Binder composition for inorganic fibers and inorganic fiber product

Abstract

To provide a binder composition for an inorganic fiber capable of obtaining an inorganic fiber product excellent in workability and shape retention under a high temperature environment such as fire.SOLUTION: An organic binder and an inorganic binder, wherein the organic binder is a thermoplastic organic binder or a thermosetting organic binder, the thermosetting organic binder contains at least one selected from the group consisting of saccharides and the like, the saccharide is at least one selected from the group consisting of monosaccharides and the like, and the inorganic binder is an inorganic compound that solidifies or condenses at a temperature equal to or higher than the thermal decomposition temperature of the organic binder, A ratio of an inorganic content of the inorganic binder to 100% by mass of an organic content of the organic binder is 20.56 to 300% by mass (provided that a case where a non-reducing oligosaccharide containing up to 10 saccharide units is contained and a case where polyvinyl alcohol is contained are excluded).SELECTED DRAWING: None

Description

[Technical Field]

[0001] The present invention relates to a binder composition for inorganic fibers and an inorganic fiber product. [Background technology]

[0002] A conventional fireproof coating method for steel frames of buildings involves attaching calcium silicate molded boards as fireproof coating materials, but this method is difficult to process to fit the shape of the steel frame because the calcium silicate molded boards are hard. Therefore, a method has been proposed in which a felt material made of inorganic fibers such as rock wool is attached to a steel frame as a fire-resistant covering material (Patent Document 1).Also proposed is a method in which a fire-resistant covering material such as a rock wool blanket or a rock wool molded plate is attached to the surface of the steel frame, and then the fire-resistant covering material is impregnated with or coated with cement slurry and allowed to solidify (Patent Document 2). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 57-197349 [Patent Document 2] Japanese Patent Application Publication No. 7-189359 Summary of the Invention [Problem to be solved by the invention]

[0004] However, the method of Patent Document 1 does not provide sufficient fire resistance. Felt materials used as fire-resistant covering materials are generally formed by binding inorganic fibers with an organic binder in order to ensure strength and flexibility and improve workability. However, organic binders are thermally decomposed during a fire. When the organic binder is thermally decomposed, the strength of the felt material decreases, and the felt material peels off in areas where it is not applied thick enough, exposing the steel frame. Even if it is applied thick enough, there is a risk that the felt material will peel off due to wind generated during a fire, etc. The method of Patent Document 2 involves impregnating or applying a cement slurry after the application of the fire-resistant coating material and then solidifying it, which increases the construction period.

[0005] The present invention aims to provide a binder composition for inorganic fibers that can yield inorganic fiber products that are excellent in workability and shape retention in high-temperature environments such as fires, and to provide inorganic fiber products that are excellent in workability and shape retention in high-temperature environments such as fires. [Means for solving the problem]

[0006] The present invention has the following aspects. [1] A binder composition for inorganic fiber products, comprising an organic binder and an inorganic binder. [2] The binder composition for inorganic fiber products according to [1] above, wherein the organic binder is a thermosetting organic binder. [3] The binder composition for inorganic fiber products according to [1] or [2], wherein the organic binder comprises at least one selected from the group consisting of sugars, phenolic resins, polyvinyl alcohol resins, and polycarboxylic acid resins. [4] The binder composition for inorganic fiber products according to any one of claims 1 to 3, wherein the inorganic binder contains at least one selected from the group consisting of hydroxides, oxides, chlorides, silicates, carbonates, sulfates, nitrates, aluminates, borates, and phosphates of metals selected from the group consisting of lithium, sodium, potassium, magnesium, calcium, barium, titanium, chromium, manganese, iron, copper, silver, zinc, and aluminum. [5] The binder composition for inorganic fiber products according to any one of [1] to [4] above, wherein the ratio of the inorganic content of the inorganic binder to 100% by mass of the organic content of the organic binder is 1 to 300% by mass. [6] The binder composition for inorganic fiber products according to any one of [1] to [5] above, further comprising a silane coupling agent. [7] A binder composition for inorganic fiber products, comprising an organic binder, an inorganic binder, and a compound containing a carbamide group or a thiocarbamide group. [8] The binder composition for inorganic fiber products according to [7], wherein the organic binder is a thermosetting organic binder. [9] The binder composition for inorganic fiber products according to [7] or [8], wherein the organic binder comprises at least one selected from the group consisting of sugars, phenolic resins, polyvinyl alcohol resins, and polycarboxylic acid resins.

[10] The binder composition for inorganic fiber products according to any one of [7] to [9] above, wherein the inorganic binder contains at least one selected from the group consisting of hydroxides, oxides, chlorides, silicates, carbonates, sulfates, nitrates, aluminates, borates, and phosphates of metals selected from the group consisting of lithium, sodium, potassium, magnesium, calcium, barium, titanium, chromium, manganese, iron, copper, silver, zinc, and aluminum.

[11] The binder composition for inorganic fiber products according to any one of the above [7] to

[10] , wherein the carbamide group- or thiocarbamide group-containing compound comprises at least one selected from the group consisting of urea, ethylene urea, thiourea, (mono-, di-, tri-, or tetra-)methyl urea, (mono-, di-, tri-, or tetra-)hydroxymethyl urea, (mono-, di-, tri-, or tetra-)ethyl urea, (mono-, di-, tri-, or tetra-)hydroxyethyl urea, (mono-, di-, tri-, or tetra-)propyl urea, (mono-, di-, tri-, or tetra-)butyl urea, and biuret.

[12] The binder composition for inorganic fiber products according to any one of [7] to

[11] above, wherein the ratio of the inorganic content of the inorganic binder to 100% by mass of the organic content of the organic binder is 1 to 300% by mass.

[13] The binder composition for inorganic fiber products according to any one of [7] to

[12] above, wherein the content of the carbamide group- or thiocarbamide group-containing compound is 0.1 to 100 mass % relative to 100 mass % of the solid content of the inorganic binder.

[14] The binder composition for inorganic fiber products according to any one of the above [7] to

[13] , further comprising a silane coupling agent.

[15] The binder composition for inorganic fiber products according to

[14] , wherein the content of the silane coupling agent is 0.1 to 100 mass% relative to 100 mass% of the total of the solid content of the organic binder, the solid content of the inorganic binder, and the carbamide group- or thiocarbamide group-containing compound.

[16] An inorganic fiber product comprising inorganic fibers and the binder composition for inorganic fiber products according to any one of [1] to [6] above, and comprising a molded body in which the inorganic fibers are bound by the organic binder.

[17] The inorganic fiber product according to

[16] , wherein the molded body is a cotton-like body.

[18] The inorganic fiber product according to

[16] or

[17] above, which is a fire-resistant coating material.

[19] The inorganic fiber product according to

[16] or

[17] above, which is a heat insulating material.

[20] An inorganic fiber product comprising inorganic fibers and the binder composition for inorganic fiber products according to any one of [7] to

[15] above, and comprising a molded body in which the inorganic fibers are bound by the organic binder.

[21] The inorganic fiber product according to

[20] , wherein the molded body is a cotton-like body.

[22] The inorganic fiber product according to

[20] or

[21] above, which is a fire-resistant coating material.

[23] The inorganic fiber product according to

[20] or

[21] above, which is a heat insulating material. [Effects of the Invention]

[0007] According to the present invention, it is possible to provide a binder composition for inorganic fibers that can produce inorganic fiber products that have excellent workability and are suppressed from decreasing in strength under high-temperature environments such as fire, and to provide inorganic fiber products that have excellent workability and are suppressed from decreasing in strength under high-temperature environments such as fire. [Brief explanation of the drawings]

[0008] [Figure 1] 1 is a graph showing the results of Test Example 1. [Figure 2] 1 is a photograph showing the results of Test Example 1. [Figure 3] 1 is a graph showing the results of Test Example 2. [Figure 4] 1 is a photograph showing the results of Test Example 2. [Figure 5] 1 is a graph showing the results of Test Example 3. [Figure 6] 1 is a photograph showing the results of Test Example 3. [Figure 7] 1 is a photograph showing the results of Test Example 4. [Figure 8] 1 is a photograph showing the results of Test Example 5. [Figure 9] 1 is a graph showing the results of Test Example 6 (substrate: rock wool (1)). [Figure 10] 1 is a graph showing the results of Test Example 6 (substrate: rock wool (2)). [Figure 11] 1 shows graphs and photographs illustrating the results of Test Example 7. [Figure 12] 1 shows graphs and photographs illustrating the results of Test Example 8. [Figure 13] 1 shows graphs and photographs illustrating the results of Test Example 9. [Figure 14] 1 is a photograph showing the results of Test Example 10. DETAILED DESCRIPTION OF THE INVENTION

[0009] In the present invention, the solid content refers to the non-volatile content when dried at 135°C for 1 hour. The inorganic content indicates the non-volatile content when fired at 800°C for 1 hour. The organic content of the organic binder refers to the residue obtained by subtracting the inorganic content from the solid content of the organic binder. The volatile content of the inorganic binder indicates the residue obtained by subtracting the inorganic content from the solid content of the inorganic binder.

