JP6834786B2 - Binder for inorganic fibers, aqueous binder solution for inorganic fibers, inorganic fiber mat and its manufacturing method - Google Patents
Binder for inorganic fibers, aqueous binder solution for inorganic fibers, inorganic fiber mat and its manufacturing method Download PDFInfo
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- 239000012784 inorganic fiber Substances 0.000 title claims description 147
- 239000011230 binding agent Substances 0.000 title claims description 86
- 238000004519 manufacturing process Methods 0.000 title description 8
- 229920001577 copolymer Polymers 0.000 claims description 35
- FPYJFEHAWHCUMM-UHFFFAOYSA-N maleic anhydride Chemical compound O=C1OC(=O)C=C1 FPYJFEHAWHCUMM-UHFFFAOYSA-N 0.000 claims description 25
- 229920002451 polyvinyl alcohol Polymers 0.000 claims description 19
- 150000001875 compounds Chemical class 0.000 claims description 18
- 229920003169 water-soluble polymer Polymers 0.000 claims description 17
- 238000006116 polymerization reaction Methods 0.000 claims description 13
- 239000004372 Polyvinyl alcohol Substances 0.000 claims description 11
- VQTUBCCKSQIDNK-UHFFFAOYSA-N Isobutene Chemical group CC(C)=C VQTUBCCKSQIDNK-UHFFFAOYSA-N 0.000 claims description 10
- 239000011491 glass wool Substances 0.000 claims description 10
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 9
- 239000011490 mineral wool Substances 0.000 claims description 7
- 238000005507 spraying Methods 0.000 claims description 6
- 229920002134 Carboxymethyl cellulose Polymers 0.000 claims description 5
- 229920002472 Starch Polymers 0.000 claims description 5
- 239000001768 carboxy methyl cellulose Substances 0.000 claims description 5
- 235000010948 carboxy methyl cellulose Nutrition 0.000 claims description 5
- 239000008112 carboxymethyl-cellulose Substances 0.000 claims description 5
- 235000019422 polyvinyl alcohol Nutrition 0.000 claims description 5
- 239000008107 starch Substances 0.000 claims description 5
- 235000019698 starch Nutrition 0.000 claims description 5
- WSFSSNUMVMOOMR-UHFFFAOYSA-N Formaldehyde Chemical compound O=C WSFSSNUMVMOOMR-UHFFFAOYSA-N 0.000 description 42
- 238000000034 method Methods 0.000 description 16
- 239000000243 solution Substances 0.000 description 12
- 239000012855 volatile organic compound Substances 0.000 description 10
- 239000005011 phenolic resin Substances 0.000 description 9
- IMROMDMJAWUWLK-UHFFFAOYSA-N Ethenol Chemical compound OC=C IMROMDMJAWUWLK-UHFFFAOYSA-N 0.000 description 7
- 238000007127 saponification reaction Methods 0.000 description 6
- 230000000052 comparative effect Effects 0.000 description 5
- 239000000835 fiber Substances 0.000 description 5
- 238000000465 moulding Methods 0.000 description 5
- KAKZBPTYRLMSJV-UHFFFAOYSA-N Butadiene Chemical compound C=CC=C KAKZBPTYRLMSJV-UHFFFAOYSA-N 0.000 description 4
- 206010016654 Fibrosis Diseases 0.000 description 4
- 239000003431 cross linking reagent Substances 0.000 description 4
- 230000004761 fibrosis Effects 0.000 description 4
- 238000005227 gel permeation chromatography Methods 0.000 description 4
- 238000010438 heat treatment Methods 0.000 description 4
- 239000011358 absorbing material Substances 0.000 description 3
- 239000007864 aqueous solution Substances 0.000 description 3
- 230000006835 compression Effects 0.000 description 3
- 238000007906 compression Methods 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 239000011810 insulating material Substances 0.000 description 3
- 239000000203 mixture Substances 0.000 description 3
- 239000000126 substance Substances 0.000 description 3
- 238000012360 testing method Methods 0.000 description 3
- HORQAOAYAYGIBM-UHFFFAOYSA-N 2,4-dinitrophenylhydrazine Chemical compound NNC1=CC=C([N+]([O-])=O)C=C1[N+]([O-])=O HORQAOAYAYGIBM-UHFFFAOYSA-N 0.000 description 2
- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical compound N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 description 2
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 2
- 239000000654 additive Substances 0.000 description 2
- 238000004458 analytical method Methods 0.000 description 2
- 239000004566 building material Substances 0.000 description 2
- 238000005119 centrifugation Methods 0.000 description 2
- 238000005520 cutting process Methods 0.000 description 2
- 238000010586 diagram Methods 0.000 description 2
- 238000005259 measurement Methods 0.000 description 2
- 230000008569 process Effects 0.000 description 2
- 238000011084 recovery Methods 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- 239000003232 water-soluble binding agent Substances 0.000 description 2
- 239000004925 Acrylic resin Substances 0.000 description 1
- 229920000178 Acrylic resin Polymers 0.000 description 1
- ISWSIDIOOBJBQZ-UHFFFAOYSA-N Phenol Chemical compound OC1=CC=CC=C1 ISWSIDIOOBJBQZ-UHFFFAOYSA-N 0.000 description 1
- OFOBLEOULBTSOW-UHFFFAOYSA-N Propanedioic acid Natural products OC(=O)CC(O)=O OFOBLEOULBTSOW-UHFFFAOYSA-N 0.000 description 1
- 239000006087 Silane Coupling Agent Substances 0.000 description 1
- XSQUKJJJFZCRTK-UHFFFAOYSA-N Urea Chemical compound NC(N)=O XSQUKJJJFZCRTK-UHFFFAOYSA-N 0.000 description 1
- 238000010521 absorption reaction Methods 0.000 description 1
- 125000005396 acrylic acid ester group Chemical group 0.000 description 1
- 229910021529 ammonia Inorganic materials 0.000 description 1
- 150000001639 boron compounds Chemical class 0.000 description 1
- 239000004202 carbamide Substances 0.000 description 1
- 150000001718 carbodiimides Chemical class 0.000 description 1
- 125000003178 carboxy group Chemical group [H]OC(*)=O 0.000 description 1
- 230000008859 change Effects 0.000 description 1
- 239000003795 chemical substances by application Substances 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 239000003086 colorant Substances 0.000 description 1
- 238000006482 condensation reaction Methods 0.000 description 1
- 238000010276 construction Methods 0.000 description 1
- 230000007423 decrease Effects 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 239000000839 emulsion Substances 0.000 description 1
- 150000002148 esters Chemical class 0.000 description 1
- -1 ethylene, ethylene Chemical group 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 125000000524 functional group Chemical group 0.000 description 1
- 238000001879 gelation Methods 0.000 description 1
