JPH0911374A - Fiber aggregate and heat-insulating sound-absorbing material - Google Patents

Abstract

PURPOSE: To provide a fiber aggregate 1 and a heat insulating sound absorbing material in which recovery properties and heat insulation properties after compressing are improved and pricking irritation to be felt by a worker at the time of building construction is reduced. CONSTITUTION: A fiber bulk material 11 is formed by mixing or laminating inorganic fibers 13 and crimping fibers 12 all together. A binder is added to the fiber bulk material 11 and formed into the mat shape, plate shape, cylinder shape, lump shape or the like, and fibers are integrated one another to manufacture a heat insulation sound absorbing material. As for the binder, thermoplastic resin of fiber shape is used preferably. Also, in the case of using organic fibers as crimping fibers 12, the heat insulation sound absorbing material can be formed by integrating the fibers by means of heat fusion bonding of organic crimping fibers 12 without using the binder.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a fiber assembly using inorganic fibers and crimped fibers and a heat insulating and sound absorbing material using the same.

[0002]

2. Description of the Related Art Conventionally, molded products made of inorganic fibers such as glass wool and rock wool have been used as heat insulating and sound absorbing materials. This heat-insulating sound-absorbing material is generally made into glass wool or rock wool by fiberizing molten glass or slag by a centrifugal method or the like, and applying a thermosetting resin binder containing a phenol resin as a main component to give a predetermined shape such as a matte shape. After that, it is manufactured by heating and curing the binder to mold it.

Further, this heat insulating sound absorbing material is compressed and packed to a volume of 1/3 to 1/8 of the volume at the time of manufacture in order to enhance the accommodation efficiency during transportation and storage, and the package is opened at the time of use to have a thickness. Is generally restored.

[0004]

In order to improve the storage efficiency of transportation and storage, it is better to increase the compression rate of the heat insulating sound absorbing material at the time of packaging, but if the conventional heat insulating sound absorbing material is compressed too much, There is a problem that even if the package is opened, it will not be restored to the prescribed thickness, and the designed sound insulation and sound absorption effect will not be obtained.
There is a limit to the degree of compression when packing.

Further, since a binder containing a thermosetting phenolic resin as a main component is used, the facility for producing the inorganic fiber needs a facility for blending and applying the binder, and further, a fiberizing step, etc. Since it is necessary to wash and remove formaldehyde, ammonia, etc. contained in the binder attached to the equipment, waste water treatment equipment is also required, and there is also a problem that the production cost increases due to the equipment cost.

Further, there is a problem that when the heat insulating and sound absorbing material is applied, fine glass pieces crushed by the inorganic fibers are apt to be generated, and the fine glass pieces cause an operator to feel a tingling stimulus on the skin.

The present invention has been made in view of the above problems, and an object thereof is to improve the restoring property of a heat insulating sound absorbing material after compression and to reduce the tingling sensation felt by an operator. An object is to provide an assembly and a heat insulating sound absorbing material.

[0008]

To achieve the above object, the fiber assembly of the present invention is characterized by comprising a mixture or a laminate of inorganic fibers and crimped fibers.

Further, the heat insulating sound absorbing material of the present invention is characterized in that the inorganic fiber and the crimped fiber of the fiber assembly are bound by a heat treatment and molded into a predetermined shape.

The present invention will be described in detail below with reference to preferred embodiments. In the present invention, as the inorganic fiber,
Long glass fibers obtained by the melt spinning method, glass fibers such as short glass fibers obtained by the centrifugation method, rock wool, silica fiber, alumina fiber, alumina silica fiber, carbon fiber and the like are preferably used. In particular, when a long glass fiber obtained from non-alkali glass is cut into a predetermined length, the strength and rigidity of the fiber itself is high, so that the recoverability of the fiber assembly after compression is high.