[0010] The nonvolatile content after drying at 135°C for 1 hour is measured by the following method. Method for measuring nonvolatile content after drying at 135°C for 1 hour: Weigh out the mass C1 (g) of an aluminum foil dish (inner diameter 50 mm, height 15 mm), and weigh out the sample to 1.5±0.1 g. This specific mass of the sample is designated as the sample mass S1 (g) before drying. The aluminum foil dish is placed in an incubator pre-heated at 135±1°C and dried for 60±2 minutes. After cooling in a desiccator, the sample mass C2 (g) is measured. From this result, calculate the sample mass D1 (the mass of the sample remaining on the aluminum foil dish after drying) (g) using the following formula (1), and then calculate the nonvolatile content after drying at 135°C for 1 hour using the following formula (2). D1=C2-C1 (1) Nonvolatile content (%) after drying at 135°C for 1 hour = D1 / S1 × 100 (2)

[0011] The nonvolatile content after firing at 800°C for 1 hour is measured by the following method. Method for measuring nonvolatile content after firing at 800°C for 1 hour: Weigh out the mass of the crucible, C3 (g), and weigh out the sample so that it weighs 10±0.1g. The specific mass of the sample is the sample mass before firing, S2 (g). Place the crucible in an electric furnace and fire it for 60±2 minutes. Then, cool it in a desiccator and measure its mass, C4 (g). From this result, calculate the sample mass after firing, D2 (the mass of the sample remaining in the crucible after firing) (g) using the following formula (3), and calculate the nonvolatile content after firing at 800°C for 1 hour using the following formula (4). D2=C4-C3 (3) Nonvolatile content (%) after firing at 800°C for 1 hour = D2 / S2 × 100 (4)

[0012] [Binder composition for inorganic fiber products] A binder composition for inorganic fiber products according to one embodiment of the present invention (hereinafter also referred to as "composition (1)") contains an organic binder and an inorganic binder. The composition (1) may further contain other components as needed, provided that the effects of the present invention are not impaired.

[0013] <Organic binder> The organic binder binds the inorganic fibers together. By binding the inorganic fibers together with the organic binder, the inorganic fiber product can be processed in a manner that involves deformation, such as wrapping it around a steel frame. The binding of the inorganic fibers by the organic binder is well maintained unless it is exposed to high temperatures due to a fire or the like.

[0014] In the production of inorganic fiber products, binders are often used in the form of an aqueous solution or dispersion. Therefore, the organic binder is preferably water-soluble or water-dispersible, more preferably water-soluble. For example, it is preferable that the solubility in ion-exchanged water at 25°C is 10 g / 100 mL or more in terms of solid content.

[0015] Examples of the organic binder include thermoplastic organic binders, thermosetting organic binders, etc. Thermosetting organic binders are preferred in terms of providing excellent heat resistance to inorganic fiber products.

[0016] The thermoplastic organic binder comprises a thermoplastic resin. Examples of thermoplastic resins include polyethylene, polypropylene, polystyrene, polytetrafluoroethylene, polychloroprene, styrene-butadiene copolymer, acrylonitrile-butadiene-styrene resin, acrylonitrile copolymer, polyisoprene, polybutadiene, polyvinyl chloride, polyvinyl acetate, polyamide, polyacetal, polycarbonate, polyester, etc. These thermoplastic resins may be used alone or in combination of two or more.

[0017] The thermosetting organic binder includes a thermosetting resin. The thermosetting resin may be any resin that can be polymerized by heat, either alone or in the presence of a curing agent, and examples thereof include carbohydrates, phenolic resins, urea resins, melamine resins, epoxy resins, polyurethane resins, resorcinol resins, unsaturated polyester resins, silicone resins, polyvinyl alcohol resins (hereinafter also referred to as "PVA"), polycarboxylic acid resins, etc. Among these, carbohydrates, phenolic resins, PVA, and polycarboxylic acid resins are preferred because of their excellent water solubility and excellent inorganic fiber binding performance. These thermosetting resins may be used alone or in combination of two or more. The thermosetting organic binder may further contain a curing agent (catalyst, crosslinking agent, etc.) as needed. Known curing agents can be used depending on the type of thermosetting resin.

[0018] Below, we will explain in more detail about thermosetting organic binders containing carbohydrates (hereinafter also referred to as "carbohydrate-based binders"), thermosetting organic binders containing phenolic resins (hereinafter also referred to as "phenolic resin-based binders"), thermosetting organic binders containing PVA (hereinafter also referred to as "PVA-based binders"), and thermosetting organic binders containing polycarboxylic acid resins (hereinafter also referred to as "polycarboxylic acid-based binders"). However, thermosetting organic binders are not limited to these.

[0019] (Carbohydrate binder) Examples of carbohydrates include monosaccharides, oligosaccharides, polysaccharides, and derivatives thereof. Examples of monosaccharides include glucose, fructose, mannose, galactose, ribose, and xylose. Oligosaccharides are formed by the combination of two to ten monosaccharides, and examples include disaccharides such as sucrose, maltose, lactose, trehalose, and isomaltose; trisaccharides such as maltotriose and raffinose; maltooligosaccharides; isomaltooligosaccharides; fructooligosaccharides; mannooligosaccharides; and galactooligosaccharides. Polysaccharides are those in which 11 or more monosaccharides are bonded together, and examples thereof include starch, pullulan, dextrin, polydextrose, and the like. Examples of derivatives of monosaccharides, oligosaccharides, or polysaccharides include sugar alcohols, glycosides, and modified starches.

[0020] Examples of modified starches include starches that have been subjected to one or more of esterification, etherification, oxidation, and crosslinking, or mixtures thereof. Examples of modified starches that have been subjected to esterification include esterified starches such as starch acetate, phosphated starch, and octenyl succinate starch. Examples of modified starches that have been subjected to etherification include etherified starches such as hydroxyethyl starch and hydroxypropyl starch. Examples of modified starches that have been subjected to oxidation include oxidized starch. Examples of modified starches that have been subjected to crosslinking include crosslinked starches such as phosphate crosslinked starch. Examples of modified starches that have been subjected to two or more of esterification, etherification, oxidation, and crosslinking (complex modified starches) include acetate adipate crosslinked starch, acetate phosphate crosslinked starch, acetate oxidized starch, hydroxypropyl phosphate crosslinked starch, and phosphate monoesterified phosphate crosslinked starch. These carbohydrates may be used alone or in combination of two or more. Among the above, the carbohydrate is preferably at least one selected from the group consisting of monosaccharides, disaccharides, and trisaccharides.

[0021] The carbohydrate-based binder may further contain a phenol. Phenols are aromatic hydroxy compounds in which hydrogen atoms in an aromatic hydrocarbon nucleus are replaced with hydroxy groups. Phenols, together with carbohydrates, form the backbone of the cured product. Note that phenolic resins are not included in the phenols category.

[0022] Examples of phenols include plant-derived phenols and fossil fuel-derived phenols. Examples of plant-derived phenols include flavonoid-based tannins, catechins, anthocyanins, rutin, and isoflavones; phenolic acid-based polyphenols such as chlorogenic acid, ellagic acid, lignans, curcumin, coumarin, and lignin; cardanol; and cashew nut shell liquid. Examples of fossil fuel-derived phenols include phenol, cresol, xylenol, trimethylphenol, ethylphenol, propylphenol, butylphenol, butylcresol, phenylphenol, cumylphenol, methoxyphenol, bromophenol, bisphenol A, bisphenol F, bisphenol S, catechol, resorcinol, hydroquinone, pyrogallol, and phloroglucinol. These phenols may be used alone or in combination. Among these, polyhydric phenols (phenols having two or more hydroxyl groups) are preferred because they have better binder performance.

[0023] The phenols are preferably water-soluble, which allows the phenols to be easily mixed uniformly with the sugars and provides better binder performance. Examples of water-soluble phenols include tannin, phenol, cresol, catechol, resorcinol, hydroquinone, pyrogallol, and phloroglucinol.

[0024] When the saccharide-based binder contains phenols, the content of the phenols is preferably 0.1 to 30% by mass, more preferably 0.5 to 20% by mass, relative to 100% by mass of the saccharide. When the content of the phenols is equal to or greater than the lower limit, the binder performance is superior, and the strength and other properties of the resulting inorganic fiber product are superior. When the content of the phenols is equal to or less than the upper limit, the strength and other properties of the inorganic fiber product can be maintained better, and the composition (1) and the inorganic fiber product can be produced at a more economical cost.

[0025] Carbohydrate-based binders typically contain ammonium salts, which function as a source of ammonia that reacts with the carbohydrate in the curing reaction of the carbohydrate-based binder, and as a source of an acidic substance that acts as a catalyst in the subsequent reaction. Examples of ammonium salts include inorganic ammonium salts and organic ammonium salts. Examples of inorganic ammonium salts include ammonium sulfate, ammonium phosphate, monoammonium phosphate, diammonium phosphate, triammonium phosphate, ammonium hydrogen phosphate, ammonium borate, ammonium carbonate, and ammonium hydrogen carbonate. Examples of organic ammonium salts include ammonium acetate, ammonium oxalate, and ammonium citrate. These ammonium salts may be used alone or in combination of two or more.

[0026] The content of the ammonium salt is preferably 1 to 30% by mass, more preferably 5 to 25% by mass, relative to 100% by mass of the total of the saccharide and the phenol. If the content of the ammonium salt is equal to or greater than the lower limit, curing can be completed within the specified molding conditions (temperature, time) when molding an inorganic fiber product, and the required performance can be easily achieved. If the content of the ammonium salt is equal to or less than the upper limit, binder performance is efficiently demonstrated, and the strength and other properties of the obtained inorganic fiber product are good.

[0027] The thermal curing mechanism of carbohydrate-based binders is thought to be similar to caramelization. When a carbohydrate-based binder is heated, if the carbohydrate is a reducing sugar, it reacts directly with ammonium ions to form glucosylamine. If the carbohydrate is a non-reducing sugar, the non-reducing sugar hydrolyzes to form a reducing sugar, which then reacts with ammonium ions to form glucosylamine. Next, ring-opening occurs to form 1-amino-1-deoxy-2-ketose. This is commonly known as the Amadori rearrangement. Subsequently, under the influence of anions (acid catalyst) and heat, the ring closes with dehydration to produce hydroxymethylfurfural (HMF). HMF is a thermally unstable compound, and the resulting HMF reacts with other HMFs and phenols with further dehydration under continued heating. As this reaction progresses, hardening progresses and eventually reaches completion. The resulting hardened material is presumed to have a caramel-like structure in which a phenolic skeleton is incorporated into a portion of the structure. The only by-product of the above reaction is thought to be water. Therefore, when the organic binder is a carbohydrate-based binder, the gas generated during the curing of composition (1) in the manufacturing process of inorganic fiber products is thought to be water vapor.

[0028] (phenolic resin binder) Phenolic resins are reaction products of phenols and aldehydes in the presence of a catalyst.

