
木質繊維の原料は、蒸解ムラを抑制するため脱気処理を施された後、蒸解、および解繊処理される。これらの処理に使用する機器には特に制限がなく、従来公知の機器を使用できる。例えば、ディファイブレーターではその構造上、蒸解と解繊を同一の機器で実施できる。また、解繊には、木材チップの水分調整の後、例えば、破砕機や粉砕機を使用しても良い。湿潤した状態で得られた木質繊維は、例えば、回転式ドラム乾燥機等により乾燥される。これらの処理により得られる木質繊維は、繊維長に特に制限は設けないが、成形性の点から、平均繊維長が3mm以上であることが好ましい。木質繊維の平均繊維長は、任意の木質繊維10本の繊維長をスケールルーペで測定し、その平均値を採用する。 The raw material of the wood fiber is subjected to deaeration treatment to suppress cooking unevenness, and then is subjected to cooking and defibrating treatment. There is no restriction | limiting in particular in the apparatus used for these processes, A conventionally well-known apparatus can be used. For example, in a defibrator, digestion and defibration can be performed with the same equipment because of its structure. For defibration, for example, a crusher or a crusher may be used after adjusting the moisture content of the wood chips. The wood fiber obtained in the wet state is dried by, for example, a rotary drum dryer. The wood fiber obtained by these treatments is not particularly limited in fiber length, but the average fiber length is preferably 3 mm or more from the viewpoint of moldability. The average fiber length of the wood fibers is obtained by measuring the length of 10 arbitrary wood fibers with a scale loupe and adopting the average value.
熱溶融性バインダー芯鞘複合繊維は、芯部の融点が、鞘部の融点より高いため、芯部融点と鞘部融点の間の温度範囲で加熱されたときに、鞘部のみが溶融し、バインダーとして働く。該複合繊維が鞘部だけでなく芯部もすべて溶ける場合は、断熱材の嵩を下げることになるが、芯部融点より低い温度で加熱すると芯部は溶けないため、断熱材の嵩の低下を阻害する。つまり、本発明において得られる断熱材では、芯部は断熱材の嵩の低下を防ぐ役割をする。該複合繊維は、融点の異なる少なくとも2種類以上の成分からなることを特徴とし、融点に特に制限は設けないが、断熱材成形時の作業性の点から、融点の最も高い芯部成分と最も低い鞘部成分の融点の差が50℃以上であることが好ましい。なお、ここで言う融点とは以下の方法で測定される。該複合繊維の融点測定には、パーキンエルマー社製示差走査熱量測定装置DSC8500(以降、DSCとも言う)を用い、窒素雰囲気下、昇温速度10℃/分で、25℃以上300℃未満の範囲における熱挙動を観察し、溶融による吸熱ピークの温度を融点とする。本発明における芯鞘型構造の複合繊維は、融点の異なる少なくとも2種類以上の成分からなるため、溶融による吸熱ピークは少なくとも2つ以上測定されるが、最も高温側に観察される吸熱ピークの温度が芯部の融点であり、低温側に観察される吸熱ピークの温度が鞘部の融点である。以降、熱溶融性バインダー芯鞘複合繊維の融点は、上記条件で測定された。 Since the melting point of the core part is higher than the melting point of the sheath part, when heated in the temperature range between the core part melting point and the sheath part melting point, only the sheath part melts. Work as a binder. When the composite fiber melts not only the sheath but also the core, the heat insulating material will be reduced in volume, but if heated at a temperature lower than the melting point of the core, the core will not melt, so the bulk of the heat insulating material will decrease. Inhibits. That is, in the heat insulating material obtained in the present invention, the core part plays a role of preventing a decrease in the bulk of the heat insulating material. The composite fiber is characterized by comprising at least two kinds of components having different melting points, and there is no particular limitation on the melting point. However, from the viewpoint of workability when forming a heat insulating material, the core component having the highest melting point and the most The difference in melting point of the low sheath component is preferably 50 ° C. or higher. In addition, melting | fusing point said here is measured with the following method. For the melting point measurement of the composite fiber, a differential scanning calorimeter DSC8500 (hereinafter, also referred to as DSC) manufactured by Perkin Elmer Co. was used. The temperature of the endothermic peak due to melting is taken as the melting point. The composite fiber having a core-sheath structure in the present invention is composed of at least two kinds of components having different melting points. Therefore, at least two endothermic peaks due to melting are measured, but the endothermic peak temperature observed on the highest temperature side is measured. Is the melting point of the core, and the temperature of the endothermic peak observed on the low temperature side is the melting point of the sheath. Thereafter, the melting point of the heat-meltable binder core-sheath composite fiber was measured under the above conditions.
