JP7226566B2 - 無機繊維用バインダー及び無機繊維マット - Google Patents
無機繊維用バインダー及び無機繊維マット Download PDFInfo
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- JP7226566B2 JP7226566B2 JP2021542795A JP2021542795A JP7226566B2 JP 7226566 B2 JP7226566 B2 JP 7226566B2 JP 2021542795 A JP2021542795 A JP 2021542795A JP 2021542795 A JP2021542795 A JP 2021542795A JP 7226566 B2 JP7226566 B2 JP 7226566B2
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Description
1.(A)重合度が100~3500であるポリビニルアルコール系樹脂:100質量部、
(B)1価または2価の金属を有する金属塩であり、該金属塩が、酸化物、水酸化物、炭酸塩、硫酸塩、ケイ酸塩、チタン酸塩、酢酸塩及び安息香酸塩の群から選ばれる少なくとも1種である金属塩:1~50質量部、及び
(C)重量平均分子量が50,000~300,000であり、且つ下記構造式を有する、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:3~20質量部
を含有することを特徴とする無機繊維用バインダー。
2.(A)ポリビニルアルコール系樹脂のケン化度が70モル%以上である上記1記載の無機繊維用バインダー。
3.(C)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.無機繊維が、グラスウール又はロックウールである上記1~3のいずれかに記載の無機繊維用バインダー。
5.(B)金属塩は、レーザ回折法によるメジアン径(D50)測定法に基づく平均粒子径が50μm以下である上記1~4のいずれかに記載の無機繊維用バインダー。
6.(B)金属塩の金属はナトリウムを除く上記1~5のいずれかに記載の無機繊維用バインダー。
7.(B)金属塩は、酸化チタン、酸化亜鉛、酸化マグネシウム、水酸化カルシウム、水酸化アルミニウム、水酸化マグネシウム、炭酸カルシウム、炭酸マグネシウム、硫酸カルシウム、硫酸バリウム、硫酸マグネシウム、ケイ酸カルシウム、チタン酸カリウム、チタン酸カルシウム、チタン酸バリウム及び酢酸カルシウムの群から選ばれる少なくとも1種である上記1~5のいずれかに記載の無機繊維用バインダー。
8.上記1~7のいずれかに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。
本発明の無機繊維用バインダーは、下記(A)~(C)成分、
(A)重合度が100~3500であるポリビニルアルコール系樹脂:100質量部、
(B)金属塩:1~50質量部、及び
(C)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
を含有することを特徴とする無機繊維用バインダーである。
表1に記載したポリビニルアルコール100部と炭酸カルシウム(D50=1.4μm)10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部と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。無機繊維としてタテ×ヨコ×厚みが10cm×10cm×0.5cm、密度が0.025g/cm3の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℃、300秒で加熱乾燥して無機繊維マットを12個作製した。無機繊維マットの厚さが10cmとなるように積み重ね、密度が0.015g/cm3の無機繊維マットを得た。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。
実施例2において、表1に示す金属塩の種類をそれぞれ変更した以外は、実施例2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。
実施例2,11において、金属塩の量をそれぞれ3部、40部とした以外は、実施例2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。
実施例2において、架橋剤の量をそれぞれ3部、10部とした以外は、実施例2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。
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)または、フェノール樹脂「FG-1032」(水溶性フェノール:DIC(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。
実施例2において、金属塩を使用しなかった以外は、実施例2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。
実施例2において、架橋剤の量を1部とした以外は、実施例2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。
