JPS60103070A - Manufacture of inorganic fiber mat - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing an inorganic fiber cloak using inorganic fibers such as glass fiber and rock wool as a base material.

Inorganic fiber mats have insulation properties for wall materials, floors, ceiling materials, etc.
It has been praised for its sound-absorbing properties as a building material.

Inorganic fiber cloaks based on glass fiber, rock wool, etc.
Mainly phenolic resin is used as a binder. Although mats manufactured using phenolic resins have excellent heat resistance and moisture resistance, they have the drawback of exhibiting a reddish-brown or dark brown color after curing. When such an inorganic fiber mantle is used, for example, as a ceiling material, uneven coloring may occur.
Due to the deterioration of the reflective properties of lighting, there is a growing demand for non-colored binders.

The general method for producing an inorganic fiber mat is to dilute a binder with water and apply the binder to a substrate by spraying.

Therefore, the binder is preferably dissolved or dispersed in water. Further, the blended binder must not cause separation, etc., and must have a blend stability of 1jV for a certain period of time or more.

Based on the above conditions, various attempts have been made to develop binders that do not cause coloring. For example, there are examples in which vinyl acetate resin emulsions; synthetic rubber latexes such as styrene-butadiene copolymer latexes; and amino resins such as melamine resins, melamine-modified urea resins, and urea resins are used as binders. However, these methods have inferior moisture resistance compared to phenolic resins, and have not achieved significant effects.

The present inventors focused on the non-coloring properties of amino resins, and as a result of various studies to improve blend stability and strength, the present inventors developed a composition consisting of amino resins and acrylic resins as a binder. The present inventors have discovered that when used as an inorganic fiber, an inorganic fiber with little coloring property and excellent moisture resistance can be obtained, and the present invention has been completed.

That is, the present invention provides a method for producing an inorganic fiber cloak, which is characterized in that a composition containing an amino resin and an acrylic resin is used as a binder in producing an inorganic #Il fiber mat. be.

The amino resin JIN used in the present invention refers to one or a mixture of two or more of melamine resin, urea resin, and urea resin, and if necessary, an aqueous emulsion such as #acid vinyl emulsion, synthetic It is also possible to use a mixture of rubber latex, acrylic emulsion, vinyl acetate-acrylic copolymer emulsion, #acid vinyl-ethylene copolymer emulzidine, and the like.

As the amino resin, melamine resins and urea-modified melamine resins are preferred in terms of heat resistance and yield, and water-soluble amino resins, such as alkyl etherified methylol melamine resins and urea-modified alkyl etherified resins, are preferred in terms of heat resistance and yield. Methylolmelamine resin and etherified urea resin are preferred.

The melamine resin used in the present invention is a reaction product of melamine and formaldehyde, and is obtained by reacting melamine and formaldehyde at a molar ratio of 2 or more, preferably at a molar ratio of 3 to 7. Alkyl etherified methylol melamine resin is prepared by adding an alkaline substance such as sodium hydroxide, potassium hydroxide, barium hydroxide, calcium hydroxide, etc. in advance and reacting melamine and formaldehyde at a temperature of 50 to 80°C. -Tai, methyl alcohol,
Adding an aliphatic alcohol such as ethyl alcohol, n-propyl alcohol, isopropyl alcohol, etc. or a mixture thereof, then adding an organic acid, an inorganic acid or a mixture thereof as necessary, and carrying out a heating reaction to perform alkyl etherification, can get. The alkyl etherified melamine resin thus obtained can be concentrated if necessary.

The urea-modified melamine resin used in the present invention can be obtained by post-adding urea to two sets of melamine resins, or by using urea as part of the melamine from the beginning and reacting it with formaldehyde.

The urea resin used in the present invention is a reaction product of urea and formaldehyde, and is obtained by reacting urea and formaldehyde at a molar ratio of 1 to 4, preferably 1.5 to 3.0. It is J's duty to use the same thing.