上記複合繊維の芯部成分としては、鞘部成分より高い融点を持っていること以外は特に制限はないが、例えば、具体的には、ポリプロピレン、ポリメチルペンテン等のポリオレフィン化合物、ポリエチレンテレフタレート(以降、本発明において、ポリエチレンテレフタレートとは、融点200℃以上のポリエチレンテレフタレートを言う)、ポリブチレンテレフタレート、ポリトリメチレンテレフタレート、ポリ乳酸等のポリエステル化合物等が挙げられる。 The core component of the composite fiber is not particularly limited except that it has a higher melting point than the sheath component. For example, specifically, polyolefin compounds such as polypropylene and polymethylpentene, polyethylene terephthalate (hereinafter referred to as “polyethylene terephthalate”) In the present invention, polyethylene terephthalate refers to polyethylene terephthalate having a melting point of 200 ° C. or higher), polyester compounds such as polybutylene terephthalate, polytrimethylene terephthalate, and polylactic acid.
上記複合繊維の鞘部成分としては、芯部成分より低い融点を持っていること以外は特に制限はないが、例えば、具体的には、ポリエチレン、ポリプロピレン等のポリオレフィン化合物、低融点ポリエチレンテレフタレート(以降、本発明において、低融点ポリエチレンテレフタレートとは、融点180℃以下のポリエチレンテレフタレートを言う)、ポリブチレンテレフタレート、ポリ乳酸等のポリエステル化合物、エチレン−ビニルアルコール共重合体等が挙げられる。 The sheath component of the composite fiber is not particularly limited except that it has a lower melting point than the core component. For example, specifically, polyolefin compounds such as polyethylene and polypropylene, low melting point polyethylene terephthalate (hereinafter referred to as “polyethylene compound”) In the present invention, the low melting point polyethylene terephthalate refers to polyethylene terephthalate having a melting point of 180 ° C. or less), polyester compounds such as polybutylene terephthalate and polylactic acid, and ethylene-vinyl alcohol copolymers.
上記複合繊維の成分は、芯部の融点が鞘部の融点より高いこと以外は特に制限はないが、その融点が200℃以上であるポリエチレンテレフタレートを含むことが好ましい。200℃以上の高い融点を持つために、他方の鞘部となる成分を選ばず、成形工程においては加熱温度の実施可能温度域に幅を持たせることができる。 The component of the composite fiber is not particularly limited except that the melting point of the core is higher than the melting point of the sheath, but preferably contains polyethylene terephthalate having a melting point of 200 ° C. or higher. Since it has a high melting point of 200 ° C. or higher, the component that becomes the other sheath portion is not selected, and the temperature range in which the heating temperature can be performed can be widened in the molding step.
さらには、上記複合繊維の芯部がポリエチレンテレフタレート、鞘部がポリエチレン、もしくは、低融点ポリエチレンテレフタレートからなる熱溶融性バインダー芯鞘複合繊維が好ましい。芯部成分と鞘部成分がこれらの組み合わせであることは、充分な融点の差が得られるため、成形工程における加熱温度の実施可能温度域にさらなる幅を持たせることができる。 Furthermore, a heat-meltable binder core-sheath composite fiber in which the core part of the composite fiber is made of polyethylene terephthalate and the sheath part is made of polyethylene or low melting point polyethylene terephthalate is preferable. When the core component and the sheath component are a combination of these, a sufficient difference in melting point can be obtained, so that it is possible to give a further range to the feasible temperature range of the heating temperature in the molding process.
