JPH0120280B2 - - Google Patents

Description

[Detailed description of the invention]

The present invention relates to an inorganic fiber felt that is mainly composed of inorganic fibers and has both fire resistance and heat insulation properties.It is suitable for mechanical pasting and has excellent dew condensation prevention properties, and is easy to manufacture, and is mainly used for roofing. The Company provides felts made of inorganic fibers that can be used as base materials for buildings and walls. Conventionally, polyethylene foam and asbestos foam have been used as base materials for roofs and walls, but although polyethylene foam has excellent heat insulation properties, it is not fire resistant and also lacks water retention capacity, resulting in condensation. Although asbestos foam has heat insulating properties, fire resistance, and anti-condensation properties, it is believed that asbestos dust generated during the manufacturing and construction of asbestos foam is a cause of lung cancer. It has the disadvantage of becoming For this reason, rock wool felt and glass fiber felt are used as inorganic fiber felts that have both heat insulation and fire resistance properties.
The former type of rock wool felt is extremely difficult to fabricate when using a wet papermaking method because the wet strength of the wet felt after papermaking and dehydration is weak, and when using a dry production method, it is difficult to produce the felt. However, the dispersion state of the fibers in the resulting felt is poor, and there are drawbacks such as the unsatisfactory appearance, strength, compression recovery rate, etc. In addition, the latter glass fiber felt has the disadvantage that it is not possible to obtain a felt with excellent dew condensation prevention properties due to its high air permeability. The reality is that this is not possible. In contrast, the present invention is an inorganic fiber felt that does not use asbestos, which has a negative impact on the health of manufacturers and contractors, and has excellent fire resistance, heat insulation, tensile strength, anti-condensation properties, and compression recovery. The present invention provides an inorganic fiber felt that has excellent properties in terms of elasticity, appearance, etc., and is easy to manufacture. The inorganic fiber felt of the present invention is composed of 20 to 97% by weight of rock wool, 1 to 50% by weight of glass fiber, 1 to 30% by weight of an organic binder, and 1 to 2% by weight of a binding aid. Formed only from solid components, or from the solid components and a small amount of coloring agent added as necessary, and whose specific gravity is suppressed to 0.5 or less. It is. In the inorganic fiber felt that has both fire resistance and heat insulation properties of the present invention, rock wool in the solid component forms a fire resistant component together with glass fiber.
20 to 97% by weight, preferably 45 to 80% by weight of the essential solid components constituting this inorganic fiber felt
must be made of rock wool. This means that if rock wool is less than 20% by weight of the essential solid components constituting the inorganic fiber felt, it will not only be difficult to provide the resulting inorganic fiber felt with sufficient fire resistance, but it will also become unsatisfactory. This is because it becomes impossible to obtain dew condensation prevention properties. Glass fiber, which is the other inorganic fiber constituting the inorganic fiber felt of the present invention, is one of the essential solid components constituting the inorganic fiber felt.