The acrylic resin used in the present invention is a (meth)acrylic acid alkyl ester in which the alkyl group has 1 to 4 carbon atoms [hereinafter simply referred to as (meth)acrylic ester] 60 to
99% by weight, preferably 70-95% by weight, and 40-1% by weight, preferably 30% by weight of an α,β-unsaturated monomer having a levoxy group (hereinafter simply referred to as carboxyl group-containing monomer) An aqueous dispersion or aqueous solution of a copolymer obtained by polymerizing the main component by a known method.

The (meth)acrylic ester used here is (
Methyl acrylate, ethyl (meth)acrylate,
Examples include n-propyl (meth)acrylate, isopropyl (meth)acrylate, and n-butyl (meth)acrylate, each of which may be used alone or in combination. Among them, methyl acrylate, ethyl acrylate, n-butyl acrylate, and methyl methacrylate are preferred. In addition, these (meth)acrylic acid esters may be copolymerized with other compounds such as n-butyl (meth)acrylate, 2-(meth)acrylic acid in a range of 50% by weight or less.
Other meth)acrylic acid esters such as ethylhexyl, lauryl (meth)acrylate, and cyclohexyl (meth)acrylate, styrene, vinyl acetate, (meth)acrylonitrile, and the like can be substituted.

On the other hand, examples of the carboxyl group-containing monomer include (meth)acrylic acid, maleic acid, fumaric acid, iconic acid, and crotonic acid, each of which may be used alone or in combination. These carboxyl group-containing monomers also have 5
Monomers having functional groups other than carboxyl groups in the range of 0% by weight or less, such as 2-hydroxyethyl (meth)acrylate, 2-hydroxypropyl methacrylate, (
It can be substituted with meth)acrylamide, N-methylol(meth)acrylamide, diacetoacrylamide, t-butylacrylamide, glycidyl (meth)acrylate, and the like. Among them, it is preferable to use N-methylol (meth)acrylamide because it has excellent reactivity with the amino tree (N).

Methods for producing acrylic resin include, for example, emulsion polymerization using known anionic or nonionic emulsifiers alone or in combination, soap-free polymerization without using an emulsifier, and dispersion using an appropriate dispersant. There are a method of polymerizing and then making it aqueous, and a method of carrying out solution polymerization using a solvent with a high affinity for water such as methanol, ethanol, n-propatol, isopropanol, etc. and then making it aqueous.

These acrylic resins have extremely good blending stability even when mixed with amino resins, and can be heated and cured to create excellent resins.
l: indicates bQ. In particular, moisture resistance is significantly improved.

Generally, amino resins are used as binders in combination with acids such as inorganic acids and organic acids, chlorides, or ammonium salts such as ammonium sulfate and ammonium chloride to accelerate curing, but compositions in which acids are combined with amino resins is unsuitable as it has a markedly reduced blending stability, and is inferior to compositions containing chloride or fat, and also causes a precure phenomenon during heat curing, making it difficult to obtain sufficient fluidity. Moreover, the strength of the inorganic fiber mat after curing is also extremely high. On the other hand, a composition in which an amino resin and an acrylic resin are combined does not have the above-mentioned drawbacks and can provide an inorganic fiber mat with excellent moisture resistance.

The amount of acrylic resin added to amino resin is based on JIS-68.
The solid content of the acrylic resin is usually in the range of 5 to 100 parts by weight, preferably 10 to 60 parts by weight, per 100 parts by weight (as measured by the measuring method in the section of amino resin adhesives in 391976). .

Silicone can also be added to the binder used as a moisture resistance strength improver. Preferred silicones are aminosilanes, representative examples being gamma-aminopropyltriethoxysilane, gammamethacryloxybrobyltrimethoxysilane, gamma-glycidoxypropyltrimethoxysilane, and the like. Furthermore,
Alkanolamine salts can also be added as hardening agents.

The binder used in the present invention can be obtained by simply mixing an amino resin, an acrylic resin, and, if necessary, an aqueous emulsion such as vinyl acetate emulsion, synthetic a rubber latex, water, silicone, alkanolamine salt, etc. It will be done.

