WO2006100985A1

WO2006100985A1 - Water-base binder for inorganic fiber and inorganic fiber heat-insulating sound absorbers

Info

Publication number: WO2006100985A1
Application number: PCT/JP2006/305156
Authority: WO
Inventors: Akira Inoue; Yoshifumi Mizuno
Original assignee: Asahi Fiber Glass Company, Limited
Priority date: 2005-03-18
Filing date: 2006-03-15
Publication date: 2006-09-28
Also published as: JP2006257595A; JP3949142B2

Abstract

A binder for inorganic fiber which can impart excellent water repellency for a long period; and inorganic fiber heat-insulating sound absorbers made by using the binder. A water-base binder for inorganic fiber which comprises a thermosetting resin precursor dissolved or dispersed in water and a water repellent emulsion, wherein the water repellent emulsion contains both a dispersant consisting of a water-soluble polycarboxylic acid resin and a water repellent containing at least one member selected from among waxes. The inorganic fiber heat-insulating sound absorbers are produced by applying the binder to inorganic fibers just after fiberization, collecting the resulting fibers, and molding them by heat curing.

Description

Specification

Aqueous binder for inorganic fiber and heat insulating sound absorbing material for inorganic fiber

Technical field

[0001] The present invention relates to a water-based binder for inorganic fibers used, for example, in the manufacture of heat insulating materials and sound-absorbing materials for detached houses, building buildings, and the like, and more specifically, imparts excellent water repellency over a long period of time. The present invention relates to a water-based binder for inorganic fibers and an inorganic fiber heat-absorbing sound-absorbing material using the same.

Background art

[0002] Conventionally, an aggregate of inorganic fibers has a high porosity and is further divided into fine spaces by the single fibers, making it difficult for air contained in the aggregate to move. Widely used as insulation or sound absorbing material in walls, cooling towers and outdoor equipment.

[0003] However, when water due to rain water or condensation is absorbed into the aggregate of inorganic fibers, the metal that contacts the aggregate of inorganic fibers or the generation of mold that is damaged by the heat and the performance of sound absorption are reduced. May cause corrosion of parts. Accordingly, aggregates of inorganic fibers that may come into contact with water are required to have as low water absorption as possible and high water repellency.

[0004] To increase the water repellency of inorganic fibers, mineral oil emulsion has been used in the past. However, as the above requirements increase, materials having higher water repellency have been proposed.

[0005] For example, Patent Document 1 below discloses the use of various organopolysiloxanes as a treatment agent for improving the water repellency of inorganic fibers.

[0006] Further, Patent Document 2 below discloses a hydrophobized resin composition for glass fiber for heat insulating material containing metal sarcophagus as an active ingredient.

Patent Document 1: Japanese Patent No. 2863585

Patent Document 2: JP-A-5-330861

Disclosure of the invention

Problems to be solved by the invention [0007] However, in order to add the water repellent used in the above prior art to the binder for inorganic fibers, it is necessary to disperse in water in advance. For this reason, nonionic or anionic surfactants are used in combination with water repellents and dispersed in water, but these surfactants remain in the cured inorganic fiber binder. In this case, it has a drawback that it is easy to absorb water. Therefore, even when a water repellent is added, there is a case where the water absorption of the surfactant is offset and there is a limit to the improvement of the water repellency of the inorganic fiber heat-absorbing sound-absorbing material.

[0008] In addition, a water repellent using mineral oil or organopolysiloxane is a liquid at room temperature, and a part of the water repellent may be washed away from the surface of the inorganic fiber over time. This has had the problem that the water repellency decreases with time.

[0009] Furthermore, in order to improve the water repellency of the inorganic fiber heat-absorbing sound-absorbing material, when a large amount of mineral oil or organopolysiloxane is contained, stickiness is likely to occur and workability during construction is improved. Is inferior and also expensive in terms of cost.

[0010] Therefore, an object of the present invention is to provide a binder for inorganic fibers capable of imparting excellent water repellency over a long period of time, and an inorganic fiber heat insulating sound absorbing material using the binder.

Means for solving the problem

[0011] The present invention provides an aqueous binder for inorganic fibers that achieves the above object, and an aqueous binder for inorganic fibers containing a thermosetting resin precursor dissolved or dispersed in water and a water repellent emulsion. The water repellent emulsion contains a dispersant composed of a water-soluble polycarboxylic acid resin and a water repellent containing at least one selected from waxes.

[0012] According to the above invention, since a nonionic or anionic surfactant is not used, a sufficient water repellent effect can be obtained even with a small addition amount without offsetting the effect of the water repellent. In addition, since the waxes are solid at room temperature, they become liquids having a relatively low viscosity when heated when the thermosetting resin precursor is cured, so that the waxes flow when the binder is cured. Since the surface of the inorganic fiber is coated and solidified when cooled, it adheres to the surface of the inorganic fiber, so that it is possible to maintain water repellency for a long time.

