Inorganic fiber insulation material and inorganic fiber insulation material packaging

Abstract

The present invention aims to provide an inorganic fiber insulation material and an inorganic fiber insulation material packaging that offer good transport efficiency. [Solution] Contains inorganic fibers with an average fiber diameter of 2.0 to 3.8 μm and a density of 14 to 32 kg / m³ 3 The rebound force when compressed twice is 2.0 kPa or less, and the thermal conductivity (W / m·K) is given by equation (1) "λ = -5.6 × 10 -7 X 3 +5.83 × 10 -5 X 2 -0.00205X+0.0006Y+0.05406 ···(1) (Equation (1) where X is the density of the core of the inorganic fiber insulation material (kg / m³) 3 An inorganic fiber insulation material characterized by having a λ (W / m·K) within ±5% of the value calculated by (where Y is the average fiber diameter of the inorganic fiber (μm)).

Description

[Technical Field]

[0001] This invention relates to an inorganic fiber insulation material and an inorganic fiber insulation material packaging. [Background technology]

[0002] Traditionally, inorganic fiber insulation materials, composed of inorganic fibers (such as glass fibers) and a binder that bonds the inorganic fibers together, have been used as insulation materials installed in the floors, walls, and ceilings of buildings such as houses. In recent years, there has been a growing demand for improved thermal insulation performance using inorganic fiber insulation materials, both from the perspective of energy conservation and living comfort.

[0003] For example, Patent Document 1 describes an inorganic fiber insulation material that has excellent heat insulation performance and achieves both excellent flexibility and resilience by making inorganic fibers into fine fibers. Furthermore, Patent Document 2 describes an inorganic fiber insulation material in which the insulation performance is improved by orienting the inorganic fibers in a direction almost perpendicular to the thickness direction of the insulation material. [Prior art documents] [Patent Documents]

[0004] [Patent Document 1] Japanese Patent Publication No. 2024-94006 [Patent Document 2] Patent No. 6103506 [Overview of the project] [Problems that the invention aims to solve]

[0005] However, inorganic fiber insulation materials are generally bulky, resulting in poor handling efficiency during transportation and storage, and thus high transportation and storage costs. Therefore, there is a need for inorganic fiber insulation materials that offer both high insulation performance and good transportation efficiency.

[0006] Therefore, an object of the present invention is to provide an inorganic fiber heat insulating material and an inorganic fiber heat insulating material package having good transport efficiency.

Means for Solving the Problems

[0007] As a result of intensive studies, the present inventors have found that the above problems can be solved by using an inorganic fiber heat insulating material containing inorganic fibers having a specific average fiber diameter and having a density, resilience, and thermal conductivity within specific ranges, and have completed the present invention.

[0008] That is, the present invention is as follows. [1] An inorganic fiber heat insulating material containing inorganic fibers having an average fiber diameter of 2.0 to 3.8 μm, having a density of 14 to 32 kg / m , 3 , -5 , , , , , , 2 , , , , and having a resilience of 2.0 kPa or less when compressed twice, and a thermal conductivity (W / m·K) within ±5% of the λ (W / m·K) calculated by the following formula (1): λ = -5.6×10 -7 X 3 +5.83×10 -5 X 2 -0.00205X + 0.0006Y + 0.05406 ···(1) (In formula (1), X is the central density (kg / m 3 ) of the inorganic fiber heat insulating material, and Y is the average fiber diameter (μm) of the inorganic fibers) and being within ±5% of the λ (W / m·K) calculated thereby. An inorganic fiber heat insulating material, characterized in that. [2] The inorganic fiber heat insulating material according to [1], wherein the resilience when compressed from a state where the inorganic fiber heat insulating material compressed so that the thickness is less than the nominal thickness is restored to a thickness of not less than the nominal thickness until it reaches the nominal thickness is 0.2 kPa or less. [3] The inorganic fiber heat insulating material according to [1] or [2], having a thermal conductivity of 0.031 to 0.035 W / m·K. [4] A plate-shaped inorganic fiber heat insulating material packaged in a folded state, Only one of the entire or main surfaces is covered with a surface material, When it is an inorganic fiber heat insulating material in which only one of the main surfaces is covered with a surface material, the double-folded state is a state in which the surface material is double-folded so as to be on the outside, the inorganic fiber heat insulating material according to any one of [1] to [3]. [5] An inorganic fiber heat insulating material package, wherein the inorganic fiber heat insulating material according to any one of [1] to [3] is packaged with a packaging material. [6] An inorganic fiber heat insulating material package, wherein the inorganic fiber heat insulating material according to [4] is packaged with a packaging material, When the inorganic fiber heat insulating material is an inorganic fiber heat insulating material in which only one of the main surfaces is covered with a surface material, the inorganic fiber heat insulating material is in a state of being double-folded so that the surface material is on the outside, an inorganic fiber heat insulating material package. [Advantages of the Invention]

[0009] According to the present invention, it is possible to provide an inorganic fiber heat insulating material and an inorganic fiber heat insulating material package having good transport efficiency. [Modes for Carrying Out the Invention]

[0010] Hereinafter, a mode for carrying out the present invention (hereinafter simply referred to as "the present embodiment") will be described in detail. The present invention is not limited to the following embodiments, and can be variously modified and implemented within the scope of the gist thereof.

