Fibrous material bound using an aqueous binder composition

Abstract

The present invention relates to an inorganic fibrous material bound using an aqueous binder composition. The aqueous binder composition contains a bio-derived raw material, a coupling agent, and a water repellent, and contains 7.0 to 9.0% by weight of the solid content of the aqueous binder composition with respect to the total weight of the bound inorganic fibrous material, and has a density of 48 kg / m 3 The compression ratio of the inorganic fibrous material against a 30 kgf load is 20% or less, and the density is 64 kg / m 3 The compression ratio of the inorganic fibrous material against a 30 kgf load is 10% or less. When the inorganic fibrous material is placed in a heating furnace at 750 °C and heated, the maximum temperature of the heating furnace does not rise more than 20 °C above the final equilibrium temperature, and the mass reduction rate after heating is 30% or less.

Description

Technical Field

[0001] The present invention relates to a fibrous material bound using an aqueous binder composition that does not use toxic substances such as formaldehyde, is less harmful to the human body, is environmentally friendly, and has excellent mechanical properties and incombustibility of cured products to be manufactured hereafter.

Background Art

[0002] Phenol-formaldehyde resin is widely used as a binder for fibrous materials such as glass wool and rock wool because of its low price and excellent physical properties. However, phenol-formaldehyde resin has a problem of releasing formaldehyde, which is a toxic substance, into the surrounding environment during processing, storage, and curing. Formaldehyde has a bad odor and is known to cause various diseases when exposed to the human body. In addition, unreacted phenol may remain in the phenol-formaldehyde resin and leak into the surrounding environment, and such phenol is also known as a toxic substance.

[0003] As an alternative to this, U.S. Registered Patent No. 7,854,980 (Patent Document 1) discloses a mineral fiber insulating material containing mineral fibers and an organic binder, and the organic binder does not contain formaldehyde. However, compared with a cured product produced from a binder containing phenol-formaldehyde resin, the cured product of Patent Document 1 has low mechanical properties, so there are limitations in applicable fields.

[0004] In addition, U.S. Patent No. 5,538,761 (Patent Document 2) discloses a method for producing a phenol-formaldehyde binder-treated fiberglass including a step of adjusting the pH to less than 5.5 using an acidifying agent selected from the group consisting of an acid hydrolysis salt, an inorganic acid, a monomeric carboxylic acid, an ester of a di- or poly-carboxylic acid, and mixtures thereof. However, controlling the formaldehyde emission using an acidifying agent as in Patent Document 2 has limitations. The acidified binder including the acidifying agent as described above lacks stability, has poor storability, and may cause equipment corrosion.

[0005] Therefore, there is a need for research and development on fibrous materials bound using an aqueous binder composition that does not use toxic substances such as formaldehyde, is less harmful to the human body, is environmentally friendly, and has excellent mechanical properties and nonflammability of the cured product produced.

Prior Art Documents

Patent Documents

[0006]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0007] The present invention aims to provide a fibrous material bound using a formaldehyde-free aqueous binder composition that does not use toxic substances such as formaldehyde, is less harmful to the human body, is environmentally friendly, and has excellent mechanical properties and nonflammability of the cured product produced.

Means for Solving the Problems

[0008] In one aspect, the present invention relates to an inorganic fibrous material bound using an aqueous binder composition, the aqueous binder composition comprising a bio-derived raw material, a coupling agent, and a water repellent, and containing 7.0 to 9.0% by weight of the solid content of the aqueous binder composition based on the total weight of the bound inorganic fibrous material, and having a density of 48 kg / m 3 The compression ratio of the inorganic fibrous material having a density of 64 kg / m 3 is 10% or less with respect to a 30 kgf load, and when the inorganic fibrous material is placed in a heating furnace at 750 °C and heated, the maximum temperature of the heating furnace does not rise more than 20 °C above the final equilibrium temperature, and the mass reduction rate after heating is 30% or less. An inorganic fibrous material can be provided.

Advantages of the Invention

[0009] The fibrous material bound using the aqueous binder composition according to the present invention does not use formaldehyde, is environmentally friendly, and has low harm to the human body. In addition, since it has excellent mechanical properties such as water resistance, cuttability, compressive strength, and weather resistance, it is similar to or has better mechanical properties than the fibrous material bound with the conventional phenol-formaldehyde resin. Further, the fibrous material is excellent in nonflammability, water immersion property, and moldability, and has a low dust rate, so it can be applied to various fields.

Embodiments for Carrying Out the Invention

[0010] Hereinafter, the present invention will be described in detail.

[0011] In the present invention, the "weight average molecular weight" of the resin can be measured by a method well known in the art. For example, a value measured by the method of GPC (gel permeation chromatograph) may be shown.