[0029] Phenols are compounds having an aromatic ring and a hydroxyl group bonded to the aromatic ring. Examples of phenols include phenol, alkylphenols (o-, m-, and p-cresols, o-, m-, and p-ethylphenols, and xylenol isomers), polycyclic phenols (α- and β-naphthols, and the like), and polyhydric phenols (bisphenol A, bisphenol F, bisphenol S, pyrogallol, resorcinol, catechol, hydroquinone, and the like). These phenols may be used alone or in combination of two or more. Among these, the most practical are phenol, o-, m-, and p-cresols, xylenol isomers, resorcinol, and catechol.

[0030] The aldehyde is at least one compound selected from the group consisting of compounds having a formyl group and polymers thereof. Examples of the aldehyde include formaldehyde, acetaldehyde, propylaldehyde, benzaldehyde, salicylaldehyde, glyoxal, etc. These aldehydes may be used alone or in combination of two or more. Of these, formaldehyde is the most practical substance.

[0031] The phenolic resin is preferably a resol-type phenolic resin that uses an alkali catalyst. When a phenol and an aldehyde are reacted in the presence of an alkali catalyst, an addition reaction occurs in which the aldehyde is added to the aromatic ring of the phenol, followed by a condensation reaction to form a polymer.

[0032] The resol phenolic resin may be urea-modified. By using a urea-modified resol phenolic resin, the amount of formaldehyde emitted during the production process of inorganic fiber products can be reduced compared to when a non-urea-modified resol phenolic resin is used.

[0033] The weight average molecular weight of the resol type phenolic resin is preferably 800 or less, more preferably 600 or less, and even more preferably 400 or less, from the viewpoints of water dilutability and stability over time. The weight-average molecular weight of the resol type phenolic resin is preferably at least 150. If the weight-average molecular weight is less than 150, there is a risk of a decrease in the yield of the binder in inorganic fiber products, a decrease in strength, and the like. The weight average molecular weight of the resol type phenolic resin is a value measured by gel permeation chromatography (GPC) using polystyrene as a standard substance.

[0034] The resol type phenolic resin is preferably in a liquid form. The solid content of the resol type phenolic resin is preferably 30% by mass or more, more preferably 40% by mass or more, from the viewpoint of transportation costs.

[0035] (PVA binder) PVA has vinyl alcohol units and may further have other monomer units (for example, vinyl acetate units) in addition to vinyl alcohol units. As PVA, those with a degree of polymerization of 500 or less are preferred because of their low viscosity. An example of PVA with a degree of polymerization of 500 or less is "JL-05E" manufactured by Nippon Vinyl Acetate & Poval Co., Ltd.

[0036] The PVA-based binder usually contains a crosslinking agent (curing agent). Examples of the crosslinking agent include an aliphatic carboxylic acid compound and a boron compound. Examples of the aliphatic carboxylic acid compounds include polymers and copolymers of aliphatic monocarboxylic acids, aliphatic monocarboxylic acids, and polymers and copolymers thereof. Examples of the aliphatic monocarboxylic acids include acrylic acid, methacrylic acid, and crotonic acid. Examples of the aliphatic dicarboxylic acids include maleic acid, fumaric acid, and itaconic acid. Examples of boron compounds include borax, boric acid, and boric acid complexes. These crosslinking agents may be used alone or in combination of two or more. The content of the crosslinking agent is, for example, 4 to 100 parts by mass relative to 100 parts by mass of PVA.

[0037] (Polycarboxylic acid resin binder) The polycarboxylic acid resin is a resin having at least two carboxy groups or acid anhydride groups. Examples of polycarboxylic acid resins include resins having a monomer unit having a carboxy group or an acid anhydride group. The polycarboxylic acid resin may further have other monomer units.

[0038] Examples of monomers having a carboxy group include unsaturated monocarboxylic acids having 3 to 20 carbon atoms (hereinafter abbreviated as C) and unsaturated dicarboxylic acids having 4 to 20 carbon atoms (preferably C4 to 16 carbon atoms). Examples of unsaturated monocarboxylic acids include (meth)acrylic acid, crotonic acid, cinnamic acid, vinylbenzoic acid, alkenoic acids [C4 to 20 (preferably C4 to 13) such as vinylacetic acid, 3-methyl-3-butenoic acid, 3-pentenoic acid, 4- and 5-hexenoic acid], monoalkyl (C1 to 8) esters of unsaturated dicarboxylic acids [C4 to 16, such as monoalkyl maleates, monoalkyl fumarate esters, monoalkyl citraconic acid esters], and monoesters of unsaturated dicarboxylic acids [C5 to 20, such as ethyl carbitol monoester of maleic acid, ethyl carbitol monoester of fumaric acid, glycol monoester of itaconic acid]. (Meth)acrylic acid refers to acrylic acid or methacrylic acid. Examples of unsaturated dicarboxylic acids include maleic acid, fumaric acid, citraconic acid, and itaconic acid. Examples of the monomer having an acid anhydride group include anhydrides of the above-mentioned unsaturated dicarboxylic acids, such as maleic anhydride and itaconic anhydride. These monomers may be used alone or in combination of two or more.

[0039] The other monomer may be any monomer that is copolymerizable with the monomer having a carboxy group or an acid anhydride group, and examples thereof include the following. C3-18 unsaturated amide compounds such as (meth)acrylamide, N-alkyl(C1-5)(meth)acrylamide, alkoxy(C1-4)alkyl(C1-5)(meth)acrylamide, N,N-dialkyl(C1-5)(meth)acrylamide, aminoalkyl(C1-5)(meth)acrylamide, N-alkyl(C1-5)aminoalkyl(C1-5)(meth)acrylamide, N,N-dialkyl(C1-5)aminoalkyl(C1-5)(meth)acrylamide, diacetone(meth)acrylamide, N-vinylformamide, N-vinylacetamide, and N-vinylpyrrolidone; C3-30 (meth)acrylates such as alkyl (C1-18) (meth)acrylates and their lower alkyl (C1-4) ethers, aminoalkyl (C1-5) (meth)acrylates, N-alkyl (C1-5) aminoalkyl (C1-5) (meth)acrylates, N,N-dialkyl (C1-5) (meth)acrylates, and N-alkyl (C1-5) aminoalkyl (C1-5) aminoalkyl (C1-5) (meth)acrylates; C3-30 vinyl compounds such as vinyl alkyl (C1-20) ether, N-alkyl (C1-5) vinylamine, N,N-dialkyl (C1-5) vinylamine, N-vinylpyridine, N-vinylimidazole, and N-(alkyl)aminoalkyl (C1-5) vinylamine; C3-10 allyl compounds, such as N-allylamine, N-alkyl(C1-5)allylamine, and N,N-dialkyl(C1-5)allylamine; C3-10, for example, nitrile compounds such as (meth)acrylonitrile; C2-30 aliphatic unsaturated hydrocarbons such as ethylene, propylene, isobutylene, isoprene, and butadiene; C8-30 aromatic vinyl compounds such as styrene, α-methylstyrene, p-methoxystyrene, vinyltoluene, p-hydroxystyrene, and p-acetoxystyrene; C3-30 vinyl ester compounds such as vinyl acetate and vinyl propionate. These monomers may be used alone or in combination of two or more.

[0040] The proportion of the monomer units having a carboxy group or an acid anhydride group relative to 100% by mass of all monomer units constituting the polycarboxylic acid resin is, for example, 20% by mass or more, further 40% by mass or more, or even 60% by mass or more, and may be 100% by mass.

[0041] The weight average molecular weight of the polycarboxylic acid resin is, for example, 500 to 100,000, further 1,000 to 80,000, or even 5,000 to 50,000. The weight average molecular weight of the polycarboxylic acid resin is a value measured by gel permeation chromatography (GPC) using polyethylene oxide as a standard substance.

[0042] The polycarboxylic acid resin binder usually contains a crosslinking agent (curing agent). Examples of crosslinking agents include C2-20 hydroxylamine and alkylene oxide (hereinafter abbreviated as "AO") adducts of amines. Examples of hydroxylamines include those with one hydroxyl group (e.g., primary amines such as monoethanolamine and 2-(2-aminoethylamino)ethanol), those with two hydroxyl groups (secondary amines such as diisopropanolamine and diethanolamine), and those with three hydroxyl groups (tertiary amines such as triethanolamine and tris(hydroxyethyl)aminomethane). Examples of the amine include aliphatic amines [C1 to C10, such as methylamine, ethylamine, n- and i-propylamine, ethylenediamine, and diethylenetriamine], aromatic amines [C6 to C12, such as aniline and toluidine], alicyclic amines [C4 to C10, such as cyclopentylamine and cyclohexylamine], and heterocyclic amines [C4 to C10, such as piperazine]. Examples of AO include unsubstituted AO such as ethylene oxide, 1,2-propylene oxide, 1,2-, 2,3- or 1,3-butylene oxide, tetrahydrofuran, 3-methyl-tetrahydrofuran, 1,3-propylene oxide, and isobutylene oxide; and substituted AO such as styrene oxide. The number of AOs added to the amine may be one or two or more. When two or more AOs are added, they may be added randomly or in blocks. The number of moles of AO added is preferably 1 to 20 moles.

[0043] <Inorganic binder> The inorganic binder binds the inorganic fibers together when the inorganic fiber product is exposed to a high temperature (for example, 500°C or higher) above the thermal decomposition temperature of the organic binder due to a fire, etc. When the inorganic fiber product is exposed to high temperatures, the organic binder thermally decomposes, but the inorganic binder bonds the inorganic fibers together, allowing the shape of the inorganic fiber product to be maintained.

[0044] The inorganic binder typically contains an inorganic compound (hereinafter also referred to as "solidified-condensed inorganic compound") that solidifies or condenses at a high temperature (e.g., 500°C or higher) that is equal to or higher than the thermal decomposition temperature of the organic binder. In this case, when the inorganic fiber product is exposed to high temperatures, the solidified-condensed inorganic compound solidifies or condenses, and the inorganic fibers are bonded together by the solidified or condensed product.

