JPH06248545A - Composite material - Google Patents

Abstract

PURPOSE:To provide the composite material having vibration-damping, sound- absorbing, self-extinguishing, antimicrobial and deodorizing effects, etc., and useful for buildings, room decoratives, air or water filters, etc. CONSTITUTION:The composite material is basically produced by making molten ceramic drops adhere to a mat layer in a filmy, the mat layer being produced by interlacing relatively hard fibers with each into a nonwoven fabric tissue or three-dimensional net tissue. The composite material has the vibration- damping property, etc., of the mat layer and further exhibits improved sound- absorbing and self-extinguishing properties and antimicrobial and deodorizing effects, etc. The composite material is used e.g. as filters for air cleaners and water-treating facilities, or laminated to a layer to give a building material, the layer containing a wooden plate as a material. Further, the composite material may be interlaced with fine and soft synthetic resin fibers, subjected to the formation of the coating film of a viscoelastic material on the composite material, or subjected to the addition of a chemical such as a deodorant, aromatic agent, or insecticidal agent to the raw material of a synthetic resin.

Description

Detailed Description of the Invention

[0001]

[Object of the Invention]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to various materials having vibration damping, sound absorption, self-extinguishing, antibacterial and deodorizing effects for construction, interior decoration, air and water filters, etc.

[0002]

BACKGROUND OF THE INVENTION Recently, as houses have become densely packed, housing estates, and high-class homes have been developed, it becomes necessary to take measures to prevent vibration and sound in each house and room. High-quality products lined with sound-insulating heat-insulating layers such as honeycombs and honeycomb structures are also available. The same applies to interior decoration such as floor walls in vehicles, ships and airplanes, as well as to soundproof walls built along roads and railroad tracks. On the other hand, as homes and rooms are hermetically sealed, indoor and outdoor odors and molds also become a problem, and fragrances, deodorants, air purifiers, etc. are becoming widespread.

In addition to these, there is also a movement to replace styrofoam, which has been widely used as a packaging material for home electric appliances, with paper corrugated board. This is because plastics such as Styrofoam generate high heat during combustion, which has an adverse effect on the waste incinerator and scatters harmful fumes around. Since the same problem of waste treatment can be applied to floor boards and the like, the applicant of the present invention has found that the fibers of palm trees, such as so-called palm skin and coconut mesocarp fibers, have a buffering property and prevent We paid attention to vibration, soundproofing, proper humidity, and low pollution when incinerated.

[0004]

[Technical Items Attempted to Develop] Therefore, the present invention is intended to
It is intended to provide a composite material such as a building material, an upholstery material, a material for a filter, which has a sound absorbing property, a self-extinguishing property, an antibacterial property, a deodorizing effect and the like. Further, it is also an attempt to provide a composite material which is close to natural pollution-free, particularly advantageous in waste disposal, by positively utilizing the characteristics of so-called coconut fiber mat.

[0005]

[Constitution of the invention]

[Means for Achieving the Object] That is, in the composite material according to the first invention of the present application, ceramics are applied by thermal spraying to a mat layer formed by entwining relatively hard fibers in a nonwoven fabric-like or three-dimensional network form. It is characterized by making it.

In addition to the above-mentioned requirements, the second embodiment of the composite material according to the present application is that the mat layer formed by intertwining in a relatively hard non-woven fabric-like or three-dimensional network structure has a separate thin and flexible composition. It is characterized in that resin fibers are intertwined.

Further, in addition to the above-mentioned requirements, the composite material according to the third invention of the present application is such that each fiber in the mat layer formed by intertwining in a relatively hard nonwoven fabric-like or three-dimensional network structure is a separate viscoelastic substance. Is characterized by being coated.

Furthermore, in addition to the above requirements, the composite material according to the fourth invention of the present application is characterized in that the mat layer is a layer in which palm fibers are entwined in a non-woven fabric form or a three-dimensional network form. It consists of

In addition to the above requirements, the matte layer of the fifth invention according to the present application is that the mat layer is a layer formed by intertwining synthetic resin filaments in a non-woven fabric-like or three-dimensional network form. It is a feature.

Furthermore, in addition to the above requirements, the sixth aspect of the composite material according to the present invention is characterized in that the ceramic is a ceramic having a photocatalytic action such as titania.

Furthermore, in addition to the above-mentioned requirements, the composite material according to the seventh invention of the present application is a mat layer formed by entwining relatively hard fibers in a non-woven fabric-like or three-dimensional network form, and further a plate-like layer. It is characterized by being laminated.

Furthermore, in addition to the above requirements, the eighth aspect of the composite material according to the present application is that the mat layer formed by intertwining relatively hard fibers in a non-woven fabric-like or three-dimensional network form further comprises a viscoelastic substance. It is characterized by being laminated with layers. With these, the above object is achieved.

[0013]

The composite material of the present invention is based on the fact that a mat layer formed by intertwining relatively hard fibers in a non-woven fabric-like or three-dimensional network form is coated with ceramics by thermal spraying. The matte layer is provided with the vibration-proof and sound-proof properties, and further the sound-absorbing property is improved by the adhered ceramics. In other words, since the surface of the adhered ceramics is highly irregular and porous, and the mass of the ceramics itself is present, a sound absorbing effect including a mass effect, heat conductivity, and heat divergence occur. When the ceramic has a photocatalytic action such as titania, antibacterial action and deodorizing action are exhibited.