It is necessary that the content be within the range of ~50% by weight. This is because if the glass fiber content is less than 1% by weight of the essential solid components constituting inorganic fiber felt, the wet strength after papermaking and dehydration during the production of inorganic fiber felt decreases, resulting in poor production efficiency. This is because it causes the disadvantage of becoming
When glass fiber exceeds 50% by weight of the essential solid components constituting the inorganic fiber felt, the air permeability of the resulting inorganic fiber felt increases, resulting in a disadvantage in that the anti-condensation properties of the felt decrease. It's for a reason. The inorganic fiber felt of the present invention uses an organic binder consisting of 1 to 30% by weight of an organic resin emulsion or a mixture of an organic resin emulsion and a heat-meltable organic fiber in the essential solid components, and combines the rock wool and glass fibers. In the inorganic fiber felt of the present invention, the organic binder is an essential solid component constituting the inorganic fiber felt. If the amount is less than 1% by weight, both the dry strength and wet strength of the inorganic fiber felt will decrease, and if it exceeds 30% by weight, the fire resistance of the inorganic fiber felt will decrease. In either case, it becomes impossible to obtain an inorganic fiber felt that is satisfied in terms of physical properties. In this inorganic fiber felt, the organic resin emulsion used as the organic binder includes acrylic resin, modified acrylic resin, polyvinyl acetate, ethylene-vinyl acetate copolymer resin,
Emulsions of various resins such as styrene-butadiene copolymer resin, nitrile-butadiene copolymer resin, polyvinylidene chloride, modified polyvinylidene chloride, etc., and heat-melting organic fibers such as polyethylene, polypropylene, polyester, nylon, and polychloride Various fibers such as vinylidene, ethylene/propylene composite fibers, etc. are suitable. As mentioned above, in the inorganic fiber felt of the present invention, an organic binder made of an organic resin emulsion or a mixture of an organic resin emulsion and a heat-melting organic fiber is used. When fibers are used in combination, the heat-melting organic fibers have the effect of improving the paper-making properties in the paper-making process when obtaining the inorganic fiber felt, and in the felt drying process,
The heat-fusible organic fibers are partially heat-fused and act as a binder for the felt, which not only improves production efficiency but also further increases the strength of the resulting inorganic fiber felt. can get. As mentioned above, this organic binder is a single organic resin emulsion or a mixture of the organic resin emulsion and heat-melting organic fibers, and is one of the essential solid components constituting the inorganic fiber felt. It is sufficient that 1 to 30% by weight of the organic binder is composed of the organic binder.
From a practical point of view, organic resin emulsions are essential components of inorganic fiber felts, whether used alone as an organic binder or in combination with heat-melting organic fibers. It is preferably about 5 to 15% by weight of the solid component, and about 3 to 10% by weight of the heat-melting organic fibers used in combination with the organic resin emulsion. The binding aid in the solid component constituting the inorganic fiber felt of the present invention is effective in adding the above-mentioned organic resin emulsion as a binder to the wet felt in the papermaking process when the inorganic fiber felt is obtained by a wet papermaking method. An anionic or cationic polymer flocculant is usually used. When using these polymer flocculants, the content should be 0.05
The agglomeration effect is fully expressed at about 0.1 to 10% by weight.
The aggregation effect is best at around 0.5% by weight, but
If it exceeds 1.0% by weight, a phenomenon will occur where the flocs once agglomerated will be redispersed, so approximately 1.0% by weight
It is preferable to keep it under control. Furthermore, when an anionic flocculant is used as a binding aid, it is preferable to use sulfuric acid in order to enhance the flocculating effect of the flocculant. For example, if polyacrylamide, which is an anionic flocculant, is used as an essential solid component, It is preferable to use about 0.1 to 1.5 weight percent of sulfuric acid, and to keep the pH of the slurry, which is a raw material for papermaking, at about 4.5 to 6.8. This is because when a large amount of sulfuric acid is added, an acid hydrolysis reaction occurs in the rock wool used as the inorganic fiber, resulting in the disadvantage that the strength of the resulting inorganic fiber felt decreases. The inorganic fiber felt of the present invention, which has the above-described components as essential solid components, can be produced by using only the above-mentioned essential solid components, or by using the above-mentioned essential solid components and a small amount of a coloring agent. The solid components described above are substantially uniformly dispersed and intertwined to form a felt-like structure. It should be noted that if the felt made of inorganic fibers has a high specific gravity exceeding 0.5, its thermal conductivity will increase and it will not be possible to obtain sufficient heat insulation properties.
It is necessary to keep it below 0.5. The inorganic fiber felt of the present invention having the above-mentioned structure can be manufactured using a normal wet papermaking method, that is, 20 to 97
1 to 2% by weight of rock wool, 1 to 50% by weight of glass fiber, 1 to 30% by weight of an organic binder, and 1 to 2% by weight of organic binder.