[0011] 〈Inorganic Fiber Heat Insulating Material〉 The inorganic fiber heat insulating material of the present embodiment contains inorganic fibers having an average fiber diameter of 2.0 to 3.8 μm, and has a density of 14 to 32 kg / m 3 and has a resilience of 2.0 kPa or less when double-compressed, and a thermal conductivity (W / m·K) within ±5% of λ (W / m·K) calculated by the following formula (1). λ = -5.6×10 -7 X 3 +5.83×10 -5 X 2-0.00205X+0.0006Y+0.05406 ···(1) (In equation (1), X is the density of the core of the inorganic fiber insulation material (kg / m³) 3 ), where Y is the average fiber diameter (μm) of the inorganic fibers.

[0012] Generally, inorganic fiber insulation materials are bulky, making them inefficient to transport and store, and thus incurring high transportation and storage costs. Therefore, it is common practice to compress and pack them to reduce their volume during transport and storage, and then unpack them and restore them to their nominal thickness when needed. To efficiently transport high-performance inorganic fiber insulation materials, that is, to improve transport efficiency per unit of thermal performance (thermal conductivity), it is conceivable to increase the number of inorganic fiber insulation materials per package (quantity) and reduce the volume of the package (packaging volume) while improving the insulation performance. Methods to improve the thermal insulation performance of inorganic fiber insulation include increasing thickness, increasing density, and using finer inorganic fibers. However, increasing thickness or density leads to a decrease in the number of units per package and an increase in packaging volume, resulting in poor transportation efficiency. In addition, it increases the load on compression balers during compression packaging and increases the mass per package (increasing the load on transportation workers, etc.). Furthermore, increased thickness reduces the room area due to increased wall thickness, and increased density increases the amount of inorganic fiber used per unit area (raw material usage) and increases CO2 emissions during logistics. Furthermore, increasing the number of items per package and reducing the package volume are in a trade-off relationship with the resilience of the product after the compressed packaging is released. Therefore, improvements are limited to those that can adequately ensure resilience from a quality standpoint. Therefore, the inventors have created an inorganic fiber that is low in thickness and density yet possesses excellent thermal insulation performance by making it ultrafine, and by reducing the rebound force and improving resilience, they have addressed the trade-off relationship between resilience, increased quantity, and reduced packaging volume, thereby improving transportation efficiency. Furthermore, because it has excellent thermal insulation performance and resilience while being low in density, it is possible to reduce the amount of raw materials used and CO2 emissions during logistics, enabling high energy efficiency and economic viability.

[0013] Inorganic fiber insulation materials have a density of 14-32 kg / m³. 3 Preferably 18-32 kg / m³ 3 More preferably, 26-32 kg / m³ 3 When the density is within the above range, it becomes an inorganic fiber insulation material that possesses excellent thermal insulation properties, as well as excellent flexibility and resilience, resulting in a material that is easy to install and has good transport efficiency. Please note that the density mentioned above refers to the actual density measured in accordance with JIS A 9521, not the "product designation density" (the density displayed on the product).

[0014] The inorganic fiber insulation material has a rebound force of 2.0 kPa or less when compressed twice, preferably 1.8 kPa or less, and more preferably 1.6 kPa or less. When the rebound force when compressed twice is within the above range, the inorganic fiber insulation material achieves both excellent flexibility and excellent resilience, resulting in excellent workability and good transport efficiency. The lower limit of the rebound force when compressed twice is not particularly limited and may be greater than 0 kPa. In conventional post-and-beam construction, bracing is used between the columns of the structural frame that makes up the wall structure, etc., to ensure strength. However, the bracing is often about half the thickness of the column, and the inorganic fiber insulation material shares its filling space with the bracing. The rebound force when compressed twice as much as described above serves as an indicator for comparing the ease of construction in areas where such bracing is used. In particular, if inorganic fiber insulation material is filled directly onto the bracing without being trimmed, the rebound force of the inorganic fiber insulation material tends to cause the interior material (gypsum board, etc.) to flex along the reinforcing material. Therefore, it is preferable that the rebound force of the inorganic fiber insulation material be as low as possible, for example, preferably 0.85 kPa or less, more preferably 0.7 kPa or less, even more preferably 0.5 kPa or less, and especially preferably 0.4 kPa or less.

[0015] It is preferable that the inorganic fiber insulation material, after being compressed to a thickness less than the nominal thickness, recovers to a thickness equal to or greater than the nominal thickness when unpacked and the compression is released. Furthermore, the rebound force at that time, that is, the rebound force when the material, which has been compressed to a thickness less than the nominal thickness, is restored to a thickness equal to or greater than the nominal thickness and then compressed again to the nominal thickness, is preferably 0.2 kPa or less, more preferably 0.17 kPa or less, and even more preferably 0.10 kPa or less. The lower limit of the above rebound force is not particularly limited and may be 0 kPa or more. When the rebound force when compressed to the nominal thickness is within the above range, the inorganic fiber insulation material tends to have a better balance of flexibility and resilience, as well as superior workability and better transport efficiency. When filling a wall with inorganic fiber insulation and then installing gypsum board, the restored inorganic fiber insulation is usually thicker than the wall's internal thickness, resulting in some rebound force. The rebound force when compressed to the aforementioned nominal thickness serves as an indicator for comparing the ease of installation in this case. Furthermore, if the restored thickness is the same as the nominal thickness, there is no need to compress it to the nominal thickness, and therefore the rebound force is assumed to be 0 kPa. In this specification, "nominal thickness" means "indicated thickness" (the thickness indicated on the product).