Further, if such a layer is laminated with, for example, corrugated cardboard as a plate-like layer, it becomes a packaging material having sufficient strength and cushioning property, and if it is laminated with a layer made of wood board as the plate-like layer, It can be used as a building material with cushioning, soundproofing, antibacterial and deodorizing effects. In addition, by entwining a thin and flexible synthetic resin fiber with a relatively hard fiber or by forming a film of a viscoelastic substance, its vibration-proof and sound-proof properties are improved. By mixing chemicals such as fragrances and insect repellents, deodorant, insect repellent, and scent will be obtained. Also,
If the fibers constituting the mat layer are palm fibers, the treatment at the time of disposal thereof can be handled to the extent of incineration of dried plant products, and the resources can be easily recycled.

[0015]

EXAMPLES Hereinafter, coconut fiber, which is an element constituting the present invention,
A mat layer formed by intertwining relatively hard synthetic resin filaments in a non-woven fabric-like or three-dimensional network form, thermal spraying, photocatalytic ceramics, viscoelastic substance, deodorant,
Chemical agents such as fragrances, insect repellents, oxide fine powder deodorants, etc. will be sequentially described, and then the illustrated examples will be specifically described.

In the present invention, the palm fiber is a fibrous bark of a palm family plant distributed from tropical to subtropical regions,
In addition to petiole base fibers, mesocarp fibers, banana trunks,
It also includes pineapple leaves, abaca leaves, etc., which are relatively thick and tough plant fibers that were often discarded in the past. All palm trees are evergreen shrubs or trees with a single trunk that does not split branches and has a crown of leaves at the tip, almost no trunk or even 30 meters high. However, some of them have a smooth surface and some are tightly wrapped in old leaf sheaths. Also, like tows, the ones with vines climbing high on the tree, the ones with bulging trunks, and the genus Hyphae.
There is an exceptional one such as ne that branches into two.

The leaves are usually large, palm-like or feather-like, leathery, and the base of the petiole forms a wide leaf sheath to hold the trunk firmly. There are many fibers in the leaf sheath, and depending on the type, when old, the soft tissue rots, leaving only the fibers, resulting in so-called palm skin. The inflorescences are large, spike-shaped panicles, either apical or aerial, and well branched,
In the case of climax, when the flowers bloom, the tree dies. When fertilized by wind or insects and the fruit is a berries or drupe, the endocarp is usually attached to the seed and the mesocarp has a thick fiber layer. These are coconut fibers, specifically, in the palm family plants where the bark is presented as fibrous, palm genus palm, spurge, Chamaelops genus scrotum, those exhibiting fibers at the petiole base, peafowl peanut palm, pearl beetle, There are coconut coconut, nippah palm nipah palm and the like which provide fibers of date palm, date palm, sago palm, black clover, sugar palm, and mesocarp.

In the present invention, these coconut fibers are entwined in a non-woven fabric-like or three-dimensional network form. In order to form a mat layer, the same method as in the non-woven fabric manufacturing process for synthetic fibers can be taken, such as unraveling these fibers once and then entwining them again. When entwining, an appropriate amount of adhesive is applied, usually about 5 mm to 20 mm. It is easy to use the one with thickness. When it is used as a sheet material or a so-called cushion material, it is desirable to stack them or use a sheet having a thickness larger than that.

In the present invention, in addition to the palm fiber, a mat layer formed by entwining relatively hard synthetic resin filaments in a non-woven fabric-like or three-dimensional network form can be used, which is at least the above-mentioned palm fiber. It is moderately hard, entangled in a relatively coarse non-woven fabric, or entangled in a three-dimensional network, as long as it has appropriate cushioning properties and can be stretched, bent, or deformed, It does not matter whether the material is thermoplastic or thermosetting. Further, the filament may be an original monofilament fiber obtained as a single filament in the spinning step, or a multifilament as long as it is strong, and further, for example, after synthetic resin is foam-molded, it is formed into an appropriate solvent. Alternatively, the remaining skeletal tissue may be obtained by immersing the membrane tissue in the solution and dissolving only the membrane tissue. In this way, the mat layer formed by intertwining relatively hard synthetic resin filaments in a non-woven fabric-like or three-dimensional network form is different from ordinary non-woven fabrics made of thin and flexible synthetic resin fibers, and for example, is constant even when lifted. It retains its shape and deforms only when a load is applied, and exhibits so-called cushioning properties like the mat layer of the palm fiber.

The coconut fiber mat layer or the mat layer formed by intertwining the relatively hard synthetic resin filaments in a non-woven fabric-like or three-dimensional network structure is used in the ordinary non-woven fabric. You may entangle various synthetic resin fibers. Various synthetic resins such as nylon, vinylon, vinylidene, urethane, polyethylene, polypropylene and acrylic can be applied to the raw material of the synthetic resin fiber, and even in the spinning method thereof,
Appropriate methods can be applied depending on the material regardless of melt spinning, polymerization spinning, dry method, wet method and the like. Further, when intertwining these, for example, a conveyor is arranged below the spinneret of the melt spinning device, and a synthetic resin as a raw material is blown out into a thread shape by being put on a high-temperature and high-speed air stream from the spinneret, and the lower part is conveyed. This is done by accumulating on top of these mat layers that are moving on board. By doing so, the thin and flexible synthetic resin fibers penetrate into the mat layer between the palm fibers or the synthetic resin filaments to some extent in the layer and become entangled with each other.