- 239000000383 hazardous chemical Substances 0.000 description 1
- 231100000206 health hazard Toxicity 0.000 description 1
- 230000007062 hydrolysis Effects 0.000 description 1
- 238000006460 hydrolysis reaction Methods 0.000 description 1
- 125000002887 hydroxy group Chemical group [H]O* 0.000 description 1
- 230000001771 impaired effect Effects 0.000 description 1
- 238000003905 indoor air pollution Methods 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 239000012948 isocyanate Substances 0.000 description 1
- 150000002513 isocyanates Chemical class 0.000 description 1
- 238000010030 laminating Methods 0.000 description 1
- 238000003754 machining Methods 0.000 description 1
- 239000011976 maleic acid Substances 0.000 description 1
- 239000000463 material Substances 0.000 description 1
- WSFSSNUMVMOOMR-NJFSPNSNSA-N methanone Chemical compound O=[14CH2] WSFSSNUMVMOOMR-NJFSPNSNSA-N 0.000 description 1
- XJRBAMWJDBPFIM-UHFFFAOYSA-N methyl vinyl ether Chemical compound COC=C XJRBAMWJDBPFIM-UHFFFAOYSA-N 0.000 description 1
- 239000006060 molten glass Substances 0.000 description 1
- 239000000178 monomer Substances 0.000 description 1
- 239000003002 pH adjusting agent Substances 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- QQONPFPTGQHPMA-UHFFFAOYSA-N propylene Natural products CC=C QQONPFPTGQHPMA-UHFFFAOYSA-N 0.000 description 1
- 125000004805 propylene group Chemical group [H]C([H])([H])C([H])([*:1])C([H])([H])[*:2] 0.000 description 1
- 239000002994 raw material Substances 0.000 description 1
- 230000001105 regulatory effect Effects 0.000 description 1
- 239000005871 repellent Substances 0.000 description 1
- 230000002940 repellent Effects 0.000 description 1
- 238000005070 sampling Methods 0.000 description 1
- 208000008842 sick building syndrome Diseases 0.000 description 1
- 239000000377 silicon dioxide Substances 0.000 description 1
- 238000009987 spinning Methods 0.000 description 1
- 239000007921 spray Substances 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 238000005728 strengthening Methods 0.000 description 1
- 208000011580 syndromic disease Diseases 0.000 description 1
- 238000010998 test method Methods 0.000 description 1
- VZCYOOQTPOCHFL-UHFFFAOYSA-N trans-butenedioic acid Natural products OC(=O)C=CC(O)=O VZCYOOQTPOCHFL-UHFFFAOYSA-N 0.000 description 1
- 238000009423 ventilation Methods 0.000 description 1
- 229920006163 vinyl copolymer Polymers 0.000 description 1
- 239000003643 water by type Substances 0.000 description 1
Images
Classifications
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- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/58—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives
- D04H1/587—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties by applying, incorporating or activating chemical or thermoplastic bonding agents, e.g. adhesives characterised by the bonding agents used
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L29/00—Compositions of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an alcohol, ether, aldehydo, ketonic, acetal or ketal radical; Compositions of hydrolysed polymers of esters of unsaturated alcohols with saturated carboxylic acids; Compositions of derivatives of such polymers
- C08L29/02—Homopolymers or copolymers of unsaturated alcohols
- C08L29/04—Polyvinyl alcohol; Partially hydrolysed homopolymers or copolymers of esters of unsaturated alcohols with saturated carboxylic acids
-
- C—CHEMISTRY; METALLURGY
- C03—GLASS; MINERAL OR SLAG WOOL
- C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
- C03C25/00—Surface treatment of fibres or filaments made from glass, minerals or slags
- C03C25/10—Coating
- C03C25/48—Coating with two or more coatings having different compositions
- C03C25/50—Coatings containing organic materials only
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
- C08L23/26—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers modified by chemical after-treatment
- C08L23/36—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers modified by chemical after-treatment by reaction with compounds containing nitrogen, e.g. by nitration
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4209—Inorganic fibres
-
- D—TEXTILES; PAPER
- D04—BRAIDING; LACE-MAKING; KNITTING; TRIMMINGS; NON-WOVEN FABRICS
- D04H—MAKING TEXTILE FABRICS, e.g. FROM FIBRES OR FILAMENTARY MATERIAL; FABRICS MADE BY SUCH PROCESSES OR APPARATUS, e.g. FELTS, NON-WOVEN FABRICS; COTTON-WOOL; WADDING ; NON-WOVEN FABRICS FROM STAPLE FIBRES, FILAMENTS OR YARNS, BONDED WITH AT LEAST ONE WEB-LIKE MATERIAL DURING THEIR CONSOLIDATION
- D04H1/00—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres
- D04H1/40—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties
- D04H1/42—Non-woven fabrics formed wholly or mainly of staple fibres or like relatively short fibres from fleeces or layers composed of fibres without existing or potential cohesive properties characterised by the use of certain kinds of fibres insofar as this use has no preponderant influence on the consolidation of the fleece
- D04H1/4209—Inorganic fibres
- D04H1/4218—Glass fibres
Description
本発明は、無機繊維用バインダー、特に、建築用の断熱材、吸音材等として好適に用いられる無機繊維マットに対して、揮発性有機化合物の放出が極めて少なく、十分な厚みを持ち、かつ優れた復元性を与える無機繊維用バインダー、及び該バインダーで処理された無機繊維マットに関する。 INDUSTRIAL APPLICABILITY The present invention has extremely little emission of volatile organic compounds, has sufficient thickness, and is excellent with respect to a binder for inorganic fibers, particularly an inorganic fiber mat preferably used as a heat insulating material for construction, a sound absorbing material, and the like. The present invention relates to a binder for inorganic fibers that imparts restorability, and an inorganic fiber mat treated with the binder.
従来、グラスウール、ロックウール等の無機繊維からなる無機繊維マットは、産業用や住宅用の断熱材や吸音材に広く用いられている。無機繊維マットは、一般に水溶性フェノール樹脂を主成分とするバインダーによって無機繊維同士が固定され、マット状に成形されて製造されている(例えば、特開昭58−070760号公報:特許文献1)。 Conventionally, inorganic fiber mats made of inorganic fibers such as glass wool and rock wool have been widely used as heat insulating materials and sound absorbing materials for industrial and residential use. Inorganic fiber mats are generally manufactured by fixing inorganic fibers to each other with a binder containing a water-soluble phenol resin as a main component and molding them into a mat shape (for example, JP-A-58-07760: Patent Document 1). ..
