JPH0939143A - Inorganic fiber mat and manufacture thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an inorganic fiber mat which can eliminate troubles including stimulus to skin by the scatter of fragments of inorganic fibers, wetting of the mat during construction, and the breakage of a skin material. SOLUTION: Synthetic resin fibers are sprayed directly on the whole surface including front, back, and four sides of an inorganic fiber mat main body 7 or the surface which is not coated with a moistureproof sheet by a melt blown method or a hotmelt spray method to form a nonwoven fabric 19. The nonwoven fabric 19, in which the resin fibers are arranged to be entwined with the inorganic fibers of the mat main body 7, has permeability and waterproofness, maintains compressibility and recoverability during packing and unpacking, removes moisture in the mat main body 7 outside, and prevents water leakage by preventing the permeation of water from the outside.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an inorganic fiber mat formed of an inorganic fiber mat main body and a skin material covering the inorganic fiber mat main body, which is used as a heat insulating, heat retaining and sound absorbing material for industrial and residential use. Regarding

[0002]

2. Description of the Related Art Conventionally, mats made of inorganic fibers such as glass wool, rock wool and slag wool have been widely used as heat insulating materials and sound absorbing materials for industrial and residential purposes. Since the inorganic fibers are non-flammable, they are more safe against fire than resin-based foam products.

Since the inorganic fiber mat used to be manufactured in a bare state, the fragments of the inorganic fiber forming the mat are scattered during the transportation, unpacking and construction of the product, and the human arm, hand,
In many cases, it adhered to exposed parts such as the face and gave a stimulus such as piercing the skin.

In order to solve this problem, in recent years, a method has been adopted in which an inorganic fiber mat is wrapped in a tubular shape with a skin material such as a polyethylene sheet and cut into a predetermined length to produce a product.

[0005]

However, even a product in which an inorganic fiber mat is wrapped with a skin material such as a polyethylene sheet remains on the four surfaces of the front and back surfaces and both side surfaces, and the cut surface cut into a predetermined length has a conventional shape. As in the case of the bare product, the mat was exposed, and the problem that the fragments of the inorganic fibers were scattered from that part was unavoidable.

In addition, in order to facilitate the inflow and outflow of the air necessary for the compression of the inorganic fiber mat during packing, the restoration during the construction, and the escape of the internal moisture by ventilation, the skin material such as polyethylene sheet is used. In addition, a large number of holes having a diameter of about 1 to 5 mm and notches having a length of several cm were made, and in some cases, fragments of inorganic fibers were scattered from these holes and notches.

Further, when water drops or water splash, water permeates into the inorganic fiber mat through the above-mentioned holes or cuts, impairing heat insulation, heat retention, sound absorption performance, wall,
There was also a bad influence on surrounding members such as columns. For this reason, it is necessary to take measures to prevent water leakage during construction, which is inconvenient for construction.

Furthermore, when the skin material is a polyethylene sheet, only a part of it is fixed to the inorganic fiber mat with an adhesive, so the polyethylene sheet floats up from the mat and is easily damaged by being caught by a sharp object. There was also something to do.

On the other hand, it is possible to cover the front and back surfaces of the inorganic fiber mat and all six surfaces of the four side surfaces with a skin material such as a polyethylene sheet, but it was not possible to eliminate the above-mentioned holes and cuts.

Therefore, an object of the present invention is to provide an inorganic fiber mat capable of solving problems such as irritation to the skin due to scattering of fragments of the inorganic fiber, wetting of the mat with water at the time of construction, breakage of the skin material, and the production thereof. To provide the law.

[0011]

In order to achieve the above object, one of the inorganic fiber mats of the present invention comprises an inorganic fiber mat body, and a melt blown method or a front surface and a back surface and four side surfaces of the inorganic fiber mat body. It is characterized by comprising a non-woven fabric made of synthetic resin fiber, which is formed by direct spraying by a hot melt spraying method and is attached so as to be entangled with the inorganic fibers of the inorganic fiber mat body.