Next, thermal spraying will be described. Thermal spraying is a technology that melts a wire or rod-shaped linear material or powder material at high temperature and sprays it as droplets on the object to be processed, forming a film such as metal on the surface of the object to be processed. It is known as a surface treatment method for rust prevention of the body. There are various types of flame spraying, such as flame type, arc type, plasma type, etc., depending on the means for melting the material, and depending on the material form at that time, wire type, rod type, powder type, etc. There are two types of operation methods, which are subdivided and stationary, and a manual method, and the manual method enables field work.

In general, thermal spraying is generally performed on a flat metal surface, but in the present invention, a mat layer formed by intertwining relatively hard fibers in a non-woven fabric-like or three-dimensional network form. Do against. Further, it is characterized in that the matte layer is uniformly deposited in the form of a film by spraying ceramics into droplets instead of spraying a metal. And since this coating is basically performed along the entanglement of a non-woven fabric or a three-dimensional network, it has a large unevenness, is porous, and has a relative mass, thus improving the sound absorbing effect, Heat conductivity and heat dissipation are improved.

The ceramics used for thermal spraying are generically referred to as metal oxides, borides, carbides, nitrides, silicates, sulfates, phosphates, carbon simple substances, etc., but ceramics having a photocatalytic action are separately mentioned. It is suitable for imparting a function, and among them, titania is recommended because it exerts a very strong photocatalytic action. Other than these, the photocatalytic action is inferior to that of titania, but CdS, CdSe, WO ₃ , Fe ₂
Semiconductor ceramics such as O ₃ are suitable. Although the material such as titania itself has a certain degree of photocatalytic action, since the activity of the material alone is small, the particle size of titania is 0.5 μm for the purpose of efficiently causing the photocatalytic action.
It is preferable to use fine particles of a certain size carrying a conductive metal such as platinum or palladium. Similarly, for photoelectrochemical action, it is desirable to bring the ceramic having a photocatalytic action into contact with the conductor metal. Therefore, the matte layer formed by intertwining relatively hard fibers in a non-woven fabric-like or three-dimensional network structure is used in advance. After spraying a metal, ceramics having a photocatalytic action may be layered and sprayed. As the conductor metal used here, various metals such as stainless steel, copper and iron can be used.

Further, the melting temperature of ceramics such as titania is generally several thousand degrees, and a material having low heat resistance cannot be sprayed by a normal spraying method, so that the particle diameter is 5 μm.
By using a fine powder of about 25 μm as the thermal spray material, thermal spraying can be performed while keeping the temperature of the thermal spray target material low, and the thermal spray target material can be easily sprayed without being damaged.

In the present invention, the mat layer of coconut fiber or the mat layer formed by intertwining relatively hard synthetic resin filaments in a non-woven fabric-like or three-dimensional network form may be coated with a viscoelastic substance. The viscoelastic substance can be partially or wholly impregnated with the mat layers or laminated on the mat layers.

First, silicone gel is suitable as the viscoelastic substance. The silicone gel is, for example, a diorganopolysiloxane (hereinafter referred to as component A) which is a stock solution of the silicone gel represented by the following formula [1]: RR ¹ ₂ SiO— (R ² ₂ SiO) _n SiR ¹ ₂ R ... [1] [ However, R is an alkenyl group, R ¹ is a monovalent hydrocarbon group having no aliphatic unsaturated bond, R ² is a monovalent aliphatic hydrocarbon group (at least 50 mol% of R ²
Is a methyl group, and when it has an alkenyl group, its content is 10 mol% or less), and n is the viscosity of this component at 25 ° C. is 100 to 100,000 cSt.
The viscosity at 25 ° C is 50
00cSt or less and at least 2 S in one molecule
Organohydrogenpolysiloxane (B) which is a stock solution of a silicone gel having a hydrogen atom directly bonded to an i atom.
Component) and the ratio (molar ratio) of the total amount of alkenyl groups contained in the component A to the total amount of hydrogen atoms directly bonded to the Si atoms in the component B is 0.1 to 2.
It is an addition reaction type silicone polymer obtained by curing a mixture adjusted to 0.

The silicone gel will be described in more detail. The component A has a linear molecular structure, and alkenyl groups R at both ends of the molecule are added to hydrogen atoms directly bonded to Si atoms in component B. And a compound capable of forming a crosslinked structure. The alkenyl group present at the terminal of this molecule is preferably a lower alkenyl group, and a vinyl group is particularly preferable in view of reactivity. R ^{1 at the} terminal of the molecule is a monovalent hydrocarbon group having no aliphatic unsaturated bond, and specific examples of such a group include an alkyl group such as a methyl group, a propyl group and a hexyl group. , Phenyl groups and fluoroalkyl groups. In the above formula [1], R ² is a monovalent aliphatic hydrocarbon, and specific examples of such a group include an alkyl group such as a methyl group, a propyl group and a hexyl group, and a vinyl group. And lower alkenyl groups. However, at least 50 of R ²
Mol% is a methyl group, and when R ² is an alkenyl group, the amount of the alkenyl group is preferably 10 mol% or less. If the amount of alkenyl groups exceeds 10 mol%, the crosslink density tends to be too high and the viscosity tends to be high. Also n
The viscosity of the component A at 25 ° C. is usually 100 to
100,000 cSt, preferably 200-20,000
It is set to fall within the range of cSt.