上記複合繊維の構造は芯鞘型に限定され、本発明における芯鞘型には、横断面が同心円状である同芯芯鞘型、横断面が非対称である偏芯芯鞘型、横断面が海島状である海島型の他、芯部繊維の表面に不連続に鞘部成分を有する、繊維側面から見て海島型の構造を含む。偏芯芯鞘型には、横断面形状が丸型や楕円型の他、異型断面(偏平状、多角形状、葉状、H字状、I字状、T字状、V字状等)も含む。 The structure of the composite fiber is limited to a core-sheath type, and the core-sheath type in the present invention includes a concentric core-sheath type whose cross section is concentric, an eccentric core-sheath type whose cross section is asymmetric, In addition to the sea-island shape, which is a sea-island shape, it includes a sea-island structure as viewed from the side of the fiber, having a sheath component discontinuously on the surface of the core fiber. The eccentric core-sheath type includes not only round and elliptical cross-sectional shapes but also irregular cross-sections (flat shape, polygonal shape, leaf shape, H shape, I shape, T shape, V shape, etc.). .
上記複合繊維は、断熱材の絶乾固形分量に対して10〜50質量%配合される。10質量%より少ない場合、成形はできても、断熱材を持ち上げたり設置したりするときに容易に木質繊維が落ちることとなる。また、50質量%より多い場合、木質繊維の割合が少なくなるため、断熱性能が劣る結果となる。 The said composite fiber is mix | blended 10-50 mass% with respect to the absolutely dry solid content of a heat insulating material. When the amount is less than 10% by mass, the wood fiber easily falls when the heat insulating material is lifted or installed even if it can be molded. Moreover, since the ratio of a wood fiber will decrease when there are more than 50 mass%, it will result in inferior heat insulation performance.
上記複合繊維の繊維長に特に制限は設けないが、成形性の点から、木質繊維の平均繊維長に対して50〜200%の繊維長であることが好ましい。 The fiber length of the composite fiber is not particularly limited, but is preferably 50 to 200% of the average fiber length of the wood fiber from the viewpoint of moldability.
本発明における断熱材の加熱成形方法に関しては、特に制限がなく、例えば、エアレイド方式や、湿潤硬化方式で成形される。エアレイド方式では、上記複合繊維の芯部融点と鞘部融点の間の温度範囲で加熱されて成形され、断熱材が得られる。湿潤硬化方式では、上記混合物を金型に投入し、上下方向から上記複合繊維の芯部融点と鞘部融点の間の温度範囲の蒸気を当てながら上からプレスして成形し、自然乾燥して、断熱材が得られる。 There is no restriction | limiting in particular regarding the heat-molding method of the heat insulating material in this invention, For example, it shape | molds by the airlaid system or the wet-curing system. In the airlaid system, the composite fiber is heated and molded in a temperature range between the core melting point and the sheath melting point to obtain a heat insulating material. In the wet curing method, the above mixture is put into a mold and pressed from above while applying steam in the temperature range between the core melting point and the sheath melting point of the composite fiber from above and below, and then naturally dried. A heat insulating material is obtained.
以下、実施例により本発明を説明するが、本発明はこれら実施例に限定されるものではない。 EXAMPLES Hereinafter, although an Example demonstrates this invention, this invention is not limited to these Examples.
(実施例1)
木質繊維の調製
製紙用パルプ原料としても用いられる、国産針葉樹であるマツおよびスギの樹皮が除去された木材チップを、15質量%のホウ酸水溶液に10時間浸漬した。蒸解ムラを抑制するため、木材チップを30分間脱気処理した。木材チップをディファイブレーターに投入し、1分間解繊処理し、30分間蒸解処理し、再度1分間解繊処理して木質繊維を得た。湿潤した状態で得られた木質繊維を、回転式ドラム乾燥機で乾燥した。
Example 1
Preparation of wood fiber Wood chips from which pine and cedar bark, which are domestic conifers, used as a raw material for papermaking pulp were removed, were immersed in a 15% by mass boric acid aqueous solution for 10 hours. In order to suppress cooking unevenness, the wood chips were degassed for 30 minutes. Wood chips were put into a defibrator, defibrated for 1 minute, digested for 30 minutes, and defibrated again for 1 minute to obtain wood fibers. The wood fiber obtained in the wet state was dried with a rotary drum dryer.