[0016] The resilience of inorganic fiber insulation can be controlled to a desired range by adjusting the density of the inorganic fiber insulation, the content of the binder and lubricant in the binder (described later), and the pressing (compression) conditions during manufacturing. For example, the resilience can be reduced by lowering the density of the inorganic fiber insulation or by adjusting the content of the binder and lubricant in the binder. Additionally, the resilience can be reduced by pressing (compressing) the inorganic fiber insulation in the thickness direction during manufacturing, thereby bending the fibers in that direction. The rebound force when compressed to twice its original thickness and the rebound force when compressed to the nominal thickness can be measured, for example, using the "V50-D type universal aptitude tester" manufactured by Toyo Seiki Seisakusho Co., Ltd. Specifically, they can be measured by the method described in the examples below.

[0017] Inorganic fiber insulation has a thermal conductivity (W / m·K) as shown in formula (1): λ = -5.6 × 10 -7 X 3 +5.83 × 10 -5 X 2 -0.00205X+0.0006Y+0.05406 ···(1) (In equation (1), X is the density of the core of the inorganic fiber insulation material (kg / m³) 3 ), where Y is the average fiber diameter (μm) of the inorganic fibers. The thermal conductivity is within ±5% of λ (W / m·K) calculated by the formula (i.e., 0.95λ to 1.05λ), preferably within ±3% of λ, more preferably within ±1% of λ, and even more preferably within ±0.7% of λ. When the thermal conductivity is within the above range, it results in an inorganic fiber insulation material with excellent heat insulation properties and good transport efficiency. Furthermore, the inorganic fiber insulation material preferably has a thermal conductivity of 0.031 to 0.035 W / m·K, more preferably 0.031 to 0.033 W / m·K, and even more preferably 0.031 to 0.032 W / m·K. When the thermal conductivity is within the above range, the inorganic fiber insulation material tends to have excellent thermal insulation properties and superior transport efficiency.

[0018] Methods for controlling the thermal conductivity of inorganic fiber insulation to the desired range include adjusting the fiber diameter and orientation of the inorganic fibers. For example, the thermal conductivity can be reduced by making the fiber diameter of the inorganic fibers smaller or by reducing the orientation angle of the inorganic fibers with respect to the direction perpendicular to the heat flow direction (thickness direction) of the inorganic fiber insulation. The thermal conductivity of inorganic fiber insulation material is measured in accordance with JIS A 1412-2, and specifically, it can be measured by the method described in the examples below. Furthermore, the density of the central part of the inorganic fiber insulation material is a value measured in accordance with JIS A 9521 for the central part of the inorganic fiber insulation material (total width × length 400 mm), and specifically, it can be measured by the method described in the examples below.

[0019] The shape of the inorganic fiber insulation material is not particularly limited, but it is preferably in the form of a plate. In this specification, "plate-like" means a rectangular parallelepiped shape having a predetermined thickness and two planes perpendicular to that thickness, with length and width greater than that thickness, and these two planes are referred to as "main planes".

[0020] Furthermore, it is preferable that the inorganic fiber insulation material is covered in whole or in part with a surface material. When inorganic fiber insulation material is packaged in a folded state, such as folded in half, the inorganic fibers are fine, so there is a risk that the inorganic fibers may be cut at the fold, causing the inorganic fiber insulation material to crack, which may result in the inorganic fiber insulation material losing its shape or the cut fibers falling and scattering. For this reason, it is preferable that the entire material is covered with a surface material, or at least the outside of the part that becomes the fold when folded (the folded part) is covered with a surface material. For example, if the inorganic fiber insulation material is a plate-shaped inorganic fiber insulation material that is packaged in a folded state (for example, a long plate-shaped inorganic fiber insulation material with a length of 1500 to 3000 mm), it is preferable that the entire material (all 6 surfaces) or only one of the two main surfaces (the surface that becomes the outside when folded in half) is covered with a surface material.

[0021] The size of inorganic fiber insulation is not particularly limited and may be set appropriately according to the application, such as to match the size of the floors, walls, ceilings, etc. of the building in which the inorganic fiber insulation is used.

[0022] As the surface material, for example, paper, synthetic resin film (polyethylene film, etc.), metal foil film, nonwoven fabric, woven fabric, or a combination thereof can be used. Among these, a moisture-permeable sheet is preferred because it can allow moisture (water vapor) to pass through, and a moisture-permeable sheet made of a composite sheet of low-density polyethylene (LDPE) and nonwoven fabric is more preferred because it has good slipperiness. The surface material preferably has a static friction coefficient of less than 0.21, and more preferably 0.16 to 0.20. When the static friction coefficient is within the above range, the inorganic fiber insulation material is easier to compress and package, which reduces the likelihood of packaging defects and tends to result in better operating efficiency. Furthermore, the static friction coefficient of the surface material can be measured in accordance with the JIS K 7125 standard, using a SUS plate as the underlying test piece (countering material).

[0023] <<Inorganic Fiber>> The inorganic fibers included in the inorganic fiber insulation material of this embodiment are not particularly limited, and those commonly used in the field of insulation materials can be used, such as glass wool and rock wool. For the process of forming inorganic fibers into fibers, conventionally known methods such as the centrifugal method (rotary method), the flame method, and the blowing method can be used. Inorganic fibers may be used individually or in combination of two or more types.

[0024] The average fiber diameter of the inorganic fibers is 2.0 to 3.8 μm. When the average fiber diameter of the inorganic fibers is 2.0 μm or more, the inorganic fibers are easy to manufacture and obtain, and when it is 3.8 μm or less, it becomes an inorganic fiber insulation material that exhibits excellent thermal insulation performance even at low thickness and low density. The average fiber diameter of the inorganic fibers is preferably 2.0 to 3.3 μm, and more preferably 2.0 to 2.9 μm. Methods for controlling the average fiber diameter of inorganic fibers include, for example, using a centrifugal method (rotary method) with a spinner or the like to create fibers when the inorganic fiber is glass wool, and reducing the size of the outlet for the molten glass in the fiberization apparatus. The average fiber diameter can be measured using cottonscopeHD manufactured by Cottonscope Pty Ltd, and specifically, by the method described in the examples below.