[0012] Aqueous binder composition The aqueous binder composition according to the present invention may contain a bio-derived raw material, a coupling agent, and a water repellent. The bio-derived raw material may contain a reducing sugar and an amino acid. The aqueous binder composition may contain a first reinforcing agent and a second reinforcing agent.

[0013] In the present invention, curing is carried out by the Maillard reaction between a reducing sugar and an amino acid. In this process, the hydroxyl group of the first reinforcing agent and the amine group of the second reinforcing agent participate in the reaction. Further, compared with a composition composed of only a conventional reducing sugar and / or an amino acid, excellent strength and weather resistance can be achieved by the reaction between the first reinforcing agent and the second reinforcing agent, or the self-reaction of each of the first reinforcing agent and the second reinforcing agent.

[0014] Reducing sugar The reducing sugar is the main raw material of the aqueous binder composition and serves to impart adhesiveness and mechanical physical properties to the composition.

[0015] The reducing sugar includes aldoses or ketose sugars that have an aldehyde or can have an aldehyde structure by isomerization, and examples thereof include monosaccharides, disaccharides, or mixtures thereof. Specifically, the reducing sugar includes, but is not limited to, glucose, maltose, fructose, galactose, lactose, cellobiose, gentiobiose, rutinose, glyceraldehyde, etc., or hydrates thereof.

[0016] The reducing sugar may have a solid content (NV) of 85 to 97% by weight or 87 to 95% by weight based on the total weight of the reducing sugar. When the solid content of the reducing sugar is within the above range, the product has excellent strength and workability due to the appropriate reducing sugar content in the aqueous binder composition. When the solid content of the reducing sugar is less than the above range, there is a problem that the viscosity becomes excessively low and the workability of the aqueous binder composition containing the same deteriorates. When it exceeds the above range, the viscosity of the reducing sugar becomes excessively high, the stability during the reaction decreases, and the mechanical physical properties of the product may decrease due to a decrease in the curing density.

[0017] Reducing sugars may be included in the composition at a content of 2 to 10% by weight or 3 to 8% by weight based on the total weight of the aqueous binder composition. If the content of reducing sugars is less than the above range, the strength of the fibrous material formed from the aqueous binder composition may decrease. If it exceeds the above range, the stability of the aqueous binder composition and the binding force of the fibrous material may decrease, or the non-combustible performance may decrease.

[0018] Amino acid Amino acids are the main resin of the aqueous binder composition and play a role in imparting adhesiveness and mechanical properties to the composition.

[0019] The amino acid may be a compound containing at least one amino group and at least one carboxyl group in one molecule. For example, the amino acid may be an amino acid such as glycine, alanine, valine, leucine, isoleucine, threonine, serine, cysteine, methionine, aspartic acid, asparagine, glutamic acid, diiodotyrosine, lysine, arginine, histidine, phenylalanine, tyrosine, tryptophan, proline, hydroxyproline, glutamine, or sulfates thereof, etc., but is not limited thereto.

[0020] The solid content (NV) of the amino acid may be 87 to 100% by weight or 90 to 100% by weight based on the total weight of the amino acid. When the solid content of the amino acid is within the above range, the storage stability of the amino acid and the storage stability of the aqueous binder composition are improved, and the product has excellent strength. When the solid content of the amino acid is less than the above range, there is a problem that the viscosity becomes excessively low and the workability of the aqueous binder composition containing it deteriorates, and there may be a problem that the product strength decreases due to a decrease in the curing density.

[0021] The amino acid may be included in the composition at a content of 1 to 5% by weight or 1.5 to 3% by weight based on the total weight of the aqueous binder composition. If the content of the amino acid is less than the above range, the stability of the aqueous binder composition, the binding force of the fibrous material, and the strength of the product may decrease. If it exceeds the above range, the strength and non-combustibility performance of the fibrous material formed from the aqueous binder composition may decrease.

[0022] First reinforcing agent The first reinforcing agent plays a role in improving the strength of the produced cured product.

[0023] The first reinforcing agent is a polymer resin containing a hydroxyl group. When a hydroxyl group-containing polymer resin is used as the first reinforcing agent, it has the effect of improving the strength of the fibrous material bound after curing.

[0024] Specifically, when a resin that contains a hydroxyl group and is a polymer is included in the aqueous binder composition as a strength reinforcing agent, the product strength can be greatly improved at the same binder content. More specifically, when a polymer resin containing a hydroxyl group is used as the strength reinforcing agent, it has good water resistance and the effect of greatly improving the product strength. This can achieve the improvement of non-combustibility performance and the reduction of formaldehyde emission by reducing the content of the organic binder in the production of products with the same strength.