熱溶融性バインダー芯鞘複合繊維
芯部がポリエチレンテレフタレート、鞘部がポリエチレンからなる、横断面が同芯芯鞘型構造の熱溶融性バインダー複合繊維を、断熱材の絶乾固形分量に対して20質量%となるように木質繊維と混合した。DSCにて該複合繊維の融点を測定したところ、芯部の融点は248℃、鞘部の融点は128℃であった。
Heat-meltable binder core-sheath composite fiber The core part is made of polyethylene terephthalate, and the sheath part is made of polyethylene. It mixed with the wood fiber so that it might become mass%. When the melting point of the composite fiber was measured by DSC, the melting point of the core part was 248 ° C., and the melting point of the sheath part was 128 ° C.
加熱成形
上記の木質繊維と複合繊維の混合物を、エアレイド方式により200℃で加熱しながら成形し、断熱材を得た。
Heat molding The mixture of the wood fiber and the composite fiber was molded while being heated at 200 ° C by an airlaid system to obtain a heat insulating material.
(実施例2)
熱溶融性バインダー芯鞘複合繊維の配合量を、断熱材の絶乾固形分量に対して10質量%となるように配合し、その他の工程はすべて実施例1と同様に実施した。
(Example 2)
The blending amount of the heat-meltable binder core-sheath composite fiber was blended so as to be 10% by mass with respect to the absolutely dry solid content of the heat insulating material, and all other steps were performed in the same manner as in Example 1.
(実施例3)
熱溶融性バインダー芯鞘複合繊維の配合量を、断熱材の絶乾固形分量に対して50質量%となるように配合し、その他の工程はすべて実施例1と同様に実施した。
(Example 3)
The blending amount of the heat-meltable binder core-sheath composite fiber was blended so as to be 50% by mass with respect to the absolutely dry solid content of the heat insulating material, and all other steps were performed in the same manner as in Example 1.
(参考例1)
熱溶融性バインダー芯鞘複合繊維として、芯部がポリエチレンテレフタレート、鞘部が低融点ポリエチレンテレフタレートからなる、横断面が同芯芯鞘型構造の繊維を配合した。DSCにて該複合繊維の融点を測定したところ、芯部の融点は248℃、鞘部の融点は109℃であった。その他の工程はすべて実施例1と同様に実施した。
( Reference Example 1 )
As the heat-meltable binder-core-sheath composite fiber, a fiber having a concentric core-sheath type structure in which the core is made of polyethylene terephthalate and the sheath is made of low-melting-point polyethylene terephthalate is blended. When the melting point of the composite fiber was measured by DSC, the melting point of the core part was 248 ° C., and the melting point of the sheath part was 109 ° C. All other steps were performed in the same manner as in Example 1.
(参考例2)
熱溶融性バインダー芯鞘複合繊維として、芯部がポリエチレンテレフタレート、鞘部が低融点ポリエチレンテレフタレートからなる、横断面が同芯芯鞘型構造の繊維を配合した。DSCにて該複合繊維の融点を測定したところ、芯部の融点は249℃、鞘部の融点は154℃であった。その他の工程はすべて実施例1と同様に実施した。
( Reference Example 2 )
As the heat-meltable binder-core-sheath composite fiber, a fiber having a concentric core-sheath type structure in which the core is made of polyethylene terephthalate and the sheath is made of low-melting-point polyethylene terephthalate is blended. When the melting point of the composite fiber was measured by DSC, the melting point of the core part was 249 ° C., and the melting point of the sheath part was 154 ° C. All other steps were performed in the same manner as in Example 1.
(参考例3)
熱溶融性バインダー芯鞘複合繊維として、芯部がポリエチレンテレフタレート、鞘部がポリプロピレンからなる、横断面が同芯芯鞘型構造の繊維を配合した。DSCにて該複合繊維の融点を測定したところ、芯部の融点は249℃、鞘部の融点は166℃であった。その他の工程はすべて実施例1と同様に実施した。
( Reference Example 3 )
As the heat-meltable binder-core-sheath composite fiber, a fiber having a core-core-sheath-type structure in which the core part is made of polyethylene terephthalate and the sheath part is made of polypropylene is blended. When the melting point of the composite fiber was measured by DSC, the melting point of the core part was 249 ° C., and the melting point of the sheath part was 166 ° C. All other steps were performed in the same manner as in Example 1.