The above-mentioned component B is a cross-linking agent for component A and is S
The hydrogen atom directly bonded to the i atom adds to the alkenyl group in the A component to cure the A component. The component B has only to have the above-mentioned action, and as the component B, those having various molecular structures such as linear, branched, cyclic, or network can be used. In addition to the hydrogen atom, an organic group is bonded to the Si atom in component B, and this organic group is usually a lower alkyl group such as a methyl group. further,
The viscosity of component B at 25 ° C. is usually 5000 cSt or less, preferably 500 cSt or less. B like this
As an example of the component, an organohydrogenpolysiloxane in which both ends of the molecule are blocked with a triorganosiloxy group,
Copolymer of diorganosiloxane and organohydrogenpolysiloxane, tetraorganotetrahydrogencyclotetrasiloxane, copolymer polysiloxane composed of HR ¹ ₂ SiO 1/2 units and SiO 4/2 units,
And HR ¹ ₂ SiO 1/2 unit, R ¹ ₃ SiO 1/2 unit and Si
A copolymer polysiloxane composed of O 4/2 units can be mentioned. However, in the above formula, R ¹ has the same meaning as described above. The ratio of the total molar amount of hydrogen atoms directly bonded to Si in the component B to the total molar amount of alkenyl groups in the component A is usually 0.1 to 2.0, preferably 0.1. A component and B to be within the range of ~ 1.0
It is manufactured by mixing the components and curing.

The curing reaction in this case is usually carried out using a catalyst. As the catalyst used here, a platinum-based catalyst is suitable, and as this example, finely divided elemental platinum,
Examples thereof include chloroplatinic acid, platinum oxide, a complex salt of platinum and an olefin, platinum alcoholate, and a complex salt of chloroplatinic acid and vinylsiloxane. Such complex salts consist of A component and B
It is usually used in an amount of 0.1 ppm (platinum equivalent, the same applies below) or more, preferably 0.5 ppm or more based on the total weight of the components. The upper limit of the amount of such a catalyst is not particularly limited, but, for example, when the catalyst is in a liquid state or can be used as a solution, 200 p
An amount of pm or less is sufficient.

The components A, B and the catalyst as described above are mixed and left to stand at room temperature or heated to cure to form the silicone gel used in the present invention. When curing by heating, the heating temperature is usually 50.
~ 160 ° C. The silicone gel thus obtained has a JIS (K2207-1980, 50 g load)
The penetration value measured in 1. is usually 5 to 250. The hardness of such a silicone gel varies depending on the cross-linking structure formed by the A component and the B component. The viscosity of the silicone gel before curing and the penetration after curing can be determined by adding silicone oil having methyl groups at both ends in an amount within the range of 5 to 75% by weight based on the obtained silicone gel. Can be adjusted. The silicone gel can be prepared as described above, or a commercially available one can be used. Examples of commercially available products that can be used in the present invention include CF502
7, TOUGH-3, TOUGH-4, TOUGH-
5, TOUGH-6, TOUGH-7 (made by Toray Dow Corning Silicone Co., Ltd.) and X32-902 / cat1
300, KE1308 / cat1300-L4 (manufactured by Shin-Etsu Chemical Co., Ltd.), F250-121 (manufactured by Nippon Unica Co., Ltd.) and the like.

In addition to the components A, B and catalysts described above, pigments, curing retardants, flame retardants, conductive fillers, etc. may be added within a range that does not impair the properties of the silicone gel. In order to improve the buffering property, the vibration damping property, etc., a silicone gel prepared by mixing a filler of fine hollow spheres may be used, and such filler material may be Philite (registered trademark) manufactured by Nippon Philite Co., Ltd. Examples include EXPANCEL (registered trademark) and Matsumoto Microsphere (manufactured and sold by Matsumoto Yushi-Seiyaku Co., Ltd.). It is also possible to apply mica (mica) pieces as a filler, and in this case, sound and vibration have the action of being attenuated by random emission between mica pieces.

In addition to the above silicone gel, polybutadiene gel is suitable as a viscoelastic substance. An example of this is Poly b manufactured and sold by Idemitsu Arco Co., Ltd.
There is dR-45HT. This is a liquid polymer of polybutadiene gel having a highly reactive hydroxyl group at the molecular end, which is easily cured by isocyanates like a normal polyurethane to give a good viscoelastic body. The polybutadiene gel has excellent water resistance, chemical resistance, and electrical characteristics because the main chain is composed of only hydrocarbons, and also has good low-temperature characteristics because the skeleton has 1,4 bonds. . Further, since it is liquid, it is easy to process and has the advantage of being easily continuous. Then, after appropriately mixing various kinds of compounding agents and first mixing, a curing agent is added and secondarily mixed, and impregnated,
It will be used after forming into a sheet.

The compounding agents include carbon black, silica, alumina, and calcium carbonate as fillers for strength and hardness and heat resistance, and process oil and asphalt as extenders for adjusting viscosity, which are There are dibutyltin and dilaurate as catalysts for adjustment, and heat resistance is improved. As an antioxidant, Irganox 565 manufactured by Ciba-Geigy Co., Knocklac NS-6 manufactured by Ouchi Shinko Chemical Co., Ltd. There is TINUVIN 327 manufactured by Ciba-Geigi Co., Ltd. as an ultraviolet absorber, aluminum hydroxide, borax, chlorinated paraffin and antimony oxide as flame retardants, and rylene diisocyanate and methylene diisocyanate as curing agents.