[0013] In the water-based binder for inorganic fibers of the present invention, the water repellent is a wax compound. A mixture of at least one selected and one selected from heavy oils is preferred.

[0014] According to this, when the binder is applied to the inorganic fiber and cured by heating, the wax melts and coats the surface of the inorganic fiber, but when a wax having a relatively high melting point is used. Since the coating state of the surface of the inorganic fiber of the wax may be uneven and the water repellency of the inorganic fiber heat-absorbing sound-absorbing material may vary, the use of heavy oil as a plasticizer for waxes It is possible to reduce the variation in the coating state of the surface and obtain a stable water repellency.

[0015] In the aqueous binder for inorganic fibers of the present invention, the thermosetting resin precursor and the water repellent are based on 100 parts by mass of the thermosetting resin precursor in terms of solid content. Water repellent 0.1-: It is preferable to contain so that it may become 10 mass parts.

[0016] By setting the amount ratio of the water repellent to the thermosetting resin precursor within the above range, sufficient water repellency can be imparted to the inorganic heat-insulating and sound-absorbing material, and the stability of the noinder is improved. Will not be damaged.

[0017] Further, in the aqueous binder for inorganic fibers according to the present invention, the thermosetting resin precursor may comprise (a) an aldehyde condensable resin precursor, (b) a polyol and a polycarboxylic acid resin. And (c) at least one selected from the group consisting of a mixture of an epoxy resin and a polycarboxylic acid resin.

[0018] According to this, since the thermosetting resin precursor shown above undergoes a curing reaction with the water-soluble polycarboxylic acid resin that is a dispersant for the water repellent emulsion, it has an undesirable effect on water repellency. There is no effect.

[0019] On the other hand, the inorganic fiber heat-absorbing sound-absorbing material of the present invention imparts the inorganic fiber aqueous binder to the inorganic fiber immediately after fiberization, deposits the inorganic fiber to which the inorganic fiber aqueous binder adheres, and then heats it. It is obtained by curing and molding.

[0020] According to the above invention, good water repellency can be maintained over a long period without stickiness of the surface of the inorganic fiber.

The invention's effect

[0021] The aqueous binder for inorganic fibers of the present invention is a component comprising a water-soluble polycarboxylic acid resin. By containing a powder and a wax that is a water repellent, sufficient water repellency can be imparted to the inorganic fiber thermal insulation material. In addition, since the inorganic fiber heat insulating sound absorbing material of the present invention using the binder has excellent water repellency, the heat insulating and sound absorbing performance does not deteriorate over a long period of time even when exposed to rainwater or condensed water, It can solve the problem of corrosion of metal parts in contact with wood and decay of wood, and can be suitably used as a heat insulating material or sound absorbing material for houses, buildings, soundproof walls, cooling towers and outdoor equipment.

BEST MODE FOR CARRYING OUT THE INVENTION

[0022] Hereinafter, the present invention will be described in detail.

The aqueous binder for inorganic fibers of the present invention contains a thermosetting resin precursor dissolved or dispersed in water and a water repellent emulsion.

[0023] First, the thermosetting resin precursor will be described.

The thermosetting resin precursor used in the present invention may be any as long as it is applicable to the production of an inorganic fiber heat-absorbing sound-absorbing material. It is preferable because it is not.

[0024] Examples of the thermosetting resin precursor include (a) aldehyde condensable thermosetting resin precursors such as resol type phenol resin, melamine resin, urea resin, furan resin, or ( b) For example, as disclosed in JP-A-6-184285, ethylene glycol, glycerin, pentaerythritol, trimethylol propane, sonorebitol, gnolecose, 1,4_hexanediol, diethanolamine, triethanol Any polyol such as amine, and methacrylic acid, attalinoleic acid, crotonic acid, fumanoleic acid, maleic acid, 2-methylmaleic acid, itaconic acid, 2-methylitaconic acid, a-β-methylenedaltalic acid , Monoalkyl maleate, monoalkyl fumarate, maleic anhydride, acrylic anhydride, etc. A mixture with a polycarboxylic acid-based resin containing a carboxylic acid; and (c) a bisphenol-diglycidyl ether, a bisphenol F diglycidyl ether, a novolak phenol poly, as described in WO2004-085729 Examples thereof include a mixture of an epoxy resin such as glycidyl ether and the polycarboxylic acid resin.

[0025] Here, the precursor in the present invention means an original compound that forms a resin by a reaction by heating. In this case, monomers contained in each resin precursor, dimer The ratio of the body, the number of functional groups per monomer, or the molecular weight of each component is not particularly limited.