[0045] The solidifying / condensing inorganic compound is selected from inorganic hydroxides, oxides, chlorides, oxoacids, and oxoacid salts. Examples include hydroxides, oxides, chlorides, silicates, carbonates, sulfates, nitrates, aluminates, borates, and phosphates of metals selected from the group consisting of lithium, sodium, potassium, magnesium, calcium, barium, titanium, chromium, manganese, iron, copper, silver, zinc, and aluminum. Specific examples include phosphoric acid, trisodium phosphate, sodium dihydrogen phosphate, disodium hydrogen phosphate, tripotassium phosphate, potassium dihydrogen phosphate, dipotassium hydrogen phosphate, potassium monohydrogen phosphate, magnesium phosphate, sodium sulfate, potassium sulfate, sodium carbonate, potassium carbonate, sodium silicate, potassium silicate, sodium chloride, and potassium chloride. These solidifying / condensing inorganic compounds may be used alone or in combination.

[0046] The inorganic binder preferably contains a phosphate, because it is water-soluble and has excellent condensation properties at relatively low temperatures (about 500°C). Phosphate may be used in combination with other solidifying and condensing inorganic compounds. The proportion of the phosphate relative to the total amount (100% by mass) of the solidified / condensed inorganic compound is preferably 1% by mass or more, and more preferably 5% by mass or more.

[0047] When phosphates are used in combination with other solidifying / condensing inorganic compounds, sulfates are preferred as the other solidifying / condensing inorganic compounds. By using phosphates in combination with sulfates, the strength of inorganic fiber products exposed to high temperatures of 1000°C or higher is superior to that of phosphates alone. The ratio of the sulfate to 100 parts by mass of the phosphate is preferably 1 to 100 parts by mass, more preferably 1 to 60 parts by mass.

[0048] <Other ingredients> The other components can be appropriately selected from those known to be blended into binders for inorganic fiber products, and examples thereof include water, curing accelerators, and additives (silane coupling agents, softeners, tack inhibitors, release agents, adhesion improvers, viscosity modifiers, antioxidants, UV absorbers, stabilizers, plasticizers, waxes, pigments, dyes, antistatic agents, antibacterial agents, antifungal agents, fragrances, flame retardants, dispersants, film-forming aids, pH adjusters, wetting agents, etc.). These may be used alone or in combination of two or more.

[0049] From the viewpoint of the strength of the inorganic fiber product, the composition (1) preferably contains a silane coupling agent. Examples of the silane coupling agent include an amino group-containing silane coupling agent, an epoxy group-containing silane coupling agent, a vinyl group-containing silane coupling agent, a methacryloyl group-containing silane coupling agent, an acryloyl group-containing silane coupling agent, a ureido group-containing silane coupling agent, an isocyanate group-containing silane coupling agent, etc. Examples of the amino group-containing silane coupling agent include N-2-(aminoethyl)-3-aminopropylmethyldimethoxysilane, N-2-(aminoethyl)-3-aminopropyltrimethoxysilane, 3-aminopropyltrimethoxysilane, 3-aminopropyltriethoxysilane, 3-triethoxysilyl-N-(1,3-dimethyl-butylidene)propylamine, N-phenyl-3-aminopropyltrimethoxysilane, and N-(vinylbenzyl)-2-aminoethyl-3-aminopropyltrimethoxysilane hydrochloride. Examples of epoxy group-containing silane coupling agents include 2-(3,4-epoxycyclohexyl)ethyltrimethoxysilane, 3-glycidoxypropylmethyldimethoxysilane, 3-glycidoxypropyltrimethoxysilane, 3-glycidoxypropylmethyldiethoxysilane, and 3-glycidoxypropyltriethoxysilane. Examples of vinyl group-containing silane coupling agents include vinyltriethoxysilane. Examples of methacryloyl group-containing silane coupling agents include 3-methacryloxypropyltrimethoxysilane. Examples of acryloyl group-containing silane coupling agents include 3-acryloxypropyltrimethoxysilane. Examples of ureido group-containing silane coupling agents include 3-ureidopropyltriethoxysilane. Examples of isocyanate group-containing silane coupling agents include 3-isocyanatepropyltriethoxysilane. These silane coupling agents may be used alone or in combination of two or more.

[0050] <Composition> In composition (1), the ratio of the inorganic content of the inorganic binder to 100% by mass of the organic content of the organic binder is preferably 1 to 300% by mass, more preferably 2 to 200% by mass, even more preferably 3 to 100% by mass, and particularly preferably 5 to 80% by mass. If the ratio of the inorganic content of the inorganic binder is equal to or greater than the lower limit, the shape retention of the inorganic fiber product in a high-temperature environment such as a fire is superior. If the ratio of the inorganic content of the inorganic binder is equal to or less than the upper limit, the strength and workability of the inorganic fiber product are superior.

[0051] In composition (1), the ratio of the solid content of the inorganic binder to 100% by mass of the solid content of the organic binder is preferably 1 to 300% by mass, more preferably 2 to 200% by mass, even more preferably 3 to 100% by mass, and particularly preferably 5 to 80% by mass. When the ratio of the solid content of the inorganic binder is equal to or greater than the lower limit, the shape retention of the inorganic fiber product in a high-temperature environment such as a fire is superior. When the ratio of the inorganic content of the inorganic binder is equal to or less than the upper limit, the strength and workability of the inorganic fiber product are superior.

[0052] The total proportion of the solid content of the organic binder and the solid content of the inorganic binder relative to 100% by mass of the solid content of the composition (1) is preferably 60% by mass or more, more preferably 80% by mass or more, and may be 100% by mass.

[0053] The content of water is set depending on the solid content of the composition (1). The solid content of composition (1) can be appropriately set taking into consideration the solubility of the organic binder and inorganic binder, the form of use of composition (1), etc., and may be, for example, 1 to 80 mass % relative to the total mass of composition (1).

[0054] In the composition (1), the content of the silane coupling agent is preferably 0 to 5 mass %, more preferably 0 to 1 mass %, relative to 100 mass % of the solid content of the organic binder.

[0055] The composition (1) described above contains an organic binder and an inorganic binder, and therefore an inorganic fiber product can be obtained that is easy to apply and has excellent shape retention in high-temperature environments such as fires. In inorganic fiber products using composition (1), the inorganic fibers are bound by an organic binder before being exposed to high temperatures (e.g., 500°C or higher) due to a fire or the like. Therefore, the inorganic fiber products have sufficient strength and can be processed by wrapping them around steel frames or other deformation processes. Furthermore, construction is completed once the product is installed on the steel frame or other construction site, so the construction period is short. When inorganic fiber products are exposed to high temperatures, the organic binder is thermally decomposed, but the inorganic binder bonds the inorganic fibers together, which prevents the strength of the inorganic fiber products from decreasing and allows the inorganic fiber products to maintain their shape.

[0056] A binder composition for inorganic fiber products according to another embodiment of the present invention (hereinafter also referred to as "composition (2)") contains an organic binder, an inorganic binder, and a carbamide group- or thiocarbamide group-containing compound (hereinafter also referred to as "compound (A)"). Composition (2) may further contain other components as needed, provided that the effects of the present invention are not impaired.

[0057] <Organic binder> Examples of the organic binder include the same as those mentioned above.

[0058] <Inorganic binder> Examples of the inorganic binder include the same as those mentioned above. As the inorganic binder in composition (2), among the above-mentioned solidified / condensed inorganic compounds, at least one selected from the group consisting of hydroxides, oxides, chlorides, silicates, carbonates, sulfates, nitrates, aluminates, borates, and phosphates of metals selected from the group consisting of lithium, sodium, potassium, magnesium, calcium, barium, titanium, chromium, manganese, iron, copper, silver, zinc, and aluminum is preferred, and at least one selected from the group consisting of silicates, borates, and phosphates is more preferred, in that the effect of improving the moisture resistance strength due to compound (A) can be easily obtained.

[0059] Among the above inorganic binders, it is more preferable to use a phosphate because of its water solubility and excellent condensation properties at relatively low temperatures (about 500°C). Phosphate may be used in combination with other solidifying and condensing inorganic compounds. The proportion of the phosphate relative to the total amount of the solidified / condensed inorganic compound (100% by mass) is preferably 50% by mass or more, and more preferably 80% by mass or more.

[0060] <Compound (A)> Compound (A) is a compound having a carbamide group (>NC(=O)-N<) or a thiocarbamide group (>NC(=S)-N<) in the molecule. When the composition (2) contains the compound (A), the moisture resistance strength of the inorganic fiber product is improved.

[0061] The molecular weight of the compound (A) is, for example, 60 to 300. Specific examples of the compound (A) include urea, ethylene urea, thiourea, (mono-, di-, tri-, or tetra-)methyl urea, (mono-, di-, tri-, or tetra-)hydroxymethyl urea, (mono-, di-, tri-, or tetra-)ethyl urea, (mono-, di-, tri-, or tetra-)hydroxyethyl urea, (mono-, di-, tri-, or tetra-)propyl urea, (mono-, di-, tri-, or tetra-)butyl urea, biuret, etc. These compounds may be used alone or in combination of two or more.

[0062] Among the above, the compound (A) is preferably at least one selected from the group consisting of urea, ethylene urea, thiourea, (mono-, di-, tri-, or tetra-)methyl urea, (mono-, di-, tri-, or tetra-)hydroxymethyl urea, and (mono-, di-, tri-, or tetra-)hydroxyethyl urea, from the viewpoint of water dilutability.

[0063] <Other ingredients> Other components include those similar to those mentioned above.

[0064] From the viewpoint of the strength of the inorganic fiber product, the composition (2) preferably contains, among the other components described above, a silane coupling agent. Examples of the silane coupling agent include those similar to those described above.