And as a preferred example, the above R-45H is used.
100 parts of T, 0.005 parts of TAS750 manufactured by Shin-Etsu Silicone Co., Ltd. as an antifoaming agent, and 0.005 parts of DBTDL KS-1260 manufactured by Kyodo Chemical Co., Ltd. as a catalyst.
5 parts, 8.3 parts of Millionate MR-200 (NCO content 30.9% by weight) manufactured by Nippon Polyurethane Industry Co., Ltd. as a curing agent, and Microsphere F manufactured by Matsumoto Yushi-Seiyaku Co., Ltd. as micro hollow spheres. -8
Using 1 part of 0ED, first, the components excluding the internal curing agent were sufficiently stirred and mixed at room temperature, then the curing agent was added thereto, and the mixture was further stirred and mixed to obtain a uniform liquid material, and the mixture was concentrated under reduced pressure. After defoaming, a sheet of polybutadiene gel can be obtained which can be poured between glass plates coated with a release agent and heat-cured to be laminated as a layer of viscoelastic material. The sheet of polybutadiene gel thus obtained has a buffering property close to that of the silicone gel and is relatively cheaper than the silicone gel.

In addition, many of vibration damping paints, soundproofing paints, and sealing materials exhibit viscoelasticity and are often inferior to the former two in terms of temperature characteristics, but are very advantageous in terms of price. Therefore, it is better to use this for low-priced products. With such a material, it is applied to the underside of automobiles and railway cars, fenders, outer panels, etc., and it is an inexpensive material that has effects such as soundproofing, rustproofing, and heat insulation. For example, knit quaunder sold by Nippon Special Coating Co., Ltd. There is a seal (registered trademark).

These viscoelastic substances are prepared by coating the matte layer of coconut fiber or the matte layer of relatively hard synthetic resin filaments entwined in a non-woven fabric-like or three-dimensional network form with the undiluted solution before curing. Be sprayed on
Once the entire mat layer has been impregnated, the palm oil or synthetic resin filaments can be coated by spraying out excess stock solution other than covering it in a film by an appropriate means. Part or all may be impregnated, or sheets obtained in advance may be used in an overlapping manner.

When these mat layers are coated with these viscoelastic substances, the elasticity of the original coconut fibers or synthetic resin filaments is added to the appropriate flexibility and restoration delay of the viscoelastic substances to form a mat layer. Has a thick and thick cushioning property. If the hardness of the substance exhibiting viscoelasticity is about 100 or more, the surface becomes sticky, and in such a case, a non-sticky skin layer may be formed. Also, it can be impregnated with a viscoelastic substance,
By stacking the sheet-shaped materials on top of each other, the cushioning, vibration-proofing, and sound-proofing properties of the viscoelastic substance layers are synergized.

Further, by mixing chemicals such as a deodorant, an aromatic agent and an insect repellent into the synthetic resin filament or a thin and flexible synthetic resin fiber which is entangled with the filament, deodorant, insect repellent and scent drifting can be obtained. Next, the chemicals such as deodorant, fragrance, antibacterial agent, insect repellent, repellant and insecticide will be explained. First, examples of the deodorant include activated carbon, zeolite, cristobalite, amyone, aluminum orisophosphate, a tightly bound body of titanium oxide, zinc oxide and water molecules, and an anico plant extract. Zeolite adsorbs polar molecules such as water and ammonia and sulfur-based gases such as hydrogen sulfide well. In addition, activated carbon exhibits excellent adsorption ability at low temperatures. Cristobalite is a kind of silicate mineral formed by diatomaceous earth, which is a kind of algae, that became diatomaceous earth for a long time and was further burned by volcanic magma, and has a high adsorption rate of ammonia. Amyeon is a powder composed of natural minerals and has the ability to deodorize by biological action in the soil and the physical and chemical action of rocks and minerals. Aluminum orthophosphate adsorbs ammonia and amines well. Anico is a green-blue liquid that contains ferrous sulfate as a main component and L-ascorbic acid as an oxidation inhibitor. The plant extract includes, for example, flavanols extracted from the Camelliaceae plants represented by tea, flavanols, conifers, and broad-leaved tree extracts.

Of these various deodorants, activated carbon, zeolite, cristobalite, amyon, aluminum orthophosphate, etc. are all powders, so that they can be mixed as they are with the synthetic resin raw material, or they can be once loaded on a separate porous fine powder. After this, it can be mixed and spun. Also, in the case of liquid anico and plant extracts, compatibility with synthetic resin raw materials can be taken into consideration.

Among the deodorizing agents, the oxide fine powder deodorizing agent represented by the close-bonded body of titanium oxide, zinc oxide and water molecules will be described in more detail. This deodorizing agent is used as a standard for comparative evaluation of deodorizing power. It is particularly excellent in low-temperature and low-concentration adsorption properties of ammonia and hydrogen sulfide, and it lowers malodorous molecules by a catalytic action, and further, zinc oxide chemically adsorbs acidic gas, and titanium dioxide physically adsorbs alkaline gas. Then it is considered. In addition to its excellent deodorizing ability, this product is advantageous in that it gives a feeling of cleanliness and is effective in coloring because it is in the form of fine powder having a particle size of micron to submicron order and is white.