[0025] The average fiber length of the inorganic fibers is preferably 5 to 200 mm, but may also be 5 to 100 mm or 5 to 50 mm. When the average fiber length of the inorganic fibers is within the above range, the resilience tends to be good. On the other hand, if the average fiber length of the inorganic fibers is shorter than the above range, the bonds between the fibers become weaker, making them more prone to losing their shape, and the fiber clumps tend to peel off from the surface of the inorganic fibers during installation. The average fiber length of inorganic fibers is measured in 1mm increments using a straight ruler by extracting fibers from the inorganic fibers immediately after fiber formation or after firing. A magnifying glass and tweezers are used as needed. The lengths of 100 or more randomly selected fibers are measured, and the average value is taken. Fibers that break during extraction are excluded from the count.

[0026] <<binder>> In order to ensure resilience, moldability, and shape retention, it is preferable that the inorganic fibers are bound (fixed) together by a binder. The igloss (amount of binder adhering in terms of solid content) of the inorganic fiber insulation material is preferably 1.5 to 8.0% by mass, more preferably 1.5 to 6.0% by mass, and even more preferably 1.5 to 3.0% by mass. When the igloss is within the above range, the inorganic fiber insulation material tends to obtain a resilience that allows it to achieve both excellent flexibility and excellent resilience. The igloss (amount of binder adhering in terms of solid content) of inorganic fiber insulation can be determined by the following method: Cut a 100 mm square test piece from the inorganic fiber insulation and measure its mass (Wa). Next, place the cut test piece in an electric furnace set to 530°C to decompose and remove the binder. Remove the test piece from the electric furnace and measure the mass (Wb) of the test piece after the binder has been decomposed and removed. Calculate the igloss (mass %) using the following formula. Igross (mass %) = {(Wa-Wb) / Wa} × 100 Furthermore, if inorganic fiber insulation is stored (left unattended) in a warehouse or similar location for a certain period without airtight packaging, it will absorb moisture due to the influence of ambient humidity, and its mass will increase. Therefore, the moisture content (water content) of inorganic fiber insulation after a certain period of storage must be considered. Specifically, the cut test piece is held in a 110°C drying oven for 60 minutes to remove moisture from the test piece. After that, it is cooled to room temperature in a desiccator to prevent moisture absorption, and its mass is measured. This value is taken as Wa, and the igloss is calculated using the formula described above.

[0027] The binder is not particularly limited, but a thermosetting resin that hardens by any of the following reactions is preferably used: amidation, imidation, esterification, and transesterification. Specific examples of such thermosetting resins include resins containing a polycarboxylic acid polymerized from an ethylenically unsaturated monomer and a crosslinking agent containing an alcohol having an amino group and / or imino group. Preferably, the acrylic resins described in Japanese Patent Publication No. 6017079 and Japanese Patent Publication No. 6850380 are used.

[0028] Furthermore, the binder may optionally contain additives such as lubricants, crosslinking agents, dust suppressants, colorants, pH adjusters, curing accelerators, silane coupling agents, and neutralizing agents for neutralizing alkaline components leached from inorganic fibers, in a quantity that does not impair the effects of the present invention.

[0029] The lubricant is applied to the inorganic fibers in a state mixed with the binder, but it is preferable that the lubricant does not react with the binder and flows on the inorganic fibers when the binder is heated. Examples of such lubricants include silicone lubricants, waxes, and surfactants.

[0030] Silicone lubricants are formed by adding hydrophilic groups such as polyethylene oxide or polypropylene oxide to the side chains or terminals of polysiloxane. In silicon lubricants, the hydrophilicity of the product changes depending on the mixing ratio of the polysiloxane chain to the hydrophilic group chain, but there are no particular limitations as long as it has sufficient hydrophilicity to be sufficiently miscible with the binder.

[0031] Waxes are solids at room temperature but become relatively fluid liquids when heated to approximately 40°C or higher. Specifically, examples include animal waxes such as beeswax, lanolin wax, and shellac wax; plant waxes such as carnauba wax, wood wax, rice wax, and candelilla wax; mineral waxes such as montane wax and ozokerite; petroleum waxes such as paraffin wax and microcrystalline wax; and synthetic waxes such as Fischer-Tropsch wax, polyethylene wax, polypropylene wax, polycarbonate wax, coconut oil fatty acid esters, beef tallow fatty acid esters, stearic acid amide, dipeptadecylketone, and hydrogenated castor oil. These may be used individually or in combination of two or more. Among these, paraffin wax, polyethylene wax, and polypropylene wax are preferred in terms of economy. In addition to the above waxes, heavy oils similar to waxes can also be used.

[0032] Generally, since waxes are hydrophobic materials, it is preferable to disperse or emulsify them in water beforehand to improve miscibility when adding them to a binder.

[0033] Surfactants include anionic surfactants, cationic surfactants, and nonionic surfactants, but nonionic surfactants are preferred in terms of miscibility with binders.

[0034] Nonionic surfactants include ester-based surfactants such as glycerin fatty acid esters, sorbitan fatty acid esters, and sucrose fatty acid esters; ether-based surfactants such as polyethylene glycol, polypropylene glycol, and their block copolymers, higher alcohols, and polyethylene oxide adducts of alkylphenols; and ether-ester-based surfactants such as polyethylene glycol fatty acid esters, polypropylene glycol fatty acid esters, and polyethylene oxide adducts of glycerin fatty acid esters, sorbitan fatty acid esters, and sucrose fatty acid esters.