Another aspect of the inorganic fiber mat of the present invention is a main body of the inorganic fiber mat, a moisture-proof sheet covering at least one of the front and back surfaces and four side surfaces of the main body of the inorganic fiber mat, and the inorganic fiber. All of the other surface of the mat body, directly formed by a melt-blown method or a hot melt spray method, is provided with a nonwoven fabric composed of synthetic resin fibers adhered to the inorganic fibers of the inorganic fiber mat body so as to be entangled with the inorganic fibers. It is characterized by being

Further, one of the methods for producing an inorganic fiber mat of the present invention is to add a binder having a thermosetting resin as a main component to the inorganic fibers to deposit them, and heat-cure the binder to form a mat-like shape. Then, a step of manufacturing the inorganic fiber mat main body by cutting it to a predetermined size, and forming a non-woven fabric made of synthetic resin fiber directly on the front and back surfaces and four side surfaces of this inorganic fiber mat main body by a melt blown method or a hot melt spray method. And a step of performing.

Further, another method for producing an inorganic fiber mat according to the present invention is to provide a binder containing a thermosetting resin as a main component on the inorganic fibers to deposit the inorganic fiber mat, and heat-cure the binder to form a mat-like shape. Forming into an inorganic fiber mat body and then cutting it to a predetermined size to produce an inorganic fiber mat body, a step of covering at least one of the front and back surfaces and four side surfaces of the inorganic fiber mat body with a moisture-proof sheet, and the inorganic fiber A step of directly spraying and forming a non-woven fabric made of synthetic resin fibers on all other surfaces of the mat body by a melt blown method or a hot melt spray method.

In the present invention, the non-woven fabric is preferably made of a thermoplastic synthetic resin fiber selected from polypropylene, polyester, polyethylene, polyethylene terephthalate, nylon and ethylene-vinyl acetate copolymer resin.

According to the inorganic fiber mat of the present invention, a synthetic resin fiber is formed by directly spraying the inorganic fiber mat body by a melt blown method or a hot melt spray method, and is attached so as to be entangled with the inorganic fibers of the inorganic fiber mat body. Since the non-woven fabric made of is composed of a fine mesh structure of extremely fine synthetic resin fibers, it is possible to almost certainly prevent the inorganic fibers from scattering to the outside, and to prevent irritation to the skin during handling.

Further, since the above-mentioned non-woven fabric is composed of a fine network structure of extremely fine synthetic resin fibers, it imparts sufficient air permeability necessary for compression and decompression of the inorganic fiber mat and diffusion of internal moisture. At the same time, water does not penetrate inside due to the water repellency of the synthetic resin fiber,
It is possible to prevent the inorganic fiber mat from getting wet with water.

Further, since the above-mentioned non-woven fabric is formed by directly spraying it onto the inorganic fiber mat body, it is adhered so as to be entangled with the inorganic fibers of the inorganic fiber mat body, so that the inorganic material can be formed without interposing an adhesive or the like. It firmly adheres to the fiber mat body and is less likely to be damaged by being caught by a sharp object during handling.

On the other hand, according to the method for producing an inorganic fiber mat of the present invention, synthetic resin fibers obtained by the melt-blowing method or the hot-melt spray method are added to the inorganic fiber mat body following the step of producing the inorganic fiber mat body. Since the inorganic fiber mat main body can be covered with the synthetic resin fiber non-woven fabric by directly spraying and covering it, the skin material can be covered by a simpler process than the case where a preformed sheet is bonded with an adhesive or the like. You can

[0020]

BEST MODE FOR CARRYING OUT THE INVENTION In the present invention, as the inorganic fiber, glass wool obtained by a centrifugal method, a flame method or the like,
Various kinds of inorganic fibers such as rock wool and slag wool can be used, but glass wool is preferably used. The average fiber diameter of the inorganic fibers is preferably 3 to 10 μm, and the average length is preferably 30 to 200 mm.

In the inorganic fiber mat body, a binder containing a thermosetting resin such as a phenol / formaldehyde resin as a main component is added to the above-mentioned inorganic fibers, and a predetermined basis weight is deposited on the perforated conveyor, and then a predetermined amount is obtained. It can be manufactured by introducing into a oven while compressing to a thickness, heat-curing the binder to form a mat, and further cutting into a predetermined size. The density of the inorganic fiber mat is 8 to 120 kg / m ³
Although it can be used in the range of, the range of 8 to 25 kg / m ³ is preferable in consideration of the compressibility at the time of packing and the recoverability at the time of unpacking.