According to JP-A-63-54935, an aqueous solution of a water-soluble titanium compound and a water-soluble zinc compound is mixed with an alkaline aqueous solution, and the resulting precipitate is dried. Obtained, for example, titanium sulfate, titanium chloride, titanium nitrate, zinc sulfate, zinc chloride, zinc nitrate, etc.,
The titanium compound and the zinc compound are in a molar ratio of 7: 3 to 3: 7.
To the mixed aqueous solution in the range of 7 to 9 with an aqueous solution of sodium hydroxide, potassium hydroxide, barium hydroxide, ammonia or the like at a reaction temperature of 40 to 60 ° C. , The precipitate formed is 15
Those dried at 0 to 220 ° C. are said to be suitable and can be obtained from Titanium Industry Co., Ltd. as a TZ deodorant. Similar oxide-based fine powder deodorants include a combination of zinc oxide, aluminum oxide, and silicon oxide (see JP-A-63-246167), a combination of titanium oxide, zinc oxide, magnesium oxide, and calcium oxide ( JP-A-63-18544
5 and JP-A-63-183065), and can be used in the same manner.

As the fragrance, natural fragrances of animals and plants, synthetic fragrances, prepared fragrances, etc. may be used as they are, or those obtained by emulsifying these fragrances and spray-drying to powder. As an antibacterial agent, since a close-bonded body of the titanium oxide, zinc oxide and water molecules can also exhibit antibacterial properties, it can be applied focusing on this effect, in addition to other metal oxides, silver, copper and other metals. Fine particles and the like can be applied. As insecticides, for example, fenitrothion for mites, organic phosphoric acid such as fenthion, and pyrethroids that collectively refer to natural pyrethrins and synthetic pyrethrin compounds,
Others include nicotine and pyrethrum. As the insect repellent, paradichlorobenzene, a combination of allenin and piperonyl ptoxide, a powdered version of Emicon or the like can be used. Further, examples of the repellant include N, N-dimethyl-m-toluamide, which has a strong repellency against tropical mosquitoes.

When these chemicals are mixed, they are mixed in a synthetic resin filament or a thin and flexible synthetic resin fiber which is entangled with the filament, but when the raw material is composed of a combination of two or more chemical substances. Means to include these chemical substances. That is, nylon 6, for example.
Taking 6 fibers as an example, in addition to nylon 6.6, which is a synthetic resin that has not yet been made into fibers by the polymerization of adipic acid and hexamethylene diamine, and adipic acid, which is the raw material of nylon 6.6 itself, Hexamethylenediamine is also included. Therefore, in the case of mixing the drug into the synthetic resin raw material, after the polymerization of adipic acid or hexamethylenediamine, the drug may be mixed in a state before spinning, or either one or both of adipic acid and hexamethylenediamine. It is also possible to mix a drug in the above and polymerize these. Further, since these chemicals do not have to be completely embedded in the synthetic resin fiber, mixing the chemicals means, for example, that the powder of these chemicals is added to the molten or softened fiber immediately after leaving the spinneret. It also includes the case of spraying and partially burying and adhering.

Next, a description will be given of an illustrated embodiment in which the composite material of the present invention is used as the interior wall material A. FIG. 1 shows a longitudinal section thereof, and in this embodiment, a mat layer of palm fiber is sprayed with titania, which is a ceramic having a photocatalytic action. That is, 1 is a mat layer having a thickness of about 5 mm in which palm fibers are entwined in a non-woven fabric-like or three-dimensional network form, and titania droplets are attached as a sprayed coating 2 on the surface thereof. Such an interior wall material A
For example, it is attached to a concrete wall without casting to decorate the room, forms a heat insulating air layer on the concrete wall, and has a titania sprayed coating 2, which results in a sound absorbing effect and self-extinguishing property. In addition to being improved, the antibacterial action and deodorizing action of titania are also exhibited, and it is most suitable for installation in a listening room, for example. Although the same applies to each of the following examples and application examples, in each of the drawings, the sprayed ceramics are drawn so as to adhere only to the surface of the mat layer. The sprayed ceramics do not always remain only on the front surface. For example, the part remains in the form of a film near the surface, part of the part reaches the middle of the mat layer, and part of the part penetrates to the back surface.

FIG. 2 shows an embodiment as the floor board material B, in which the titania droplets are deposited as the sprayed coating 3 on one surface of the mat layer 1 of palm fiber having a thickness of about 10 mm, as described above. A so-called plywood 4 is adhered to the other surface. The surface of the plywood is a decorative surface 4a, and the decorative surface 4a is used as a floor surface fixed to a skeleton. Therefore, although not shown,
It should be used by fitting it together as tiles of appropriate size such as cm × 30 cm, and there is a part on the back surface where the mat layer of palm fiber is not laminated because it sticks to the skeleton. Good.

The one shown in FIG. 3 is also finished as a floor board material C, and a layer 5 impregnated with polybutadiene gel as a viscoelastic substance is contained in 30% volume of the mat layer 1 of palm fiber. 2 is different from the embodiment shown in FIG. According to such floor board materials B and C, the mat layer 1 of coconut fiber and the layer 5 impregnated with the viscoelastic substance further improve the vibration damping, soundproofing, and heat insulating effects.

When the mat layer of palm fibers is impregnated with a viscoelastic substance such as polybutadiene gel or silicone gel, these stock solutions before curing are poured onto the mat layer and then the upper and lower rolls are rolled. It is possible to adopt a method of adjusting the degree of impregnation by passing it through a space and then passing it through a heating tunnel for curing. In addition, an appropriate commercially available adhesive may be used for adhering the mat layer and the plate-like layer, and when a viscoelastic substance is laminated, it may be viscous adhered due to its tackiness.

