JPH06294493A - Lightweight, hard heat insulating material - Google Patents

Abstract

PURPOSE:To provide a lightweight, hard heat insulating material excellent in the heat insulation property with a layer made of an inorganic mineral, hard and excellent in the compressive strength with the flake-like inorganic mineral on a soft, flexible substrate by sticking the flake-like inorganic mineral at least to the surface of the porous substrate. CONSTITUTION:A lightweight, hard heat insulating material is stuck with a flake-like inorganic mineral at least to the surface of a porous substrate. For manufacturing the lightweight, hard heat insulating material, the surface of the porous substrate is coated or sprayed with a processing liquid containing the flake-like inorganic mineral, or the porous substrate is dipped in a bath tub filled with the processing liquid, then the processing liquid is stuck on the whole or part of the porous substrate through a nip roll kept at a fixed thickness. The porous substrate is molded via a drying oven, and it can be cut and molded into the fixed size by a guillotine. Impregnation processing is preferable to uniformly stick the scale-like inorganic mineral on the whole porous substrate.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a lightweight rigid heat insulating material used particularly in building materials and structural materials.

[0002]

2. Description of the Related Art Conventionally, the problems to be solved by the invention
As a heat insulating material such as a building material, a rigid synthetic resin foam such as polystyrene foam or rigid polyurethane foam, glass wool, or an inorganic foam is used. Although each of the rigid synthetic resin foams has excellent heat insulation performance, polystyrene foam has a big drawback that it is easily burned, and rigid polyurethane foam has a problem of CFC used as a foaming agent. Glass wool is not self-supporting, and requires a pressing means to be applied to the wall surface of a wooden house, and further has problems such as internal condensation. Inorganic foams have excellent fire resistance, but they are brittle and heavy, and if they are made thinner and lighter, their strength becomes weaker and they tend to crack during transportation and construction. is there.

[0003]

That is, the lightweight rigid heat insulating material of the present invention is characterized in that a scale-like inorganic mineral is adhered to at least the surface of a porous substrate.

The porous substrate used in the present invention is, for example, an inorganic substance such as glass nonwoven fabric, rock wool or ceramic wool, or cotton, nylon, rayon, acrylic,
Examples include natural fibers such as polypropylene and polyester, woven fabrics, knitted fabrics, non-woven fabrics made of synthetic fibers, organic foams such as soft urethane foam, and laminates thereof.

The scale-like inorganic minerals (hereinafter referred to as scale-like minerals) used in the present invention are preferably inorganic natural minerals such as muscovite, flocovite, biotite and vermiculite. The components of the inorganic natural minerals are SiO ₂ 35 to 45, respectively.
%, Al ₂ O ₃ 8 to 15%, MgO 7 to 20%, K
₂ O 5-10%, other FeO, H ₂ O, Na ₂ O ₃
Etc. are included. It is preferable that the scaly mineral (inorganic natural mineral) has a high aspect ratio (average major axis / average thickness), but this scaly mineral is a treatment in which the porous base material contains water, an organic emulsion, or the like. If the particle size is too large (that is, if the aspect ratio becomes too high), the dispersibility in the processing liquid may deteriorate, so that the particle size is preferably 200 μm or less, more preferably 30 to 150 μm. good.

Examples of the organic emulsion include acrylic acid ester emulsions such as acrylic acid esters, methacrylic acid esters, and methacrylic acid ester homopolymers,
Examples thereof include vinyl acetate-based and cellulose acetate-based emulsions. These organic emulsions preferably contain the solid content of the homopolymer resin in an amount of 40 to 45% by weight based on the total amount of the organic emulsion. Also,
The amount of this organic emulsion added to the treatment liquid is 2
It is preferably 5 parts by weight or less, and more preferably 5 to 18 parts by weight. When the addition amount of the organic emulsion is 25 parts by weight or more, the amount of the scale-like minerals attached to the porous substrate is small, that is, when the number of scale-like layers is small and the amount of resin solids attached is large, In some cases, it may not be possible to obtain a product with excellent heat insulation and flame retardancy.