[0065] <Composition> In composition (2), the ratio of the inorganic content of the inorganic binder to 100% by mass of the organic content of the organic binder is preferably 1 to 300% by mass, more preferably 2 to 200% by mass, even more preferably 3 to 100% by mass, and particularly preferably 5 to 80% by mass. If the ratio of the inorganic content of the inorganic binder is equal to or greater than the lower limit, the shape retention of the inorganic fiber product in a high-temperature environment such as a fire is superior. If the ratio of the inorganic content of the inorganic binder is equal to or less than the upper limit, the strength and workability of the inorganic fiber product are superior.

[0066] In composition (2), the ratio of the solid content of the inorganic binder to 100% by mass of the solid content of the organic binder is preferably 1 to 300% by mass, more preferably 2 to 200% by mass, even more preferably 3 to 100% by mass, and particularly preferably 5 to 80% by mass. If the ratio of the solid content of the inorganic binder is equal to or greater than the lower limit, the shape retention of the inorganic fiber product in a high-temperature environment such as a fire is superior. If the ratio of the inorganic content of the inorganic binder is equal to or less than the upper limit, the strength and workability of the inorganic fiber product are superior.

[0067] In composition (2), the content of compound (A) is preferably 0.1 to 100 mass%, more preferably 1 to 80 mass%, further preferably 2 to 50 mass%, particularly preferably 5 to 30 mass%, relative to 100 mass% of the solid content of the inorganic binder. When the content of compound (A) is within the above range, the moisture resistance strength of the inorganic fiber product is superior. When the compound (A) contains bound water, the content of the compound (A) indicates the amount excluding the bound water.

[0068] The total proportion of the solid content of the organic binder, the solid content of the inorganic binder, and the compound (A) relative to 100% by mass of the solid content of the composition (2) is preferably 60% by mass or more, more preferably 80% by mass or more, and may be 100% by mass.

[0069] The content of water is set depending on the solid content of the composition (2). The solid content concentration of the composition (2) can be appropriately set in consideration of the solubility of the organic binder, the inorganic binder, the compound (A), etc., the form of use of the composition (2), etc., and may be, for example, 1 to 80 mass% relative to the total mass of the composition (2).

[0070] In composition (2), the content of the silane coupling agent is preferably 0.1 to 100% by mass, more preferably 1 to 80% by mass, even more preferably 2 to 50% by mass, and particularly preferably 5 to 30% by mass, relative to 100% by mass of the total of the solid content of the organic binder, the solid content of the inorganic binder, and compound (A). If the content of the silane coupling agent is equal to or greater than the lower limit, the strength (normal strength, wet strength) of the inorganic fiber product will be superior, and if it is equal to or less than the upper limit, the shape retention under high-temperature environments such as fire will be superior.

[0071] The composition (2) described above contains an organic binder, an inorganic binder, and the compound (A), and therefore an inorganic fiber product having excellent workability, shape retention in high-temperature environments such as fire, and moisture resistance strength can be obtained. In inorganic fiber products using composition (2), the inorganic fibers are bound by an organic binder before they are exposed to high temperatures (e.g., 500°C or higher) due to a fire or the like. This allows the inorganic fiber products to have sufficient strength and allows them to be processed in a manner that involves deformation, such as by wrapping them around steel frames. Furthermore, construction is completed once the product is installed at the construction site on the steel frame, etc., so the construction period is short. When inorganic fiber products are exposed to high temperatures, the organic binder is thermally decomposed, but the inorganic binder bonds the inorganic fibers together, which prevents the strength of the inorganic fiber products from decreasing and allows the inorganic fiber products to maintain their shape.

[0072] The compound (A) contributes to improving the moisture resistance strength of inorganic fiber products before they are exposed to high temperatures due to a fire, etc. The reason why the compound (A) exhibits such an effect is presumed to be as follows. In the absence of compound (A), it is believed that inorganic binders are dispersed and arranged without being bonded to each other in the inorganic fiber product before it is exposed to high temperatures due to a fire, etc. Inorganic binders are relatively hydrophilic, and it is believed that the dispersed and arranged inorganic binders as described above result in a decrease in moisture resistance strength. The carbamide or thiocarbamide group of compound (A) decomposes due to heat during the production of inorganic fiber products. For example, urea decomposes into isocyanic acid and ammonia when exposed to heat. The decomposition products then act on the inorganic binder, causing the hydrophilic groups of the inorganic binder to react with each other (for example, hydroxyl groups of phosphate salts undergo a condensation reaction). As a result, a network of the inorganic binder is formed, suppressing the effects of the hydrophilic groups and improving moisture resistance.

[0073] [Inorganic fiber products] The inorganic fiber product of the present invention comprises a molded article containing inorganic fibers and the present composition. The molded article can also be said to contain inorganic fibers, an organic binder, and an inorganic binder.

[0074] The inorganic fiber is not particularly limited, and examples thereof include glass wool, rock wool, ceramic fiber, etc. These may be used alone or in combination of two or more. As the inorganic fiber, glass wool or rock wool is preferred in terms of versatility and heat insulating performance.

[0075] In the molded body, the inorganic fibers are bound by an organic binder, which gives the molded body flexibility and allows for processing such as wrapping the inorganic fiber product around the surface of a steel frame. When the organic binder of the present composition is a thermosetting organic binder, the organic binder that binds the inorganic fibers is a cured product of the thermosetting organic binder. The inorganic fibers are typically not bound by an inorganic binder.

[0076] The molded body is preferably a cotton-like body from the viewpoint of winding processability. Examples of flocculants include felt, mats, boards, etc. These are usually classified by density. In the case of rock wool, the density of felt is generally 20 to 40 kg / m 3 , mat density is 40~80kg / m 3 , board density is 80~250kg / m 3 In the case of glass wool, the density of the felt is generally 10 to 16 kg / m 3 , Mat density is 10~32kg / m 3 , board density is 32~96kg / m 3 is. The thickness of the flocculent material is preferably 25 to 100 mm, more preferably 25 to 50 mm.

[0077] The inorganic fiber product of the present invention may be made of the molded article, or may further include other members in addition to the molded article, such as a skin material for packaging.

[0078] <Method of manufacturing inorganic fiber products> The inorganic fiber product of the present invention can be produced, for example, by a production method including a step of using the present composition to mold inorganic fibers at a temperature below the thermal decomposition temperature of the organic binder to obtain a molded product. As a method for producing the molded body, any known method conventionally used for producing inorganic fiber products can be used, except that the present composition is used as a binder.

[0079] An example of the method for producing a molded body will be described below, taking as an example a case where the organic binder is a thermosetting organic binder. The manufacturing method of this example includes a step of adhering the composition to inorganic fibers (hereinafter referred to as the adhering step), and a step of aggregating the inorganic fibers with the composition adhered thereto to form an aggregate having a shape corresponding to the inorganic fiber product to be manufactured, and then heating the aggregate to cure the thermosetting organic binder in the composition (hereinafter referred to as the molding step). Each step will be described in more detail below.

[0080] (Attachment process) The fiber length and fiber diameter of the inorganic fibers are not particularly limited and may be appropriately set depending on the inorganic fiber product to be manufactured. Fiber diameters within the range of 3 to 10 μm are usually used. The inorganic fibers may be commercially available or may be produced by a known method. Inorganic fibers are generally produced by fiberizing raw materials (waste glass, basalt, iron furnace slag, etc.). Examples of fiberization methods include the flame method and the centrifugal method. Fiberization by these various methods can be carried out using a corresponding fiberization device.

[0081] Methods for attaching the present composition to inorganic fibers include, for example, a method of spraying the present composition onto inorganic fibers using a spray device or the like, or a method of impregnating inorganic fibers with the present composition, and either method may be used. The amount of the present composition to be applied to the inorganic fibers is not particularly limited, but is usually in the range of 0.5 to 20 mass% of the solid content (non-volatile content) of the present composition relative to the inorganic fibers (100 mass%). This amount affects the physical properties (mechanical strength, etc.) of the resulting molded product. For example, the greater the amount of the present composition applied to the inorganic fibers, the higher the mechanical strength of the resulting molded product tends to be.

[0082] (molding process) Next, the inorganic fibers to which the composition is attached are accumulated to form an aggregate having a shape corresponding to the inorganic fiber product to be manufactured, and then the aggregate is heated to cure the composition. The molding step can be carried out by a known method. For example, in the case of producing a cotton-like molded body, inorganic fibers are piled up on a conveyor, and the pile is compressed by pressing from above and below the conveyor to form an aggregate, which is then sent to a heating oven (curing oven) and heated to cure the composition, thereby obtaining a cotton-like molded body. The amount of inorganic fibers used (the amount of inorganic fibers deposited on the conveyor) and the compression conditions are set according to the thickness, bulk density, etc. of the inorganic fiber product to be manufactured. The heating conditions (heating temperature, heating time) for the aggregate are not particularly limited as long as they are below the thermal decomposition temperature of the thermosetting organic binder and within a range in which the thermosetting organic binder hardens, but the heating temperature is preferably within a range of 180 to 270°C. If the heating temperature is below 180°C, hardening may be insufficient, resulting in insufficient mechanical strength. If the heating temperature exceeds 270°C, the thermosetting organic binder may decompose, resulting in a decrease in yield and a decrease in mechanical strength. The heating time varies depending on the size of the aggregate, the heating temperature, etc., and is not particularly limited.

[0083] The obtained molded article may be used as an inorganic fiber product as it is, or may be further subjected to processing such as cutting and packaging with a skin material, if necessary.

[0084] The inorganic fiber product of the present invention can be used, for example, as a fire-resistant coating material, a heat insulating material, a sound absorbing material, and various other molded articles (such as automobile roofs and hood liners). As described above, the inorganic fiber product of the present invention has excellent shape retention in high-temperature environments such as fires. Therefore, the inorganic fiber product of the present invention is suitable for use in buildings, for example, as a fire-resistant covering material or a heat insulating material, and is particularly suitable as a fire-resistant covering material. When this inorganic fiber product is used as a fire-resistant covering material, it is possible to prevent the fire-resistant covering material from peeling off from a steel frame during a fire, thereby preventing a decrease in fire resistance.