[0025] On the other hand, when a hydroxyl group-containing monomer molecule that is not a polymer is used as the strength reinforcing agent, not only is the product strength effect minimal, but also the problem of decreased water resistance occurs.

[0026] For example, the first reinforcing agent may contain a repeating unit represented by the following Chemical Formula 1, and the first reinforcing agent can be obtained from a radical or condensation reaction, or a natural extract.

[0027] [Chemical Formula 1] [Chem.]

[0028] In the above Chemical Formula 1, n + m may be an integer from 100 to 5,000. Specifically, n + m may be an integer from 300 to 3,000, or an integer from 400 to 2,000.

[0029] More specifically, n / (n + m) may be from 0.75 to 0.97 or from 0.8 to 0.92.

[0030] When the strength reinforcing agent has n / (n + m) within the above range in Chemical Formula 1, the solubility of the composition is improved, the product has excellent non-combustion performance, and the strength of the product can be improved. In contrast, when the strength reinforcing agent has n / (n + m) less than the above range in Chemical Formula 1, the strength improvement effect is negligible. When n / (n + m) in Chemical Formula 1 exceeds the above range, the solubility of the composition decreases, and the stability of the aqueous binder composition and the mechanical properties of the product deteriorate, making it difficult to apply to the inorganic fiber binder.

[0031] The first reinforcing agent may be a resin having a weight average molecular weight (Mw) of 5,000 to 200,000 g / mol, or 10,000 to 100,000 g / mol. When the weight average molecular weight of the first reinforcing agent is within the above range, the strength of the bound fibrous material is improved. In contrast, when the weight average molecular weight of the first reinforcing agent is less than the above range, the strength improvement effect of the produced cured product is negligible. When the weight average molecular weight exceeds the above range, the viscosity of the aqueous binder composition containing this increases significantly, making it difficult to apply to the fibrous material binder.

[0032] The solid content (NV) of the first reinforcing agent may be 15 to 25% by weight or 17 to 23% by weight based on the total weight of the first reinforcing agent. When the solid content of the first reinforcing agent is within the above range, the storage stability of the first reinforcing agent and the storage stability of the aqueous binder composition can be improved, and the strength reinforcement effect can be enhanced. When the solid content of the first reinforcing agent is less than the above range, there is a problem that the strength reinforcement effect decreases. When it exceeds the above range, the viscosity of the first reinforcing agent becomes excessively high, the stability during the reaction decreases, and there may be a problem that the water resistance decreases.

[0033] Also, the first reinforcing agent may be included in the composition at a content of 1 to 5% by weight or 2 to 4% by weight based on the total weight of the aqueous binder composition. When the content of the first reinforcing agent is within the above range, the storage stability of the first reinforcing agent and the storage stability of the aqueous binder composition can be improved, and the strength reinforcement effect can be enhanced. When the content of the first reinforcing agent is less than the above range, there is a problem that the strength reinforcement effect decreases. When it exceeds the above range, there may be a problem that the viscosity of the composition increases or the water resistance deteriorates.

[0034] Second reinforcing agent The second reinforcing agent plays a role in improving the strength of the produced cured product.

[0035] The second reinforcing agent is a polyamide-based resin. When a polyamide-based resin is used as the second reinforcing agent, it has the effect of improving the strength while ensuring the water resistance of the bound fibrous material. This is the result of improving the water resistance of the bound fibrous material by the reaction of the second reinforcing agent with the hydroxyl groups of the first reinforcing agent or reducing sugar in the binder, or the self-reaction of the second reinforcing agent.

[0036] The second reinforcing agent may be directly synthesized by a known method or a commercially available product may be used. For example, the second reinforcing agent may contain a repeating unit represented by the following Chemical Formula 2, and the second reinforcing agent can be produced from a first monomer containing an amine group, a second monomer containing a carboxy group, and a third monomer containing an epoxy group.

[0037] [Chemical Formula 2] [Chemical Structure]

[0038] In the Chemical Formula 2 R 1 、R 2 、R 3 are a substituted or unsubstituted aliphatic hydrocarbon group having 1 to 12 carbon atoms.

[0039] At this time, "substituted" means that a hydrogen atom bonded to a carbon atom of the compound is replaced by another organic group, and the position where substitution occurs is not limited as long as it is the position where the hydrogen atom is substituted, that is, the position where the organic group can be substituted, and the number of substituents is also not limited.

[0040] At this time, the first monomer containing an amine group may be, for example, a monomer containing 3 or more amine groups per molecule. Specifically, the first monomer containing an amine group includes N-(2-aminoethyl)-1,2-ethanediamine, diethylenetriamine, triethylenetetramine, N-(3-aminopropyl)-1,4-diaminobutane (1,8-diamino-4-azaoctane), etc.

