JPH05132840A - Thick glass fiber mat - Google Patents

Abstract

PURPOSE:To provide a thick glass fiber mat excellent in the peeling resistance and non-flammability and useful for industrial materials by nipping a non-woven fabric between a glass fiber mat and a glass fiber mat and subsequently subjected the nipped product to a needle-punching treatment for its incorporative binding. CONSTITUTION:A non-woven fabric comprising synthetic fibers such as polyester fibers, nylon fibers or Vinylon fibers, chemical fibers such as rayon or acetate fibers or natural fibers such as cotton or linter and having an unit weight of 15-55g/m<2> is nipped with a glass fiber mat and a glass fiber mat and subsequently punched with a needle to form an incorporated thick mat. But, the organic content contained in the thick mat is limited to <=88mg per 80cm <3> of the mat.

Description

Detailed Description of the Invention

[0001]

FIELD OF THE INVENTION The present invention relates to a thick glass fiber mat used as an industrial material.

[0002]

2. Description of the Related Art Conventionally, single-layer thick glass fiber mats for industrial materials have a thickness of more than 20 mm and are easily peeled off by bending, so that it is difficult to rely solely on needle punching. As the thick glass fiber mat having a thickness of 30 mm or more, a plurality of glass fiber mats having a thickness of 3 to 20 mm are laminated with an organic synthetic resin adhesive.

[0003]

In order to maintain a sufficient adhesive force on the adhesive surface of a conventional thick glass fiber mat, an organic synthetic resin adhesive such as butyl rubber, urethane rubber, silicone rubber or the like generally having a weight of 90 g / m ² or more is used. Has been applied. However, when the application amount of the organic synthetic resin adhesive is 90 g / m ² or more, the adhesion between the glass fiber mats is sufficient, but when the thick glass fiber mat is bent and transported or used, as shown in FIG. The problem shown in (1) occurs. Figure 2 (a)
3 is a cross-sectional view of a thick glass fiber mat, in which the glass fiber mats 11 and 12 are bonded by an adhesive agent 13.
When this thick glass fiber mat is bent as shown in FIG. 2 (b), the bent portion has a bending tendency, and when the bent portion is opened, the glass fiber mats 11 and 12 have different resilience. ) Glass fiber mat 1 in the bent part like
1 and 12 are peeled off to form a peeled portion 14. Therefore, the thick glass fiber mat cannot be bent and transported,
In addition, even in the case of transporting in a roll, there is a problem that the cost is increased because it is necessary to take measures such as increasing the diameter of the core of the roll to prevent the peeling. Further, when a large amount of the organic synthetic resin adhesive is used, the combustible content increases and it is not possible to satisfy the JIS A 1321 regulations, which makes it unsuitable as a non-combustible material. Therefore, a first object of the present invention is to provide a thick glass fiber mat in which peeling does not occur between the glass fiber mats even when bent and transported. A second object of the present invention is to provide a thick glass fiber mat that achieves the first object and has excellent nonflammability.

[0004]

A first object of the present invention is to provide a thick glass fiber mat characterized in that a non-woven fabric is sandwiched between glass fiber mats and glass fiber mats and entangled together by needle punching. Achieved
Moreover, the said 2nd objective WHEREIN: In the thick glass fiber mat which achieves the said 1st objective, the fabric weight of a nonwoven fabric is 15-55.
It was achieved by setting g / m ² . Furthermore, the organic content contained in the thick glass fiber mat 80 cm ³
By setting the amount to be 88 mg or less, the nonflammability of the thick glass fiber mat is further improved.

The glass fiber mat used in the present invention is a glass fiber deposited and formed into a mat by needling or resin. The thickness is preferably 3 to 20 mm. Examples of the type of glass fiber mat include glass fiber mats such as chopped strand mats, continuous strand mats, and glass fiber non-woven fabrics.

In the present invention, the non-woven fabric sandwiched between the glass fiber mats is a non-woven fabric composed of synthetic fibers such as polyester, nylon and vinylon, chemical fibers such as rayon and acetate, and natural fibers such as cotton and linter. When it is desired to impart not only the adhesiveness between glass fiber mats but also nonflammability to the obtained thick glass fiber mat, the basis weight of the nonwoven fabric is preferably 15 to 55 g / m ² . If the basis weight is more than 55 g / m ² , the organic content occupying the thick glass fiber mat is large and the incombustibility becomes insufficient, making it unsuitable as a noncombustible building material. On the other hand, the basis weight is 15g /
If it is smaller than m ^2, the amount of fibers constituting the non-woven fabric is small, so that it is less likely to be caught by the needle during needling, which is not preferable in terms of adhesiveness. Especially when the number of the glass fiber mats is two, the non-woven fabric used preferably has a basis weight of 20 to 40 g / m ² . In addition, in the thick glass fiber mat of the present invention, the nonflammability is further improved by defining the basis weight range of the non-woven fabric and setting the organic content per 80 cm ^{3 of the} thick glass fiber mat to 88 mg or less. In the case of a non-woven fabric made of synthetic fibers such as polyester, nylon, vinylon or the like or chemical fibers such as rayon, acetate, etc., the thickness of the fibers is 1.5 to 3.0 denier, but when needle punching is performed with a glass fiber mat, needles It is also preferred from the viewpoint of strength because it is easily affected. The non-woven fabric may itself be obtained by needle punching. It may be thermocompression bonded with an embossing roll. In any case, the more fluffy the fibers are, the better the entanglement of the fibers when needle punching together with the glass fiber mat. Therefore, thermocompression bonding (for example, polyester,
The one that is thermocompression-bonded with a low-temperature embossing roll (for example, 210 ° C in the case of polyester or vinylon) is more likely to have fluffs than the one that is 280 ° C in the case of vinylon, and the entanglement of fibers by needle punching is better.