The melt-blowing method in the present invention is a method in which a molten thermoplastic resin is extruded through a minute opening, and a high-temperature high-speed air stream supplied in the vicinity of the opening causes spinning and drawing at the same time to form a fiber. It means a method of forming a nonwoven fabric by laminating. More specifically explaining this method, generally, a minute nozzle is provided in a row on the bottom surface of the die, and the molten resin extruded from the die flows out of a slit provided so as to sandwich the row of nozzles at a high temperature and high speed air stream. The fiber is spun and stretched into a fiber. Then, the fibrous resin can be directly sprayed and laminated on the inorganic fiber mat body moving at a constant speed to form a nonwoven fabric.

The conditions for producing a nonwoven fabric by the melt-blowing method may be appropriately set depending on the resin used, the average fiber diameter of the nonwoven fabric, and the basis weight. For example, the melting temperature of the resin is 15
It is preferable that the temperature is 0 to 300 ° C., the extrusion pressure of the molten resin is 30 to 50 kg / cm ² , and the temperature of the high-temperature high-speed airflow is 200 to 400 ° C.

The hot melt spray method in the present invention is a method of using a curtain spray which is generally used for adhesives, and the molten resin pumped from the molten resin tank by a pump or the like is used to produce a large number of small particles. A method of forming a non-woven fabric by extruding from a spray nozzle with holes arranged in a row, spinning and stretching by a high-speed high-speed air flow through a slit provided so as to sandwich the row of small holes, and directly spraying and laminating on the inorganic fiber mat main body Is.

As the synthetic resin used in the melt-blowing method and the hot-melt spraying method, any non-woven fabric can be formed as long as it is a thermoplastic resin. In the case of the melt blown method, polypropylene, polyester, polyethylene, polyethylene terephthalate, nylon and the like are preferably used. Among them, the water repellency of the fiber itself is high, and the adhesion between the formed nonwoven fabric and the inorganic fiber mat body is the best. Polypropylene is particularly preferably used. In the case of a hot melt spray method, a low melt viscosity resins such as polyethylene, ethylene - vinyl copolymer resin such as acetic acid is preferably used, and the extrusion pressure of the molten resin even 0.5 ~2.0kg / cm ²
And relatively low pressure is enough.

The average fiber diameter of the synthetic resin fibers constituting the non-woven fabric is preferably 0.1 to 10 μm, more preferably 1 to 5 μm. In addition, the basis weight of the nonwoven fabric is 0.5 to 50 g / m ²
Is preferred and ² to 20 g / m ² is more preferred.

FIG. 1 is a schematic explanatory view showing an example of an apparatus for producing an inorganic fiber mat of the present invention, and FIG. 2 is a schematic sectional view showing the structure of a die part of a melt-blowing apparatus used in the apparatus. is there.

In FIG. 1, reference numeral 1 denotes a fiber riser for spinning inorganic fibers such as glass wool by a centrifugal method. Reference numeral 2 denotes a binder application device that applies a binder containing a thermosetting resin as a main component to the inorganic fibers spun from the fiber riser 1 by a spray method or the like. Reference numeral 4a is a conveyor arranged below the fiber riser 1 for depositing the inorganic fibers 3. It should be noted that a plurality of conveyors 4b to 4e are arrayed along the line direction continuously to the conveyor 4a.

A narrow pressure conveyor 5 is arranged on the conveyor 4b so as to face each other at predetermined intervals, and the deposited inorganic fibers 3 are compression-molded to a predetermined thickness. Reference numeral 6 denotes an oven arranged at the position of the conveyor 4b, which heat-cures the thermosetting resin applied to the inorganic fibers 3 to form the inorganic fiber mat body 7. A cutting machine 8 is installed in the portion of the conveyor 4c and cuts the inorganic fiber mat body 7 into a predetermined size.

Reference numeral 9 denotes a melt-blowing device arranged between the conveyor 4c and the conveyor 4d, which is arranged on the upper and lower surfaces and both side surfaces of the inorganic fiber mat body 7 to be conveyed. However, in FIG. 1, for convenience, only those arranged on the upper and lower surfaces are shown. The melt blowers on the top and bottom are
Although it may be set perpendicularly to the conveyors 4d and 4e, in order to ensure the covering of the end face of the inorganic fiber mat body 7 in the moving direction of the line, the one on the upper side is the upstream side of the line (in FIG. 1). 45 to 60 degrees toward the left side, and 45 to 60 degrees toward the downstream side (right side in FIG. 1) of the lower surface.
It is preferable to arrange it at an angle of 60 degrees.