A dispersant may be added to the treatment liquid in order to improve the dispersibility, wettability and permeability of the scaly mineral on the porous substrate. Examples of the dispersant include naphthalene-
Formaldehyde condensate sulfonate, dioctyl sodium sulfosuccinate, polyoxyethylene alkyl ether, polyoxyethylene alkyl allyl ether, etc., having an HLB (hydrophilic and lipophilic ratio) of 10 or more,
That is, a water-soluble surfactant or the like is used.

A softening agent may be added to the treatment liquid. It is preferable to add a softening agent, since the light weight hard heat insulating material obtained by molding can have appropriate flexibility.
Examples of the softening agent include rubber-based latex such as acrylonitrile-butadiene copolymer, styrene-butadiene polymer, and methylmethacrylate-butadiene copolymer, and these resins have a solid content based on the total amount of the softening agent. It is preferable to use 40 to 45% by weight. Further, the addition amount of this softening agent is preferably 20 parts by weight or less with respect to the treatment liquid. From the viewpoint of flame retardancy, more preferably 10 to 18 parts by weight. For example, when the softening agent is present in an amount of 20 parts by weight or more with respect to the treatment liquid, the flexibility is improved, but the flame retardancy may be deteriorated.

The scale-like mineral is preferably dispersed in the treatment liquid and then attached to the porous substrate. Even when flake-like minerals get into the pores of the porous substrate,
The holes do not agglomerate in a part, and they are present in a state where they are randomly overlapped with each other to some extent or in a point contact state, so that heat is difficult to transfer, heat insulation is improved, and compression is also achieved. It is thought that the strength is also improved.

Further, the density of the lightweight rigid heat insulating material in the present invention is adjusted by the amount of the flake-like minerals and the emulsion adhering, and the flake-like minerals adhere to the porous substrate in the best condition of 80 to 200 kg / m ^3. Is preferred. For example, when the density is 80 kg / m ³ or less, that is, when the content of the inorganic component (scaly mineral) is small, it is lightweight but weak in strength and may be easily burned.

To produce the lightweight rigid insulation of the present invention,
For example, the surface of the porous substrate is coated with a treatment liquid containing a scale-like mineral, or sprayed, or the porous substrate is immersed in a bath containing the treatment liquid and then passed through a nip roll kept at a constant thickness. Then, it can be molded by a method of adhering it to the whole or a part thereof, molding it through a drying oven or the like, and then cutting it into a fixed size with a cutting machine and molding.
The impregnation treatment is preferable when the scale-like mineral is uniformly attached to the entire porous substrate.

[0012]

EXAMPLES The present invention will be specifically described below based on examples. In addition, the compounding parts number in an Example and a comparative example is a basis of weight unless there is particular notice.

Examples 1 to 2 Scale-like inorganic minerals, water, organic emulsions, and dispersants were weighed in the proportions shown in Table 1, mixed with each other, and sufficiently stirred. The basis weight was adjusted by impregnating a polyester non-woven fabric and maintaining a constant thickness with a nip roll. Then, it was dried in an oven heated to 90 to 130 ° C. to obtain a lightweight hard heat insulating material.
After further curing at room temperature for 3 days, it was tested for density, compressive strength and thermal conductivity. The results are shown in Table 1. Also,
When tested for flame retardancy (in accordance with the surface test of JIS A 1321), they each passed Class 1 flame retardancy.

Examples 3 to 4 Using a flexible urethane foam having a thickness of 15 mm as a base material, a light weight hard heat insulating material was obtained by the same method as in Example 1. The results are shown in Table 1. Moreover, when the flame retardancy was tested in the same manner as in Example 1, each passed the flame retardancy class 1.

Example 5 Scale-like inorganic minerals, water, organic emulsions, softeners and dispersants were weighed in the proportions shown in Table 1,
These were mixed and sufficiently stirred, then impregnated with a 15 mm-thick soft urethane foam and kept at a constant thickness with a nip roll to adjust the basis weight. Then 90
It was dried in an oven heated to ˜130 ° C. to obtain a lightweight hard heat insulating material. After further curing at room temperature for 3 days, it was tested for density, compressive strength and thermal conductivity. The results are shown in Table 1. Moreover, when the flame retardancy was tested, it passed the flame retardancy class 2.