In the present invention, the needle punching performed by sandwiching a non-woven fabric between glass fiber mats uses a known needle link device as described in, for example, Japanese Utility Model Laid-Open No. 63-30393. A non-woven fabric is sandwiched between mats and fed, and the needle is penetrated through the glass fiber mat and the non-woven fabric from above and below. That is, as shown in FIG. 1A, after the nonwoven fabric 3 is sandwiched between the glass fiber mat 2a and the glass fiber mat 2b and fed into the needle punching machine 5, these are set on the needle board 6 and the needle 7 By needle punching with, the thick glass fiber mat 1 in which the glass fiber mats 2a and 2b and the nonwoven fabric 3 are integrally entangled is obtained. A schematic cross-sectional view of the obtained thick glass fiber mat 1 is shown in FIG. As is clear from the figure, in the thick glass fiber mat 1,
The fibers 4 constituting the non-woven fabric 3 enter the glass fiber mats 2a and 2b by the needle punching and are knitted. Therefore, unlike the case of being bonded with a resin, the nonwoven fabric 3 has the elasticity as it is without being fixed, so that even if it is bent, the bent portion does not have a bending tendency, and when the bent portion is opened, the glass fiber mats 2a and 2b are not attached. Non-woven fabric 3
The entangled part of the film does not peel off. The degree of needling is preferably 13 to 20 per cm ² of mat. 1
If it is less than 3 pieces / cm ² , the peel strength will be weak, 20 pieces / c
There is no particular advantage if it is more than m ² .

The thick glass fiber mat of the present invention has a structure in which a non-woven fabric is sandwiched between glass fiber mats and two glass fiber mats. In particular, two glass fiber mats and one non-woven fabric or three glass fiber mats and three non-woven fabrics are used. The one having a single sheet structure is inexpensive and easy to manufacture as an interior material for construction.

[0009]

【Example】

(Example 1) As a glass fiber mat, an average fiber diameter of 9μ
18 mm thick glass fiber mat (manufactured by Chubu Kogyo Co., Ltd .: trade name SWM-18) produced by cutting the long glass fiber of No. 3 into a length of 3 inches, defibrating it, layering it with a wave manufacturing device and needle punching. ) Is used as a non-woven fabric, a non-woven fabric having a basis weight of 30 g / m ² and an average thickness of 0.17 mm, which is produced by drawing polyester fibers having a fiber diameter of 2 denier and heat-fusing with an embossing roll having a surface temperature of 280 ° C. One piece of non-woven fabric is sandwiched between two pieces of glass fiber mat, and the top and bottom sides are 1 with a needle punching machine manufactured by Kyowa Co., Ltd.
15 needles per cm ² , thickness 30 mm, width 5
A thick glass fiber mat of 00 mm was produced.

Example 2 A polyester fiber having a fiber diameter of 2 denier was drawn and heat-fused with an embossing roll having a surface temperature of 210 ° C. to produce a fabric weight of 30 g / m ² and an average thickness of 0.2.
A thick glass fiber mat having a thickness of 30 mm and a width of 500 mm was produced in the same manner as in Example 1 except that a non-woven fabric of 3 mm was used.

(Example 3) A vinylon fiber having a fiber diameter of 2 denier was drawn and heat-fused with an embossing roll having a surface temperature of 210 ° C. to produce a basis weight of 30 g / m ² and an average thickness of 0.20 m.
A thick glass fiber mat having a thickness of 30 mm and a width of 500 mm was manufactured in the same manner as in Example 1 except that the nonwoven fabric of m was used.

(Example 4) As a glass fiber mat, long glass fibers having an average fiber diameter of 9μ were cut into 3 inch lengths, defibrated, layered by a wave manufacturing device and needle punched to a thickness of 12 mm. Glass fiber mat (manufactured by Chubu Kogyo Co., Ltd .: trade name SWM-12) was used, while polyester fiber having a fiber diameter of 2 denier was stretched as a nonwoven fabric and heat-bonded with an embossing roll having a surface temperature of 210 ° C. Basis weight 20 g / m ² , average thickness 0.21
mm non-woven fabric is used, and one non-woven fabric is sandwiched between each of three glass fiber mats, and a needle punching machine manufactured by Kyowa Co., Ltd. is used from both upper and lower surfaces to make 15 needles per 1 cm ² with a thickness of 30 mm and a width of 30 mm. A 500 mm thick glass fiber mat was produced.