[0026] In a general process for producing an inorganic fiber heat-absorbing and sound-absorbing material, a binder is often applied in an atmosphere of 200 ° C or more immediately after melting an inorganic raw material for fiber and fiberizing it by a centripetal method or the like. Including a flammable solvent such as an organic solvent may cause a fire or the like. Therefore, the thermosetting resin precursor used is dissolved or dispersed in water.

[0027] Next, the water repellent emulsion will be described.

The water repellent emulsion of the present invention contains at least a water repellent, a dispersant, and water. The waxes used in the water repellent of the present invention are not strictly defined, but are those that are solid at room temperature but become liquid with relatively high fluidity when heated to about 40 ° C or higher. Point

[0028] Examples of the waxes include animal waxes such as beeswax, lanolin wax, and shellac wax; plant waxes such as carnauba wax, wood wax, rice wax, and candelilla wax; minerals such as montan wax and ozokerite -Based wax; petroleum wax such as paraffin wax and mica crystallin wax, Fischer-Tropsch wax, polyethylene wax, polypropylene wax, polycarbonate wax, palm oil fatty acid ester, beef tallow fatty acid ester, stearic acid amide, dipeptadesinoreketone, Synthetic waxes such as hardened castor oil. In this case, waxes can be used alone or in combination of two or more.

[0029] Among these, paraffin wax, polyethylene wax, or polypropylene wax is more preferable in terms of economy.

[0030] Generally, the waxes are hydrophobic materials, and when added to an aqueous binder, it is preferable to disperse or emulsify in water in advance in order to improve miscibility.

In the present invention, a water-soluble polycarboxylic acid resin is used as a dispersant for the above waxes in water. In this case, the water-soluble polycarboxylic acid-based resin means that a resin having an acid value of 50 mgKOHZg or more, preferably 80 mgKOH / g or more is neutralized with ammonia, amines, or alkali metals, and water-soluble at pH 7 or more. It refers to what has become. If the acid value of the water-soluble polycarboxylic acid-based resin is less than 50 mg KH / g, the solubility of the resin in water decreases. The dispersibility of water repellents such as waxes in water may decrease.

[0031] Examples of the polycarboxylic acid resin used as a dispersant in the present invention include acrylic acid, methacrylic acid, crotonic acid, fumaric acid, maleic acid, 2-methylmaleic acid, itaconic acid, 2-methylitacon. Resin obtained by polymerizing an ethylenically unsaturated carboxylic acid such as an acid, j3- (meth) atalylooxychetyl hydrogen succinate; the ethylenically unsaturated carboxylic acid and methinole, ethinole, propinole, butinole , Pentinoles, hexinoles, peptinoles, octinoles, noninoles, decyl and other (meth) acrylic acid esters and one or several ethylenically unsaturated monomers of styrene are used in combination. .

[0032] The amount ratio of the ethylenically unsaturated carboxylic acid to the ethylenically unsaturated monomer is not particularly limited, but as described above, ammonia, amines, or alkali metals are used. Any material that dissolves in water by neutralization can be used as the dispersant for the water repellent of the present invention.

[0033] It should be noted that the dispersion of waxes. As an emulsifier, α-olefin sulfonate, alkylbenzene sulfonate, paraffin sulfonate, α-sulfo fatty acid ester salt, dioctyl sulfosuccinate are generally used. Anionic surfactants such as acid ester salts, alkyl sulfate ester salts, and polyoxyethylene alkyl sulfate ester salts, and nonionic interfaces such as polyoxyethylene alkyl ether, polyoxyethylene alkyl phenyl ether, and polyoxyethylene polyoxypropylene block copolymers Activators are used. However, as described above, when the surfactant remains in the cured binder, the cured binder is likely to absorb water due to the hydrophilic portion in the surfactant, and the desired water-repellent performance may not be obtained. is there. Therefore, in order to impart high water repellency to the inorganic fiber heat insulating sound absorbing material, it is necessary to add a large amount of water repellent emulsion to the inorganic fiber aqueous binder. May impair stability such as separation in an aqueous binder.

[0034] In contrast, the water-soluble polycarboxylic acid-based resin dispersant used in the present invention undergoes a curing reaction with any of the above thermosetting resin precursors, so that the conventional anionic or nonionic type is used. There is no adverse effect as described above due to the surfactant.

[0035] For the above reasons, the mass ratio of the dispersant to the water repellent in the water repellent emulsion is limited. Although it is not necessary to determine, preferably, the polycarboxylic acid-based resin dispersant is 10 parts by mass or less with respect to 100 parts by mass of the wax as a water repellent, and further 5 mass parts or less. More preferable than force.

[0036] When the amount of the dispersant used exceeds 10 parts by mass, the ratio of the water repellent in the water repellent emulsion is decreased. The amount of water repellent emulsifier added increases, which may impair economic efficiency.