Further, in the above embodiment, the mat layer of coconut fiber is a flat layer having a uniform thickness as a whole, but the present invention is not limited to this, and the mat layer may be provided with irregularities in an appropriate pattern. In this case, a triangular pyramid-shaped emboss 6 as shown in FIG. 4 is formed as an example. Incidentally, such an emboss 6 can further promote the functions of vibration proof and sound proof, and can be applied, for example, as an interior of an automobile. The coconut fibers may be pressed to increase the density, and such densified palm fibers may be embossed during pressing.

In addition, the palm fiber can be subjected to a non-combustible treatment in advance. As a concrete method of non-combustible treatment,
It is also possible to apply what is obtained by firing coconut fiber in a nitrogen atmosphere or in an inert gas atmosphere and carbonizing it, or to apply a difficult twisting agent such as polysilazane or organic titanate for use at high temperature. Furthermore, in the above examples, the mat layer of palm fiber was used, but the present invention is not limited to this, and it is of course possible to use a mat layer composed of synthetic resin filaments, in which case a plant like palm fiber is used. Since fiber or wood is used as the starting material, there is no advantage in that there are few problems in disposal processing, but the sound absorption effect and self-extinguishing property are improved.

Further, in the above-mentioned embodiment, the mat layer of coconut fiber or the mat layer formed by intertwining relatively hard synthetic resin filaments in a non-woven fabric-like or three-dimensional network structure is made of coconut fiber or synthetic resin, respectively. Although it is assumed that the filaments are entangled, the present invention is not limited to this, and another thin and flexible synthetic resin fiber is entangled with the coconut fiber or the synthetic resin filament, or the coconut fiber or the synthetic resin filament Is coated with a viscoelastic substance, or synthetic resin, which is the raw material for the thin and flexible fibers, or synthetic resin filament raw material, the deodorant, fragrance, antibacterial agent, insect repellent, insecticide, insecticide Of course, one or more drugs selected from the above may be mixed. According to these, its buffering property,
Vibration-proofing properties, sound-proofing properties, etc. are improved, and additional effects such as deodorization, insect repellent, and scent drifting due to the chemicals are also brought about.

Although plywood was applied as the plate-shaped layer in the above-mentioned examples, the present invention is not limited to this, and other than this, a gypsum board, a metal plate, a plastic plate, a carpet mat, a carpet, a foam layer such as urethane, an artificial layer, or the like. Various materials such as leather can be applied. And using them, for example,
It can be provided as an interior material for doors, walls, ceilings, floors, etc., or as a filling material for soundproof walls, and also as a fence material.

Further, some more specific application examples of the composite material of the present invention will be given. First, the one shown in FIG. 5 is an exhaust pipe 9 provided with a cylindrical body 8 having an expanded diameter around the exhaust pipe 7. The composite material 10 in which the sprayed coating 2 of titania droplets is formed on the mat layer 1 of coconut fiber so as to cover the exhaust pipe 7 in the cylindrical body 8 is applied, for example, exhaust noise of a kerosene burner or the like. It is intended to eliminate the exhaust odor as well as to eliminate. The composite material 10 has a difference in the density of coconut fibers between the inside and the outside so as to increase the sound deadening effect.

Further, as shown in FIGS. 6 and 7, a composite material 10 having a sprayed coating 15 of titania droplets on a mat layer 1 of coconut fiber is applied to a filter 14 of an air cleaner. In such a filter 14, a normal filter action is obtained by the coconut fiber, and a deodorizing action is achieved by the photocatalytic action of titania with respect to the air to be cleaned, and the filter itself has an antibacterial action. In this case, as shown in FIG. 6, an ultraviolet lamp 12 is provided in the vicinity of the filter 14, or a daylighting window 13 is provided so that external light can well hit the thermal spray coating 15 of the titania droplets.
It is advisable to provide a structure that promotes the photocatalytic action of titania. Further, FIG. 7 shows that the spray coating 15 of titania droplets is further subjected to a heat exchange action when the inside and outside air is exchanged. When used as such a filter, it is particularly desirable that the ceramic to be adhered is fine particles such as titania supported by a conductive metal such as platinum or palladium as described above. Alternatively, it is desirable to spray a conductive metal such as stainless steel in advance on a mat layer formed by intertwining relatively hard fibers in a non-woven fabric-like or three-dimensional network form, and then spraying a titania layer or the like.

Of course, in addition to such various application examples, the composite material of the present invention may be simply used in the same manner as an ordinary nonwoven fabric. Further, although the plywood is laminated only on one surface in the above-mentioned embodiment, it goes without saying that a mat layer may be sandwiched between plate-like layers in some cases. Furthermore, although titania having a photocatalytic action was used as the ceramics in the above-mentioned examples, the present invention is not limited to this.
Other ceramics can be used. Further, although the filter of the air purifier has been described in the above embodiment, the present invention is not limited to this, and can be similarly applied to a water-based filter. In this case, in addition to a normal filter action, water spoilage prevention, bacteria It is possible to prevent the occurrence of algae and the algae.