[0035] The lubricant content in the binder is preferably 1.5 to 15.0% by mass in terms of solid content, more preferably 5.0 to 15.0% by mass, and even more preferably 10.0 to 15.0% by mass. When the lubricant content is within the above range, the inorganic fiber insulation material tends to obtain a resilience that allows for both excellent flexibility and excellent resilience.

[0036] The binder can be used by mixing the above components according to a conventional method and adjusting the concentration to a predetermined level by adding water.

[0037] <Method for manufacturing inorganic fiber insulation material> The method for manufacturing the inorganic fiber insulation material of this embodiment is not particularly limited. For example, the inorganic fiber insulation material can be manufactured by applying or spraying a binder onto inorganic fibers using a spray device, collecting the fibers using a conveyor, and then heating them in an oven to harden the binder. Furthermore, the inorganic fiber insulation material may be covered in whole or in part with a surface material.

[0038] A method for manufacturing inorganic fiber insulation material may include, for example, a step of laminating inorganic fiber mats obtained by collecting inorganic fibers so that they are oriented in one direction, in order to adjust the orientation angle of the inorganic fibers. One example of a lamination method is to use a swinging device. The swinging device has two swinging belts that swing like a pendulum in the width direction or direction of travel of a conveyor located below it. The inorganic fiber mat is sandwiched between the two swinging belts, and the inorganic fiber mat is swung onto the conveyor by the pendulum motion, so that the inorganic fiber mats partially overlap and are laminated. The orientation angle of the inorganic fibers can be controlled by adjusting the moving speed of the conveyor and the width of the inorganic fiber mat. In addition, the number of layers of inorganic fiber mats can be changed by adjusting the swinging speed of the swinging device, the delivery speed of the inorganic fiber mat from the swinging device, and the moving speed of the conveyor. Furthermore, the method for manufacturing inorganic fiber insulation material may include a step of pressing (compressing) the inorganic fiber mat in order to reduce the resilience of the inorganic fiber insulation material and make it more flexible. More specifically, for example, an inorganic fiber mat whose binder has been hardened by heating in an oven or the like can be compressed in the thickness direction while being sandwiched between upper and lower conveyors, thereby bending the fibers in the thickness direction and producing a flexible inorganic fiber insulation material.

[0039] While the binder can be added to inorganic fibers at any time after fiber formation, it is preferable to add it immediately after fiber formation for efficient binder application.

[0040] In the process of heat-curing the binder, the heat-curing temperature is preferably 200 to 350°C. The heat-curing time is preferably adjusted appropriately between 30 seconds and 10 minutes, depending on the density and thickness of the inorganic fiber insulation material.

[0041] As described above, the thermal conductivity of inorganic fiber insulation materials can be adjusted and their insulation performance enhanced by adjusting the orientation angle of the inorganic fibers during the lamination process, thereby reducing the orientation angle of the inorganic fibers with respect to the direction perpendicular to the direction of heat transfer (thickness direction) of the inorganic fiber insulation material. The orientation angle of inorganic fibers in inorganic fiber insulation material with respect to the direction perpendicular to the flow direction (thickness direction) is preferably 0 to 20°, and the closer it is to 0°, the higher the insulation performance can be obtained. The number of layers of the inorganic fiber mat is preferably 4 to 12, and more preferably 6 to 10. The orientation angle of the inorganic fibers tends to increase as the number of layers increases. The oscillation speed of the oscillating device may be, for example, 10 to 65 m / min in a back-and-forth motion. The discharge speed of the inorganic fiber mat from the oscillating device may also be, for example, 10 to 65 m / min.

[0042] As described above, in the process of pressing inorganic fiber insulation material in the thickness direction while sandwiched between upper and lower conveyors after the binder has been heated and hardened (fired), the fibers in the thickness direction can be folded, thereby suppressing the resilience of the inorganic fiber insulation material and increasing its flexibility. As a result, the resulting inorganic fiber insulation material will have resilience that allows for both superior flexibility and excellent resilience. The density during the above pressing (compression) is 100-400 kg / m³. 3 It is preferable that the density during pressing (compression) falls within the above range. When pressed (compressed) in such a way that the density during pressing (compression) falls within the above range, the fibers in the thickness direction are folded, increasing flexibility, and the inorganic fiber insulation material tends to obtain a rebound force that allows it to achieve both excellent flexibility and excellent resilience. The density under compression ranges from 100 to 400 kg / m³, depending on the desired actual density and rebound force. 3 It should be set appropriately within the range. Depending on the binder and lubricant content, for example, the actual density is 20±2 kg / m³. 3 (Product density is 20 kg / m³) 3 Inorganic fiber insulation material, which has a density of 150-300 kg / m³ when pressed (compressed) 3 When compressed in this manner, inorganic fiber insulation materials with a rebound force of 0.7 kPa or less when compressed twice tend to be obtained. Furthermore, for example, a real density of 36 ± 4 kg / m³ is obtained. 3 (Product density is 36 kg / m³) 3 The inorganic fiber insulation material has a density of 250-400 kg / m³ when compressed. 3 When compressed in this manner, inorganic fiber insulation materials with a rebound force of 2.0 kPa or less when compressed twice tend to be obtained.