[0037] In the present invention, it is preferable to use a mixture of at least one selected from waxes and at least one selected from heavy oils as the water repellent.

The heavy oils have a chemical structure relatively similar to that of waxes and have high fluidity, and thus act as a plasticizer for waxes. When heating to cure the aqueous binder, the fluidity of the wax is increased, and the water repellent can be applied evenly on the surface of the inorganic fiber, reducing the variation in water repellency of the inorganic fiber heat-absorbing sound absorbing material. It becomes possible to do.

[0038] The heavy oils used in the present invention refer to those composed of paraffin or naphthene, which are aliphatic hydrocarbons having approximately 15 to 120 carbon atoms. Heavy oils are classified according to their kinematic viscosity, and the viscosity grade (Viscosity Grade, hereinafter referred to as VG) is in the range of 320 mm ² / s to 680 mm ² / s. . Heavy oils with relatively low kinematic viscosity, for example, VG less than 320 mm ² / s, have an increase in the number of carbon atoms of 30 or less, especially 20 or less, and volatilize during heating during binder curing It becomes easy to do. On the other hand, if the kinematic viscosity is high, for example, VG exceeds 680 mm ² Zs, it takes time to mix with the dispersant when emulsifying, and productivity may be impaired. In the present invention, it is more preferable to use heavy oils having a VG of 360 mm ² / s to 430 mm ² / s.

[0039] The mass ratio of the waxes to the heavy oils in the water repellent used in the present invention is not particularly limited, but the ability to be waxes: heavy oils = 40:60 to 95: 5 preferable.

[0040] When the ratio of heavy oils in the water repellent exceeds 60% by mass, the fluidity of the water repellent increases at room temperature. Water repellency in use May decrease. On the other hand, when the ratio of heavy oils is less than 5% by mass, when using high melting point waxes, the plasticizing effect of the waxes is reduced, and the water repellency of the resulting inorganic fiber thermal insulation material is reduced. Variations may occur. Therefore, it is more preferable that the use ratio of the heavy oils is appropriately adjusted in accordance with the melting point of the waxes used or the desired water repellency.

[0041] In the aqueous binder for inorganic fibers of the present invention, the water repellent is preferably 0.1 to 10 parts by mass, more preferably 0.5 to 100 parts by mass of the thermosetting resin precursor. -5 parts by mass, particularly preferably: from 5 to 5 parts by mass.

[0042] If the content of the water repellent is less than 0.1 parts by mass, sufficient water repellency cannot be imparted to the resulting inorganic fiber heat-absorbing sound-absorbing material. Moreover, even if the content of the water repellent exceeds 10 parts by mass, it is not preferable because the water repellency is not improved in proportion to the increase in the content, which is uneconomical.

[0043] In addition, in the aqueous binder for inorganic fibers of the present invention, a silane coupling agent, a dustproof agent, a curing accelerator, a colorant, or the like may be added as necessary.

[0044] Examples of the silane coupling agent include γ- (2-aminoethyl) aminopropyltrimethoxysilane, γ- (2-aminoethyl) aminopropylmethyldimethoxysilane, and other aminosilane catdimethoxysilane and other epoxy. Examples include silane coupling agents, and are mainly used to increase the adhesion between the binder and inorganic fibers.

[0045] Examples of the curing accelerator include sodium sulfate, ammonium sulfate, dodecinolebenzene sulfonic acid, and ρ_toluenesulfonic acid.

[0046] The aqueous binder for inorganic fibers is preferably adjusted so that the solid content is preferably 2 to 50% by mass, particularly preferably 5 to 40% by mass. In this case, the aqueous binder for inorganic fibers of the present invention can be obtained by blending using a tank equipped with a stirrer such as a dissolver.

[0047] Next, the inorganic fiber thermal insulation material of the present invention obtained using the above-mentioned inorganic fiber aqueous binder will be described.

[0048] In the production of the inorganic fiber heat-absorbing and sound-absorbing material of the present invention, first, the melted inorganic raw material is fiberized with a fiberizer, and immediately thereafter, the above-mentioned aqueous binder for inorganic fibers is converted into inorganic fibers. Give. Next, inorganic fibers to which a water-based binder for inorganic fibers has been applied are deposited on a perforated competitor to form a bulky inorganic fiber heat-absorbing sound-absorbing material intermediate, and spaced to achieve a desired thickness. The mixture is fed into a pair of upper and lower perforated conveyors and heated while being narrowed to cure the inorganic fiber aqueous binder to form an inorganic fiber heat insulating sound absorbing material. In the next step, a skin material or the like is coated if necessary, and the product is obtained by cutting the inorganic fiber thermal insulation material into the desired width and length. Hereinafter, each step will be described.