実施例2,11において、金属塩の量を0.5部とした以外は、実施例2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。
実施例1~19及び比較例1~6の無機繊維マットの復元率、ホルムアルデヒド放散速度、ホルムアルデヒド濃度及び貯蔵安定性を測定した。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。
無機繊維マットの梱包体製造時に、10cm×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及び表2に併記した。
復元率は65%以上であることが好ましく、より好ましくは70%以上である。
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)
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、チャンバー内の空気を捕集し、アセトニトリルを溶媒として用い、捕集体積は10Lとし、捕集流量は167mL/minとし、カルボニル化合物の濃度を測定した。その結果を「JIS A 1901」及び「JIS A 1902」に準拠し、ホルムアルデヒド放散速度を求めた。表1及び表2に併記した。
MBTH比色法に基づく方法で、上記実施例で得られた2質量%バインダー水溶液1.5mLに対して、(株)共立理化学研究所の製品名「パックテスト ホルムアルデヒド」(型式:WAK-FOR)のK-1試薬(小パック1包)を添加し、室温で5~6回振とうして反応させ、3分間静置する。これをポリチューブに全量を吸い込み5~6回振とうして発色させ、1分間静置する。静置後、標準色と比色し、その標準色に近い濃度(色)を測定する。その結果を表1及び表2に併記した。
常温で1ヶ月静置させた後の上記バインダー水溶液(濃度2質量%)の状態を目視により観察した。
〇:バインダー水溶液に分離は見られなかった。
×:バインダー水溶液が分離またはゲル化した。
バインダー水溶液が分離やゲル化をすると、ノズル詰まりが発生してスプレー塗工できない場合がある。
・JF-05(完全鹸化ポバール:鹸化度98~99%、重合度500)
・JP-05(部分鹸化ポバール:鹸化度87~89%、重合度500)
・JL-05E(部分鹸化ポバール:鹸化度80~84%、重合度500)
・JM-17(中間鹸化ポバール:鹸化度95~97%、重合度1700)
・JC-25(完全鹸化ポバール:鹸化度99~99.4%、重合度2500)
・JP-33(部分鹸化ポバール:鹸化度87~89%、重合度3300)
上記いずれも日本・酢ビポバール社製である。
・水酸化マグネシウム(協和化学工業(株)、キョ―ワスイマグ:D50=11.1μm)
・水酸化カルシウム(近江鉱業(株)、消石灰1号)
・水酸化アルミニウム(昭和電工(株)、ハイジライトH-42:D50=1.0μm)
・炭酸ナトリウム((株)トクヤマ、ソーダ灰(ライト))
・炭酸カルシウム(三共精粉(株)、エスカロン#2300:D50=1.4μm)
・硫酸マグネシウム(馬居化成工業(株)、硫酸マグネシウム)
・硫酸バリウム(堺化学工業(株)、BF-10:D50=0.06μm)
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
Claims (8)
- (A)重合度が100~3500であるポリビニルアルコール系樹脂:100質量部、
(B)1価または2価の金属を有する金属塩であり、該金属塩が、酸化物、水酸化物、炭酸塩、硫酸塩、ケイ酸塩、チタン酸塩、酢酸塩及び安息香酸塩の群から選ばれる少なくとも1種である金属塩:1~50質量部、及び
(C)重量平均分子量が50,000~300,000であり、且つ下記構造式を有する、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:3~20質量部
を含有することを特徴とする無機繊維用バインダー。 - (A)ポリビニルアルコール系樹脂のケン化度が70モル%以上である請求項1記載の無機繊維用バインダー。
- (C)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請求項1又は2記載の無機繊維用バインダー。
- 無機繊維が、グラスウール又はロックウールである請求項1~3のいずれか1項記載の無機繊維用バインダー。
- (B)金属塩は、レーザ回折法によるメジアン径(D50)測定法に基づく平均粒子径が50μm以下である請求項1~4のいずれか1項記載の無機繊維用バインダー。
- (B)金属塩の金属はナトリウムを除く請求項1~5のいずれか1項記載の無機繊維用バインダー。
- (B)金属塩は、酸化チタン、酸化亜鉛、酸化マグネシウム、水酸化カルシウム、水酸化アルミニウム、水酸化マグネシウム、炭酸カルシウム、炭酸マグネシウム、硫酸カルシウム、硫酸バリウム、硫酸マグネシウム、ケイ酸カルシウム、チタン酸カリウム、チタン酸カルシウム、チタン酸バリウム及び酢酸カルシウムの群から選ばれる少なくとも1種である請求項1~5のいずれか1項記載の無機繊維用バインダー。
- 請求項1~7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。
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