[0041] Further, the carboxy group-containing second monomer may be, for example, a monomer containing one or more carboxy groups or two or more carboxy groups per molecule. Specifically, examples of the carboxy group-containing second monomer include adipic acid, dodecanedicarboxylic acid, isophthalic acid, and terephthalic acid, and esters and anhydrides of carboxylic acids as described above.

[0042] The epoxy group-containing third monomer may be, for example, a monomer containing one or more epoxy groups or one or more glycidyl groups per molecule. Specifically, the epoxy group-containing third monomer may be epichlorohydrin.

[0043] For example, the second reinforcing agent may be an epoxidized polyamide obtained by neutralizing a polyamido-amine obtained by polymerizing diethylenetriamine and adipic acid with epichlorohydrin, that is, polyamidoamine-epichlorohydrin (PAE). Further, the second reinforcing agent may be a water-solubilized polyamido-amine.

[0044] The second reinforcing agent may have a solid content (NV) of 10 to 20% by weight or 8 to 15% by weight based on the total weight of the second reinforcing agent.

[0045] When the solid content of the second reinforcing agent is within the above range, the storage stability and strength reinforcing effect of the second reinforcing agent can be improved. When the solid content of the second reinforcing agent is less than the above range, there is a problem that the strength reinforcing effect is reduced. When it exceeds the above range, the viscosity of the second reinforcing agent becomes excessively high, the stability during the reaction is reduced, and there is a possibility that the water resistance is reduced.

[0046] The second reinforcing agent may be included in the composition at a content of 2 to 8% by weight or 3 to 7% by weight based on the total weight of the aqueous binder composition. When the content of the second reinforcing agent is within the above range, the storage stability of the second reinforcing agent and the aqueous binder composition can be improved, and the strength reinforcing effect can be enhanced.

[0047] When the content of the second reinforcing agent is less than the above range, the strength reinforcing effect decreases. When it exceeds the above range, since the strength improvement effect with respect to the input amount is negligible, there is a problem of reduced economy.

[0048] The first reinforcing agent and the following second reinforcing agent may be included at a weight ratio of 1:0.5 to 1:3.0, or 1:1 to 1:2. When it is less than the above range, there is a problem that the strength reinforcing effect decreases and the water resistance deteriorates. When it exceeds the above range, there is a problem that the strength reinforcing effect decreases.

[0049] The total amount of the first reinforcing agent and the following second reinforcing agent may be included at a content of 3 to 13% by weight, 4 to 12% by weight, or 5 to 10% by weight based on the total weight of the aqueous binder composition. When the total amount of the first reinforcing agent and the second reinforcing agent is less than the above range due to the reaction between the hydroxyl group of the first reinforcing agent and the second reinforcing agent, or the reaction and self-reaction of the first reinforcing agent and the second reinforcing agent with reducing sugar / amino acid, there is a problem that the strength reinforcing effect decreases. When it exceeds the above range, there may be a problem that the viscosity of the composition increases or the water resistance deteriorates.

[0050] Additive The aqueous binder composition may further include one or more additives selected from the group consisting of a condensation catalyst, a pH adjuster, a coupling agent, a dustproof agent, and a water repellent.

[0051] The additive may be included in the composition at a content of 0.5 to 6% by weight or 0.7 to 5% by weight based on the total weight of the aqueous binder composition.

[0052] The condensation catalyst serves to promote the condensation reaction within the aqueous binder composition. The condensation catalyst may generally be used without special limitation as long as it can be used in the aqueous binder composition. For example, it may include aluminum ammonium sulfate, ammonium sulfonate, ammonium paratoluenesulfonate, ammonium citrate, and the like.

[0053] The pH adjuster serves to adjust and neutralize the pH of the binder. The pH adjuster may generally be used without special limitation as long as it can be used in the aqueous binder composition. For example, it may include ammonia, sodium hydroxide, potassium hydroxide, sodium carbonate, potassium carbonate, silane, amino alcohol, polyamine, and the like.

[0054] The coupling agent serves to enhance the interfacial adhesion force between the fibrous material and the aqueous binder composition. The coupling agent may generally be used without special limitation as long as it can be used in the aqueous binder composition. For example, it may be an organosilicon compound. The organosilicon compound may, for example, be an aminosilane-based compound.

[0055] The dust-proof agent serves to reduce the dust generation rate of the product. At this time, as the dust-proof agent, it may generally be used without special limitation as long as it can be used in the aqueous binder composition. For example, it may include dust-proof oil and the like.