Next, as another embodiment of the present invention, a combination with another material having a vibration damping effect will be described. Here, as an example of a material having a vibration damping effect, the Knitku Edykel (registered trademark) series manufactured by Nippon Special Paint Co., Ltd. can be mentioned. That is, for example, Edykel-
The 3500 is a pressure-sensitive adhesive type sheet-like material that has a vibration damping effect and can itself be used for vibration damping of metal components such as automobiles, vehicles, machinery, home appliances, audio products, etc. is there. Also Edykel-M200
Nos. 0 and M2500 are damping materials having a spray type paint property, and also have an action of preventing dew and rust. Furthermore, Edykel-M5000 is a sandwich type damping sheet,
It can be used for damping the motor cover.

As an example in which such a material having a vibration damping effect is applied to the present invention, for example, as shown in FIG. 8, the sheet 16a of the above Edykel-M3500 is laminated with the mat layer 1 of palm fiber by hot pressing. Alternatively, as shown in FIG. 9, the above-mentioned Edykel-M2000 or M may be added to the viscoelastic liquid.
2500 coatings 16b are added and this mixed solution is impregnated between the mat layers 1 of coconut fibers, or as shown in FIG. 10, the above-mentioned Edykel-M5000 is used as a plate 16c to add the mat layers 1 of coconut fibers. The composite material 10 may be created by pressing.

[0057]

As described above, according to the composite material of the present invention, the mat layer has the anti-vibration property, the sound absorbing property, etc., and the sound absorbing property and the self-extinguishing property are improved. It can be provided as various composite materials that are developed and are for vibration damping, sound absorption, self-extinguishing, antibacterial, deodorizing, etc. for packaging, construction, interior decoration, air and water filters, and the like. Further, when the palm fiber is used in the present invention, the problem of pollution at the time of incineration of plastics can be solved at the same time, and the unprecedented advanced and positive utilization of the palm fiber can be achieved.

[Brief description of drawings]

FIG. 1 is a vertical cross-sectional view of a composite material according to the present invention configured as an interior wall material, in which titania droplets are attached to a mat layer of coconut fiber.

FIG. 2 is a longitudinal sectional view showing an example as a floor board material, in which a mat layer of palm fiber is laminated on plywood, and a titania droplet is attached to the other surface of the mat layer of palm fiber. .

[Fig. 3] Fig. 3 is a vertical cross-sectional view showing still another embodiment as a floor board material, in which a mat layer of palm fibers impregnated with a viscoelastic substance is used.

FIG. 4 shows an example as an interior material of an automobile,
FIG. 3 is a vertical cross-sectional view of a coconut fiber mat layer surface with triangular pyramid-shaped embossing.

FIG. 5 is a perspective view showing a specific application example in which the composite material according to the present invention is applied to an exhaust stack.

FIG. 6 is a vertical cross-sectional view showing a specific application example applied to a filter of the above air purifier, the example including an ultraviolet irradiation lamp and a lighting window.

FIG. 7 is a vertical cross-sectional view showing an operating state when the same heat exchange action is attempted.

FIG. 8 shows an embodiment in which the composite material of the present invention is combined with another material having a vibration damping effect.
It is a longitudinal cross-sectional view of a sheet of M3500 and a mat layer of coconut fibers, which is heat-pressed.

FIG. 9 is a vertical cross-sectional view showing another example of the same, showing a state in which a viscoelastic liquid to which the paint of Edykel-M2000 or M2500 is added is impregnated between the mat layers of coconut fibers.

FIG. 10 is a vertical cross-sectional view showing a composite material according to still another embodiment of the present invention, in which a plate body of Edykel-M5000 is laminated with a mat layer of coconut fiber and pressed.

[Explanation of symbols]

1 Matte layer of palm fiber 2 Thermal spray coating of titania droplets 3 Thermal spray coating of titania droplets 4 Plywood 4a Decorative surface 5 Layer in which the mat layer of palm fiber is impregnated with polybutadiene gel 6 Embossing 7 Exhaust pipe 8 Cylindrical body 9 Exhaust stack 10 Composite material 12 Ultraviolet irradiation lamp 13 Lighting window 14 Filter 15 Spray coating of titania droplets 16a Damping material sheet 16b Damping material paint 16c Damping material plate A Interior coating wall material B Floorboard material C Floorboard material

Claims (8)

[Claims] 1. A composite material, wherein ceramics are applied by thermal spraying to a mat layer formed by intertwining relatively hard fibers in a nonwoven fabric-like or three-dimensional network form. 2. The mat layer formed by intertwining a relatively hard non-woven fabric or a three-dimensional network structure has separate thin and flexible synthetic resin fibers intertwined with the mat layer. The listed composite material. 3. A separate viscoelastic substance is coated on each fiber in the mat layer formed by intertwining in a relatively hard nonwoven fabric-like or three-dimensional network form. Composite material. 4. The composite material according to claim 1, wherein the mat layer is a layer formed by intertwining coconut fibers in a nonwoven fabric-like or three-dimensional network form. 5. The composite material according to claim 1, 2 or 3, wherein the mat layer is a layer formed by entwining synthetic resin filaments in a non-woven fabric-like or three-dimensional network form. 6. The composite material according to claim 1, wherein the ceramic is a ceramic having a photocatalytic action such as titania. 7. The mat layer formed by intertwining the relatively hard fibers in a non-woven fabric-like or three-dimensional network form is further laminated with a plate-like layer.
The composite material according to 2, 3, 4, 5 or 6. 8. The matte layer formed by intertwining the relatively hard fibers in a non-woven fabric-like or three-dimensional network form is further laminated with a layer of a viscoelastic substance. The composite material described in 3, 4, 5, 6 or 7.