JPH0460064B2 - - Google Patents

Description

[Detailed description of the invention]

(Industrial Application Field) The present invention uses iron concentrate slag, a by-product of the copper smelting process, as a sound insulating material, and has improved fire protection performance by using flame-retardant fibers to reinforce the resin matrix of the organic binder material. The present invention relates to a sound insulating material having. (Prior art) Noise includes traffic noise such as cars, trains, and airplanes, as well as external noise from nearby facilities such as factories, schools, parks, and ball fields, and internal noise generated within the same residence. There is something. Musical noise from televisions, stereos, pianos, etc. is also a serious social problem in residential areas. In order to obtain a sound insulation material that has a high blocking effect against these noises, it is necessary to use the sound insulation mass law [TL = a log mf + b, TL is transmission loss (dB), m is Areal density (Kg/m ² ), f is frequency (Hz),
a, b are constants], it is necessary to mix a filler with a large specific gravity into a binder material with good processability. Therefore, the sound insulation material is made flexible by mixing a filler with a high specific gravity into an organic binder material, and the specific gravity of the sound insulation material is increased to enhance the sound insulation effect. By the way, in order for a sound insulating material to be used as a building material, it must have excellent sound insulating properties, as well as the ability to prevent the sound insulating material from burning even when exposed to flames in the event of a fire, and to have excellent fire retardant properties to prevent the spread of flames. It is hoped that it will be something. However, some of the sound insulation materials known so far have excellent sound insulation properties but have poor flame retardancy, and even if they have excellent sound insulation properties, they are susceptible to fire. If this happens, the organic binder will melt and fall off, or cracks will occur, so the reality is that there is nothing that can serve to prevent the spread of flame. (Problems to be Solved by the Invention) The present invention has been made in view of the above-mentioned actual situation. Even when the sound insulating material comes into contact with flame, it is difficult to burn, melts and falls off, and does not cause cracks. First, it is an object of the present invention to provide a sound insulating material that has excellent flame retardancy and fire prevention performance to prevent the propagation of flame. (Means for Solving the Problems) The present inventors have completed the present invention as a result of intensive studies to solve the above objects. The structure of the present invention consists of ethylene vinyl acetate copolymer
For 100 parts by weight, 10 to 100 parts by weight of liquid rubber, 400 to 1500 parts by weight of iron concentrate slag, which is a by-product of copper smelting,
It is characterized by containing 3 to 120 parts by weight of flame retardant fibers and 50 to 300 parts by weight of an inorganic hydrated compound. Hereinafter, the composition of the sound insulation material according to the present invention will be explained in more detail. The ethylene vinyl acetate copolymer used in the present invention has a vinyl acetate content of 15% by weight or more, preferably 30 to 60% by weight. If the vinyl acetate content is less than 15% by weight, it is not possible to highly fill the iron concentrate slag used in the present invention, so the specific gravity of the resulting sound insulating material becomes low, resulting in poor sound insulating properties, which is not preferable. The liquid rubber used in the present invention is liquid chloroprene rubber (LCR), butadiene acrylonitrile rubber (NBR), and styrene butadiene rubber (SBR).
etc., and is used in combination with ethylene vinyl acetate copolymer to modify the ethylene vinyl acetate copolymer to make it softer and to make it easier to fill with the flame retardant fibers and iron concentrate slag described below. . In particular, liquid chloroprene rubber having a molecular weight in the range of 1,500 to 2,500 is preferably used. The amount of liquid rubber blended is ethylene vinyl acetate copolymer 100%
The range is 10 to 100 parts by weight,
Preferably it is 40 to 60 parts by weight. If the amount of liquid rubber blended is less than 10 parts by weight, it is not preferable because it becomes difficult to highly fill the iron concentrate slag and flame-retardant fibers. On the other hand, when it exceeds 100 parts by weight, the adhesiveness increases, making it difficult to separate the sound insulating material sheet from the roll, and the processability of sheeting is poor, which is not preferable. The iron concentrate slag that is produced as a by-product in the copper smelting process used in the present invention is made by adding silicon dioxide and oxygen to the matte obtained from the flash furnace in the copper smelting process in a converter to convert it into silicate and oxidize it. Iron concentrate slag is obtained by magnetically separating the generated slag, flotation of the obtained slag, and dehydrating the residue after recovering copper concentrate. An example of the chemical composition of the iron concentrate slag is:
2FeO・_SiO2 (40-50% by weight as FeO, 15-30% by weight as _SiO2 ), _{Fe304 10-30} % _by weight, _Fe203
5% by weight, MgO 5% by weight or less, and contains almost no CaO. The iron concentrate slag is a by-product obtained in the copper smelting process, so it is inexpensive and produced in large quantities. Furthermore, it has undergone flotation and is conveniently crushed particles. Since the bulk density of the slag is 3 to 4 and the specific gravity is 4 to 4.2, it is preferable as a filler for sound insulation materials. The particle size of the iron concentrate slag used in the present invention is preferably 100 mesh or less, particularly preferably 200 mesh or less. The amount of iron concentrate slag blended is in the range of 400 to 1,500 parts by weight, preferably 600 to 1,200 parts by weight, based on 100 parts by weight of the ethylene-vinyl acetate copolymer.
If the blending amount of iron concentrate slag is less than 400 parts by weight, the specific gravity of the sound insulation material will not increase, resulting in poor sound insulation properties. On the other hand, if it exceeds 1500 parts by weight, the kneading processability will be poor, the resulting sound insulating material will lack flexibility, and its mechanical strength will decrease, which is not preferable. The flame-retardant fibers used in the present invention are inorganic fibers such as glass wool and asbestos, and organic flame-retardant fibers, and the fiber length is in the range of 1 to 15 mm, preferably in the range of 3 to 10 mm. be. In particular, organic flame-retardant fibers (for example, Kynol, manufactured by Gunei Chemical Co., Ltd.) are preferably used. The purpose of using flame-retardant fibers is to strengthen the resin matrix filled with a large amount of iron concentrate slag by blending the flame-retardant fibers into an organic binder material, thereby preventing the sound insulation sheet from cracking when bent. It also prevents the thermoplastic resin of the binder material from melting and the sound insulation material falling off in the event of a fire. If flame-retardant fibers are not blended, the binder material of the sound insulation material will melt when it comes into contact with flame, and the sound insulation material will fall off and burn as a result, forming holes in the material. The flame will transfer to the combustible material, which is undesirable. In particular, when organic flame-retardant fibers are used as flame-retardant fibers, when they come into contact with flame, the fibers charcoal and form a non-flammable film, which becomes self-extinguishing due to the interaction with inorganic hydrated compounds. This is preferable because it shows The blending amount of flame retardant fiber is ethylene vinyl acetate copolymer 100%
The range is 3 to 120 parts by weight,
Preferably it is 20 to 60 parts by weight. If the blending amount of the flame-retardant fiber is less than 3 parts by weight, the binder material will melt when it comes into contact with flame, and the prevention of the sound insulating material from falling off will not be satisfied. On the other hand, when the amount exceeds 120 parts by weight, the binder material will melt when it comes into contact with flame, but the sound insulation material will be prevented from falling off and its effectiveness will be saturated.
Excessive blending is not preferred because it becomes uneconomical and reduces processability and flexibility. The inorganic hydrated compounds used in the present invention include aluminum hydroxide, magnesium hydroxide, basic magnesium carbonate, calcium hydroxide, barium hydroxide, clay, calcium carbonate, dolomite (magnesium carbonate + calcium carbonate), and hydrotalcite. (Mg4.5A ₂ (OH) ₁₃ CO ₃・35H ₂ O),
It is a material such as zeolite that absorbs heat by desorbing crystal water in the event of a fire, lowering the surrounding temperature and imparting flame retardancy to the sound insulation material. Particularly preferred is magnesium hydroxide. The amount of the inorganic hydrated compound is in the range of 50 to 300 parts by weight, preferably 100 to 200 parts by weight, based on 100 parts by weight of the ethylene vinyl acetate copolymer. If the amount of the inorganic hydrated compound is less than 50 parts by weight, flame retardancy will not be satisfied. On the other hand, if it exceeds 300 parts by weight, the flame retardant effect will be saturated and the flame retardancy will decrease, which is not preferable. (Examples) Hereinafter, the present invention will be explained in more detail based on Examples and Comparative Examples, but the present invention is not limited only to these Examples. The blended composition shown in Table 1 was stirred at room temperature for 3 minutes using a Hensel mixer, then kneaded for 10 to 15 minutes at 150 to 160°C using a 22-inch open roll.