A solid component mixture consisting of a binding aid of % by weight, or a total solid component obtained by adding a certain amount of a coloring agent to the solid component mixture, is dispersed in water of approximately 100 times the amount of the total solid component. A first step of forming an aqueous slurry consisting of a 1% by weight dispersion; the aqueous slurry obtained in the first step is made into a paper using a fourdrinier type paper making machine, and dehydrated; It can be easily obtained by a wet paper-making method, which consists of a second step of obtaining a paper-made felt, and a third step of drying the paper-made felt obtained in the second step to complete the forming. It can also be obtained by impregnating a part of the organic resin emulsion by spraying or impregnating a wet felt after papermaking or a felt after papermaking and drying, followed by drying. I can do it. The inorganic fiber felt of the present invention has the structure as described above, and since it is composed of inorganic fibers whose main components are rock wool and glass fiber, it has a low specific gravity structure with many voids. Therefore, it has the effect of exhibiting not only excellent fire resistance but also excellent heat insulation properties and dew condensation prevention properties. Furthermore, since the inorganic fiber felt of the present invention can be easily obtained by a wet papermaking method, it can be manufactured using the same wet papermaking equipment used to obtain conventional inorganic fiber felts. However, in particular, when the inorganic fiber felt of the present invention is obtained by a wet papermaking method, the fibers are dispersed in a better state than inorganic fiber felts obtained by a dry or semi-dry method. Not only can you obtain an inorganic fiber felt with an excellent appearance, but it also has approximately the same strength and compression recovery rate.
It is possible to make inorganic fiber felt that is 1.5 times better. The inorganic fiber felt of the present invention, which has this excellent compression recovery rate, is particularly useful when used as a folded roof base material. However, since the thickness remains almost the same before and after the roll-forming process, even if the roll-forming process is used as the construction method, the insulation of the inorganic fiber felt itself will be reduced by approximately 50%. There is no deterioration in performance or anti-condensation properties. Furthermore, when the inorganic fiber felt of the present invention is obtained by a wet papermaking method, an emulsion type organic pigment is mixed into the aqueous slurry to obtain an inorganic fiber felt that is colored even inside the product. Therefore, even if some scratches occur on the surface of the felt, the product can be made without unsightly hue. Hereinafter, the specific structure of the inorganic fiber felt having both fire resistance and heat insulation properties of the present invention will be explained with reference to manufacturing method examples, and the properties of the obtained inorganic fiber felt will also be explained. Example 1 (1) Rock wool 97.0% by weight (fiber length 1 to 20 mm) (2) Glass fiber (fiber length 6 mm) 1.0 (3) Acrylic resin emulsion 0.5 [AP-5950: manufactured by Toagosei Co., Ltd.] ( (solid component equivalent) (4) Ethylene-propylene composite fiber 0.5 〃 (Fiber length 10 mm, 3 denier) [ES fiber: manufactured by Chitsuso Co., Ltd.] (5) Sulfate band 0.9 〃 (6) Anionic polymer flocculant 0.1 〃 [A-102: Manufactured by Toagosei Co., Ltd.] Each of the above components was sequentially dispersed and mixed in water to prepare an aqueous slurry with a solid component concentration of 1% by weight, and then the resulting aqueous slurry was subjected to fourdrinier papermaking. The paper was made using a machine, dehydrated by suction, and then dried at 140°C for 10 minutes to obtain inorganic fiber felt A of the present invention. The properties of the obtained inorganic fiber felt A are as follows:
It is as shown in Table 1 below. Example 2 (1) Rock wool 20.0% by weight (fiber length 1 to 20 mm) (2) Glass fiber (fiber length 6 mm) 50.0 (3) Acrylic resin emulsion 18.5 [AP-5950: manufactured by Toagosei Co., Ltd.] ( (solid component equivalent) (4) Ethylene-propylene composite fiber 10.0 (fiber length 10 mm, 3 denier) [ES fiber: manufactured by Chitsuso Co., Ltd.] (5) Sulfate band 1.35 (6) Anionic polymer flocculant 0.15 [A-102: Manufactured by Toagosei Co., Ltd.] Using the above components, the same procedure as in Example 1 was repeated to obtain inorganic fiber felt B of the present invention having the properties shown in Table 1 below. I got it. Example 3 (1) Rock wool 71.44% by weight (fiber length 1 to 20 mm) (2) Glass fiber (fiber length 6 mm) 5.0 〃 (3) Ethylene-vinyl acetate 13.0 〃 Emulsion (solid component conversion) [Yodozol: Kanebo NSC Co., Ltd. (4) Polyethylene fiber 9.0 (Chemivest FDSS2: Mitsui Zerapack Co., Ltd.) (5) Sulfate band 1.43 (6) Polyacrylamide 0.13 (Polystron A117: Arakawa Chemical Co., Ltd.) Using each of the above components, The same procedure as in Example 1 was repeated to obtain inorganic fiber felt C of the present invention having properties shown in Table 1 below. Example 4 (1) Rock wool 71.44 parts by weight (fiber length 1 to 20 mm) (2) Glass fiber (fiber length 6 mm) 5.0 (3) Ethylene-vinyl acetate 5.0 Emulsion (solid component equivalent) [Yodozol: Kanebo NSC Co., Ltd. (4) Polypropylene fiber 9.0 (fiber length 10 mm, 3 denier) (manufactured by Ube Nitto Kasei Co., Ltd.) (5) Sulfate band 1.43 (6) Polyacrylamide 0.13 (Polystron A117: manufactured by Arakawa Chemical Co., Ltd.) Each of the above components is sequentially dispersed and mixed in water to prepare an aqueous slurry with a solid component concentration of 1% by weight.The obtained aqueous slurry is then made into paper using a Fourdrinier paper machine, and after suction dehydration, the obtained On the surface of the wet felt, 8 parts by weight of vinylidene chloride emulsion (Kurehalon R7, manufactured by Kureha Chemical Co., Ltd.) in terms of solid content was sprayed and dried at 140° C. for 10 minutes. The properties of the obtained inorganic fiber felt D are as shown in Table 1 below. In addition, the inorganic fiber felt D obtained in this example was pasted on a folding plate with a thickness of 0.8 mm, and the size was 600 x 600 mm.
A heating test was conducted in an open hearth for 30 minutes at a maximum temperature of 840°C to measure the fire resistance of the felt. As a result, there was no thermal deformation of the folded plates, and no flame penetration from the joints of the folded plates was observed. It had fire resistance as specified in JIS A-1304. Example 5 (1) Rock wool 70.94% by weight (fiber length 1 to 20 mm) (2) Glass fiber (fiber length 6 mm) 5.0 〃 (3) Ethylene-vinyl acetate 13.0 〃 Emulsion (solid component conversion) [Yodozol: Kanebo NSC Co., Ltd. (4) Polyethylene fiber 9.0 (fiber length 0.6 mm) [Chemivest FDSS2: manufactured by Mitsui Zerapack Co., Ltd.] (5) Sulfuric acid band 1.43 (6) Polyacrylamide 0.13 (7) [Polystron A117: manufactured by Arakawa Chemical Co., Ltd.] (7) ) Blue pigment 0.5 [Blue FL2B: manufactured by Dainichiseika Co., Ltd.] Using the above components, the same procedure as in Example 1 was repeated to obtain the inorganic fiber felt of the present invention. A beautiful blue-colored inorganic fiber felt having the same properties as the inorganic fiber felt C obtained in Example 3 was obtained. Comparative example 1 (1) Rock wool 98.0% by weight (fiber length 1-20mm) (2) Acrylic resin emulsion 0.5 [AP-5950: manufactured by Toagosei Co., Ltd.] (solid component equivalent) (3) Ethylene-propylene composite fiber 0.5 〃 (Fiber length 10mm, 3 denier) [Manufactured by ES Fiber Chitsuso Co., Ltd.] (4) Sulfate band 0.9 〃 (5) Anionic polymer flocculant 0.1 〃 [A-102: Manufactured by Toagosei Co., Ltd.] Glass Using each of the components (1) to (5) above, which do not contain fiber components, the same procedure as in Example 1 was carried out to obtain an inorganic fiber felt a for comparison. During this