しかし、上記バインダーの主成分として用いられている水溶性フェノール樹脂は、架橋剤として一般的にホルムアルデヒドが使用されているため、バインダーを加熱硬化する際に、未反応のホルムアルデヒドが無機繊維マットに残留してしまうという問題がある。また、硬化後も、バインダーの加水分解や縮合反応の進行によってホルムアルデヒドが発生するという問題がある。この場合、上記ホルムアルデヒドが、製造後の無機繊維マットの表面や側面から放出されることになる。 However, since formaldehyde is generally used as a cross-linking agent in the water-soluble phenol resin used as the main component of the binder, unreacted formaldehyde remains in the inorganic fiber mat when the binder is heat-cured. There is a problem of doing it. Further, even after curing, there is a problem that formaldehyde is generated due to the progress of hydrolysis and condensation reaction of the binder. In this case, the formaldehyde is released from the surface and side surfaces of the manufactured inorganic fiber mat.
ホルムアルデヒドのように常温常圧で空気中に容易に揮発する揮発性有機化合物に関して、近年、揮発性有機化合物による室内空気の汚染が顕在化するとともに、揮発性有機化合物が原因のひとつとされるシックハウス症候群などの健康被害が問題となっている。そのため、建築材料からのホルムアルデヒドの放出量が法律で規制されている。よって、建築材料からのホルムアルデヒド及びその他の揮発性有機化合物の放出量を極めて少なくするために、これらの含有量を極めて少なくすることが有効であると考えられる。 Regarding volatile organic compounds that easily volatilize in the air at normal temperature and pressure, such as formaldehyde, in recent years, indoor air pollution by volatile organic compounds has become apparent, and sick house syndrome is considered to be one of the causes. Health hazards such as syndrome have become a problem. Therefore, the amount of formaldehyde emitted from building materials is regulated by law. Therefore, in order to extremely reduce the amount of formaldehyde and other volatile organic compounds released from building materials, it is considered effective to reduce their content extremely.
無機繊維マットから放出される揮発性有機化合物とは、主にバインダーに含まれるホルムアルデヒドであるため、上記問題点を解決するためには、バインダーに用いる組成物をホルムアルデヒド非含有組成物とする必要がある。しかし、従来のフェノール樹脂を主成分とするバインダーを用いた無機繊維マットは、原料コストが安く、更にマットの復元率や表面強度等が非常に優れたものであった。そのため、ホルムアルデヒド非含有組成物を主成分とするバインダーを用いてもこれらの性能を有する必要があるが、同等の性能を具備させることは困難であった。 Since the volatile organic compound released from the inorganic fiber mat is mainly formaldehyde contained in the binder, in order to solve the above problems, it is necessary to make the composition used for the binder a formaldehyde-free composition. is there. However, the conventional inorganic fiber mat using a binder containing a phenol resin as a main component has a low raw material cost and is extremely excellent in the restoration rate and surface strength of the mat. Therefore, it is necessary to have these performances even if a binder containing a formaldehyde-free composition as a main component is used, but it has been difficult to provide the same performances.
上記問題に対応するために、特開2005−299013号公報(特許文献2)では、アクリル樹脂系エマルジョンを主成分とするバインダー、また、特開2006−089906号公報(特許文献3)では、カルボキシル基等の官能基を持ったビニル共重合体からなるバインダーが提案されている。しかし、これらのバインダーを用いて得られる無機繊維マットの復元率や表面強度等は、水溶性フェノール樹脂を含むバインダーを用いて得られる無機繊維マットと比較して劣るものであった。さらに、本願出願人も特開2011−153395号公報(特許文献4)で、ヒドロキシル基を持つ水溶性高分子化合物とホウ素化合物を含有するバインダーを開示している。しかし、当該バインダーを用いて得られる無機繊維マットは、揮発性有機化合物の問題はクリアできていたものの、水溶性フェノール樹脂に比べて復元率や表面強化度等はやや劣っていた。 In order to deal with the above problems, in Japanese Patent Application Laid-Open No. 2005-299013 (Patent Document 2), a binder containing an acrylic resin emulsion as a main component, and in Japanese Patent Application Laid-Open No. 2006-089906 (Patent Document 3), carboxyl. A binder made of a vinyl copolymer having a functional group such as a group has been proposed. However, the restoration rate, surface strength, etc. of the inorganic fiber mats obtained by using these binders were inferior to those of the inorganic fiber mats obtained by using the binder containing a water-soluble phenol resin. Further, the applicant of the present application also discloses Japanese Patent Application Laid-Open No. 2011-153395 (Patent Document 4), which discloses a binder containing a water-soluble polymer compound having a hydroxyl group and a boron compound. However, although the inorganic fiber mat obtained by using the binder was able to solve the problem of volatile organic compounds, the restoration rate and the surface strengthening degree were slightly inferior to those of the water-soluble phenol resin.
国際公開第2005/092814号(特許文献5)では無水マレイン酸と不飽和単量体との不飽和共重合物(具体的には無水マレイン酸とブタジエンとの不飽和共重合物)が、特開2012−136385号公報(特許文献6)では無水マレイン酸とアクリル酸エステルの共重合化合物が、特開2016−108707号公報(特許文献7)と特開2016−108708号公報(特許文献8)ではマレイン酸共重合物(メチルビニルエーテル/無水マレイン酸共重合体モノアルキルエステルと思われる)が、特開昭60−046951号公報(特許文献9)ではイソブチレン・無水マレイン酸の共重合体が、それぞれ提案されている。無機繊維からなる無機繊維マットは、溶融ガラスに低濃度の水溶性バインダーを噴霧することで製造されるが、前述した化合物等は、いずれも水への溶解度が乏しく、必ずしも好適な水溶性バインダーが得られるものではなかった。 In International Publication No. 2005/092814 (Patent Document 5), an unsaturated copolymer of maleic anhydride and an unsaturated monomer (specifically, an unsaturated copolymer of maleic anhydride and butadiene) is a special feature. In Kai 2012-136385 (Patent Document 6), the copolymer compound of maleic anhydride and acrylic acid ester is found in JP-A-2016-108707 (Patent Document 7) and JP-A-2016-108708 (Patent Document 8). In this article, a maleic acid copolymer (which seems to be a methyl vinyl ether / maleic anhydride copolymer monoalkyl ester) is used, and in JP-A-60-046951 (Patent Document 9), a copolymer of isobutylene and maleic anhydride is used. Each has been proposed. Inorganic fiber mats made of inorganic fibers are produced by spraying a low-concentration water-soluble binder on molten glass, but all of the above-mentioned compounds and the like have poor solubility in water, and a suitable water-soluble binder is not always suitable. It was not obtained.
本発明は、上記事情に鑑みなされたもので、揮発性有機化合物の放出が極めて少なく、かつ、十分な厚みと復元性に優れた無機繊維マットを製造することが可能な無機繊維用バインダー、及び該バインダーで処理された無機繊維マットを提供することを目的とする。 The present invention has been made in view of the above circumstances, and is a binder for inorganic fibers capable of producing an inorganic fiber mat having extremely low release of volatile organic compounds and excellent thickness and resilience, and a binder for inorganic fibers. It is an object of the present invention to provide an inorganic fiber mat treated with the binder.