(参考例4)
熱溶融性バインダー芯鞘複合繊維として、芯部がポリブチレンテレフタレート、鞘部が低融点ポリエチレンテレフタレートからなる、横断面が同芯芯鞘型構造の繊維を配合した。DSCにて該複合繊維の融点を測定したところ、芯部の融点は223℃、鞘部の融点は153℃であった。その他の工程はすべて実施例1と同様に実施した。
( Reference Example 4 )
As the heat-meltable binder core-sheath composite fiber, a fiber having a core-core-sheath-type structure in which the core portion is made of polybutylene terephthalate and the sheath portion is made of low melting point polyethylene terephthalate is blended. When the melting point of the composite fiber was measured by DSC, the melting point of the core part was 223 ° C., and the melting point of the sheath part was 153 ° C. All other steps were performed in the same manner as in Example 1.
(参考例5)
熱溶融性バインダー芯鞘複合繊維として、芯部がポリブチレンテレフタレート、鞘部がポリプロピレンからなる、横断面が同芯芯鞘型構造の繊維を配合した。DSCにて該複合繊維の融点を測定したところ、芯部の融点は224℃、鞘部の融点は165℃であった。その他の工程はすべて実施例1と同様に実施した。
( Reference Example 5 )
As the heat-meltable binder-core-sheath composite fiber, a fiber having a core-core-sheath-type structure in which the core part is made of polybutylene terephthalate and the sheath part is made of polypropylene is blended. When the melting point of the composite fiber was measured by DSC, the melting point of the core part was 224 ° C., and the melting point of the sheath part was 165 ° C. All other steps were performed in the same manner as in Example 1.
(参考例6)
熱溶融性バインダー芯鞘複合繊維として、芯部がポリ乳酸系重合体、鞘部がポリエチレンからなる、横断面が同芯芯鞘型構造の繊維を配合した。DSCにて該複合繊維の融点を測定したところ、芯部の融点は183℃、鞘部の融点は131℃であった。エアレイド方式による成形時の温度は140℃で加熱し、その他の工程はすべて実施例1と同様に実施した。
( Reference Example 6 )
As the heat-meltable binder core-sheath composite fiber, a fiber having a core part made of a polylactic acid polymer and a sheath part made of polyethylene and having a concentric core-sheath type structure in a transverse section was blended. When the melting point of the composite fiber was measured by DSC, the melting point of the core part was 183 ° C., and the melting point of the sheath part was 131 ° C. The temperature at the time of molding by the airlaid system was heated at 140 ° C., and all other processes were performed in the same manner as in Example 1.
(参考例7)
熱溶融性バインダー芯鞘複合繊維として、芯部がポリプロピレン、鞘部がポリエチレンからなる、横断面が同芯芯鞘型構造の繊維を配合した。DSCにて該複合繊維の融点を測定したところ、芯部の融点は166℃、鞘部の融点は130℃であった。エアレイド方式による成形時の温度は140℃で加熱し、その他の工程はすべて実施例1と同様に実施した。
( Reference Example 7 )
As the heat-meltable binder-core-sheath composite fiber, a fiber having a core-core-sheath structure in which the core part is made of polypropylene and the sheath part is made of polyethylene and the cross-section is a concentric core-sheath structure is blended. When the melting point of the composite fiber was measured by DSC, the melting point of the core part was 166 ° C., and the melting point of the sheath part was 130 ° C. The temperature at the time of molding by the airlaid system was heated at 140 ° C., and all other processes were performed in the same manner as in Example 1.
(実施例4)
熱溶融性バインダー芯鞘複合繊維として、芯部がポリエチレンテレフタレート、鞘部がポリエチレンからなる、横断面が海島型構造の繊維を配合した。DSCにて該複合繊維の融点を測定したところ、海島型の島の部分である芯部の融点は248℃、海島型の海の部分である鞘部の融点は128℃であった。その他の工程はすべて実施例1と同様に実施した。
(Example 4 )
As a heat-meltable binder core-sheath composite fiber, a fiber having a core part made of polyethylene terephthalate and a sheath part made of polyethylene and having a sea-island structure in a cross section was blended. When the melting point of the composite fiber was measured by DSC, the melting point of the core part which is the sea-island type island part was 248 ° C., and the melting point of the sheath part which was the sea-island type sea part was 128 ° C. All other steps were performed in the same manner as in Example 1.