Example 5 Polyester fiber having a fiber diameter of 2 denier was drawn and heat-fused with an embossing roll having a surface temperature of 280 ° C. to produce a fabric weight of 60 g / m ² and an average thickness of 0.2.
A thick glass fiber mat having a thickness of 30 mm and a width of 500 mm was produced in the same manner as in Example 1 except that a non-woven fabric of 3 mm was used.

Comparative Example 1 Glass fiber mat having a thickness of 15 mm (manufactured by Nippon Glass Fiber Industry Co., Ltd .: trade name MN)
Two pieces of A-2000-1000) were adhered using 90 g of urethane rubber-based organic synthetic resin adhesive per 1 m ² to produce a thick glass fiber mat having a thickness of 30 mm and a width of 500 mm.

(Test) The thick glass fiber mats obtained in Examples 1 to 5 and Comparative Example 1 were subjected to a transportation test and a building base material test. Transport test: The thick glass fiber mats obtained in Examples 1 to 5 and Comparative Example 1 were cut into a length of 2,100 mm to obtain a transport test sample. Fold 5 pieces of each sample into a double-sided cardboard box with a depth of 310 mm, a width of 520 mm, and a length of 1150 mm, and prepare 3 boxes for each example, and make two round trips between Chiba City and Konan City in Aichi Prefecture by a mixed loading truck. Check the peeling condition of the sample and mark the ones that did not peel off, and mark the ones that peeled off.
It is shown in Table 1 as a mark. Base material test for building: Non-flammability test as an interior material for buildings using a base material tester manufactured by Toyo Seiki Co., Ltd. according to JIS A 1321 (measurement sample size is 40 (mm) x
40 (mm) × 50 (mm) = 80 cm ³ ) and the base temperature is set to 75 according to the Ministry of Construction Notification No. 1828.
Passed if the peak temperature was 800 ° C or less as 0 ° C (○
The result is shown in Table 1 as a failure (x mark) when the temperature exceeds 800 ° C.

The results are shown in Table 1.

[Table 1] As is clear from Table 1, the thick glass fiber mats of Examples 1 to 6 obtained by needle punching with a non-woven fabric sandwiched between glass fiber mats all showed good results in the transportation test, and peeling was observed. It became clear that they could not. On the other hand, the thick glass fiber mat of Comparative Example 1 obtained by adhering the glass fiber mat with the adhesive had a poor result in the transportation test. Moreover, the basis weight is 15 to 55 g /
It was confirmed that the thick glass fiber mats of Examples 1 to 5 using the nonwoven fabric in the range of m ² also passed the building base material test and had excellent noncombustibility. Particularly, when the organic content was 88 mg or less per 80 cm ^{3 of the} thick glass fiber mat (Examples 1 to 4), particularly excellent incombustibility was obtained. On the other hand, the thick glass fiber mat of Comparative Example 1 failed the building base material test.

[0017]

The thick glass fiber mat of the present invention is integrally entangled by sandwiching a non-woven fabric between the glass fiber mat and the glass fiber mat by needle punching, so that the glass fiber mat and the glass fiber may be bent during transportation. The mat will not come off. In addition, the basis weight of the nonwoven fabric is 15 to 5
When the amount is 5 g / m ² , excellent incombustibility can be imparted to the thick glass fiber mat. Further, by setting the organic content to 88 mg or less per 80 cm ^{3 of the} thick glass fiber mat, particularly excellent nonflammability can be imparted.

[Brief description of drawings]

FIG. 1A is a schematic production drawing of a thick glass fiber mat of the present invention, and FIG. 1B is a schematic configuration diagram of a thick glass fiber mat of the present invention.

2 (a), (b) and (c) are diagrams showing that peeling occurs between glass fiber mats when a conventional thick glass fiber mat is bent.

[Explanation of symbols]

 1 Thick Glass Fiber Mat 2a, 2b Glass Fiber Mat 3 Nonwoven Fabric 4 Nonwoven Fabric Fiber 5 Needle Punching Machine 6 Needle Board 7 Needle 11 Glass Fiber Mat 12 Glass Fiber Mat 13 Adhesive 14 Peeling Space

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Munehiro Ichinose 147-2 Kojima Nakajima, Konan City, Aichi Prefecture

Claims (3)

[Claims] 1. A thick glass fiber mat, wherein a nonwoven fabric is sandwiched between the glass fiber mat and the glass fiber mat and entangled together by needle punching. 2. The thick glass fiber mat according to claim 1, wherein the non-woven fabric has a basis weight of 15 to 55 g / m ² . 3. The thick glass fiber mat according to claim 2, wherein an organic component contained in the thick glass fiber mat is 88 mg or less per 80 cm ³ of the thick glass fiber mat.