In the method for manufacturing the inorganic fiber cloak of the present invention, the binder obtained as described above is sprayed onto conventionally known inorganic fibers such as glass fibers and rock wool, and
A method of obtaining an inorganic fiber mantle by molding at a temperature of 0° C. is usually adopted, but it is also possible to obtain it by other known methods such as an impregnation method. At this time, the amount of binder attached to the inorganic fibers is determined so that the amount of binder attached after solidification is T;
@fFf, part, preferably 1 to 20M1 part @I!
! It is I. If the amount of adhesion 9 is less than 30 parts by weight, the inorganic fiber mat will not have sufficient strength, while if it exceeds 30 parts by weight, the density of the inorganic fiber mant will become high and its original properties such as sound absorption and heat insulation will be inferior. Therefore, each is not desirable.

Next, the present invention will be further explained by examples, but the present invention is not limited thereto. All percentages in examples are by weight.

Reference Example 1 (Synthesis example of acrylic resin) Ion-exchanged water (150 g, Hytenol N-08C'15-Industrial Pharmaceuticals) was placed in a 2β five-bottle flask equipped with a thermometer, stirrer, nitrogen inlet tube, and two dropping funnels. ammonium oxyethylene nonylphenyl ether sulfonate)
30 g of Noigen E^-170 (i-Kogyo Seiyaku side layer polyoxyethylene nonylphenyl ether) log were charged, and the temperature was raised to 80° C. while blowing nitrogen. Next, a monomer mixture consisting of methyl methacrylate 3 (l Of!, 220 g of ethyl acrylate, 60 g of methacrylic acid, and 20 g of N-methylolacrylamide was added to one of the dropping funnels, and 3 g of calcium persulfate was dissolved in 50 g of ion-exchanged water. The aqueous solution was simultaneously dropped from the other dropping funnel over a period of 4 hours.After the dropping was completed, an additional 4
The reaction was completed by keeping the temperature at 80°C for a period of time to obtain an acrylic resin emulsion (1). This acrylic resin emulsion (J) had a solid content of 39.7%, a viscosity of 15 centivoise/25°C, and a pH of 3.1.

Reference Example 2 (same as above) In a 2β fifth flask equipped with a thermometer, a stirrer, a nitrogen inlet tube, and two dropping funnels, 850 g of ion-exchanged water, 1 ml of Emar O (sodium alkyl sulfate, manufactured by Kao Atlas A-United)
8g, Emagen 950 [polyoxyethylene nonylphenyl ether manufactured by Kao Atlas A1] 12g, methyl methacrylate 60g, butyl acrylate 60g, styrene 4
0g1 28g of acrylic acid, 12g of itaconic acid, and 1.5g of ammonium persulfate were charged, and while blowing nitrogen,
The temperature was raised to 5°C. Then 120g of methyl methacrylate,
A monomer mixture consisting of 120 g of butyl acrylate, 80 g of styrene, and 80 g of acrylic acid was added dropwise from one dropping funnel, and an aqueous solution of 3 g of ammonium persulfate dissolved in 50 g of ion-exchanged water was added dropwise from the other dropping funnel over a period of 3 hours. . After the dropwise addition was completed, the temperature was maintained at 75° C. for another 4 hours to complete the reaction, and an acrylic resin Jirf emulsion (II) was obtained. This acrylic resin emulsion (n
) has a solid content of 40.1% and a viscosity of 8 cm/25
°C, pl+ was 2.9.

Example 1 7 g of short glass fibers were uniformly spread on a wire mesh measuring 60 cm x 90 cm. Plyamine FK-4232 (Methyl etherified methylol melamine resin manufactured by Dainippon Ink and Chemicals F11, solid content 75%) 1. 68 g was mixed with Ml in Reference Example 1.
0.7 g of the obtained acrylic resin emulsion (1) was mixed and further diluted with 67.62 g of water to obtain a binder. After spraying 35g of this binder on both sides of the expanded short glass fibers, dry at room temperature for 30 minutes,
The resulting material was cut into sheets of 50 m, stacked on top of each other, and cured in a forced circulation electric furnace at 180° C. for 10 minutes to obtain a white short glass fiber mat. The specific gravity of this man] was 0.034, and the amount of the binder attached was 9.4 parts per 100 parts of glass fiber (hereinafter simply referred to as the amount of attached 9.4 parts).