Example 6 Using a polyester non-woven fabric having a thickness of 10 mm as a base material, a light weight hard heat insulating material was obtained in the same manner as in Example 1. The results are shown in Table 1. Example 7 A hard heat insulating material was obtained by the same method as in Example 1 using a flexible urethane foam having a thickness of 10 mm as a base material. The results are shown in Table 1. Example 8 A hard heat insulating material was obtained by the same method as in Example 5 using a flexible urethane foam having a thickness of 10 mm as a base material. The results are shown in Table 1.

[0017]

[Table 1]

Comparative Examples 1 to 2 Scale-like inorganic minerals, water, organic emulsions, and dispersants were weighed in the proportions shown in Table 2, mixed and sufficiently stirred, and then a thickness of 10 mm. The basis weight was adjusted by impregnating a polyester non-woven fabric and maintaining a constant thickness with a nip roll. Then, it was dried in an oven heated to 90 to 130 ° C. to obtain a lightweight hard heat insulating material.
After further curing at room temperature for 3 days, it was tested for density, compressive strength and thermal conductivity. The results are shown in Table 2.

Comparative Example 3 Water, an organic emulsion and a dispersant were weighed in the proportions shown in Table 2, mixed and sufficiently stirred, and then impregnated into a polyester non-woven fabric having a thickness of 10 mm and fixed with a nip roll. The weight per unit area was adjusted by keeping the thickness of. Then, it was dried in an oven heated to 90 to 130 ° C. to obtain a lightweight hard heat insulating material. After further curing at room temperature for 3 days, it was tested for density, compressive strength and thermal conductivity. The results are shown in Table 2.

Comparative Example 4 A 15 mm thick flexible polyurethane foam itself was tested for density, compressive strength and thermal conductivity without using any inorganic minerals, water, organic emulsions, dispersants or softeners. The results are shown in Table 2.

Comparative Example 5 A 15 mm thick polyester nonwoven fabric itself was tested for density, compressive strength and thermal conductivity without using any inorganic minerals, water, organic emulsions, dispersants or softeners. The results are shown in Table 2.

[0022]

[Table 2]

[0023]

[Description of table]

* 1 Flake-like mineral A: Muscovite with an average particle size of 160 μm * 2 Flake-like mineral B: Vermiculite with an average particle size of 45 μm * 3 Inorganic mineral C: Aluminum hydroxide powder with an average particle size of 5 μm or less * 4 Inorganic mineral D : Soft calcium carbonate powder with an average particle size of 6 μm or less * 5 Organic emulsion A: Acrylic ester emulsion (solid content 45% by weight) * 6 Organic emulsion B: Cellulose acetate butyl emulsion (solid content 45% by weight) * 7 Dispersant: Sodium dioctyl sulfosuccinate * 8 Softener: Styrene-butadiene copolymer latex (solid content 40% by weight) * 9 Density, compressive strength: Compliant with JIS A 9514 * 10 Density, compressive strength: Compliant with JIS A 9514 * 11 Thermal conductivity: JIS A 1412 compliant

[0024]

As described above, in the lightweight hard heat insulating material of the present invention, the scale-like inorganic mineral adheres to at least the surface of the porous substrate, whereby a layer of the inorganic mineral is formed and the heat insulating property is improved. Will be excellent. In addition, even if it is a soft flexible substrate, it becomes hard and has excellent compressive strength due to the scale-like inorganic minerals, and it is lighter than conventional inorganic heat insulating materials, and construction materials, structural materials, etc. When used for, it is easy to carry, and the strength is large and it is difficult to crack even when it is fitted during installation or when it is installed on a wall having a curved surface.

Claims (1)

[Claims] 1. A lightweight hard heat insulating material comprising a scale-like inorganic mineral adhered to at least the surface of a porous substrate.