本発明者らは、上記目的を達成するために鋭意検討を行った結果、水溶性高分子化合物と、無水マレイン酸を含有する共重合物のアンモニア変性物とを含有するバインダーが、フェノール樹脂に近い復元率を無機繊維マットに与え、かつ極めて少ない揮発性有機化合物放出量を実現することができることを見出し、本発明をなすに至った。 As a result of diligent studies to achieve the above object, the present inventors have converted a binder containing a water-soluble polymer compound and an ammonia-modified copolymer containing maleic anhydride into a phenol resin. We have found that it is possible to give an inorganic fiber mat a close restoration rate and realize an extremely small amount of volatile organic compounds released, and have completed the present invention.
従って、本発明は、下記無機繊維用バインダー、無機繊維用バインダー水溶液、無機繊維マット及びその製造方法を提供する。
1.(A)重合度が200〜500であり、且つ、ポリビニルアルコール、カルボキシメチルセルロース及び澱粉の群から選ばれる水溶性高分子化合物:100質量部、及び
(B)無水マレイン酸を含有する共重合物のアンモニア変性物:3質量部以上
を含有する無機繊維用バインダーであり、該無機繊維はグラスウール又はロックウールであることを特徴とする無機繊維用バインダー。
2.(A)水溶性高分子化合物がポリビニルアルコールである上記1記載の無機繊維用バインダー。
3.(B)無水マレイン酸を含有する共重合物のアンモニア変性物が、イソブチレン・無水マレイン酸共重合物のアンモニア変性物である上記1又は2記載の無機繊維用バインダー。
4.上記イソブチレン・無水マレイン酸共重合物のアンモニア変性物が下記式で表される上記3記載の無機繊維用バインダー。
5.上記1〜4のいずれか1項記載の無機繊維用バインダーで処理した無機繊維からなる無機繊維マット。
6.上記1〜4のいずれか1項記載の無機繊維用バインダーを水に溶解してなる無機繊維用バインダー水溶液であって、該無機繊維用バインダー水溶液の粘度が25℃において1〜100mPa・sであることを特徴とする無機繊維用バインダー水溶液。
7.(A)重合度が200〜500であり、且つ、ポリビニルアルコール、カルボキシメチルセルロース及び澱粉の群から選ばれる水溶性高分子化合物:100質量部、及び
(B)無水マレイン酸を含有する共重合物のアンモニア変性物:3質量部以上
を含有する無機繊維用バインダーを無機繊維に対してスプレーにより噴霧して製造する工程を含むと共に、上記無機繊維はグラスウール又はロックウールであることを特徴とする無機繊維マットの製造方法。
Therefore, the present invention provides the following binder for inorganic fibers, an aqueous binder solution for inorganic fibers, an inorganic fiber mat, and a method for producing the same.
1. 1. (A) A copolymer having a degree of polymerization of 200 to 500 and containing 100 parts by mass of a water-soluble polymer compound selected from the group of polyvinyl alcohol, carboxymethyl cellulose and starch , and (B) maleic anhydride. Ammonia-modified product: A binder for inorganic fibers containing 3 parts by mass or more, wherein the inorganic fibers are glass wool or rock wool.
2. 2. (A) The binder for inorganic fibers according to 1 above, wherein the water-soluble polymer compound is polyvinyl alcohol.
3. 3. (B) The binder for inorganic fibers according to 1 or 2 above, wherein the ammonia-modified product of the copolymer containing maleic anhydride is an ammonia-modified product of the isobutylene / maleic anhydride copolymer.
4. The binder for inorganic fibers according to the above 3 , wherein the ammonia-modified product of the isobutylene / maleic anhydride copolymer is represented by the following formula.
5. An inorganic fiber mat made of inorganic fibers treated with the binder for inorganic fibers according to any one of 1 to 4 above.
6. An aqueous binder solution for inorganic fibers obtained by dissolving the binder for inorganic fibers according to any one of 1 to 4 above in water, and the viscosity of the aqueous binder solution for inorganic fibers is 1 to 100 mPa · s at 25 ° C. A binder aqueous solution for inorganic fibers.
7. (A) A copolymer having a degree of polymerization of 200 to 500 and containing 100 parts by mass of a water-soluble polymer compound selected from the group of polyvinyl alcohol, carboxymethyl cellulose and starch , and (B) maleic anhydride. Ammonia-modified product: An inorganic fiber comprising a step of spraying a binder for inorganic fibers containing 3 parts by mass or more onto the inorganic fiber to produce the inorganic fiber, and the inorganic fiber is glass wool or rock wool. How to make a mat.
本発明の無機繊維用バインダーを用いれば、フェノール樹脂に近い復元率を持つ無機繊維マットを作製することができ、またその無機繊維マットからの揮発性有機化合物の放出量は極めて少ない。 By using the binder for inorganic fibers of the present invention, an inorganic fiber mat having a restoration rate close to that of a phenol resin can be produced, and the amount of volatile organic compounds released from the inorganic fiber mat is extremely small.
以下、本発明を具体的に説明する。
本発明の無機繊維用バインダーは、
(A)水溶性高分子化合物:100質量部、及び
(B)無水マレイン酸を含有する共重合物のアンモニア変性物:3質量部以上
を含有するものである。
Hereinafter, the present invention will be specifically described.
The binder for inorganic fibers of the present invention
(A) Water-soluble polymer compound: 100 parts by mass, and (B) Ammonia-modified product of a copolymer containing maleic anhydride: 3 parts by mass or more.
(A)成分の水溶性高分子化合物は、本発明の無機繊維用バインダーの主剤である。(A)成分の持つ水溶性高分子化合物としては、特に限定されないが、好ましくはポリビニルアルコール、カルボキシメチルセルロース、澱粉などである。これらの中でも、ポリビニルアルコールが特に好ましい。 The water-soluble polymer compound of the component (A) is the main agent of the binder for inorganic fibers of the present invention. The water-soluble polymer compound contained in the component (A) is not particularly limited, but is preferably polyvinyl alcohol, carboxymethyl cellulose, starch and the like. Of these, polyvinyl alcohol is particularly preferable.