operation, the wet strength of the wet felt after papermaking and dewatering was low (approximately 0.5 Kg/cm ² ), making it difficult to manufacture the inorganic fiber felt A, and the product yield was poor. Incidentally, in order to carry out smooth operations throughout the papermaking process, it is necessary that the wet strength of the wet felt after papermaking and dehydration be approximately 1 Kg/cm ² or more. The properties of the inorganic fiber felt a are as shown in Table 1 below. Comparative Example 2 (1) Glass fiber (fiber length 6 mm) 98.0% by weight (2) Acrylic resin emulsion 0.5 [AP-5950: manufactured by Toagosei Co., Ltd.] (solid component equivalent) (3) Ethylene-propylene composite fiber 0.5 (Fiber length 10 mm, 3 denier) [Manufactured by ES Fiber Chitsuso Co., Ltd.] (4) Sulfate band 0.9 (5) Anionic polymer flocculant 0.1 [A-102: Manufactured by Toagosei Co., Ltd.] Rock wool component Using each of the components (1) to (5) above, which did not contain , the same procedure as in Example 1 was performed to obtain an inorganic fiber felt b for comparison. The properties of the obtained inorganic fiber felt B are as shown in Table 1 below, and were not particularly satisfactory in terms of anti-condensation properties. Comparative Example 3 Each component having the same composition ratio as the solid component used in Example 1 was dispersed and mixed in water to prepare an aqueous slurry with a solid component concentration of 1.5% by weight, and then the obtained slurry was An inorganic fiber felt c for comparison was obtained by subjecting it to the same paper-making process as described in Example 1. The properties of the obtained inorganic fiber felt c are as shown in Table 1 below, and in particular, the heat insulation performance was insufficient.

【table】

[Table] The tensile strength, wet strength, condensation dripping time, compression recovery rate, and thermal conductivity of the inorganic fiber felt shown in Table 1 were obtained according to the following measurement method. It is something that was given. Tensile strength: Tensilon machine manufactured by Shimadzu Corporation Sample size: 40 mm x 120 mm Distance between chucks: 50 mm Tensile speed: 50 mm/min Wet strength: Tensile strength of wet felt after papermaking and dewatering.
These are the results measured using the same measuring method as the tensile strength described above. Condensation dripping time A tin cone with a thickness of 0.3 mm is made with the joints soldered to prevent water leakage, and inorganic fiber felt is pasted on the entire outside of this cone using a rubber adhesive. After that, the inside of the cone is heated to 0℃ with ice.
Fill it with water and leave it in an atmosphere of 30℃ and 80% RH. Determine the time it takes for condensation to form on the outside of the felt and for water droplets to start falling from the bottom end of the cone to which the felt is attached. This is referred to as the dew condensation dripping time. Compression recovery rate Sample size 20 mm x 20 mm x 4 mm (thickness) Using Tensilon manufactured by Shimadzu Corporation, the load was applied at a compression speed of 5 mm/min when the maximum compression load of 80 kg (20 kg/cm ² ) was reached. The thickness dmm after being released and allowed to stand for 24 hours was measured, and the value was obtained according to the compression recovery rate (%) = d/4 x 100. Thermal conductivity This is the result measured by JIS A-1413 direct plate method.

Claims (1)

[Claims] 1 A specific gravity of 0.5 in which the essential solid components are rock wool, glass fiber, an organic binder made of a mixture of an organic resin emulsion or an organic resin emulsion and a heat-fusible organic fiber, and a binding aid.
It is made of the following inorganic fiber felt, and
The composition ratio of the above-mentioned essential solid components is
20 to 97% by weight, glass fiber 1 to 50% by weight, organic binder 1 to 30% by weight, and binding aid 1 to 2% by weight.It has both fire resistance and heat insulation properties. Inorganic fiber felt.