[0056] The water-repellent agent serves to enhance the water resistance of the fiber material. The water-repellent agent may generally be used without special limitation as long as it can be used in the aqueous binder composition. For example, it may include silicone emulsion and the like.

[0057] Solvent The solvent plays a role in adjusting the viscosity and drying property of the composition. At this time, the solvent may be water, for example, deionized water, pure water, ultrapure water, distilled water, and recycled process water after use, etc. Further, the solvent may be contained in the composition at a content of 70 to 90% by weight or 73 to 87% by weight based on the total weight of the aqueous binder composition.

[0058] The aqueous binder composition according to the present invention as described above has a formaldehyde emission amount of 0.008 mg / m 3 ·hr or less, so it is environmentally friendly and has low harm to the human body.

[0059] Fibrous material The fibrous material according to the present invention is bound using the aqueous binder composition as described above. That is, the fibrous material may include an aqueous binder composition and a raw material fibrous material.

[0060] At this time, the raw material fibrous material (that is, the fibrous material to be bound) includes, but is not limited to, inorganic fibers (for example, rock wool, glass wool, ceramic fibers, etc.) or organic fibers such as natural and synthetic resins. Further, the raw material fibrous material may be short fibers or medium fibers.

[0061] Further, the fibrous material may be one obtained by spraying or applying an aqueous binder composition to a raw material fibrous material and then thermosetting the aqueous binder composition to bind it. At this time, the thermosetting may be performed at 120°C or higher, 120 to 300°C, or 150 to 250°C. If the heat treatment temperature is too low, uncuring occurs and the curing time becomes long, resulting in a problem of reduced productivity. Also, if the heat treatment temperature is too high, binder decomposition occurs during the curing process, the tensile physical properties are very reduced, and it causes carbonization and dust generation.

[0062] The fibrous material may have a volatile organic compound emission amount of 0.008 mg / m 3 ·hr or less as measured by the small chamber method described in KS M ISO 16000-9.

[0063] The fibrous material according to the present invention as described above is excellent in water resistance, cuttability, water wettability, compressive strength, weather resistance, formability, and non-combustibility performance, has a low dust rate, and emits a small amount of volatile organic compounds such as formaldehyde, so it is environmentally friendly and has low toxicity.

[0064] On the other hand, in one specific example of the present invention, the inorganic fibrous material according to the present invention may contain a solid content of an aqueous binder composition of 7.0 to 9.0% by weight, 7.0 to 8.5% by weight, 7.5 to 9.0% by weight, or 7.5 to 8.5% by weight based on the total weight of the bundled inorganic fibrous material.

[0065] Specifically, the content of the aqueous binder composition in the bundled inorganic fibrous material is, for example, by manufacturing a test piece of the fibrous material in a first unit volume (150 mm in width × 150 mm in length × 100 mm in thickness), heat-treating three or more test pieces in an oven at 480°C for 2 hours, measuring the weight of the fibrous material before and after the heat treatment, and taking the average of the values calculated by the following formula.

[0066]

Equation

[0067] For example, the fibrous material with a density of 48 kg / m 3 may contain a solid content of an aqueous binder composition of 7.5 to 9.0% by weight, 7.5 to 8.5% by weight, or 7.5 to 8.0% by weight based on the total weight of the bundled inorganic fibrous material. In another example, the fibrous material with a density of 64 kg / m 3The fibrous material may contain 7.0 to 8.5% by weight, 7.0 to 8.0% by weight, or 7.0 to 7.5% by weight of the solid content of the aqueous binder composition based on the total weight of the bundled inorganic fibrous material. Under the content condition of the aqueous binder composition within the above range, the fibrous material exhibits excellent mechanical strength such as compressibility and self-supporting degree and satisfies the non-combustible performance. When the content of the aqueous binder composition is less than the above range, the absorption amount increases due to the decrease in the strength reinforcement effect of the product, resulting in a decrease in water resistance. When it exceeds the above range, there is a problem that the non-combustible performance decreases due to the increase in the content of the organic binder.

[0068] Also, in another specific example, when the inorganic fibrous material with a density of 48 kg / m 3 is compressed under a load of 30 kgf, the compressibility may be 20% or less, and when the inorganic fibrous material with a density of 64 kg / m 3 is compressed under a load of 30 kgf, the compressibility may be 10% or less.

[0069] Specifically, for the fibrous material of the present invention, test pieces with an average density of 48 kg / m 3 or 64 kg / m 3 are manufactured, for example, in a second unit volume (250 mm in width × 250 mm in length × 100 mm in thickness), and the average thickness reduction rate, that is, the compressibility, measured by pressing with a 30 kgf load can satisfy 20% or less and 10% or less respectively.