Next, the peel strength (normal strength, moisture resistance strength) of this cloak was measured using the following method, and the normal strength was 142 g.
/36d1 moisture resistance strength was 9 g/36-1 part.

Mat peel strength test: Cut Masoto into 6σ x 6 sides, apply rubber adhesive to both sides, sandwich it between two metal plates, and after adhering sufficiently, load in a direction perpendicular to the metal surface. Measure the peel strength of the mantle (the peel strength of the binder inside the mantle). Note that the normal strength is the mantle peeling strength of a sample left in a desiccator, and the humidity resistance strength is the mantle peeling strength of a sample left at room temperature for one week in an atmosphere of 90% relative humidity.

Example 2 7 g of short glass fibers were spread uniformly on a wire mesh measuring 60 cm x 90 au. 1. The acrylic resin emulsion (If) obtained in Reference Example 2 was added to 3 g of Primamine FK-42321.
A binder was obtained by mixing 4 g and diluting with (i 7.3 g of water).A white glass fiber mat was obtained in the same manner as in Example 1 except that this binder was used. The specific gravity of the mat was 0.035, and the adhesion amount of the binder was 9.5 parts.The normal strength of the mat was 144 g/36 crA.

Moisture resistance strength is 113 g / 36 cn? Met.

Example 3 7 g of short glass fibers were uniformly spread on a wire mesh measuring 60 cm x gO2. 0.78 g of Luxcoo 1087 (Dainippon Ink Chemical Industry a grade synthetic rubber latex 1. solid content 45%) was mixed with 94 g of Priamine FK-42320, and then 1.16 g of acrylic resin emulsion (II) was mixed.
g was mixed and diluted with 67.12 g of water to obtain a binder. A white glass fiber mat was obtained in the same manner as in Example 1 except that this binder was used. The specific gravity of this cloak is 0.
032, the adhesion amount of binder was 9.4 parts. In addition, the normal strength of the mat is 141 g736cn+, and the moisture resistance strength is 1
It was 12g/36cTA.

Comparative Example 1 7 g of short glass fibers were uniformly spread on a 60 cm x 90 an inch wire mesh. Praiofen 1'D-2350-60
(Water-soluble phenol tree JIF manufactured by Dainippon Ink Chemical Industry
1. Solid content 62. -5%) 22.4g to 677.6g
A binder was obtained by diluting with water. A short glass fiber mat was obtained in the same manner as in Example 1 except that this binder was used. The specific gravity of this mat is 0.033, and the amount of bonding agent attached is 9.
There were 2 parts, and the color was reddish brown. Also, Matt's normal state 4
11 degrees is 143 g/36 cm! , Moisture resistance strength: 111
g/36cIIl.

Comparative Example 2 7 g of short glass fibers were uniformly spread on a wire mesh measuring 60 cm x 90 cm. Priamine J-402 (methylol urea resin manufactured by Dairomoto Ink Kagaku Kogyo A, solid content 61%) 2.
A binder was obtained by diluting 3 g with 67.7 g of water. Short glass fiber pine 1- was obtained in the same manner as in Example 1 except that this binder was used. The specific gravity of this mat was 0.032, the amount of binder deposited was 9.3 parts, and the color was white. 8. The normal strength of the mat is 139 g / 36 ctA, and the moisture resistance strength is 50 g / 36 ci! Met.

Comparative Example 3 7 g of short glass fibers was spread uniformly on a wire mesh measuring 60 cm x 90 cm.
Add 0.49 g of urea to 31.75 g of 2% to give 67.7
A binder was obtained by diluting with 6 g of water. Curing conditions: 200℃
Short glass fibers were obtained in the same manner as in Example 1, except that the heating time was 10 minutes. The specific gravity of this man's throat is 0.03
1. The amount of binder attached was 9.5 parts, and the color was yellow. Also, the normal strength of the mat is 140 g / 35 cn
l, iii+wet strength was 108g/36c+d.

Agent: Patent Attorney Katsutoshi Takahashi

Claims (1)

[Claims] A method for producing an inorganic fiber mat, which comprises using a composition containing an amino resin and an acrylic resin as a binder in producing the inorganic fiber cloak.