上記(A)成分の水溶性高分子化合物としては、重合度が1,000以下のものが好ましく、500以下のものが更に好ましく、200〜500のものが最も好ましい。1,000を超えると、スプレーによる塗布不良が生じ必要な付着量が得られず無機繊維マットに十分な復元性が得られないなどの不具合が生じる場合がある。上記重合度は、重量平均重合度として、水系ゲルパーミエーションクロマトグラフィ(GPC)分析によるポリスチレン換算の値である。また、水溶性高分子化合物のケン化度は、JIS K 6726の試験方法に基づいて、80mol%以上が好ましく、88mol%以上が更に好ましく、上限値は99mol%未満であることが好ましい。このケン化度が99mol%以上であると、低温で粘度上昇が大きくなり、ゲル化することがある。 As the water-soluble polymer compound of the component (A), those having a degree of polymerization of 1,000 or less are preferable, those having a degree of polymerization of 500 or less are more preferable, and those having a degree of polymerization of 200 to 500 are most preferable. If it exceeds 1,000, coating defects due to spraying may occur, the required amount of adhesion may not be obtained, and problems such as insufficient resilience of the inorganic fiber mat may occur. The degree of polymerization is a polystyrene-equivalent value obtained by water-based gel permeation chromatography (GPC) analysis as the weight average degree of polymerization. The degree of saponification of the water-soluble polymer compound is preferably 80 mol% or more, more preferably 88 mol% or more, and the upper limit value is preferably less than 99 mol%, based on the test method of JIS K 6726. If the degree of saponification is 99 mol% or more, the viscosity increases significantly at low temperatures, and gelation may occur.
上記(A)成分の水溶性高分子化合物としては、市販品を使用することができ、例えば、日本・酢ビポバール社製の「ポバール(PVA)」等が挙げられる。 As the water-soluble polymer compound of the component (A), a commercially available product can be used, and examples thereof include "Poval (PVA)" manufactured by Japan Vam & Poval Co., Ltd.
(B)成分の無水マレイン酸を含有する共重合物のアンモニア変性物は、本発明において架橋剤として機能する。(B)成分の無水マレイン酸を含有する共重合物のアンモニア変性物としては、特に限定されず、無水マレイン酸とイソブチレン、イソプロピレン、エチレン、エチレン・プロピレン、ブタジエンなどとの共重合物のアンモニア変性物が挙げられる。特に、下記構造式で表されるイソブチレン・無水マレイン酸共重合物のアンモニア変性物が好ましい。
(B)成分の無水マレイン酸を含有する共重合物のアンモニア変性物の重量平均分子量は、5,000〜30,000が好ましく、10,000〜20,000が更に好ましく、15,000〜20,000が最も好ましい。この重量平均分子量は、水系ゲルパーミエーションクロマトグラフィ(GPC)分析によるポリスチレン換算の値である。また、上記式中のnとmは質量割合を表し、nは、n+mの合計100質量%に対して、0.1〜3質量%が好ましく、0.3〜2質量%が更に好ましく、0.5〜1質量%が最も好ましい。 The weight average molecular weight of the ammonia-modified copolymer containing maleic anhydride as the component (B) is preferably 5,000 to 30,000, more preferably 10,000 to 20,000, and 15,000 to 20. 000 is the most preferable. This weight average molecular weight is a polystyrene-equivalent value obtained by aqueous gel permeation chromatography (GPC) analysis. Further, n and m in the above formula represent mass ratios, and n is preferably 0.1 to 3% by mass, more preferably 0.3 to 2% by mass, and 0, based on 100% by mass of the total of n + m. .5 to 1% by mass is most preferable.
(B)成分の無水マレイン酸を含有する共重合物のアンモニア変性物の含有量は、(A)成分の水溶性高分子化合物100質量部に対し、3質量部以上であり、好ましくは3〜20質量部、更に好ましくは3〜5質量部である。無水マレイン酸を含有する共重合物のアンモニア変性物の含有量が3質量部未満であると、架橋性不足などの不具合が生じる場合があり、20質量部を超えた場合は、(A)成分の水溶性高分子化合物との混和性には問題はないが、処理水溶液が黄色に着色し製品品質低下となり、更にコストアップにも繋がる。 The content of the ammonia-modified product of the copolymer containing maleic anhydride as the component (B) is 3 parts by mass or more, preferably 3 to 3 parts by mass, based on 100 parts by mass of the water-soluble polymer compound of the component (A). It is 20 parts by mass, more preferably 3 to 5 parts by mass. If the content of the ammonia-modified product of the copolymer containing maleic anhydride is less than 3 parts by mass, problems such as insufficient crosslinkability may occur, and if it exceeds 20 parts by mass, the component (A) There is no problem with the miscibility with the water-soluble polymer compound, but the treated aqueous solution is colored yellow, which deteriorates the product quality and further increases the cost.
上記(B)成分の無水マレイン酸含有共重合物としては、市販品を使用することができ、例えば、クラレ社製の「イソバン」等が挙げられる。 As the maleic anhydride-containing copolymer of the component (B), a commercially available product can be used, and examples thereof include "Isoban" manufactured by Kuraray.
更に、本発明の無機繊維用バインダーには、(A)水溶性高分子化合物及び(B)無水マレイン酸を含有する共重合物のアンモニア変性物以外に、尿素等の保水材、シランカップリング剤、撥水剤、pH調整剤、着色剤などの添加剤を必要により加えてもよい。これらの添加剤の添加量は、本発明の効果を損なわない範囲で任意とすることができる。 Further, the binder for inorganic fibers of the present invention includes (A) a water-soluble polymer compound and (B) an ammonia-modified copolymer containing maleic anhydride, a water retention material such as urea, and a silane coupling agent. , Water repellent, pH adjuster, colorant and other additives may be added as needed. The amount of these additives added can be arbitrary as long as the effects of the present invention are not impaired.
本発明の無機繊維用バインダーは、水に溶解して無機繊維用バインダー水溶液として使用することが好ましい。上記無機繊維用バインダー水溶液の粘度は、25℃において1〜100mPa・sであることが好ましく、特に好ましいのは、1〜50mPa・sである。なお、この粘度値は、回転粘度計による測定値である。粘度が100mPa・sを超えると噴霧(吐出)不良となり加工後のバインダー付着量が減少する為、本発明の効果が発揮できない場合がある。また、その濃度は10質量%以下が好ましく、5質量%以下が更に好ましく、3質量%以下が最も好ましい。 The binder for inorganic fibers of the present invention is preferably dissolved in water and used as an aqueous binder solution for inorganic fibers. The viscosity of the aqueous binder solution for inorganic fibers is preferably 1 to 100 mPa · s at 25 ° C., and particularly preferably 1 to 50 mPa · s. This viscosity value is a value measured by a rotational viscometer. If the viscosity exceeds 100 mPa · s, spraying (discharge) failure occurs and the amount of binder adhered after processing decreases, so that the effect of the present invention may not be exhibited. The concentration thereof is preferably 10% by mass or less, more preferably 5% by mass or less, and most preferably 3% by mass or less.
また、上記無機繊維用バインダー水溶液のpHは、4〜8であることが好ましく、4〜6がより好ましい。pHが上記範囲から外れると、架橋性が変化し、復元性に影響を及ぼす場合がある。 The pH of the aqueous binder solution for inorganic fibers is preferably 4 to 8, and more preferably 4 to 6. If the pH deviates from the above range, the crosslinkability may change, which may affect the stability.