[0070] Under the compressibility condition within the above range, the fibrous material exhibits excellent mechanical strength and satisfies the non-combustible performance. When the compressibility of the fibrous material exceeds the above range, problems occur such as an increase in the absorption amount due to a decrease in product strength, a decrease in water resistance, an increase in the dust rate during cutting work, and a decrease in workability and processability.

[0071] In another specific example of the present invention, when the inorganic fibrous material according to the present invention is placed in a heating furnace at 750 °C and heated, the maximum temperature of the heating furnace does not rise more than 20 °C above the final equilibrium temperature, and the mass reduction rate after heating can be 30% or less.

[0072] Specifically, when a cylindrical third unit volume (diameter 45 mm × height 50 mm) fibrous material is placed in a heating furnace at 750°C and heated, the temperature in the heating furnace rises due to the combustion of the aqueous binder composition. At this time, the maximum temperature reached does not rise more than 20°C above the final equilibrium temperature, and the mass reduction rate of the test piece measured after the test can be 30% or less compared to the initial test piece mass before the test.

[0073] Under the mass reduction rate condition within the above range, the fibrous material exhibits excellent mechanical strength such as compressibility and self-supporting degree and satisfies the non-combustible performance. When the mass reduction rate exceeds the above range, there may be a problem of deterioration of non-combustible performance due to an increase in the content of the organic binder.

[0074] Hereinafter, the present invention will be described more specifically through examples. However, these examples are for facilitating the understanding of the present invention, and in no way is the scope of the present invention limited by these examples.

[0075] [Examples] Example 1. Production of an aqueous binder composition 5.07 kg of glucose hydrate (solid content: 91% by weight) as a reducing sugar, 1.63 kg of lysine sulfate (solid content: 100% by weight) as an amino acid, 0.05 kg of aluminum ammonium sulfate as a condensation catalyst (solid content: 52.4% by weight), 3.51 kg of the first reinforcing agent -1 (Mw: 24,000 g / mol, solid content: 20% by weight, n + m: 550, n / (n + m): 0.85 in Chemical Formula 1), 5.34 kg of polyamidoamine - epichlorohydrin (FINEX 323, Taegwang Chemicals Co., Ltd.) as the second reinforcing agent (solid content: 12.5% by weight), 0.02 kg of (3 - aminopropyl)triethoxysilane as a coupling agent (solid content: 99% by weight), 0.72 kg of anti - vibration oil (TC - 97A of Time Chemicals, solid content: 50% by weight), 0.1 kg of silicone emulsion (SI1479Z of KCC, solid content: 40% by weight) as a water - repellent agent and 83 kg of water were charged into a reaction vessel and stirred for 30 minutes. Thereafter, the pH was adjusted to 7 - 8 using 0.56 kg of aqueous ammonia (solid content: 9.0% by weight), and stirring was continued for an additional 10 minutes to produce an aqueous binder composition.

[0076] Examples 2 to 10 and Comparative Examples 1 to 10 An aqueous binder composition was produced in the same manner as in Example 1, except that the content of each component described in Tables 1 and 2 was used.

[0077] [Table 1]

[0078] [Table 2]

[0079] The physical properties of the strength reinforcing agents used in the examples and comparative examples are shown in Table 3 below.

[0080] [Table 3]

[0081] Experimental Example. Binding of fibrous materials using an aqueous binder composition For fibrous materials with a density of 64 kg / m 3 and fibrous materials with a density of 48 kg / m 3 To produce the fibrous materials, the following steps were carried out respectively.

[0082] While passing high-temperature water glass through a spinneret and fiberizing it at a rate of 4,100 kg per hour, the aqueous binder compositions of the examples and comparative examples were injected onto the glass fibers descending into the fiber collecting chamber at a rate of 75 L / min. After passing through a drying process, glass materials with densities of 64 kg / m 3 and 48 kg / m 3 were obtained respectively.

[0083] Thereafter, the physical properties were measured by the following method. The results for the fibrous material with a density of 64 kg / m 3 are shown in Table 4, and the results for the fibrous material with a density of 48 kg / m 3 are shown in Table 5.

[0084] (1) Binder content To measure the binder content in the test piece, test pieces with dimensions of 150 mm (width) × 150 mm (length) × 100 mm (thickness) were prepared. After measuring the initial weight of the test piece, three or more test pieces were heat-treated in an oven at 480 °C for 2 hours. Then, after measuring the weight of the test piece, the weight change rate was calculated based on the initial weight of the test piece to obtain the binder content. The binder content is the solid content of the aqueous binder composition in the test piece, which is the bound fibrous material. Since the binder in the test piece is flammable, it can affect the non-flammability of the test piece.