As shown in FIG. 2, the melt blower 9
The die portion 11 of the extruded molten resin 12 is pressure-fed from an extruder (not shown), and has a plurality of pores 13 arranged in a line.
The air slits 15 for ejecting the primary heating air 14 are arranged so as to sandwich the row of the pores 13.
Further, the secondary heating air 16 is blown from the surroundings from a heating air supply means (not shown).

Therefore, according to this manufacturing apparatus, the binder is applied to the inorganic fibers 3 spun from the fiber riser 1 by the binder applying device 2, deposited on the conveyor 4a, and conveyed on the conveyor 4b. . Then, while being compression molded to a predetermined thickness by the narrow pressure conveyor 5, it is introduced into the oven 6 to cure the binder,
The inorganic fiber mat body 7 is formed.

The inorganic fiber mat body 7 is moved onto the conveyor 4c, where it is cut into a predetermined size by a cutting machine 8. Furthermore, the inorganic fiber mat main body 7 cut into a predetermined size
Moves on the conveyors 4d and 4e, and synthetic resin fibers are directly sprayed between them by the melt-blowing device 9 to cover the upper and lower surfaces and the four side surfaces of the inorganic fiber mat body 7 with a nonwoven fabric. In this way, the inorganic fiber mat 10 in which the upper and lower surfaces and the four side surfaces are coated with the nonwoven fabric is continuously manufactured.

The inorganic fiber mat 10 thus obtained is
As shown in FIG. 3, the upper and lower surfaces and the four side surfaces of the inorganic fiber mat body 7 are covered with a nonwoven fabric 19 made of synthetic resin fiber formed by the melt-blowing method.

In the above manufacturing apparatus, the conveyor 4
A moisture-proof sheet such as asphalt kraft paper is supplied between b and the conveyor 4c, the moisture-proof sheet is attached to the lower surface of the inorganic fiber mat main body 7, and a melt blower arranged between the conveyor 4d and the conveyor 4e. The lower part of the device 9 may be omitted, and the upper surface and the four side surfaces of the inorganic fiber mat main body 7 which are not covered with the moisture-proof sheet may be covered with a nonwoven fabric.

In this case, as shown in FIG. 4, an inorganic fiber mat 18 in which the lower surface of the inorganic fiber mat body 7 is covered with the moisture-proof sheet 17 and the upper surface and the four side surfaces are covered with the nonwoven fabric 19 is obtained.

[0037]

【Example】

Example A glass wool mat having a density of 10 kg / m ³ , a width of 430 mm, a length of 1730 mm, and a thickness of 50 mm was coated with a polypropylene nonwoven fabric directly formed by a melt blown method on the entire front and back surfaces and four side surfaces. The conditions of the melt-blowing method were a resin melting temperature of 180 ° C., an extrusion pressure of 42 kg / cm ² , a hot air temperature of 310 ° C., an average fiber diameter of the nonwoven fabric of 3 μm, and a basis weight of 7 g / m ² . In the inorganic fiber mat thus obtained, the non-woven fabric was extremely well adhered to the glass wool mat. After rubbing this inorganic fiber mat on the arm and observing changes in the skin,
No abnormalities such as irritation appeared. Also, place this inorganic fiber mat horizontally and pour 1 liter of water into the center,
After a minute, the non-woven fabric was stripped off and the surface of the mat was observed.
No water permeation was observed. Furthermore, the air permeability of the nonwoven fabric was measured and found to be 103.0 m ³ / m ² · sec. Comparative Example The lower surface of the same glass wool mat as in Example was covered with asphalt kraft paper, and the upper surface and two side surfaces in the width direction were covered with perforated aluminum vapor-deposited polypropylene film,
An inorganic fiber mat was produced. In this inorganic fiber mat, the inorganic fiber mat body is exposed at both end faces in the length direction.

After rubbing the film surface of this inorganic fiber mat against the arm and observing the change in the skin, the skin was slightly reddish and the itchy irritation remained for a while. In addition, place this inorganic fiber mat horizontally and
After pouring liter of water, peeling off the film after 30 minutes and observing the surface of the mat, water permeation was observed,
The central part was wet. Furthermore, when the ventilation rate of the perforated aluminum vapor-deposited polypropylene film was measured, it was 11.5 m ³
/ m ² · sec, which was 1/9 of the nonwoven fabric of the example.