[0049] First, the inorganic fibers used in the present invention are not particularly limited, and glass wool, rock wool, and the like used in ordinary heat-absorbing sound-absorbing materials can be used. For the fiberization method of inorganic fibers, various methods such as a flame method, a blow-off method, and a centrifugal method (also referred to as a rotary method) can be used. In particular, when the inorganic fiber is glass wool, the centrifugal method is preferably used. The density of the target inorganic fiber heat-absorbing and sound-absorbing material is a density used in ordinary heat-insulating materials and sound-absorbing materials, and is preferably in the range of 5 to 300 kg / m ³ .

[0050] Next, in order to impart a binder to the inorganic fiber, it can be applied and sprayed using a spray device or the like. Adjustment of the application amount of the aqueous binder for inorganic fibers can be adjusted in the same manner as a conventional binder not containing a water repellent. The amount of binder applied varies depending on the density and use of the inorganic fiber heat-absorbing material, but the solid content is preferably in the range of 0.5 to 15% by mass based on the mass of the inorganic fiber heat-absorbing sound-absorbing material to which the binder is applied. The range of 0.5-9 mass% is more preferable.

[0051] The timing of applying the water-based binder to the inorganic fiber sound-absorbing heat insulating material may be any time after fiberization, but it is preferable to apply it immediately after fiberization for efficient application. The water repellent emulsion is a water-based binder mixed with a thermosetting resin precursor. A water-repellent emulsion may be separately added before and after applying an aqueous binder that does not contain a water-repellent emulsion that may be applied to inorganic fibers. You may give to an inorganic fiber.

[0052] Thus, by providing the inorganic fiber with the aqueous binder for inorganic fibers obtained by the present invention, sufficient water repellency can be imparted to the inorganic fiber heat-absorbing and sound-absorbing material.

[0053] The inorganic fibers to which the binder has been applied in the above process are deposited on a perforated conveyor to form a bulky inorganic fiber intermediate. Here, when depositing on the perforated conveyor, it is more possible to suck from the opposite side of the perforated conveyor where the organic fibers are deposited by a suction device. preferable. After that, the inorganic fiber intermediate that continuously moves on the perforated conveyor is sent to a pair of upper and lower perforated conveyors that are spaced to have a desired thickness, and at the same time, heated hot air is used. After curing the thermosetting resin precursor contained in the binder and forming the inorganic fiber heat-absorbing sound-absorbing material into a mat, it is cut into the desired width and length.

[0054] The temperature at which the thermosetting resin precursor contained in the binder is cured is not particularly limited, but can be the same as in the case of applying a binder that does not contain a conventional water repellent. It can be ~ 350 ° C. Moreover, the heating time is appropriately performed between 30 seconds and 10 minutes depending on the density and thickness of the inorganic fiber heat-absorbing sound-absorbing material.

[0055] The inorganic fiber heat-absorbing and sound-absorbing material of the present invention may be used as it is or may be used after being covered with a skin material. As the skin material, paper, synthetic resin film, metal foil film, non-woven fabric, woven fabric, or a combination thereof can be used. As the skin material, it is preferable to use a material having low water absorption and water repellency.

[0056] The inorganic fiber heat insulating sound absorbing material of the present invention obtained in this way has long heat insulating and sound absorbing performance because no moisture is accumulated in the heat insulating sound absorbing material even when exposed to rain water or condensed water. It does not decrease over time, and can solve the problems of mold generation, corrosion of metal parts in contact with it, and decay of wood.

[0057] Further, since the hydrophobic portion of the water repellent agent present on the contact surface between the inorganic fiber heat insulating sound absorbing material and the perforated conveyor improves the releasability of the inorganic fiber heat insulating sound absorbing material with respect to the perforated conveyor, The trouble inside is also reduced.

Example

[0058] Hereinafter, the present invention will be described in more detail by way of examples. In the following explanation

, Parts and% represent mass standards unless otherwise specified.

[0059] [Formulation of water repellent emulsion]

Formulation 1

20 parts of a styrene-maleic acid copolymer having a solid content of 25% and an acid value of 200 mg KOH / g, neutralized with ammonia and dissolved in 100 parts of a paraffin wax having a melting point of 55 ° C. melted at 60 ° C. In addition, mix well. Further, 150 parts of water is gradually dropped while stirring is continued. . The obtained emulsion was further dispersed with a high-pressure homogenizer to obtain a solid content of 38.9% (including wax).

[0060] The paraffin wax is a paraffin wax 130 specified in JIS K2235.

Corresponds to P (melting point 54.4 ° C or more, less than 57.2 ° C).