[0085] (2) Compression ratio After binding a test piece with dimensions of 250 mm (width) × 250 mm (length) × 100 mm (thickness) to the jig for compression rate measurement, it is positioned at the center of a universal testing machine. Thereafter, the displacement compressed under a load of 30 kgf is measured, and the compression rate is measured using three test pieces each in the examples and comparative examples, and the arithmetic mean value is calculated. At this time, the compression rate is calculated by the following formula 1.

[0086] [Formula 1] Compression rate (%) = [(Initial thickness - Compression displacement) / Initial thickness] × 100

[0087] (3) Mass reduction rate After preparing a test piece with dimensions of 45 mm (diameter) × 50 mm (height), the reduction rate of the mass of the test piece measured after the test compared to the initial test piece mass before the test was calculated in a heating furnace at 750 °C where the maximum temperature reached did not rise more than 20 °C above the final equilibrium temperature.

[0088] (4) Absorption amount The glass material was cut into a size of 254 mm × 254 mm (width × length) to prepare three samples, and the weight (W1) was accurately measured up to 0.01 g. Thereafter, the water tank was filled with normal temperature water from the bottom to 10 steps (30 mm per step), and after placing the test piece, the screen (square mesh wire net) was fixed so as to be positioned at 7 steps from the bottom. Thereafter, the sample was placed in the water tank on the screen so as not to float, and absorbed for 15 minutes. After 15 minutes, the sample was taken out, held at a corner with a fingertip, and held vertically for 150 ± 5 seconds so that water droplets would fall. Thereafter, the sample was placed on a pre-weighed silver foil dish (W2), the weight was accurately measured up to 0.01 g, and the average value (W3) of the three samples was calculated. Thereafter, the absorption amount was calculated by the following mathematical formula 2.

[0089] [Formula 2] Absorption amount (kg / m 2 ) = [(W3 - W2 - W1] × 15.5 (m 2 Area conversion index)

[0090] (5) Formaldehyde emission amount After placing a test piece of 100 mm (width) × 100 mm (length) × 50 mm (thickness) in a small chamber according to the small chamber method specified in KS M ISO 16000 and KS M 1998, the chamber air on the 7th day was collected, and the collected air was analyzed by HPLC (High Performance Liquid Chromatography) to measure the formaldehyde emission. The specific test method followed the method set by the Air Cleaning Association.

[0091] (6) Dust ratio Four pieces of glass material were cut and made into samples with a size of 150 mm (width) × 100 mm (length). After weighing the initial weight of the samples, they were placed in a dust ratio measuring instrument and shaken back and forth, left and right at a speed of 1 m / min. The total measurement time was 10 minutes per sample. After the tester automatically stopped, the weight of the sample (weight after dust) was measured. At this time, the dust ratio was calculated by the following formula 3, and the average value of the four samples was used as the dust ratio.

[0092] [Formula 3] Dust ratio = [(weight after dust / initial weight) - 1] × 100

[0093] (7) Non-combustible performance The non-combustibility test for the presence or absence of non-combustible and semi-non-combustible properties of the manufactured test pieces of 45 mm (diameter) × 50 mm (height) was measured by the method specified in KS F ISO 1182. Specifically, the non-combustible performance can be quantified by the degree of temperature rise in the heating furnace. In particular, when the temperature in the heating furnace at 750 °C did not rise by more than 20 °C from the equilibrium temperature, it was evaluated as "qualified".

[0094] (7) Cutability When cutting the glass material using a cutting machine, the cutability was evaluated by observing the appearance such as the fluff in the cut surface. At this time, the closer the cutability was to 0, the more fluff was generated on the cut surface and the appearance was poor. The closer it was to 5, the less fluff was in the cut surface and it was judged that the cutability was excellent.

[0095] <Table 4: Results for fibrous materials with a density of 64 kg / m 3 >

Table 4

[0096] <Table 5: Results for fibrous materials with a density of 48 kg / m 3 >

Table 5

[0097] As shown in Tables 4 and 5, the fibrous materials bound with the compositions of the examples were incombustible, had excellent water resistance with low absorption, excellent cutting processability, low compression rate, low dust rate, and low formaldehyde emission. Comparative Examples 1, 3, 5, and 7 containing an aqueous binder composition in excess of the content lacked the incombustible performance of the fibrous materials produced due to the flammability of the aqueous binder composition. Comparative Examples 2, 4, 6, and 8 containing an aqueous binder composition less than the content were insufficient in absorption, dust rate, and cutting processability.