(実施例5)
熱溶融性バインダー芯鞘複合繊維として、芯部がポリエチレンテレフタレート、鞘部がポリエチレンからなる、横断面が偏芯芯鞘型構造の繊維を配合した。DSCにて該複合繊維の融点を測定したところ、芯部の融点は248℃、鞘部の融点は128℃であった。その他の工程はすべて実施例1と同様に実施した。
(Example 5 )
As the heat-meltable binder-core-sheath composite fiber, a fiber having a core part made of polyethylene terephthalate and a sheath part made of polyethylene and having an eccentric core-sheath structure in a transverse section was blended. When the melting point of the composite fiber was measured by DSC, the melting point of the core part was 248 ° C., and the melting point of the sheath part was 128 ° C. All other steps were performed in the same manner as in Example 1.
(参考例8)
成形方法を湿潤硬化方式で成形する以外は、すべて参考例1と同様に実施した。湿潤硬化方式は、木質繊維と熱溶融性バインダー芯鞘複合繊維の混合物を金型に投入し、上下方向から120℃の蒸気を当てながら上からプレスし、成形した。成形後、自然乾燥した。
( Reference Example 8 )
All were carried out in the same manner as in Reference Example 1 except that the molding method was a wet curing method. In the wet curing method, a mixture of a wood fiber and a heat-meltable binder core-sheath composite fiber was put into a mold and pressed from above while applying steam at 120 ° C. from above and below to form. After molding, it was naturally dried.
(比較例1)
熱溶融性バインダー芯鞘複合繊維の配合量を、断熱材の絶乾固形分量に対して5質量%となるように配合し、その他の工程はすべて実施例1と同様に実施した。
(Comparative Example 1)
The blending amount of the heat-meltable binder core-sheath composite fiber was blended so as to be 5% by mass with respect to the absolutely dry solid content of the heat insulating material, and all other steps were performed in the same manner as in Example 1.
(比較例2)
熱溶融性バインダー芯鞘複合繊維の配合量を、断熱材の絶乾固形分量に対して60質量%となるように配合し、その他の工程はすべて実施例1と同様に実施した。
(Comparative Example 2)
The blending amount of the heat-meltable binder core-sheath composite fiber was blended so as to be 60% by mass with respect to the absolutely dry solid content of the heat insulating material, and all other steps were performed in the same manner as in Example 1.
(比較例3)
熱溶融性バインダー芯鞘複合繊維の配合量を、断熱材の絶乾固形分量に対して80質量%となるように配合し、その他の工程はすべて実施例1と同様に実施した。
(Comparative Example 3)
The blending amount of the heat-meltable binder core-sheath composite fiber was blended so as to be 80% by mass with respect to the absolutely dry solid content of the heat insulating material, and all other steps were performed in the same manner as in Example 1.
(比較例4)
熱溶融性バインダー繊維として、ポリエチレンの単成分繊維を配合した。DSCにて該単成分繊維の融点を測定したところ、129℃であった。エアレイド方式による成形時の温度は140℃で加熱し、その他の工程はすべて実施例1と同様に実施した。
(Comparative Example 4)
A polyethylene single component fiber was blended as the hot-melt binder fiber. It was 129 degreeC when melting | fusing point of this single component fiber was measured in DSC. The temperature at the time of molding by the airlaid system was heated at 140 ° C., and all other processes were performed in the same manner as in Example 1.
(比較例5)
熱溶融性バインダー繊維として、ポリエチレンテレフタレートの単成分繊維、およびポリエチレンの単成分繊維を、断熱材の絶乾固形分量に対して、それぞれ10質量%ずつ、計20質量%となるように配合した。DSCにて各単成分繊維の融点を測定したところ、ポリエチレンテレフタレートの単成分繊維の融点は248℃、ポリエチレンの単成分繊維の融点は129℃であった。その他の工程はすべて実施例1と同様に実施した。
(Comparative Example 5)
As heat-meltable binder fibers, polyethylene terephthalate single component fibers and polyethylene single component fibers were blended in an amount of 10% by mass with respect to the absolute dry solid content of the heat insulating material, respectively, so that the total amount was 20% by mass. When the melting point of each single component fiber was measured by DSC, the melting point of the single component fiber of polyethylene terephthalate was 248 ° C., and the melting point of the single component fiber of polyethylene was 129 ° C. All other steps were performed in the same manner as in Example 1.