[0061] Formulation 2

Mix 7 parts of a methyl acrylate-styrene-maleic acid copolymer with an acid value of 350 mgKH / g in 100 parts of polyethylene wax with a melting point of 110 ° C, dissolve at 120 ° C, and mix well. . Next, 3 parts of methyl jetanolamine and 165 parts of water are added, and the mixture is pressurized in an autoclave and stirred and mixed at 120 ° C. By treating this mixture with a high-pressure homogenizer, an emulsion having a solid content of 39.8% (wax content 36.4%) is obtained.

[0062] Formulation 3

Add 80 parts of polyethylene wax with a melting point of 110 ° C, 30 parts of heavy oil with a VG of 430, and 7 parts of methyl acrylate-styrene maleic acid copolymer with an acid value of 350 mgKH / g at 120 ° C. Dissolve and mix well. Subsequently, 3 parts of methyl jetanolamine and 165 parts of water are added under pressure in an autoclave and stirred and mixed at 120 ° C. By treating this mixture with a high-pressure homogenizer, the solid content was 39.8% (water repellent component content 36.

[0063] Formulation 4

Melt 100 parts of paraffin wax used in Formulation 1 at 60 ° C, add 10 parts of polyoxyethylene lauryl ether and 2 parts of dipalmityldimethylammonium chloride and mix well. Further, 150 parts of water are gradually added dropwise while stirring is continued. The obtained emulsion was further dispersed with a high-pressure homogenizer to obtain a solid content of 42.7. /. An emulsion with a wax content of 38.2% is obtained.

[0064] [Preparation of aqueous dispersion of heavy oil]

Formulation 5

Add 20 parts of a styrene-maleic acid copolymer with a solid content of 25% and an acid value of 200 mg KOHZg, neutralized with ammonia, to 100 parts of a heavy oil with a VG of 430 mm ² / s, and mix well. Further, 150 parts of water are gradually added dropwise while stirring is continued. Milk obtained The compound is further dispersed with a high-pressure homogenizer to obtain an emulsion having a solid content of 38.9% (oil content 37%).

[0065] [Preparation of aqueous dispersion of dimethylpolysiloxane]

Formulation 6

15 parts of polyoxyethylene polyoxypropylene was added to 60 parts of dimethylenopolysiloxane having a molecular weight of 5000. While stirring, 200 parts of water is added dropwise to obtain an aqueous dispersion having a solid content of 27.3% (content of dimethylpolysiloxane of 21.8%).

[0066] Example 1

[Preparation of aqueous binder for inorganic fibers]

The repellent phenol resin precursor dispersed in water and having a monomer content of 10% or less, dimer 80% or more, and free phenol 1% or less, in 100 parts in terms of solid content, was obtained in Formulation 1. Prepare 1.5 parts of water repellent emulsion, 0.2 parts of γ- (2-aminoethyl) aminopropyltrimethoxysilane, and 450 parts of water in an open tank with a stirrer. Then, with sufficient stirring, water was added so that the solid content was 15% to obtain an aqueous binder for inorganic fibers.

[0067] [Manufacture of inorganic fiber heat insulating material]

Inorganic fiber insulation sound-absorbing material, which is applied to glass fibers that have been fiberized by a centrifugal method by spraying with a binder so that a predetermined amount is applied, and then deposited on a perforated conveyor while sucking with a suction device. Intermediate was formed. The intermediate is heated in hot air at 260 ° C. for 3 minutes to cure the binder, the density is 16 kg / m ³ , the thickness is 100 mm, and the binder application amount is 3.0%. Glass wool was obtained.

[0068] Examples 2-3

Except for using the water repellent emulsion obtained in Formulations 2-3, the inorganic fiber insulation sound-absorbing material of Examples 2-3 was prepared by the same binder preparation method as Example 1 and the production method of the inorganic fiber insulation material, respectively. Glass wool was obtained.

[0069] Example 4

A 30% aqueous solution of a methacrylic acid / monomaleic acid / methyl methacrylate copolymer having an acid value of 650 mg KH / g is converted to 100 parts in terms of solid content, 16.7 parts of glycerin, 21 parts of pentaerythritol, 3.0 parts of sodium hypophosphite, 0.2 part of γ_ (2 aminoethyl) aminopropyltrimethoxysilane, 2 parts of the water repellent obtained in Formula 2 in terms of solid content, and 450 parts of water were dissolved in a dissolver. The mixture was prepared in a single open tank, and water was added so that the solid content was 15% with sufficient stirring to obtain an aqueous binder for inorganic fibers.

[0070] Next, glass wool to be an inorganic fiber heat-absorbing and sound-absorbing material of Example 4 was obtained by the same production method as Example 1 except that the binder was used.