[0043] Furthermore, when performing a pressing (compression) process, considering that the fibers in the thickness direction will be bent, the average fiber length of the inorganic fibers before bending due to pressing (immediately after fiber formation or after firing) is preferably 5 to 100 mm, more preferably 5 to 50 mm, and even more preferably 5 to 30 mm. The average fiber length of inorganic fibers can be determined by taking 100 or more fibers, measuring their lengths with a ruler, and averaging them. Specifically, it can be measured by the method described in the examples below.

[0044] Furthermore, the method for manufacturing inorganic fiber insulation material may include a coating step of covering all or part of the inorganic fiber mat with a surface material. The size and number of the surface material are not particularly limited, as long as it can cover the desired portion (whole or part) of the inorganic fiber mat. For example, it may be covered with one piece or with two pieces. The adhesive used to bond the inorganic fiber mat to the surface material, or to the surface materials themselves, is not particularly limited as long as it can bond the surface materials. Examples include thermosetting resins (hot melt adhesives), rubber cement, water-soluble adhesives, and emulsion-based adhesives. Among these, thermosetting resins (hot melt adhesives) are preferred because they require a short bonding time. The method of covering the inorganic fiber mat is not particularly limited. For example, the following method can be used to cover the entire plate-shaped inorganic fiber mat: One or two surface materials are placed so as to sandwich both main surfaces (front and back) of the inorganic fiber mat, and the surface materials are bonded to both main surfaces and both sides along the long side direction (length direction) of the inorganic fiber mat with adhesive to cover it, and the ends of the surface materials along the long side direction are extended from both sides (end faces) along the short side direction (width direction) of the inorganic fiber mat, so that the sides along the short side direction of the inorganic fiber mat are also covered with the surface materials. The surface materials and both main surfaces and both sides along the long side direction of the inorganic fiber mat only need to be partially bonded with adhesive to prevent the inorganic fiber mat from moving within the surface materials. Next, the overlapping parts of the surface materials, that is, the edges along the long side direction and the edges along the short side direction of the surface materials, are bonded with adhesive to completely cover the inorganic fiber mat with the surface materials. Alternatively, multiple inorganic fiber mats may be laid out at once, covered with a surface material, and then the surface material may be separated so that each inorganic fiber insulation material is exposed individually. Furthermore, for example, if only one side of the main surface of an inorganic fiber mat is to be covered with a surface material, the surface material can be bonded with an adhesive so as to cover only one side of the main surface of the inorganic fiber mat.

[0045] The inorganic fiber insulation material of this embodiment can be suitably used as an insulation material in buildings (houses, office buildings, etc.). The method of installing inorganic fiber insulation in the walls, floors, and ceilings of a building is not particularly limited, and any method commonly known for installing fiber-based insulation in the structural elements of walls, floors, and ceilings of a building can be used, and the material is installed by filling (inserting) it into the frame that constitutes each structure.

[0046] <Inorganic fiber insulation packaging> The inorganic fiber insulation material packaging of this embodiment is a compressed packaging in which the inorganic fiber insulation material of this embodiment described above is packaged with packaging material. From the viewpoint of transportation efficiency, it is preferable that multiple sheets of inorganic fiber insulation material are packaged in one packaging material (the number of sheets is two or more). In inorganic fiber insulation packaging, the inorganic fiber insulation may be compressed and packaged without being folded, or, in the case of long, flat sheets (for example, those with a length of 1500 mm or more), it may be compressed and packaged in a folded state such as in half or in thirds. When inorganic fiber insulation, which is only partially covered with a surface material, is folded and compressed, it is preferable that the surface material is positioned on the outside of the fold to prevent the inorganic fiber insulation from being cut at the fold, causing it to crack, lose its shape, or for the cut fibers to fall and scatter. For example, when a flat inorganic fiber insulation, with only one main surface covered with a surface material, is compressed and packaged in a folded state, it is preferable that the fold is made in the middle of the longitudinal direction (length direction), with the surface material on the outside. The packaging material is not particularly limited, and any known packaging material for inorganic fiber insulation can be used.

[0047] <Method for manufacturing inorganic fiber insulation packaging> An inorganic fiber insulation material package can be obtained, for example, by using a compression baler to compress the inorganic fiber insulation material of the above embodiment and then packaging it with packaging material. When compressing and packaging multiple sheets of inorganic fiber insulation material in one packaging material, it is preferable to compress the multiple sheets of inorganic fiber insulation material in a stacked state and then packaging them with packaging material. The inorganic fiber insulation material may be compressed and packaged without folding it, or if the inorganic fiber insulation material is in the form of a long plate (for example, if the length is 1500 mm or more), the inorganic fiber insulation material may be folded in half or in thirds before being compressed and packaged. When folding inorganic fiber insulation material that is only partially covered with a surface material, it is preferable to fold it so that the surface material is located outside the fold to prevent the inorganic fibers from being cut at the fold, which could cause the inorganic fiber insulation material to crack, lose its shape, or for the cut fibers to fall and scatter. For example, when folding a plate-shaped inorganic fiber insulation material in half, where only one main surface is covered with a surface material, it is preferable to fold it in half with the fold line in the center of the longitudinal direction (length direction) so that the surface material is on the outside. [Examples]

[0048] The present invention will be described in more detail below with reference to examples. The present invention is not limited to the following examples unless it exceeds the scope of its essence.

[0049] The measurement and evaluation methods used in the examples and comparative examples are as follows.

[0050] [Static friction coefficient of surface material] Regarding the surface material, the static friction coefficient was measured in accordance with JIS K 7125, using a SUS plate as the underlying test piece (countering material).