[0085] Fire-resistant coating materials are used to cover the steel frames (beams, columns, etc.) of buildings. By covering the steel frames with fire-resistant coating materials, it is possible to prevent the steel frames from melting due to heat during a fire. The application method of the fire-resistant covering material may be the same as known methods. For example, when the fire-resistant covering material is in the form of felt, the fire-resistant covering material may be wrapped around the steel frame and fixed with pins or the like. [Example]

[0086] The present invention will be described in more detail below with reference to examples, but is not limited to these examples. In the following examples, "parts" and "%" represent "parts by mass" and "% by mass", respectively, unless otherwise specified.

[0087] (Production Example 1: Preparation of Carbohydrate-Based Binder) 2.7 g of an 85% aqueous phosphoric acid solution and 7.3 g of a 65% aqueous phenolsulfonic acid solution were dissolved in 13.2 g of ion-exchanged water. While checking the pH (inserting a pH meter electrode and stirring), 25% aqueous ammonia solution was added to the solution, ultimately adjusting the pH to 5.5. Next, 2.7 g of tannin was added and dissolved. Next, 69.0 g of an aqueous isomerized sugar solution with a solids concentration of 75% was added and dissolved uniformly. Subsequently, ion-exchanged water was added so that the total amount of the binder composition finally reached 100 g, yielding a saccharide-based binder (solids concentration 47%). The tannin used was powdered Mimosa NT manufactured by UCL Company Pty Ltd., 85% phosphoric acid aqueous solution manufactured by Katakura Co-op Agri, 65% phenolsulfonic acid aqueous solution manufactured by Nippon Chemical Industries, 25% ammonia aqueous solution manufactured by Mitsubishi Chemical, and isomerized sugar "75FG" manufactured by Gunei Chemical Industry (25% moisture, 45% glucose and 42% fructose relative to the total carbohydrate content).

[0088] <Test Example 1> (Preparation of Binder Composition) The binder compositions of Examples 1-1 to 1-5 were prepared by mixing 100 parts of a saccharide-based binder (organic binder) in terms of solid content with the amount of 36% sodium dihydrogen phosphate aqueous solution (inorganic binder) shown in Table 1 in terms of solid content, and diluting with ion-exchanged water. The blending amount of ion-exchanged water was set so that the total solid content concentration after dilution would be 36%. Sodium dihydrogen phosphate manufactured by Kanto Chemical Co., Inc. was used. A binder composition of Comparative Example 1 was prepared by diluting a saccharide-based binder with ion-exchanged water so that the total solid concentration after dilution was 36%. The 36% aqueous solution of sodium dihydrogen phosphate was used as the binder composition of Comparative Example 2 as it was.

[0089] [Table 1]

[0090] (Measurement of inorganic and organic components) The solid content (non-volatile content when dried at 135°C for 1 hour) (%) of the binder composition was measured. The inorganic content (non-volatile content when fired at 800°C for 1 hour) (%) of the binder composition was measured. The organic content (%) of the binder composition was determined by subtracting the inorganic content (%) from the solid content (%) of the binder composition. When measuring the inorganic content of this composition (after baking at 800°C for 1 hour), the organic binder decomposes and volatilizes, and the moisture and metal components generated by condensation of the inorganic binder also volatilize. The organic content of this composition includes the organic content of the organic binder and the volatile content of the inorganic binder. The results are shown in Table 2.

[0091] [Table 2]

[0092] The solid content (parts) of the binder composition was calculated by the formula: mass (parts) of the binder composition x solid content (%) / 100. The inorganic content (parts) of the binder composition was calculated by the formula: mass (parts) of binder composition x inorganic content (%) / 100. The value obtained by subtracting the inorganic content (parts) from the solid content (parts) of the binder composition was taken as the organic content (parts) of the binder composition. The results are shown in Table 3.

[0093] [Table 3]

[0094] The solid content (parts) of the binder composition was calculated by the formula: mass (parts) of the binder composition x solid content (%) / 100. The inorganic content (%) of the binder composition of Comparative Example 1 was measured. This value corresponds to the inorganic content (parts) of the saccharide-based binder (organic binder) in the binder compositions of Comparative Example 1 and Examples 1-1 to 1-5. The inorganic content (parts) of the inorganic binder was determined by subtracting the inorganic content (parts) of the saccharide-based binder from the inorganic content (parts) of the binder compositions of Comparative Example 1 and Examples 1-1 to 1-5. The organic content in Comparative Example 2 corresponds to the volatile content of the inorganic binder. The ratio of the organic content (=volatile content) to the inorganic content in Comparative Example 2 (16.99 / 85.65) was defined as the volatile content ratio of the inorganic binder. For the binder compositions of Examples 1-1 to 1-5, the volatile content (parts) of the inorganic binder was calculated by multiplying the inorganic content (parts) by the volatile content ratio of the inorganic binder. The organic content (parts) of the saccharide-based binder (organic binder) was determined by subtracting the volatile content (parts) of the inorganic binder from the organic content (parts) of the binder composition. The results are shown in Table 4.

[0095] [Table 4]

[0096] (evaluation) The binder composition was added to 150 g of substrate and mixed so that the solid content of the carbohydrate-based binder was 3%. Sand (Cerabeads manufactured by Itochu Ceratec Co., Ltd., average particle size 300 μm) was used as the substrate. The resulting mixture was uniformly filled into a dogbone-shaped mold (length 75 mm x width 25-42 mm x thickness 7 mm) to prepare test pieces. The test pieces were fired at 200°C for 30 minutes to simulate the manufacturing process of fire-resistant coating materials, and then refired at 800°C for 30 minutes to simulate the outbreak of a fire. The tensile strength (N) of the test pieces was measured after firing and refired. The tensile strength was measured at a loading rate of 5 mm / min. The tensile strength is generally calculated as the measured value (N) / breaking area 25 x 7 (mm 2 ) is calculated as follows (N / mm 2 ), but in this evaluation, the fracture cross section is 175 (mm 2 ), so only the measured value (N) is listed.

[0097] The measurement results are shown in Table 5. Also, a graph in which the ratio of the inorganic binder solid content to the organic binder solid content (inorganic binder mixing ratio) (%) is plotted on the horizontal axis and tensile strength is plotted on the vertical axis is shown in Figure 1. The appearance (photograph) of the test piece after measuring the tensile strength is shown in Figure 2. Note that the test piece of Example 1-1 after re-firing was divided into three pieces and partially collapsed, but this was because the tester broke one of the two pieces by hand to check the condition. The condition immediately after re-firing was the same as that of Examples 1-2 to 1-4.

[0098] [Table 5]

[0099] As shown in the above results, in Examples 1-1 to 1-5 in which an inorganic binder was blended with an organic binder, the shape of the test pieces was maintained after re-firing at 800° C. Furthermore, the tensile strength after re-firing increased as the inorganic binder mixing ratio increased.

[0100] <Test Example 2> (Preparation of Binder Composition) 100 parts of a saccharide-based binder (organic binder) calculated as solid content and 25 parts of an inorganic binder calculated as solid content were mixed and diluted with ion-exchanged water to obtain binder compositions of Examples 2-1 to 2-4. The inorganic binder was prepared by adding the amount of sodium sulfate shown in Table 6 calculated as solid content to 100 parts of a 36% aqueous solution of sodium dihydrogen phosphate calculated as solid content. The blending of the ion-exchanged water was set so that the overall solid content concentration after dilution would be 36%. Sodium sulfate manufactured by Kanto Chemical Co., Inc. was used. Separately, a binder composition of Comparative Example 1 was prepared in the same manner as in Test Example 1.

[0101] (evaluation) Each binder composition was evaluated in the same manner as in Test Example 1. However, re-firing was carried out at 550°C, 800°C, and 1100°C. The measurement results are shown in Table 6. In addition, a graph in which the ratio of sodium sulfate (solid content) to 100% sodium dihydrogen phosphate (solid content) (sodium sulfate mixing ratio) (%) is plotted on the horizontal axis and tensile strength is plotted on the vertical axis is shown in Figure 3. Figure 4 shows the appearance (photo) of the test piece after measuring the tensile strength.

[0102] [Table 6]

[0103] As shown in the above results, in Examples 2-1 to 2-4 in which an inorganic binder was mixed with an organic binder, the shape of the test pieces was maintained after re-firing at 550 to 1100°C. When the sodium sulfate content in the inorganic binder was 33.3%, the tensile strength after firing and re-firing was improved compared to when the sodium sulfate content was 0%. When the sodium sulfate content in the inorganic binder was 100%, the tensile strength after re-firing at 1100°C was improved compared to when the sodium sulfate content was 0%.

[0104] <Test Example 3> (Preparation of Binder Composition) The binder compositions of Examples 3-1 to 3-6 were prepared by mixing 100 parts, in solids equivalent, of a carbohydrate-based binder (organic binder), 25 parts, in solids equivalent, of an inorganic binder, and 1 part, in solids equivalent, of a silane coupling agent ("KBE-903" manufactured by Shin-Etsu Chemical Co., Ltd.), and diluting the mixture with ion-exchanged water. The inorganic binder was prepared by adding the amount of sodium sulfate, in solids equivalent, shown in Table 7, to 100 parts, in solids equivalent, of a 36% aqueous solution of sodium dihydrogen phosphate. The blending amount of ion-exchanged water was set so that the overall solids concentration after dilution would be 36%. Separately, 100 parts of a saccharide-based binder (organic binder) in terms of solid content and 1 part of a silane coupling agent ("KBE-903" manufactured by Shin-Etsu Chemical Co., Ltd.) in terms of solid content were mixed and diluted with ion-exchanged water to prepare a binder composition of Comparative Example 1. The blending amount of ion-exchanged water was set so that the total solid content concentration after dilution would be 36%.

[0105] (evaluation) Each binder composition was evaluated in the same manner as in Test Example 1, except that re-firing was carried out at 550°C. The measurement results are shown in Table 7. In addition, a graph in which the ratio of sodium sulfate (solid content) to 100% sodium dihydrogen phosphate (solid content) (sodium sulfate mixing ratio) (%) is plotted on the horizontal axis and tensile strength is plotted on the vertical axis is shown in Figure 5. Figure 6 shows the appearance (photo) of the test piece after measuring the tensile strength.