[0071] Example 5

A bisphenol A diglycidyl ether-based epoxy resin having an epoxy equivalent of 340 g / eq in 100 parts of 30% aqueous solution of methacrylic acid maleic acid monomethacrylol methyl methacrylate copolymer having an acid value of 650 mg KOH / g used in Example 4 118 parts were mixed and stirred thoroughly to obtain an emulsion. The water repellent emulsion obtained in Formulation 3 with respect to 100 parts of this emulsion was 2.8 parts in terms of solid content of the water repellent component, 3 parts trimethylenediamine, γ-glycidoxypropyltrimethoxysilane 0 2 parts and 450 parts of water were prepared in an open tank equipped with a dissolver, and water was added so that the solid content was 15% with sufficient stirring to obtain an aqueous binder for inorganic fibers.

[0072] Next, glass wool used as the inorganic fiber heat-absorbing sound-absorbing material of Example 5 was obtained by the same production method as in Example 1 except that the binder was used.

[0073] Example 6

The same procedure as in Example 1 except that the water repellent emulsion obtained in Formulation 1 was changed to 12.5 parts in terms of solid content of the water repellent component. The glass wool used as the inorganic fiber heat insulating sound absorbing material of Example 6 was obtained.

[0074] Example 7

Using the aqueous binder for inorganic fibers obtained in Example 1, the density was 10 kg / m ³ , the thickness was 100 mm, and the amount of binder applied was 3.0 by the same production method as in Example 1. Glass wool that was an inorganic fiber heat-absorbing sound-absorbing material of Example 7 was obtained under the condition of / ₀ .

[0075] Example 8

Using the aqueous binder for inorganic fibers obtained in Example 5, the same production method as in Example 1 was carried out under the conditions of a density of 24 kg / m ³ , a thickness of 100 mm, and a binder application amount of 4.0%. The glass wool used as the inorganic fiber heat insulating sound absorbing material of Example 8 was obtained.

[0076] Comparative Example 1

100 parts of the water-dispersed resol-type phenol resin precursor used in Example 1 in terms of solid content, 0.1 part of γ_ (2 aminoethyl) aminopropyltrimethoxysilane, and 450 parts of water were dissolved in a dissolver. Then, water was added so that the solid content was 15% with sufficient stirring, and an aqueous binder for inorganic fibers containing no water repellent was obtained.

[0077] Further, using the above-mentioned binder, glass wool as an inorganic fiber heat-absorbing and sound-absorbing material of Comparative Example 1 was obtained by the same production method as Example 1.

[0078] Comparative Example 2

30 parts aqueous solution of 650 mg KOH / g of methacrylic acid maleic acid monomethacrylolate methyl copolymer used in Example 4 in 100 parts of solid content, 16.7 parts of glycerin, 21 parts of pentaerythritol, hypophosphorous acid Prepare 3.0 parts of sodium, 0.2 part of γ- (2aminoethyl) aminopropyltrimethoxysilane, and 450 parts of water in an open tank equipped with a dissolver. Was added to obtain a water-based inorganic fiber binder containing no water repellent.

[0079] Next, glass wool used as the inorganic fiber heat-absorbing and sound-absorbing material of Comparative Example 2 was obtained by the same production method as in Example 1 except that the binder was used.

[0080] Comparative Example 3

100 parts of the water-dispersed resol-type phenol resin precursor used in Example 1 in terms of solid content, 5 parts of the paraffin wax emulsion obtained in Formulation 4 in terms of solid content of the water repellent component, and water 450 parts were mixed in an open tank with a dissolver, and water was added so that the solid content was 15% with sufficient stirring to obtain an aqueous binder for inorganic fibers.

[0081] Further, using the above-mentioned binder, glass wool as an inorganic fiber heat-absorbing and sound-absorbing material of Comparative Example 3 was obtained by the same production method as in Example 1.

[0082] Comparative Example 4

100 parts of the water-dispersed resol-type phenol resin precursor used in Example 1 in terms of solid content and 5 parts of the heavy oil obtained in Formulation 5 in terms of solid content of the water repellent component. Part Then, 450 parts of water was prepared in an open tank equipped with a dissolver, and water was added so that the solid content was 15% with sufficient stirring to obtain an aqueous binder for inorganic fibers.

[0083] Further, using the above-mentioned binder, glass wool serving as an inorganic fiber heat insulating sound absorbing material of Comparative Example 4 was obtained by the same production method as in Example 1.

[0084] Comparative Example 5

100 parts of the water-dispersed resol-type phenol resin precursor used in Example 1 in terms of solid content and 5 parts of the dimethylpolysiloxane aqueous dispersion obtained in Formulation 6 in terms of solid content of the water repellent component Then, 450 parts of water was prepared in an open tank equipped with a dissolver, and water was added so that the solid content was 15% while fully stirring to obtain an aqueous binder for inorganic fibers.