本発明の無機繊維用バインダーは、様々な無機繊維に使用可能であり、特にグラスウール、ロックウールに対して優れた効果を発揮する。 The binder for inorganic fibers of the present invention can be used for various inorganic fibers, and particularly exerts an excellent effect on glass wool and rock wool.
本発明の無機繊維マットは、無機繊維を上記無機繊維用バインダーで処理して形成されるものである。上記無機繊維マットに用いられる無機繊維としては、特に限定されないが、グラスウールやロックウールであることが好ましい。 The inorganic fiber mat of the present invention is formed by treating an inorganic fiber with the above-mentioned binder for inorganic fibers. The inorganic fiber used in the inorganic fiber mat is not particularly limited, but glass wool or rock wool is preferable.
無機繊維の繊維化方法としては、遠心法、吹き飛ばし法など従来公知の方法を採用できる。更に、無機繊維マットの密度も通常の断熱材や吸音材に使用されている密度でよく、好ましくは40kg/m3以下、より好ましくは32kg/m3以下である。 As a method for fiberizing the inorganic fiber, a conventionally known method such as a centrifugation method or a blow-off method can be adopted. Further, the density of the inorganic fiber mat may be the density used for ordinary heat insulating materials and sound absorbing materials, and is preferably 40 kg / m 3 or less, more preferably 32 kg / m 3 or less.
無機繊維用バインダーの使用量は、無機繊維に対して固形分比率で1〜10質量%が好ましく、1〜5質量%がより好ましい。1質量%未満であると、復元性の乏しい無機繊維マットが成形されるなどの不具合が生じる場合があり、10質量%を超えると、硬く潰れた無機繊維マットが成形されるなどの不具合が生じる場合がある。 The amount of the binder for inorganic fibers used is preferably 1 to 10% by mass, more preferably 1 to 5% by mass, in terms of the solid content ratio with respect to the inorganic fibers. If it is less than 1% by mass, problems such as molding of an inorganic fiber mat having poor resilience may occur, and if it exceeds 10% by mass, problems such as molding of a hard and crushed inorganic fiber mat may occur. In some cases.
本発明の無機繊維用バインダーを使用して無機繊維マットを製造する方法の一例を、図1及び図2を参照して説明する。図1は、本発明の無機繊維用バインダーを使用して無機繊維マットを製造する工程の一実施形態を示す模式図であり、図2は、本発明の無機繊維用バインダーを無機繊維に付与する工程の一実施形態を示す斜視図である。 An example of a method for producing an inorganic fiber mat using the binder for inorganic fibers of the present invention will be described with reference to FIGS. 1 and 2. FIG. 1 is a schematic view showing an embodiment of a step of manufacturing an inorganic fiber mat using the binder for inorganic fibers of the present invention, and FIG. 2 is a diagram showing the binder for inorganic fibers of the present invention applied to the inorganic fibers. It is a perspective view which shows one Embodiment of a process.
まず、繊維化装置1によりグラスウール等の無機繊維を紡出させる繊維化工程が行われる。ここで、繊維化装置1による繊維化の方法としては、特に限定されず、従来公知の遠心法、吹き飛ばし法などが挙げられる。また、繊維化装置1は、製造する無機繊維マット7の密度、厚さ、及び幅方向の長さに応じて複数設けることも可能である。 First, a fibrosis step of spinning inorganic fibers such as glass wool is performed by the fibrosis apparatus 1. Here, the method of fibrosis by the fibrosis device 1 is not particularly limited, and examples thereof include a conventionally known centrifugation method and a blow-off method. Further, a plurality of fibrous devices 1 can be provided according to the density, thickness, and length in the width direction of the inorganic fiber mat 7 to be manufactured.
次いで、図2で示すように、バインダー付与装置2によって、繊維化装置1から紡出された無機繊維3に、本発明のバインダーを付与する。バインダーの付与方法としては、従来公知の方法を採用することができ、例えば、上記バインダー水溶液を用いて、スプレー法などで付与することができる。繊維の上層部より直接又は斜め方向から繊維同士の交点部分をメインに交点以外の部分にもバインダーを付着させて処理する。
Next, as shown in FIG. 2, the binder of the present invention is applied to the
コンベア41は、未硬化のバインダーが付着した無機繊維3を有孔のコンベア上に積層する装置であり、繊維を均一に積層させるために、コンベア41は吸引装置を有する有孔のコンベアであることが好ましい。
The
ここで、本発明におけるバインダーの付着量とは、強熱減量法又はLOI(Loss of Ignition)と呼ばれる方法により測定される量であり、約550℃でバインダー付着後の無機繊維マットの乾燥試料を強熱し、減量することにより失われる物質の質量を意味する。 Here, the amount of the binder attached in the present invention is an amount measured by a method called ignition loss method or LOI (Loss of Ignition), and a dried sample of the inorganic fiber mat after the binder is attached at about 550 ° C. It means the mass of a substance that is lost by igniting and losing weight.
上記工程によって、バインダーが付与された無機繊維3は、繊維化装置1の下方に配置されたコンベア41に堆積され、連続して、ライン方向に沿って設けられているコンベア42に移動する。そして、コンベア42及びコンベア42上に所定間隔で対向配置されたコンベア5によって、堆積した無機繊維3は所定の厚さに圧縮されつつ、コンベア42、及びコンベア5の位置に配設された成形炉6に入る。
By the above step, the
成形炉6において、無機繊維3に付与された本発明のバインダーが加熱硬化して、所定の厚さの無機繊維マット7が形成される。なお、加工条件は、ラインの長さ等で大きく変わるため、適宜設定すればよい。例えば、本実施例の場合は、加熱温度は、好ましくは150〜300℃、より好ましくは180〜250℃である。加熱温度が150℃よりも低いと、無機繊維マット7の水分が完全に蒸発しないことがあり、300℃よりも高いと無機繊維マット7に処理されたバインダーが炭化することがある。また、加熱時間は、好ましくは120〜360秒、より好ましくは180〜300秒である。加熱温度が120秒よりも短いと、無機繊維マット7の水分が完全に蒸発しないことがあり、360秒よりも長いと無機繊維マット7に処理されたバインダーが炭化することがある。そして、形成された無機繊維マット7は、コンベア43の部分に設置された切断機8によって所定の製品寸法に切断された後、コンベア44によって運ばれ、包装、梱包される。
In the molding furnace 6, the binder of the present invention applied to the
このようにして製造された本発明の無機繊維マットは、フェノール樹脂をはじめとしてこれまで提案されてきたバインダーで処理した無機繊維マットと比較して優れた復元率や表面強度等を持ちながらも、無機繊維マットからの揮発性有機化合物の放出量は極めて少ないものである。 The inorganic fiber mat of the present invention produced in this manner has excellent recovery rate, surface strength, etc. as compared with the inorganic fiber mats treated with binders proposed so far, such as phenol resin, while having excellent recovery rate and surface strength. The amount of volatile organic compounds released from the inorganic fiber mat is extremely small.