(比較例6)
熱溶融性バインダー複合繊維として、片方がポリエチレンテレフタレート、もう一方がポリエチレンからなる、並列型構造の繊維を配合した。DSCにて該複合繊維の融点を測定したところ、248℃と、128℃に吸熱ピークが観察された。その他の工程はすべて実施例1と同様に実施した。
(Comparative Example 6)
As the heat-meltable binder composite fiber, a fiber having a parallel structure in which one side is made of polyethylene terephthalate and the other side is made of polyethylene was blended. When the melting point of the composite fiber was measured by DSC, endothermic peaks were observed at 248 ° C. and 128 ° C. All other steps were performed in the same manner as in Example 1.
断熱材の断熱性
断熱材の断熱性は、以下の方法で評価した。成形後、幅100mm、奥行き100mm、厚み40mmにカットされた断熱材を、200℃に保たれたホットプレートの上に置き、10分後の断熱材のホットプレート接触面表面温度(E)と、その対面である上部表面温度(F)を、テストー社製接触式表面温度計testo905−T2にて測定し、温度の差(E−F)を求めた。この温度の差(E−F)が、「◎:50℃以上」、「○:40℃以上50℃未満」、「△:30℃以上40℃未満」、「×:30℃未満」として4段階で評価した。本発明においては、◎、○、△を発明の対象とした。
Insulation property of the heat insulating material The heat insulating property of the heat insulating material was evaluated by the following method. After the molding, the heat insulating material cut to a width of 100 mm, a depth of 100 mm, and a thickness of 40 mm is placed on a hot plate maintained at 200 ° C., and the hot plate contact surface temperature (E) of the heat insulating material after 10 minutes, The upper surface temperature (F) which is the opposite surface was measured by a contact type surface thermometer testo905-T2 manufactured by Testo, and a temperature difference (E-F) was obtained. This temperature difference (E−F) is 4 as “◎: 50 ° C. or more”, “◯: 40 ° C. or more and less than 50 ° C.”, “Δ: 30 ° C. or more and less than 40 ° C.”, “×: less than 30 ° C.” Rated by stage. In the present invention, ◎, ○, and Δ are the objects of the invention.
断熱材の成形性
断熱材の成形性を、「○:成形しやすく、木質繊維が落ちることがない」、「×:成形はできるが、持ち上げたり設置したりするときに容易に木質繊維が落ちる」の2段階で評価した。本発明においては、○を発明の対象とした。持ち上げたり設置したりするときに容易に木質繊維が落ちる場合、断熱材を容易に施工することができない。即ち、本発明の断熱材において、良い成形性を達成することは、容易な施工を可能にすることに繋がる。
Formability of heat insulating material The formability of heat insulating material is as follows: “○: Easy to mold, wood fiber does not fall”, “×: Can be molded, but wood fiber easily falls when lifted or installed ”Was evaluated in two stages. In the present invention, ○ is the subject of the invention. If the wood fiber falls easily when lifting or installing, the insulation cannot be easily applied. That is, in the heat insulating material of the present invention, achieving good moldability leads to easy construction.