[0085] Further, glass wool used as the inorganic fiber heat-insulating and sound-absorbing material of Comparative Example 5 was obtained by the same production method as in Example 1 using the binder. In Examples:! To 8 and Comparative Examples:! To 5, all of the aqueous binders for inorganic fibers had good stability. Further, the water repellent emulsion used in the examples could be uniformly mixed in the aqueous binder, and the compatibility with components other than the thermoplastic resin precursor contained in the aqueous binder was also good.

[0086] The following evaluation was performed on the glass wool obtained in Examples 1 to 8 and Comparative Examples 1 to 5.

[0087] [Evaluation of water repellency (water float test)]

From the obtained glass wool, a 50 × 100 × 100 mm square test piece was cut out, floated in a water tank filled with water, and the length of the flooded portion after 7 days at room temperature was measured. Also, if it was submerged before that, the number of days elapsed was counted.

[0088] [Evaluation of long-term water repellency]

From the obtained glass wool, a 50 × 100 × 100 mm square test piece was cut out and stored for 1 month in a thermostat at 50 ° C. atmosphere. Thereafter, the test piece was taken out of the thermostat and subjected to water repellency evaluation (water floating test) in the same manner as described above, thereby evaluating long-term water repellency. The test piece submerged by the 7th day in the above water repellency evaluation was evaluated for long-term water repellency. It was a powerful effort.

[0089] The results of the above evaluation are summarized in Table 1.

[0090] [Table 1]

table 1

Compared to complete submersion and that in Comparative Example 3 did not submerge but submerged more than half of the thickness on the 7th day, the specimens of Examples: 8 to 8 floated in water for 7 days. I can see that. This indicates that the water repellency of glass wool was improved by the various water repellents used in the examples.

[0092] Further, from comparison between Example 1 and Example 6, it can be seen that even if the water repellent is added in an amount exceeding the above preferred range, no significant improvement in water repellency is observed. Furthermore, comparison between Example 2 and Example 3 shows that a uniform water-repellent performance can be obtained by using a mixture of waxes and heavy oils as the water-repellent component.

[0093] In the evaluation of long-term water repellency, in Examples:! To 8, no change in water repellency was observed even during long-term storage in an atmosphere at 50 ° C, indicating that high water repellency was maintained. . On the other hand, in Comparative Example 4 and Comparative Example 5, although the initial water repellency is relatively high, it can be seen that the water repellency performance deteriorated after long-term storage in an atmosphere at 50 ° C.

Industrial applicability

[0094] Since the inorganic fiber heat-absorbing and sound-absorbing material obtained by using the aqueous binder for inorganic fibers of the present invention has excellent water repellency, the heat-insulating and sound-absorbing performance is extended over a long period of time even when exposed to rain water or condensed water. Therefore, it can solve the problems of mold generation, corrosion of metal parts in contact with it, and decay of wood, and is suitable as a heat insulating material or sound absorbing material for houses, buildings, noise barriers, cooling towers, outdoor equipment, etc. Can be used. It should be noted that the entire contents of Maki Itoda, the claims, drawings and abstract of Japanese Patent Application 2005-78807 filed on March 18, 2005 are incorporated herein by reference. It is included as an indication.

Claims

The scope of the claims

[1] A water-based binder for inorganic fibers containing a thermosetting resin precursor dissolved or dispersed in water and a water repellent emulsion, wherein the water repellent emulsion power is a dispersion composed of the water-soluble polycarbonate resin. A water-based binder for inorganic fibers, comprising: an agent; and a water repellent containing at least one selected from the group of waxes.

[2] The aqueous binder for inorganic fibers according to claim 1, wherein the water repellent is a mixture of at least one selected from waxes and at least one selected from heavy oils.

[3] The aqueous binder for inorganic fibers according to claim 1 or 2, wherein the water repellent is contained in an amount of 0.1 to 10 parts by mass in terms of solid content with respect to 100 parts by mass of the thermosetting resin precursor. .

[4] The aqueous inorganic fiber binder according to any one of claims 1 to 3, wherein the solid content is 2 to 50% by mass.

[5] The thermosetting resin precursor comprises (a) an aldehyde condensable resin precursor, (b) a mixture of a polyol and a polycarboxylic acid resin, and (c) an epoxy resin and a polycarboxylic acid resin. The aqueous binder for inorganic fibers according to any one of claims 1 to 4, wherein the aqueous binder is at least one selected from the group consisting of:

[6] The strength of any one of claims 1 to 5, wherein the inorganic fiber aqueous binder according to 1 is applied to the inorganic fiber immediately after fiberization, and the inorganic fiber to which the inorganic fiber aqueous binder is adhered is deposited and then heat-cured. An inorganic fiber heat-absorbing sound-absorbing material characterized by being obtained by molding.