なお、JISによって、ホルムアルデヒド放散速度は、数段階に区別されている。たとえばJIS−A9504ではF☆☆〜F☆☆☆☆の3段階に区分されており、それぞれ、ホルムアルデヒド放散速度が5μg/m2・h以下の場合がF☆☆☆☆タイプ、5μg/m2・hを超えて20μg/m2・h以下の場合がF☆☆☆タイプ、20μg/m2・hを超えて120μg/m2・h以下の場合がF☆☆タイプである。F☆☆☆☆タイプが最も優れており、本発明の無機繊維用バインダーを用いた場合、JIS−A1901のチャンバー法に基づいた試験において、F☆☆☆☆タイプの無機繊維マットを製造することができる。 According to JIS, the formaldehyde emission rate is divided into several stages. For example, JIS-A9504 is divided into three stages, F ☆☆ to F ☆☆☆☆, and when the formaldehyde emission rate is 5 μg / m 2 · h or less, the F ☆☆☆☆ type, 5 μg / m 2 The case of more than h and 20 μg / m 2 · h or less is the F ☆☆☆ type, and the case of more than 20 μg / m 2 · h and 120 μg / m 2 · h or less is the F ☆☆ type. The F ☆☆☆☆ type is the most excellent, and when the binder for inorganic fibers of the present invention is used, an F ☆☆☆☆ type inorganic fiber mat is manufactured in a test based on the chamber method of JIS-A1901. Can be done.
また、本発明における無機繊維マットの復元率とは、外力を加えて圧縮させた後、外力を除いて復元させた後の無機繊維マットの厚さと、圧縮前の無機繊維マットの厚さの比で表される。無機繊維マットは保管や輸送の効率を上げるために、一定数量以上の無機繊維マットをまとめて圧縮して梱包する場合がある。そのため、開梱して得られる無機繊維マットが圧縮前の厚さを確保できない場合、すなわち、無機繊維マットの復元率が悪い場合には、断熱性や吸音性などの性能が充分に得られない場合がある。 The restoration rate of the inorganic fiber mat in the present invention is the ratio of the thickness of the inorganic fiber mat after compression by applying an external force and then by removing the external force to the thickness of the inorganic fiber mat before compression. It is represented by. Inorganic fiber mats may be packed by compressing a certain number or more of inorganic fiber mats together in order to improve the efficiency of storage and transportation. Therefore, when the thickness of the inorganic fiber mat obtained by unpacking cannot be secured before compression, that is, when the restoration rate of the inorganic fiber mat is poor, sufficient performance such as heat insulation and sound absorption cannot be obtained. In some cases.
以下、製造例と実施例及び比較例を示し、本発明を具体的に説明するが、本発明は下記の実施例に制限されるものではない。なお、下記の例において、部及び%はそれぞれ質量部、質量%を示す。 Hereinafter, the present invention will be specifically described with reference to Production Examples, Examples and Comparative Examples, but the present invention is not limited to the following Examples. In the following example, parts and% indicate parts by mass and% by mass, respectively.
[実施例1〜4]
表1に記載したポリビニルアルコール100部とイソブチレン・無水マレイン酸共重合物のアンモニア変性物5部をイオン交換水に溶解し2質量%の濃度である無機繊維用バインダー水溶液を調製した。無機繊維としてグラスウールを用い、調製した無機繊維用バインダー水溶液を用いてスプレー塗布してグラスウールを処理し、実施例における処理条件、200℃、180秒で加熱乾燥して無機繊維マットを作製した。無機繊維マットへの無機繊維用バインダーの処理量は、処理後の無機繊維マットを質量基準として、無機繊維への付着量が無機繊維用バインダーの固形分比率で4%となるようにした。
[Examples 1 to 4]
100 parts of polyvinyl alcohol shown in Table 1 and 5 parts of an ammonia-modified product of an isobutylene / maleic anhydride copolymer were dissolved in ion-exchanged water to prepare an aqueous binder solution for inorganic fibers having a concentration of 2% by mass. Glass wool was used as the inorganic fiber, and the glass wool was treated by spray coating using the prepared binder aqueous solution for inorganic fiber, and heated and dried at 200 ° C. for 180 seconds under the treatment conditions in the examples to prepare an inorganic fiber mat. The amount of the binder for inorganic fibers treated on the inorganic fiber mat was set so that the amount of adhesion to the inorganic fibers was 4% in terms of the solid content ratio of the binder for inorganic fibers, based on the treated inorganic fiber mat.
[実施例5〜8]
実施例1において、イソブチレン・無水マレイン酸共重合物のアンモニア変性物の量を、それぞれ3部、7部、10部、20部とした以外は、実施例1と同様の製造方法により無機繊維用バインダー水溶液を調製し、無機繊維マットを作製した。
[Examples 5 to 8]
For inorganic fibers by the same production method as in Example 1 except that the amounts of the ammonia-modified product of the isobutylene / maleic anhydride copolymer were set to 3, 7, 10 and 20 parts, respectively, in Example 1. An aqueous binder solution was prepared to prepare an inorganic fiber mat.
[比較例1]
ポリビニルアルコールに代えて、フェノール樹脂「ショーノールBRL−1015」(水溶性フェノール:昭和高分子(株)製)を使用した以外は、実施例1と同様の方法により無機繊維用バインダー水溶液を調製し、無機繊維マットを作製した。
[Comparative Example 1]
An aqueous binder solution for inorganic fibers was prepared by the same method as in Example 1 except that the phenol resin "Shonol BRL-1015" (water-soluble phenol: manufactured by Showa High Polymer Co., Ltd.) was used instead of polyvinyl alcohol. , An inorganic fiber mat was prepared.
[比較例2,3]
実施例1において、無水マレイン酸を含有する共重合物のアンモニア変性物の量をそれぞれ0部、1部とした以外は、実施例1と同様の方法により無機繊維用バインダー水溶液を調製し、無機繊維マットを作製した。
[Comparative Examples 2 and 3]
In Example 1, an aqueous binder solution for inorganic fibers was prepared by the same method as in Example 1 except that the amount of the ammonia-modified product of the copolymer containing maleic anhydride was set to 0 parts and 1 part, respectively. A fiber mat was prepared.