[0051] [Average fiber diameter of inorganic fibers] The average fiber diameter (μm) of inorganic fibers was determined using a cottonscopeHD manufactured by Cottonscope Pty Ltd. Specifically, fibers dispersed in water were magnified under a microscope, images were captured with a camera and imported into a computer, and the fiber diameter was measured using image processing. The average fiber diameter was calculated by averaging the measurements obtained from 30,000 fibers. Fibers shorter than 50 μm and short fibers with a length less than three times their fiber diameter were excluded from the calculation.

[0052] [Average fiber length of inorganic fibers] Inorganic fibers were extracted immediately after fiber formation or after firing, and their lengths were measured in 1 mm increments using a ruler. Measurements were taken for 100 or more fibers, and the average of these measurements was defined as the average fiber length (mm). Fibers that broke during extraction were excluded from the measurement, using a magnifying glass or tweezers as needed.

[0053] [Density of inorganic fiber insulation, density of the core] For the entire inorganic fiber insulation material, the density (actual density) (kg / m³) is determined in accordance with JIS A 9521. 3 ) was sought. Density = Total mass / (Width × Length × Nominal thickness) Furthermore, test specimens measuring 910mm x 910mm x each thickness were prepared from inorganic fiber insulation material (by cutting and joining pieces of inorganic fiber insulation material as needed). The central portion (product width x 400mm x each thickness) of the obtained test specimens was cut out, and its density (actual density) (kg / m³) was determined in accordance with JIS A 9521. 3 The core density of the inorganic fiber insulation material was determined. Note that the product width refers to the width of the inorganic fiber insulation material before the test specimen was prepared (the width listed in Table 1). Density of the core of inorganic fiber insulation material = Mass of the core of the test piece / (Product width × 400 mm × Nominal thickness)

[0054] [Thickness, width, and length of inorganic fiber insulation material] The thickness (actual thickness), width, and length (all in mm) of the inorganic fiber insulation material were measured in accordance with JIS A 9521.

[0055] [Rebound force when compressed twice] A 100mm square test piece was cut from the inorganic fiber insulation material, and the actual density of the entire inorganic fiber insulation material, measured using the method described above [Density of inorganic fiber insulation material, density of the core], was compared with a value of ±0.5 kg / m³. 3 Five or more test specimens with densities within the following ranges were prepared. The clearance between the compression plates of the universal aptitude test apparatus (Toyo Seiki Seisakusho Co., Ltd. "V50-D") was set to within 50 ± 5% of the nominal thickness (50 mm for a nominal thickness of 105 mm). The test specimens were inserted between the compression plates, and the rebound force was measured. The average value of the measurements from the five or more test specimens was taken as the rebound force (kPa) when compressed twice.

[0056] [Rebound force when compressed to the nominal thickness] After compressing and packaging the inorganic fiber insulation material into a package, a 100mm square test piece was cut from the unpacked and restored inorganic fiber insulation material, and the actual density of the entire inorganic fiber insulation material, measured using the method described above [Density of inorganic fiber insulation material, density of the core], was compared to ±0.5 kg / m³. 3 Five or more test specimens with densities within the following ranges were prepared. The clearance between the compression plates of the universal aptitude test apparatus (Toyo Seiki Seisakusho Co., Ltd. "V50-D") was set to the nominal thickness value (105 mm for a nominal thickness of 105 mm). The test specimens were inserted between the compression plates, and the rebound force was measured. The average value of the measurements from the five or more test specimens was taken as the rebound force (kPa) when compressed to the nominal thickness.

[0057] [Thermal conductivity and thermal resistance of inorganic fiber insulation materials] A 910 mm square test specimen was prepared from inorganic fiber insulation material, and the thermal conductivity (W / m·K) in the thickness direction of the test specimen was measured using the heat flow meter (HFM) method in accordance with JIS A 1412-2 at an average temperature of 23°C (13°C on the top surface, 33°C on the bottom surface). Furthermore, based on the obtained thermal conductivity, the thermal resistance value (m) can be calculated using the following formula. 2 We calculated the (K / W) ratio. Thermal resistance = Nominal thickness / Thermal conductivity

[0058] [λ of inorganic fiber insulation, and the ratio of the difference between λ and thermal conductivity] For inorganic fiber insulation, the value of λ (W / m·K) was determined using the following formula (1). λ = -5.6 × 10 -7 X 3 +5.83 × 10 -5 X 2 -0.00205X+0.0006Y+0.05406 ···(1) (In equation (1), X is the density of the core of the inorganic fiber insulation material (kg / m³) 3 ), Y is the average fiber diameter (μm) of the inorganic fibers. Furthermore, the percentage difference between λ and thermal conductivity was calculated using the following formula. The ratio of the difference between λ and thermal conductivity = ((λ - thermal conductivity) / λ) × 100

[0059] [Transport efficiency of inorganic fiber insulation materials] Inorganic fiber insulation was compressed and packaged using packaging material to create an inorganic fiber insulation package, and the transport efficiency E (m·K / W) per unit of thermal performance (thermal conductivity) was calculated using the following formula. Transport efficiency E (m·K / W) = Thermal resistance value (m 2 (K / W) × (Length × Width (m) 2 (per sheet) × Number of sheets per pack ÷ Packaging volume (m³) 3 (packaging) (In the formula, "quantity" represents the number of inorganic fiber insulation materials per package, and "package volume" represents the volume of one package.) Furthermore, transportability was evaluated by classifying transport efficiency E as follows: "A (Excellent)" if it was 64.0 m·K / W or higher, "B (Good)" if it was between 55.0 m·K / W and 64.0 m·K / W, and "C (Poor)" if it was below 55.0 m·K / W.