[0106] [Table 7]

[0107] As shown in the above results, in Examples 3-1 to 3-6 in which an inorganic binder was mixed with an organic binder, the shape of the test pieces was maintained after re-firing at 550°C. When the sodium sulfate content in the inorganic binder was 25%, the tensile strength at 200°C firing was improved compared to when the sodium sulfate content was 0%. When the sodium sulfate content in the inorganic binder was 42.9%, the strength after re-firing at 550°C was improved compared to when the sodium sulfate content was 0%.

[0108] <Test Example 4> (Preparation of Binder Composition) A binder composition of Comparative Example 1 was prepared in the same manner as in Test Example 1. The binder composition of Comparative Example 1 and a diluted solution of sodium dihydrogen phosphate diluted with pure water to a solid content of 36% were mixed in the solid content mass ratio shown in Table 8 to prepare the binder composition of Example 4-1. A binder composition of Comparative Example 4 was prepared by diluting phenol (PF) resin (PL-6757 manufactured by Gunei Chemical Industry Co., Ltd.) (organic binder) with pure water so that the total solid content after dilution was 36%. The binder composition of Comparative Example 4 and a diluted solution of sodium dihydrogen phosphate diluted with pure water to a solid content of 36% were mixed in the solid content mass ratio shown in Table 8 to prepare the binder composition of Example 4-2.

[0109] (evaluation) The binder composition was added to 150 g of substrate and mixed so that the solid content of the binder composition was 3%. Sand (Cerabeads manufactured by Itochu Ceratec Co., Ltd., average particle size 300 μm) was used as the substrate. The resulting mixture was uniformly filled into a dogbone-shaped mold (length 75 mm x width 25-42 mm x thickness 7 mm) to prepare a test piece. The test piece was fired at 200°C for 30 minutes to simulate the manufacturing process of a fire-resistant coating material, and then refired at 800°C for 30 minutes to simulate the outbreak of a fire. The tensile strength (N) of the test piece after baking at 200°C was measured, and this value was taken as the normal strength. Separately, the test piece after baking at 200°C was held in an environment of 60°C and 90% RH for 12 hours, and the tensile strength (N) was measured, and this value was taken as the moisture resistance strength. The tensile strength was measured at a loading rate of 5 mm / min. The tensile strength is generally calculated as the ratio of measured value (N) to fracture cross-sectional area 25 x 7 (mm 2 ) is calculated as follows (N / mm 2 ), but in this evaluation, the fracture cross section is 175 (mm 2 ), so only the measured value (N) is listed. Whether the test piece retained its shape after re-firing at 800°C was checked visually to evaluate heat resistance. The measurement results of normal strength and moisture resistance strength for each example are shown in Table 8. Also, Fig. 7 shows the appearance (photograph) of the test piece after re-firing at 800°C.

[0110] [Table 8]

[0111] As shown in the above results, in Examples 4-1 and 4-2 in which an inorganic binder was mixed with an organic binder, the shape of the test pieces was maintained after re-firing at 800°C. These results confirmed that inorganic binders contribute to improving shape retention in high-temperature environments, not only when the organic binder is a carbohydrate-based binder but also when it is a PF resin.

[0112] <Test Example 5> (Preparation of Binder Composition) A carbohydrate-based binder (organic binder) and sodium dihydrogen phosphate (inorganic binder) were each diluted with pure water to obtain a diluted solution with a solid content of 36%. Dilutions of the raw materials shown in Table 9 and the following aminosilane (silane coupling agent) were mixed in the solid content mass ratios shown in Table 9 to obtain binder compositions of Examples 5-1 and 5-2. Aminosilane: Shin-Etsu Chemical KBE-903, 3-aminopropyltriethoxysilane. Separately, a binder composition of Comparative Example 1 was prepared in the same manner as in Test Example 1.

[0113] (evaluation) Each binder composition was evaluated in the same manner as in Test Example 4. The measurement results of normal strength and moisture resistance strength for each example are shown in Table 9. Also, Fig. 8 shows the appearance (photograph) of the test piece after re-firing at 800°C.

[0114] [Table 9]

[0115] As shown in the above results, in Examples 5-1 and 5-2 in which an inorganic binder was mixed with an organic binder, the shape of the test pieces was maintained after re-firing at 800°C. Furthermore, in Example 5-2, in which a silane coupling agent was blended, the moisture resistance strength and normal strength after baking at 200°C were improved compared to Example 5-1, in which a silane coupling agent was not blended.

[0116] <Test Example 6> In this test, the binder composition was actually impregnated into inorganic fibers and its performance was evaluated.

[0117] (inorganic fiber) The following two types of rock wool were prepared as inorganic fibers. Rock wool (1): density 80 kg / m 3 , thickness 20mm. Rock wool (2): density 32 kg / m 3 , thickness 120mm. Table 10 shows the results of metal element analysis for each rock wool using an inductively coupled plasma (ICP) emission spectrometer. Each rock wool was used after being baked at 600°C for 30 minutes to remove the adhering binder.

[0118] [Table 10]

[0119] (Production of molded product 1) The following three types of binders were prepared: PF resin: Phenolic resin, PL-6757 manufactured by Gunei Chemical Industry Co., Ltd. Carbohydrate binder: Obtained in Production Example 1. High heat-resistant binder: The above-mentioned saccharide-based binder and sodium dihydrogen phosphate are mixed in a solid mass ratio of saccharide-based binder:sodium dihydrogen phosphate = 90:10.

[0120] Each binder was diluted with ion-exchanged water to a total solids content of 2% after dilution to obtain a diluted solution. Rock wool (1) was cut to a width of 100 mm, length of 100 mm, and thickness of 20 mm, and the diluted solution was uniformly impregnated while being compressed to a thickness of 10 mm so that the binder adhered at a rate of 2% in terms of solids content relative to the total mass of the rock wool (1). This was sandwiched between punching metal and subjected to moisture drying at 110°C for 1 hour. During this time, the material was turned over every 30 minutes. Subsequently, a molded product was produced by hot pressing at 200°C for 30 minutes to a thickness of 10 mm. The area A of the obtained molded product was calculated from the width and length dimensions. The molded product was then fired for 1 hour in an electric furnace whose temperature had been raised in advance to 1050° C. The area B was calculated from the width and length dimensions of the molded product after firing. The shrinkage rate was calculated by applying the area A of the molded product before firing and the area B of the molded product after firing to the following formula. The results are shown in Table 11 and Figure 9. Shrinkage rate (%) = {(AB) / A} x 100

[0121] [Table 11]

[0122] (Production of molded product 2) The following two types of binders were prepared: Carbohydrate binder: Obtained in Production Example 1. High heat-resistant binder: The above-mentioned saccharide-based binder and sodium dihydrogen phosphate are mixed in a solid mass ratio of saccharide-based binder:sodium dihydrogen phosphate = 90:10.

[0123] Each binder was diluted with ion-exchange water to a total solids content of 0.5% after dilution to obtain a diluted solution. Rock wool (2) was cut to a width of 120 mm, length of 120 mm, and thickness of 120 mm. The diluted solution was uniformly impregnated while being compressed to a thickness of 20 mm so that the binder adhered at a ratio of 4% in terms of solids content relative to the total mass of the rock wool (2). This was sandwiched between punching metal and subjected to moisture drying at 110°C for 1 hour. During this time, the material was turned over every 30 minutes. Subsequently, a molded product was produced by hot pressing at 200°C for 30 minutes to a thickness of 20 mm. The area A of the obtained molded product was calculated from the width and length dimensions. The molded product was then fired for 1 hour in an electric furnace whose temperature had been raised in advance to 1050° C. The area B was calculated from the width and length dimensions of the molded product after firing. The shrinkage rate was calculated by applying the area A of the molded product before firing and the area B of the molded product after firing to the above formula. The results are shown in Table 12 and Figure 10.

[0124] [Table 12]

[0125] As shown in the above results, the molded products of Examples 6-1 and 6-2, which used a binder in which an inorganic binder was mixed with an organic binder, had a lower shrinkage rate when fired at 1050°C and were superior in heat resistance compared to molded products that did not use a binder or molded products that used an organic binder (PF resin, carbohydrate-based binder) alone.

[0126] <Test Example 7> (Preparation of Binder Composition) A saccharide-based binder (organic binder), sodium dihydrogen phosphate (inorganic binder), and urea (compound (A)) were each diluted with pure water to obtain a diluted solution with a solid content of 36%. Dilutions of the raw materials shown in Table 13 were mixed in the solid content mass ratios shown in Table 13 to obtain binder compositions of Examples 7-1 to 7-4. Separately, a binder composition of Comparative Example 1 was prepared in the same manner as in Test Example 1.

[0127] (evaluation) Each binder composition was evaluated in the same manner as in Test Example 4. The measurement results of the normal strength and moisture resistance strength of each example are shown in Table 13 and Fig. 11. Fig. 11 also shows the appearance (photograph) of the test piece after re-firing at 800°C.

[0128] [Table 13]

[0129] As shown in the above results, in Examples 7-1 to 7-4 in which an inorganic binder was mixed with an organic binder, the shape of the test pieces was maintained after re-firing at 800°C. Furthermore, in Examples 7-2 to 7-4 in which urea was blended, the moisture resistance strength after baking at 200°C was improved compared to Example 7-1 in which urea was not blended.

[0130] <Test Example 8> (Preparation of Binder Composition) A carbohydrate-based binder (organic binder), sodium dihydrogen phosphate (inorganic binder), urea, ethylene urea, thiourea, and 1,3-dimethyl urea (compound (A)) were each diluted with pure water to obtain a diluted solution with a solid content of 36%. Dilutions of the raw materials shown in Table 14 were mixed in the solid content mass ratios shown in Table 14 to obtain binder compositions of Examples 8-1 to 8-5. Separately, a binder composition of Comparative Example 1 was prepared in the same manner as in Test Example 1.