[0098] Comparative Examples 2 and 4 containing a small amount of strength reinforcing agent were particularly lacking in absorption, dust rate, and cutting processability.

[0099] Hereinafter, various embodiments of the present invention will be described.

[0100] (1) In an inorganic fibrous material bound using an aqueous binder composition, the aqueous binder composition contains a bio-derived raw material, a coupling agent, and a water repellent, and contains a solid content of the aqueous binder composition of 7.0 to 9.0% by weight based on the total weight of the bound inorganic fibrous material, and the compression rate of the inorganic fibrous material with a density of 48 kg / m 3 against a 30 kgf load is 20% or less, and the compression rate of the inorganic fibrous material with a density of 64 kg / m 3 against a 30 kgf load is 10% or less. When the inorganic fibrous material is placed in a heating furnace at 750 °C and heated, the maximum temperature of the heating furnace does not rise more than 20 °C above the final equilibrium temperature, and the mass reduction rate after heating is 30% or less. Inorganic fibrous material.

[0101] (2) With a density of 48 kg / m3 The fibrous material contains 7.5 to 9.0% by weight of the solid content of the aqueous binder composition based on the total weight of the bundled inorganic fibrous material, and has a density of 64 kg / m 3 The fibrous material is an inorganic fibrous material containing 7.0 to 8.5% by weight of the solid content of the aqueous binder composition based on the total weight of the bundled inorganic fibrous material.

[0102] (3) The inorganic fibrous material, wherein the aqueous binder composition further contains a first reinforcing agent containing a repeating unit represented by the following Chemical Formula 1: [Chemical Formula 1] [Chemical Structure]

[0103] In Chemical Formula 1, n + m is an integer of 100 to 5,000, and n / (n + m) is 0.75 to 0.97.

[0104] (4) The bio-derived raw materials contain reducing sugars and amino acids, and the inorganic fibrous material, wherein the aqueous binder composition contains 2 to 10% by weight of reducing sugars and 1 to 5% by weight of amino acids based on the total weight of the binder composition.

[0105] (5) The inorganic fibrous material, wherein the aqueous binder composition further contains a second reinforcing agent, and the second reinforcing agent is produced from a first monomer containing an amine group, a second monomer containing a carboxy group, and a third monomer containing an epoxy group.

[0106] (6) The inorganic fibrous material, wherein the aqueous binder composition contains the first reinforcing agent and the second reinforcing agent in a weight ratio of 1:0.5 to 1:3.0.

Claims

1. In an inorganic fibrous material bound using an aqueous binder composition, the aqueous binder composition contains a bio-derived raw material, a coupling agent, and a water repellent, contains 7.0 to 9.0% by weight of the solid content of the aqueous binder composition based on the total weight of the bound inorganic fibrous material, The density is 48 kg / m ３ and the compression ratio of the inorganic fibrous material against a load of 30 kgf is 20% or less, The density is 64 kg / m ３ and the compression ratio of the inorganic fibrous material against a load of 30 kgf is 10% or less, an inorganic fibrous material in which the maximum temperature of the heating furnace when the inorganic fibrous material is placed in a heating furnace at 750 °C and heated does not rise more than 20 °C above the final equilibrium temperature, and the mass reduction rate after the heating is 30% or less.

2. The fibrous material with a density of 48 kg / m ３ contains 7.5 to 9.0% by weight of the solid content of the aqueous binder composition, based on the total weight of the bundled inorganic fibrous material, The fibrous material with a density of 64 kg / m ３ is the inorganic fibrous material according to claim 1, comprising 7.0 to 8.5% by weight of the solid content of the aqueous binder composition based on the total weight of the bundled inorganic fibrous material.

3. The inorganic fibrous material according to claim 1, wherein the aqueous binder composition further contains a first reinforcing agent containing a repeating unit represented by the following Chemical Formula 1: [Chemical Formula 1] 【Chemical 1】 In Chemical Formula 1, n + m is an integer of 100 to 5,000, and n / (n + m) is 0.75 to 0.

97.

4. The bio-derived raw material contains a reducing sugar and an amino acid, The inorganic fibrous material according to claim 1, wherein the aqueous binder composition contains 2 to 10% by weight of the reducing sugar and 1 to 5% by weight of the amino acid based on the total weight of the binder composition.

5. The aqueous binder composition further contains a second reinforcing agent, The inorganic fibrous material according to claim 3, wherein the second reinforcing agent is produced from a first monomer containing an amine group, a second monomer containing a carboxy group, and a third monomer containing an epoxy group.

6. The inorganic fibrous material according to claim 5, wherein the aqueous binder composition contains the first reinforcing agent and the second reinforcing agent in a weight ratio of 1:0.5 to 1:3.0.

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