[0039]

As described above, according to the inorganic fiber mat of the present invention, the whole surface of the inorganic fiber mat body, the front and back surfaces and the four side surfaces, or the surface other than the surface covered with the moisture-proof sheet is melt-blown or Since it is covered with a non-woven fabric made of synthetic resin fiber that is directly sprayed by the hot melt spray method, it can prevent skin irritation during handling, compressing when packing and unpacking, and for recovering internal moisture. While maintaining breathability, it is possible to prevent internal permeation of water and prevent the inorganic fiber mat body from getting wet with water, and firmly adhere the nonwoven fabric to the inorganic fiber mat body to prevent damage during handling. Workability can be improved. Further, according to the method for producing an inorganic fiber mat of the present invention, a nonwoven fabric made of synthetic resin fibers can be coated with good workability by a melt-blowing method or a hot-melt spray method, which is continuous with the production line of the inorganic fiber mat body. The production efficiency of the inorganic fiber mat can be improved.

[Brief description of drawings]

FIG. 1 is a schematic explanatory view showing an example of an apparatus for producing an inorganic fiber mat of the present invention.

FIG. 2 is a schematic cross-sectional view showing a structure of a die part of a melt-blowing device used in the manufacturing apparatus.

FIG. 3 is a partially cutaway perspective view showing an embodiment of an inorganic fiber mat of the present invention.

FIG. 4 is a partially cutaway perspective view showing another embodiment of the inorganic fiber mat of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Fiberizer 2 Binder application device 3 Inorganic fiber 4a, 4b, 4c, 4d, 4e Conveyor 6 Oven 7 Inorganic fiber mat body 8 Cutting machine 9 Melt blown device 10, 18 Inorganic fiber mat 11 Die part 17 of melt blown device Moisture-proof sheet 19 non-woven fabric

Claims (6)

[Claims] 1. An inorganic fiber mat main body and the front and back surfaces and four side surfaces of this inorganic fiber mat main body are directly formed by spraying by a melt-blowing method or a hot melt spray method so that they are entangled with the inorganic fibers of the inorganic fiber mat main body. An inorganic fiber mat, comprising: a non-woven fabric made of synthetic resin fiber adhered thereto. 2. The inorganic fiber mat body, the moisture-proof sheet covering at least one of the front and back surfaces and the four side surfaces of the inorganic fiber mat body, and the other surface of the inorganic fiber mat body are all melt-blown. And a non-woven fabric made of synthetic resin fiber which is formed by direct spraying by a hot melt spraying method or is entangled with the inorganic fibers of the inorganic fiber mat body. 3. The non-woven fabric is polypropylene, polyester, polyethylene, polyethylene terephthalate,
The inorganic fiber mat according to claim 1 or 2, comprising a synthetic resin fiber selected from nylon and an ethylene-vinyl acetate copolymer resin. 4. An inorganic fiber mat main body is manufactured by applying a binder containing a thermosetting resin as a main component to inorganic fibers, depositing the binder, heating and curing the binder to form a mat, and cutting the mat into a predetermined size. And a step of directly spraying a non-woven fabric made of synthetic resin fibers on the front and back surfaces and four side surfaces of the inorganic fiber mat body by a melt blown method or a hot melt spray method to form the inorganic fiber mat. Manufacturing method. 5. A binder comprising a thermosetting resin as a main component is applied to and deposited on the inorganic fibers, the binder is heat-cured to be molded into a mat shape, and further cut into a predetermined size to form an inorganic fiber mat body. A step of producing, a step of covering at least one surface of the front and back surfaces and four side surfaces of the inorganic fiber mat body with a moisture-proof sheet, and all of the other surfaces of the inorganic fiber mat body, a melt blown method or a hot melt method. And a step of directly spraying a non-woven fabric made of synthetic resin fibers by a spray method to form the inorganic fiber mat. 6. The non-woven fabric, polypropylene, polyester, polyethylene, polyethylene terephthalate,
The method for producing an inorganic fiber mat according to claim 4 or 5, wherein the inorganic fiber mat is formed of a synthetic resin fiber selected from nylon and an ethylene-vinyl acetate copolymer resin.