[0131] (evaluation) Each binder composition was evaluated in the same manner as in Test Example 4. The measurement results of the normal strength and moisture resistance strength of each example are shown in Table 14 and Fig. 12. Fig. 12 also shows the appearance (photograph) of the test piece after re-firing at 800°C.

[0132] [Table 14]

[0133] As shown in the above results, in Examples 8-1 to 8-5 in which an inorganic binder was mixed with an organic binder, the shape of the test pieces was maintained after re-firing at 800°C. Furthermore, in Examples 8-2 to 8-5 in which compound (A) was blended, the moisture resistance strength after baking at 200° C. was improved compared to Example 8-1 in which compound (A) was not blended. Among Examples 8-2 to 8-5, Example 8-4, which used thiourea as the compound (A), had the best moisture resistance strength.

[0134] <Test Example 9> (Preparation of Binder Composition) A saccharide-based binder (organic binder), sodium dihydrogen phosphate (inorganic binder), and urea (compound (A)) were each diluted with pure water to obtain a diluted solution with a solid content of 36%. Dilutions of the raw materials shown in Table 15 and the following aminosilane (silane coupling agent) were mixed in the solid content mass ratios shown in Table 15 to obtain binder compositions of Examples 9-1 to 9-5. Aminosilane: Shin-Etsu Chemical KBE-903, 3-aminopropyltriethoxysilane. Separately, a binder composition of Comparative Example 1 was prepared in the same manner as in Test Example 1.

[0135] (evaluation) Each binder composition was evaluated in the same manner as in Test Example 4. The measurement results of the normal strength and moisture resistance strength of each example are shown in Table 15 and Fig. 13. Fig. 13 also shows the appearance (photograph) of the test piece after re-firing at 800°C.

[0136] [Table 15]

[0137] As shown in the above results, in Examples 9-1 to 9-5 in which an inorganic binder was mixed with an organic binder, the shape of the test pieces was maintained after re-firing at 800°C. Furthermore, in Examples 9-2 to 9-5, which contained compound (A), the moisture resistance strength and normal strength after firing at 200°C were improved compared to Example 9-1, which did not contain compound (A). Furthermore, in Examples 9-3 to 9-5, which contained a silane coupling agent, the moisture resistance strength and normal strength were improved compared to Example 9-2. In particular, Example 9-5 achieved a moisture resistance strength equivalent to that of Comparative Example 1, which did not contain an inorganic binder.

[0138] <Test Example 10> (Preparation of Binder Composition) A saccharide-based binder (organic binder), sodium dihydrogen phosphate (inorganic binder), urea, and ethylene urea (compound (A)) were each diluted with pure water to obtain a diluted solution with a solid content of 36%. Dilutions of the raw materials shown in Table 16, and the following aminosilane and epoxysilane (these are silane coupling agents) were mixed in the solid content mass ratios shown in Table 16 to obtain binder compositions of Examples 10-1 to 10-4. Aminosilane: Shin-Etsu Chemical KBE-903, 3-aminopropyltriethoxysilane. Epoxy silane: Shin-Etsu Chemical KBM-403, 3-glycidoxypropyltrimethoxysilane. Separately, a binder composition of Comparative Example 1 was prepared in the same manner as in Test Example 1.

[0139] (evaluation) Each binder composition was evaluated in the same manner as in Test Example 4. The measurement results of the normal strength and moisture resistance strength of each example are shown in Table 16. Also, Fig. 14 shows the appearance (photograph) of the test piece after re-firing at 800°C.

[0140] [Table 16]

[0141] As shown in the above results, in Examples 10-1 to 10-4 in which an inorganic binder was mixed with an organic binder, the shape of the test pieces was maintained after re-firing at 800°C. Furthermore, in Examples 10-2 to 10-4, in which compound (A) and a silane coupling agent were blended, the moisture resistance strength and normal strength after baking at 200°C were improved compared to Example 10-1, in which compound (A) and a silane coupling agent were not blended. Comparing Examples 10-2 and 10-3, Example 9-2 using aminosilane was superior to Example 10-3 using epoxysilane in terms of moisture resistance strength and normal strength. Comparing Examples 10-2 and 10-4, Example 10-4 using ethylene urea was superior to Example 10-2 using urea in terms of moisture resistance strength and normal strength.

Claims

1. Contains an organic binder and an inorganic binder, the organic binder is a thermoplastic organic binder or a thermosetting organic binder, the thermosetting organic binder contains at least one selected from the group consisting of saccharides, phenolic resins, urea resins, melamine resins, epoxy resins, polyurethane resins, resorcinol resins, unsaturated polyester resins, silicone resins, and polycarboxylic acid resins, the saccharide is at least one selected from the group consisting of monosaccharides, oligosaccharides, polysaccharides, sugar alcohols, glycosides, and modified starches, the inorganic binder is an inorganic compound that solidifies or condenses at a temperature equal to or higher than the thermal decomposition temperature of the organic binder, A binder composition for inorganic fiber products, in which the ratio of the inorganic content of the inorganic binder to 100% by mass of the organic content of the organic binder is 20.56 to 300% by mass (excluding cases in which a non-reducing oligosaccharide containing a maximum of 10 sugar units is contained and cases in which polyvinyl alcohol is contained).

2. 2. The binder composition for inorganic fiber products according to claim 1, wherein the organic binder is a thermosetting organic binder.

3. 3. The binder composition for inorganic fiber products according to claim 1, wherein the organic binder comprises at least one selected from the group consisting of the saccharide, a phenolic resin, and a polycarboxylic acid resin.

4. The binder composition for inorganic fiber products according to any one of claims 1 to 3, wherein the inorganic binder contains a phosphate of a metal selected from the group consisting of lithium, sodium, potassium, magnesium, calcium, barium, titanium, chromium, manganese, iron, copper, silver, zinc, and aluminum.

5. 5. The binder composition for inorganic fiber products according to claim 4, wherein said inorganic binder comprises said phosphate and said metal sulfate.

6. The binder composition for inorganic fiber products according to any one of claims 1 to 5, further comprising a silane coupling agent.

7. The binder comprises an organic binder, an inorganic binder, and a compound containing a carbamide group or a thiocarbamide group, the organic binder is a thermoplastic organic binder or a thermosetting organic binder, the thermosetting organic binder contains at least one selected from the group consisting of saccharides, phenolic resins, urea resins, melamine resins, epoxy resins, polyurethane resins, resorcinol resins, unsaturated polyester resins, silicone resins, and polycarboxylic acid resins, the saccharide is at least one selected from the group consisting of monosaccharides, oligosaccharides, polysaccharides, sugar alcohols, glycosides, and modified starches, the inorganic binder is an inorganic compound that solidifies or condenses at a temperature equal to or higher than the thermal decomposition temperature of the organic binder, A binder composition for inorganic fiber products, in which the ratio of the inorganic content of the inorganic binder to 100% by mass of the organic content of the organic binder is 20.56 to 300% by mass (excluding cases in which a non-reducing oligosaccharide containing a maximum of 10 sugar units is contained and cases in which polyvinyl alcohol is contained).

8. 8. The binder composition for inorganic fiber products according to claim 7, wherein the organic binder is a thermosetting organic binder.

9. 9. The binder composition for inorganic fiber products according to claim 7, wherein the organic binder comprises at least one selected from the group consisting of the saccharide, a phenolic resin, and a polycarboxylic acid resin.

10. The binder composition for inorganic fiber products according to any one of claims 7 to 9, wherein the inorganic binder contains a phosphate of a metal selected from the group consisting of lithium, sodium, potassium, magnesium, calcium, barium, titanium, chromium, manganese, iron, copper, silver, zinc, and aluminum.

11. 11. The inorganic fiber binder composition according to claim 10, wherein the inorganic binder comprises the phosphate and the metal sulfate.

12. The binder composition for inorganic fiber products according to any one of claims 7 to 11, wherein the carbamide group- or thiocarbamide group-containing compound comprises at least one selected from the group consisting of urea, ethylene urea, thiourea, (mono-, di-, tri-, or tetra-)methyl urea, (mono-, di-, tri-, or tetra-)hydroxymethyl urea, (mono-, di-, tri-, or tetra-)ethyl urea, (mono-, di-, tri-, or tetra-)hydroxyethyl urea, (mono-, di-, tri-, or tetra-)propyl urea, (mono-, di-, tri-, or tetra-)butyl urea, and biuret.

13. The binder composition for inorganic fiber products according to any one of claims 7 to 12, wherein the content of the carbamide group- or thiocarbamide group-containing compound is 0.1 to 100 mass% relative to 100 mass% of the solid content of the inorganic binder.

14. The binder composition for inorganic fiber products according to any one of claims 7 to 13, further comprising a silane coupling agent.

15. The binder composition for inorganic fiber products according to claim 14, wherein the content of the silane coupling agent is 0.1 to 100 mass% relative to 100 mass% of the total of the solid content of the organic binder, the solid content of the inorganic binder, and the carbamide group- or thiocarbamide group-containing compound.

16. An inorganic fiber product comprising inorganic fibers and the binder composition for inorganic fiber products according to any one of claims 1 to 6, and a molded body in which the inorganic fibers are bound by the organic binder.

17. The inorganic fiber product according to claim 16, wherein the molded body is a cotton-like body.

18. The inorganic fiber product according to claim 16 or 17, which is a fire-resistant coating material.

19. The inorganic fiber product according to claim 16 or 17, which is a thermal insulating material.

20. An inorganic fiber product comprising inorganic fibers and the binder composition for inorganic fiber products according to any one of claims 7 to 15, and comprising a molded body in which the inorganic fibers are bound by the organic binder.

21. The inorganic fiber product according to claim 20, wherein the molded body is a cotton-like body.

22. The inorganic fiber product according to claim 20 or 21, which is a fire-resistant coating material.

23. The inorganic fiber product according to claim 20 or 21, which is a thermal insulating material.

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