[比較例4〜7]
無水マレイン酸を含有する共重合物のアンモニア変性物に代えて、それぞれホウ砂((株)松葉薬品製)、カルボジライトV−02(カルボジイミド系架橋剤:日清紡(株)製)、メイカネートTP−120(イソシアネート系架橋剤:名成化学工業(株)製)、ガントレンツAN−119(マレイン酸・メチルビニルエーテル共重合物:五協産業(株)製)を使用した以外は、実施例1と同様の方法により無機繊維用バインダー水溶液を調製し、無機繊維マットを作製した。
[Comparative Examples 4 to 7]
Instead of the ammonia-modified copolymer containing maleic anhydride, Hosago (manufactured by Matsuba Yakuhin Co., Ltd.), Carbodilite V-02 (Carbodiimide-based cross-linking agent: manufactured by Nisshinbo Co., Ltd.), Maycanate TP-120 The same as in Example 1 except that (isocyanate-based cross-linking agent: manufactured by Meisei Chemical Industry Co., Ltd.) and Gantrentz AN-119 (maleic anhydride / methyl vinyl ether copolymer: manufactured by Gokyo Sangyo Co., Ltd.) were used. An aqueous binder solution for inorganic fibers was prepared by the method to prepare an inorganic fiber mat.
[評価方法]
実施例1〜8及び比較例1〜7の無機繊維マットの復元率及びホルムアルデヒド放散速度を測定した。なお、ホルムアルデヒド放散速度はJIS−A1901に基づいて測定した。
[Evaluation methods]
The restoration rate and formaldehyde emission rate of the inorganic fiber mats of Examples 1 to 8 and Comparative Examples 1 to 7 were measured. The formaldehyde emission rate was measured based on JIS-A1901.
無機繊維マットの復元率
無機繊維マットの梱包体製造時に、10cm×10cmのサンプルを取り出し、20kgの加重を1時間かけ、加重後の無機繊維マットの厚み(dx)を測定し、下記式(1)により復元率を求めた(n=5)。その結果を表1に併記した。
R=(dx/d)×100 (1)
R :復元率(%)
dx:復元後の無機繊維マットの厚み(mm)
d :試験前の無機繊維マットの呼び厚み(mm)
Restoration rate of inorganic fiber mat When manufacturing the package of the inorganic fiber mat, a sample of 10 cm × 10 cm was taken out, a weight of 20 kg was applied for 1 hour, and the thickness (dx) of the weighted inorganic fiber mat was measured. ) To determine the restoration rate (n = 5). The results are also shown in Table 1.
R = (dx / d) x 100 (1)
R: Restoration rate (%)
dx: Thickness of inorganic fiber mat after restoration (mm)
d: Nominal thickness (mm) of the inorganic fiber mat before the test
ホルムアルデヒド放散速度
また、無機繊維マットの梱包体を適宜切断し、表面積を440cm2に調整したものを、ホルムアルデヒドの放散速度の測定用試験体とした。ホルムアルデヒド放散速度の測定条件について、測定日数は7日間として、チャンバー内の温度を28℃、相対湿度を50%として、チャンバー体積を20L、換気回数を1時間当り0.5回とした。サンプリングには、DNPH(2,4−ジニトロフェニルヒドラジン)シリカショートボディ(Waters社製)を用いて、捕集体積は10Lとし、捕集流量は167mL/minとした。その結果を表1に併記した。
Formaldehyde emission rate Further , the package of the inorganic fiber mat was appropriately cut to adjust the surface area to 440 cm 2 , and this was used as a test body for measuring the formaldehyde emission rate. Regarding the measurement conditions of the formaldehyde emission rate, the measurement days were 7 days, the temperature in the chamber was 28 ° C., the relative humidity was 50%, the chamber volume was 20 L, and the ventilation rate was 0.5 times per hour. For sampling, a DNPH (2,4-dinitrophenylhydrazine) silica short body (manufactured by Waters) was used, the collection volume was 10 L, and the collection flow rate was 167 mL / min. The results are also shown in Table 1.
上記表中のポリビニルアルコールの詳細は、下記のとおりである。
・JF−05(完全鹸化ポバール:鹸化度98〜99%、重合度500)
・JL−05E(部分鹸化ポバール:鹸化度78〜81%、重合度500)
・JP−05(部分鹸化ポバール:鹸化度87〜89%、重合度500)
・JP−10(部分鹸化ポバール:鹸化度87〜89%、重合度1000)
上記いずれも日本・酢ビポバール社製
Details of polyvinyl alcohol in the above table are as follows.
-JF-05 (Completely saponified Poval: Saponification degree 98-99%, Polymerization degree 500)
-JL-05E (partially saponified Poval: saponification degree 78-81%, polymerization degree 500)
-JP-05 (partially saponified Poval: saponification degree 87-89%, polymerization degree 500)
-JP-10 (partially saponified Poval: saponification degree 87-89%, polymerization degree 1000)
All of the above are made by Japan Vam & Poval
上記表中のイソブチレン・無水マレイン酸共重合物のアンモニア変性物は、「ISOBAM−104」(株)クラレ製であり、化学構造式は下記のとおりであり、重量平均分子量16,000〜17,000、n=0.7〜0.8質量%、m=99.2〜99.3質量%である。
上記表中の無水マレイン酸系共重合物は、「ガントレンツAN−119」(無水マレイン酸・メチルビニルエーテル共重合物:五協産業(株)製)である。 The maleic anhydride-based copolymer in the above table is "Gantrentz AN-119" (maleic anhydride / methyl vinyl ether copolymer: manufactured by Gokyo Sangyo Co., Ltd.).
1 繊維化装置
2 バインダー付与装置
3 無機繊維
41,42,43,44,5 コンベア
6 成形炉
7 無機繊維マット
8 切断機
1 Fibrizing device 2
Claims (7)
(B)無水マレイン酸を含有する共重合物のアンモニア変性物:3質量部以上
を含有する無機繊維用バインダーであり、該無機繊維はグラスウール又はロックウールであることを特徴とする無機繊維用バインダー。 (A) A copolymer having a degree of polymerization of 200 to 500 and containing 100 parts by mass of a water-soluble polymer compound selected from the group of polyvinyl alcohol, carboxymethyl cellulose and starch , and (B) maleic anhydride. Ammonia-modified product: A binder for inorganic fibers containing 3 parts by mass or more, wherein the inorganic fibers are glass wool or rock wool.
(B)無水マレイン酸を含有する共重合物のアンモニア変性物:3質量部以上
を含有する無機繊維用バインダーを無機繊維に対してスプレーにより噴霧して製造する工程を含むと共に、上記無機繊維はグラスウール又はロックウールであることを特徴とする無機繊維マットの製造方法。 (A) A copolymer having a degree of polymerization of 200 to 500 and containing 100 parts by mass of a water-soluble polymer compound selected from the group of polyvinyl alcohol, carboxymethyl cellulose and starch , and (B) maleic anhydride. Ammonia-modified product: An inorganic fiber comprising a step of spraying a binder for inorganic fibers containing 3 parts by mass or more onto the inorganic fiber to produce the inorganic fiber, and the inorganic fiber is glass wool or rock wool. How to make a mat.
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