The diameter of the inorganic fiber is preferably 0.5 to 20 μm. If the diameter of the inorganic fiber is less than 0.5 μm, the bending rigidity of the fiber will be low, and the recoverability after compression will be impaired.
When it exceeds 20 μm, the surface area per unit volume becomes small for the same bulk density, so that the heat insulating effect and the sound absorbing effect cannot be sufficiently obtained, which is not preferable. In addition, the length of the inorganic fiber is not particularly limited, and may be the length used for ordinary fiber aggregates and heat-insulating sound absorbing materials, but if it is too short, sufficient resilience after compression cannot be obtained. Therefore, it is preferable not to use one having a thickness of 1 mm or less.

In the present invention, the crimped fiber means a fiber having a crimp in the longitudinal direction of the fiber, for example, at least a part of the fiber has a spiral shape, and at least a part of the fiber has a wavy shape. A fiber means a fiber in which one or more curved portions are three-dimensionally and irregularly continuous.

The crimped fiber may be an organic fiber or an inorganic fiber, and these may be used in combination.
Further, two or more kinds of organic fibers and two or more kinds of inorganic fibers may be used in combination.

As the organic crimped fibers, it is preferable to use crimped fibers of thermoplastic synthetic fibers such as polyester, polypropylene, nylon and polyethylene. As a method of providing crimp to these organic fibers, for example, two kinds of materials having different heat shrinkages are respectively melted and spun into a single fiber of a core-sheath structure or a joint type structure, A method of crimping, or a method of mechanically crimping the fiber by sandwiching it between two gears or rubbing with a jig such as a knife edge, or quenching only one side during spinning of the hollow fiber. Then, a method of giving a spiral crimp by forming a bilateral structure can be mentioned.

The organic crimped fibers are heat-bonded to each other to function as a binder and maintain the crimpability of the fibers when the fiber assembly is heat-formed into a heat insulating and sound absorbing material. For this reason, it is preferable that the crimped fiber has a core-sheath structure in which the outside of the radial cross section has a low melting point and the inside has a high melting point.

On the other hand, as the inorganic crimped fiber, for example, two kinds of glass having different heat shrinkages are melted to form a single fiber of a joint type structure or a core-sheath structure, which is self-crimped. Glass fiber, pressurized at a temperature above the softening point,
It is preferable to use glass fibers having a curved portion imparted by a mechanical method, crimped metal fibers such as steel wool, or the like.

The fiber assembly of the present invention comprises a mixture or a lamination of inorganic fibers and crimped fibers. The mixing ratio of these is such that the crimped fibers are 2% by weight or more in the whole fiber. Is preferable, and more preferably 5% by weight or more. If the proportion of the crimped fibers in the whole fibers is less than 2% by weight, the effect of improving the restoring property after compression and reducing the tingling stimulus cannot be sufficiently obtained, which is not preferable.

When an organic fiber is used as the crimped fiber, and when it is used as a heat insulating and sound absorbing material for a building or the like, the ratio of the crimped fiber to the whole fiber is mixed in consideration of fire resistance. The amount is preferably 50% by weight or less, and more preferably 30% by weight or less in consideration of economical aspects.

The fiber assembly of the present invention may further contain a binder in order to maintain a stable shape, and the binder may be a powdery, fibrous or liquid thermoplastic resin or a thermosetting resin. A low melting point powdered inorganic material or the like can be used. Of these, the thermoplastic resin is a wastewater treatment for washing and removing formaldehyde, ammonia, etc. contained in the binder, as in the case of using a binder containing a thermosetting phenol resin as a main component as in the past. Since there is no need for equipment and the like, it is particularly preferably used, and a fibrous thermoplastic resin is more preferable.

When a thermoplastic resin or a powdered inorganic fiber material having a low melting point is used as the binder, in order to maintain the crimpability of the crimped fiber, the melting point of the crimped fiber used in the fiber assembly is more than the melting point of the crimped fiber. It is preferable to use one having a low melting point.