[0060] [Example 1] Glass was melted in a glass melting furnace to obtain molten glass. Using the molten glass, fiberization was performed using a fiberization device to obtain short glass fibers (average fiber diameter 2.97 μm, average fiber length 11.5 mm). Immediately after fiberization, an acrylic resin binder, using 17.2% by mass of silicone lubricant (manufactured by Asahi Wacker Silicone Co., Ltd.) on a solid content basis instead of the heavy oil dispersion in the binder described in Example 1 of Japanese Patent Publication No. 6017079, was sprayed onto the short glass fibers. The amount of binder used was assumed to be 2.5% by mass relative to the total mass of the short glass fibers and binder after curing. Next, the fibers were collected on a fiber collection belt by suction from below and airflow from above to form a glass fiber mat, which was then transported to an oscillating device. The glass fiber mat was stacked in 6 layers at an oscillating speed of 25 m / min in the oscillating device, and then baked in an oven under pressure to a thickness of 118.0 mm to cure the binder. Next, the material was cut to the product dimensions after slitting, trimming, and other processes. The entire resulting plate-shaped glass fiber mat was covered with polyethylene film (static friction coefficient 0.17). A thermosetting resin (hot melt adhesive) was used to bond the polyethylene film to the glass fiber mat. Specifically, two polyethylene films were placed so as to sandwich both main surfaces (front and back) of multiple glass fiber mats arranged in the long-side direction (length direction). The polyethylene films were partially bonded and covered with adhesive to both main surfaces and both sides along the long-side direction of each glass fiber mat. The ends of the polyethylene films along the long-side direction were extended from both sides along the short-side direction (width direction) of the glass fiber mat, and both sides along the short-side direction of the glass fiber mat were also covered with polyethylene film. Next, the overlapping parts of the polyethylene films, i.e., the edges along the long-side direction and the edges along the short-side direction of the polyethylene films, were bonded with adhesive to completely cover the glass fiber mat with polyethylene film. Subsequently, the polyethylene films were separated so that each product was individually separated, and the density was 305 kg / m³. 3 By pressing and compressing the material while sandwiching it between upper and lower conveyors, and folding the fibers in the thickness direction, a flexible glass fiber insulation material was obtained. The obtained glass fiber insulation material was folded in half along the center of its longer side. Four sheets of the folded glass fiber insulation material were stacked flat and compressed into packaging material using a compression baler to obtain a glass fiber insulation material package. The results of each measurement and evaluation are shown in Table 1.

[0061] [Examples 2, 3, Comparative Example 1] Glass fiber insulation material and glass fiber insulation material packaging were obtained in the same manner as in Example 1, except that the size of the glass fiber insulation material and the average fiber diameter of the glass fibers were changed as shown in Table 1. In Example 3, only one main surface of the glass fiber mat was covered with a microporous polyethylene film (static friction coefficient 0.24) as a surface material. A thermosetting resin (hot melt adhesive) was used to bond the surface material to the glass fiber mat. Comparative Example 1 did not have a surface material covering. In Example 3, Comparative Examples 1 and 2 were not folded in half, but were stacked flat and compressed for packaging. The measurement and evaluation results are shown in Table 1.

[0062] [Comparative Example 2] Using commercially available products (glass fiber insulation material and its packaging), each measurement and evaluation was performed in the same manner as in Example 1. The measurement and evaluation results are shown in Table 1.

[0063] [Table 1] [Industrial applicability]

[0064] The inorganic fiber insulation material of the present invention is suitable for use as an insulation material in buildings (houses, office buildings, etc.) because it has excellent thermal insulation properties, flexibility, resilience, and workability, as well as good transport efficiency.

Claims

1. It contains inorganic fibers with an average fiber diameter of 2.0 to 3.8 μm. Density of 14-32 kg / m³ ３ And, The rebound force when compressed twice is 2.0 kPa or less. The thermal conductivity (W / m·K) is given by the following formula (1): λ=-5.6×10 －７ X ３ +5.83×10 －５ X ２ -0. (In formula (1), X is the density of the central part of the inorganic fiber insulation material (kg / m³) ３ (Y is the average fiber diameter (μm) of the inorganic fiber.) It is within ±5% of the λ (W / m·K) calculated by [the specified method]. An inorganic fiber insulation material characterized by the following features.

2. The inorganic fiber insulation material according to claim 1, wherein the inorganic fiber insulation material, which has been compressed to a thickness less than the nominal thickness, is restored to a thickness equal to or greater than the nominal thickness, and the rebound force when it is compressed again to the nominal thickness is 0.2 kPa or less.

3. The inorganic fiber insulation material according to claim 1, wherein the thermal conductivity is 0.031 to 0.035 W / m·K.

4. It is a sheet-shaped inorganic fiber insulation material that is packaged in a folded state. The entire surface or only one of the main surfaces is covered with a surface material. In the case of an inorganic fiber insulation material in which only one of the main surfaces is covered with a surface material, the folded state is a state in which the material is folded in half so that the surface material is on the outside, according to claim 1.

5. An inorganic fiber insulation material package comprising an inorganic fiber insulation material according to any one of claims 1 to 3, packaged with a packaging material.

6. An inorganic fiber insulation material package is formed by packaging the inorganic fiber insulation material described in claim 4 with a packaging material, In the case where the inorganic fiber insulation material is an inorganic fiber insulation material in which only one of the main surfaces is covered with a surface material, the inorganic fiber insulation material is folded in half so that the surface material is on the outside, in an inorganic fiber insulation material packaging body.

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