断熱材成形時の作業性
断熱材成形時の作業性とは、エアレイド方式で成形する場合のエアレイド機の加熱温度の実施可能温度域に幅を持たせられるかどうかの指標である。広い実施可能温度域を持つことは、温度設定作業、および温度管理作業を容易にし、製造の効率化を図ることができる。実施可能温度域は、以下の方法で求めた。実施例1〜5、参考例1〜7、および比較例1〜6とは別に、それぞれ、実施例1〜5、参考例1〜7、および比較例1〜6と同じ条件で、木質繊維と熱溶融性バインダー繊維を配合し、エアレイド機の加熱温度を80℃から280℃まで5℃間隔で変えて、それぞれの加熱温度で断熱材を成形した。80℃から280℃までの加熱温度で、該バインダー繊維の一部が溶融し、持ち上げたときに容易に木質繊維が落ちることなく成形できた温度(G)と、200℃で成形したときの断熱材の密度(表3に記載、ただし、実施例9、10、および比較例4の条件においては140℃で成形したときの断熱材の密度とする)より0.005g/cm3以上高い密度となったときの加熱温度(H)の差(H−G)が、「◎:100℃超え」、「○:50℃超え100℃以下」、「△:25℃超え50℃以下」、「×:25℃以下、もしくは、いずれの温度においても持ち上げたときに容易に木質繊維が落ちることなく成形することができない」の4段階で評価した。本発明においては、◎、○、△を発明の対象とするが、好ましくは◎、○であることが製造の効率を高める。
Workability at the time of forming a heat insulating material The workability at the time of forming a heat insulating material is an index of whether or not a range can be given to the temperature range in which the heating temperature of the air laid machine is formed in the air laid method. Having a wide practicable temperature range facilitates temperature setting work and temperature management work, and can improve manufacturing efficiency. The feasible temperature range was determined by the following method. Examples 1 5 apart from the reference examples 1-7, and Comparative Examples 1 to 6, respectively, under the same conditions as in Example 1 to 5 Reference Example 1-7, and Comparative Examples 1 to 6, and wood fiber A heat-meltable binder fiber was blended, and the heating temperature of the airlaid machine was changed from 80 ° C. to 280 ° C. at intervals of 5 ° C., and a heat insulating material was molded at each heating temperature. A temperature (G) at which a part of the binder fiber is melted at a heating temperature from 80 ° C. to 280 ° C. and can be easily molded without being dropped when lifted, and heat insulation when molded at 200 ° C. A density higher by 0.005 g / cm 3 or more than the density of the material (described in Table 3, except that in the conditions of Examples 9, 10 and Comparative Example 4, the density of the heat insulating material when molded at 140 ° C.) The difference (H-G) in the heating temperature (H) at that time was “◎: over 100 ° C.”, “◯: over 50 ° C. over 100 ° C.”, “Δ: over 25 ° C. over 50 ° C.”, “× : 25 degrees C or less, or when it raises at any temperature, it cannot be shape | molded without dropping a wood fiber easily. " In the present invention, ◎, 、, and Δ are the objects of the invention, but preferably ◎ and ○ improve the production efficiency.
実施例1〜5、参考例1〜8、および比較例1〜6における、熱溶融性バインダー繊維の構造、組成、配合割合を表1に示す。 Table 1 shows the structures, compositions, and blending ratios of the heat-meltable binder fibers in Examples 1 to 5, Reference Examples 1 to 8 and Comparative Examples 1 to 6.
実施例1〜5、参考例1〜8、および比較例1〜6における成形方法を表2に示す。 Table 2 shows molding methods in Examples 1 to 5, Reference Examples 1 to 8 and Comparative Examples 1 to 6.
実施例1〜5、参考例1〜8、および比較例1〜6における評価結果を表3に示す。 Table 3 shows the evaluation results in Examples 1 to 5, Reference Examples 1 to 8 and Comparative Examples 1 to 6.
表3の結果から明らかなように、木質繊維と、熱溶融性バインダー芯鞘複合繊維とを加熱成形して得られる本発明の断熱材は、該複合繊維が融点の異なる少なくとも2種類以上の成分からなり、該複合繊維を断熱材の絶乾固形分質量に対して10〜50質量%含むことで、環境に配慮した素材を原料としながら、低密度で優れた断熱性能を持ち、製造時の作業性に優れ、容易に成形でき、容易に施工することができる断熱材が提供される。また、作業性の点から、該複合繊維の融点の最も高い芯部成分と最も低い鞘部成分の融点の差が50℃以上であることが好ましい。 As is apparent from the results in Table 3, the heat insulating material of the present invention obtained by thermoforming wood fibers and heat-meltable binder core-sheath composite fibers has at least two types of components in which the composite fibers have different melting points. Containing 10 to 50% by mass of the composite fiber with respect to the absolutely dry solid content mass of the heat insulating material, while having an environmentally friendly material as a raw material, it has excellent heat insulating performance at low density, An insulating material that is excellent in workability, can be easily molded, and can be easily constructed is provided. From the viewpoint of workability, the difference in melting point between the core component having the highest melting point and the sheath component having the lowest melting point of the composite fiber is preferably 50 ° C. or more.
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