The fiber assembly of the present invention is produced by mixing or laminating inorganic fibers and crimped fibers. As a method for mixing, the inorganic fibers and the crimped fibers are simultaneously compressed in a container. A method of blowing, stirring, and mixing with air,
Inorganic fibers and crimped fibers are defibrated and mixed with a card machine,
A method of laminating on a conveyor or in a container is preferably adopted. Particularly, according to the latter method, a more uniform mixture can be obtained.

As a method of laminating the inorganic fibers and the crimped fibers, for example, a plurality of inorganic fiber feeding devices and a plurality of crimped fiber feeding devices are provided on a perforated conveyor which moves at a constant speed. Alternatively, a method of alternately installing at predetermined intervals and alternately stacking by air suction of a perforated conveyor is adopted. When laminating, it is preferable to simultaneously stir the inorganic fibers and the crimped fibers by an air flow or the like.

FIG. 1 shows an example of the fiber assembly of the present invention thus obtained. That is, the fiber assembly 11 is in a three-dimensionally entangled state in which the crimped fibers 12 and the inorganic fibers 13 are mixed.

The heat-insulating sound-absorbing material of the present invention is formed by molding the above-mentioned fiber aggregate into a predetermined shape such as a mat, a plate, a cylinder or a lump, and optionally adding the binder as described above, followed by heating. It can be processed and manufactured. The fiber assembly can be molded by a method similar to the conventional method for molding a heat insulating and sound absorbing material composed only of inorganic fibers such as glass wool and rock wool. For example, the fiber aggregate can be formed into a mat-like or plate-like shape by sandwiching it between a pair of upper and lower conveyors, compressing it, and simultaneously heating it continuously in an oven or the like. Further, the fiber assembly can be formed into a tubular shape by winding it around a metal tube and heating it in an oven or the like. Furthermore, the mat-shaped or plate-shaped fiber aggregate after heating and molding can be cut into a desired size to form a lump. In addition, when an organic fiber is used as at least a part of the crimped fiber, the organic crimped fiber is thermally fused by heating and acts as a binder. Good.

The heat insulating and sound absorbing material of the present invention can be applied to various uses depending on its shape. For example, a mat-shaped material is preferable as a heat insulating material for a wall of a house, and a cylindrical material is preferable as a heat insulating material for various pipes. It can be preferably used as a heat insulating and sound absorbing material blown by. Further, by using a thermoplastic resin fiber as the crimped fiber, or by using a thermoplastic resin as a binder, and by heat compression molding using a mold device having a specific shape, as an interior material for an automobile ceiling, etc. It can also be used.

The fiber assembly of the present invention can be used as an adiabatic sound absorbing material by putting it into an exterior material such as a bag made of a resin film without being molded, and in that case, the shape of the place to be constructed is changed. It can be used in each case.

The density of the fiber assembly of the present invention is 1 to 50 kg / m.
^It is preferably ³ , but more preferably 5 to 20 kg / m ³ in order to uniformly mix the inorganic fibers and the crimped fibers. Furthermore, the density of the heat-insulating sound-absorbing material formed by molding the fiber assembly may be appropriately set depending on its application.
It is preferably 10 to 120 kg / m ³ .

[0028]

In the fiber assembly of the present invention and the heat insulating and sound absorbing material using the same, since the inorganic fibers and the crimped fibers are mixed or laminated, the crimped fibers function like springs, and three-dimensionally. Even if compressed in any direction, it has the same high resilience in any direction.

In particular, when a thermoplastic resin fiber is used as the crimped fiber and the fiber assembly is heated to heat-bond the fibers together, a comparison is made with a conventional product in which only the inorganic fiber is bonded using a binder. As a result, the number of binding points between the inorganic fibers via the crimped fibers is increased, and therefore, there are many places to fix the fibers and the slippage of the fibers due to compression is reduced, so that the restoring property after compression is further improved.

When organic crimped fibers having a specific gravity lower than that of inorganic fibers are mixed or laminated, the number of fibers per unit volume in the same bulk density is increased, and therefore the pores formed between the fibers are increased. Since the number is large, the heat insulation performance is improved. In particular, this effect is remarkable when the bulk density of the fiber assembly is a low density of 1 to ³⁰ kg / m ³ .