Each sheet with a thickness of 0.9 to 1.2 mm was produced. Table 1 also shows the results of examining the various properties shown below for each sheet. Specific gravity: Since sound insulation depends largely on the density of the material, sound insulation was evaluated based on specific gravity. Flexibility: A 30 x 70 x 1 mm test piece was punched out from the prepared sheet, and the test piece was bent 180 degrees to examine its flexibility. ○: No cracks occur. △: Tracks but no cracks. ×: Cracks occur. Workability: Each compounded composition shown in Table 1 is rolled in an open roll at 150-160℃ x 10~ The rollability, stickiness, and Kynol filling properties were examined and evaluated during kneading for 15 minutes. ○: Good workability △: Slightly difficult workability ×: Poor workability Flame retardance: A 182 x 257 mm sample measured by the combustion test method for non-metallic materials for railway vehicles (Tetsuken method) The center of the bottom of the fuel container with a diameter of 18 x height of 7 x thickness of 1 mm is held at an angle of 45°, and the center of the bottom of the fuel container is 25.4 mm vertically below the center of the bottom surface of the sample.
Place it on a stand made of a material with low thermal conductivity so that it is at 0.6 mm, add 0.65 cc of ethyl alcohol, ignite it, and wait about 1 minute and 30 minutes until the fuel burns out.
Leave for a second. ○ mark: There is no ignition flame during combustion, and the distance of carbonization and deformation after combustion is 100 mm or less. × mark: During combustion, the binder material melts and the sound insulation material falls off, forming holes in the material. As can be seen from the results, in Examples 1 to 8, the specific gravity used in the present invention was appropriately combined, so the specific gravity of the sound insulating material was in the range of 2.35 to 3.04, and it exhibited sound insulating properties and was flexible. Various properties such as hardness, workability, and flame retardancy by iron polishing method are improved. Next, looking at Comparative Examples, Comparative Example 1 has a small amount of kynol, so it is not suitable for the severe flame retardance of iron construction methods. Comparative Example 2 has problems in processability and flexibility due to the large amount of kynol. In Comparative Example 3, the amount of iron concentrate slag is large, so the flexibility is significantly reduced, which is not preferable. In Comparative Example 4, since the amount of iron concentrate slag is small, the specific gravity is low and lacks sound insulation properties. In Comparative Example 5, since the amount of liquid chloroprene rubber is small, it is difficult to fill with Kynol and the flexibility is also reduced. In Comparative Example 6, the vinyl acetate content of the ethylene vinyl acetate copolymer was not appropriate. Comparative Example 7 is not preferable because it does not contain flame retardant fibers, so the binder material melts and the sound insulating material falls off, forming holes in the material. Comparative Example 8 contains a large amount of liquid chloroprene, and Comparative Example 9 contains a large amount of magnesium hydroxide, so both are unfavorable. Although not shown in this example, it should be noted that the sound insulating material according to the present invention passes a surface test and a perforation test based on the Enforcement Order of the Building Standards Act of Ministry of Construction Notification No. 1231. (Effect of the invention) As explained above, the sound insulation material according to the present invention has the following features:
This product makes effective use of iron concentrate slag, a by-product of the copper smelting process.By recycling resources, we aim to reduce the amount of raw materials used.Flame-retardant fibers are blended into the binder material to reinforce the resin matrix, and the binder can be used in the event of a fire. Since the material melts and the sound insulation material is prevented from falling off, and it can be supplied at low cost, it has a great effect that it can be used as a wide range of sound insulation materials.

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Claims (1)

[Claims] 1. 10 to 100 parts by weight of liquid rubber, 400 to 1,500 parts by weight of iron concentrate slag produced as a by-product in the copper smelting process, and flame-retardant fibers to 100 parts by weight of ethylene-vinyl acetate copolymer. ~120 parts by weight and 50-300 parts of inorganic hydrated compound
A sound insulating material having fire-retardant performance, characterized in that it is made by blending parts by weight. 2. The sound insulating material having fireproof performance according to claim 1, wherein the vinyl acetate content of the ethylene vinyl acetate copolymer is 15% by weight or more. 3. The sound insulating material having fireproof performance according to claim 1, wherein the liquid rubber is liquid chloroprene rubber, butadiene acrylonitrile rubber, or styrene butadiene rubber.