Furthermore, since the crimped fiber having elasticity is mixed or laminated with the inorganic fiber, the exposure of the sharp fiber end and the generation of minute glass fragments due to the crushing of the inorganic fiber are suppressed, and the operator feels tingling. It reduces the feeling of irritation.

[0032]

[Example] 80% by weight of glass wool having an average fiber diameter of 8 μm, which is an inorganic fiber, and denier x, which is an organic crimp fiber
Core-sheath type crimped polyester fiber 20 having a fiber length of 3d × 51 mm 20
After being defibrated by a card machine, they were laminated on a conveyor while being stirred by an air flow to obtain a mat-like fiber assembly. The bulk density of this fiber assembly was 10 kg / m ³ .

Next, this fiber assembly was heated to 170 ° C. in an oven without adding a binder to melt the sheath portion of the core-sheath type crimped polyester fiber and weld the fibers together. As a result, a mat-like heat insulating and sound absorbing material was obtained. This heat insulating and sound absorbing material is used as an example product.

Comparative Example 3% by weight of a binder containing a thermosetting phenolic resin as a main component was added to glass wool having the average fiber diameter of 8 μm, which is the same inorganic fiber as that used in the example, and was heated in an oven. It was heated and compressed at 230 ° C. to obtain a heat-insulating sound-absorbing material consisting only of matte inorganic fibers. This heat insulating and sound absorbing material is used as a comparative example product.

Test Example The bulk density, compression resilience, and thermal conductivity of the flat plate method were measured for the product of the example and the product of the comparative example. Also,
The magnitude of tingling stimulus to the skin when touched with bare hands was evaluated as the irritancy. The compression resilience is the ratio of the work when the elastic body is restored by restoring the elastic body to the work when the elastic body is compressed by an external force, and is a compression tester "KES-G5" Name, manufactured by Kato Tech Co., Ltd.). These results are shown in Table 1.
Shown in

[0036]

[Table 1]

As shown in Table 1, the bulk densities of the example product and the comparative product are the same, but the compressive resilience of the product of the embodiment is improved by about 21% as compared with the product of the comparative example. It can be seen that the recoverability after compression is improved. Further, it can be seen that the thermal conductivity of the example product is smaller than that of the comparative product, and has the same or higher heat insulating property. Furthermore, it can be seen that the product of the example has less irritation to the skin than the product of the comparative example.

[0038]

As described above, since the fiber assembly of the present invention and the heat insulating sound absorbing material using the same are made by mixing or laminating the inorganic fibers and the crimped fibers, the fiber assembly after being compressed is compared with the conventional product. Resilience is improved. Therefore, it can be packed with a higher degree of compression than conventional products, and the storage efficiency during transportation and storage can be improved. Also, the heat insulating property is improved as compared with the conventional product. Further, the operator is less likely to feel a tingling stimulus during the construction.

[Brief description of the drawings]

FIG. 1 is a conceptual diagram showing an example of a fiber assembly of the present invention.

[Explanation of symbols]

 11 Fiber Aggregate 12 Crimped Fiber 13 Inorganic Fiber

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Claims (6)

[Claims] 1. A fiber assembly comprising a mixture or a laminate of inorganic fibers and crimped fibers. 2. The fiber assembly according to claim 1, wherein the crimped fibers are organic crimped fibers. 3. The fiber assembly according to claim 1, further comprising an inorganic fiber, a crimped fiber, and a binder. 4. The fiber assembly according to claim 3, wherein the binder is a fibrous thermoplastic resin binder. 5. An adiabatic sound absorbing material, characterized in that the inorganic fibers and crimped fibers of the fiber assembly according to claim 2, 3 or 4 are bound by heat treatment and formed into a predetermined shape. 6. The heat insulating and sound absorbing material according to claim 5, wherein the heat insulating and sound absorbing material is formed into a mat shape, a cylinder shape, a lump shape, or a plate shape.