U.S. patent application number 14/361894 was filed with the patent office on 2014-12-04 for biosoluble inorganic fiber and method for producing same.
The applicant listed for this patent is NICHIAS CORPORATION. Invention is credited to Tomohiko Kishiki, Tetsuya Mihara, Takashi Nakajima, Ken Yonaiyama.
Application Number | 20140356622 14/361894 |
Document ID | / |
Family ID | 47789821 |
Filed Date | 2014-12-04 |
United States Patent
Application |
20140356622 |
Kind Code |
A1 |
Nakajima; Takashi ; et
al. |
December 4, 2014 |
BIOSOLUBLE INORGANIC FIBER AND METHOD FOR PRODUCING SAME
Abstract
An inorganic fiber including biosoluble fiber and a cationic
surfactant adhering to the biosoluble fiber. An inorganic fiber
including biosoluble fiber and a surfactant adhering to the
biosoluble fiber, wherein the amount of the surfactant is 0.01 to 2
wt %, based on 100 wt % of the whole inorganic fiber comprising the
surfactant adhered thereto.
Inventors: |
Nakajima; Takashi; (Tokyo,
JP) ; Yonaiyama; Ken; (Tokyo, JP) ; Mihara;
Tetsuya; (Tokyo, JP) ; Kishiki; Tomohiko;
(Tokyo, JP) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
NICHIAS CORPORATION |
Tokyo |
|
JP |
|
|
Family ID: |
47789821 |
Appl. No.: |
14/361894 |
Filed: |
November 12, 2012 |
PCT Filed: |
November 12, 2012 |
PCT NO: |
PCT/JP2012/007237 |
371 Date: |
May 30, 2014 |
Current U.S.
Class: |
428/379 ;
427/421.1 |
Current CPC
Class: |
C04B 2235/3224 20130101;
D02G 3/36 20130101; D06M 2200/35 20130101; D06M 2200/40 20130101;
C04B 2235/3244 20130101; C04B 2235/3227 20130101; C04B 2235/3409
20130101; Y10T 428/294 20150115; C03C 25/25 20180101; C04B
2235/3272 20130101; D02G 3/443 20130101; C03C 3/087 20130101; C04B
2235/3206 20130101; C04B 2235/3201 20130101; C04B 2235/3217
20130101; D06M 2101/00 20130101; C04B 35/6224 20130101; C04B
2235/72 20130101; C04B 2235/3208 20130101; C04B 2235/3262 20130101;
C03C 13/00 20130101; D06M 2200/30 20130101; C04B 2235/3232
20130101; D02G 3/045 20130101; C04B 2235/34 20130101; D06M 13/2246
20130101; C03C 2213/02 20130101; C04B 2235/3229 20130101; C04B
35/62844 20130101; D10B 2101/08 20130101; D06M 13/325 20130101;
C04B 2235/3225 20130101 |
Class at
Publication: |
428/379 ;
427/421.1 |
International
Class: |
D02G 3/36 20060101
D02G003/36; D06M 13/325 20060101 D06M013/325; D06M 13/224 20060101
D06M013/224; D02G 3/44 20060101 D02G003/44; D02G 3/04 20060101
D02G003/04 |
Foreign Application Data
Date |
Code |
Application Number |
Dec 1, 2011 |
JP |
2011-263414 |
Claims
1. Inorganic fiber comprising biosoluble fiber and a cationic
surfactant adhering to the biosoluble fiber.
2. Inorganic fiber comprising biosoluble fiber and a surfactant
adhering to the biosoluble fiber, wherein the amount of the
surfactant is 0.01 to 2 wt %, based on 100 wt % of the whole
inorganic fiber comprising the surfactant adhered thereto.
3. The inorganic fiber according to claim 1, wherein the biosoluble
fiber has the following composition ratio: the total of SiO.sub.2,
Al.sub.2O.sub.3, ZrO.sub.2 and TiO.sub.2 50 to 82 wt %; and the
total of CaO and MgO 18 to 50 wt %.
4. The inorganic fiber according to claim 1, wherein the biosoluble
fiber has the following composition ratio: SiO.sub.2 50 to 82 wt %;
and the total of CaO and MgO 10 to 43 wt %.
5. The inorganic fiber according to claim 1, wherein the biosoluble
fiber has the following composition ratio 1 or 2: [Composition
ratio 1] SiO.sub.2 70 to 82 wt %; CaO 1 to 9 wt %; MgO 10 to 29 wt
%; and Al.sub.2O.sub.3 less than 3 wt % [Composition ratio 2]
SiO.sub.2 70 to 82 wt %; CaO 10 to 29 wt %; MgO 1 wt % or less; and
Al.sub.2O.sub.3 less than 5 wt %.
6. The inorganic fiber according to claim 5, wherein the biosoluble
fiber has the composition ratio 2.
7. The inorganic fiber according to claim 6, wherein
Al.sub.2O.sub.3 is 2 wt % or more.
8. The inorganic fiber according to claim 1, wherein the surfactant
is an alkyl amine acetate.
9. A method for producing the inorganic fiber according to claim 1,
comprising spraying a surfactant to biosoluble fiber or
impregnating biosoluble fiber with a surfactant.
10. A formed product or an unshaped product obtained from the
inorganic fiber according to claim 1.
Description
TECHNICAL FIELD
[0001] The invention relates to biosoluble inorganic fibers and a
method for producing the same.
BACKGROUND ART
[0002] Inorganic fibers are light in weight, easy to handle, and
have excellent heat resistance. Therefore, they are used as a
heat-insulating sealing material, for example. On the other hand,
in recent years, a problem has been pointed out that inorganic
fibers are inhaled by a human body and the inhaled fibers invade
the lung. Therefore, biosoluble inorganic fibers that do not cause
or hardly cause problems even if inhaled by a human body have been
developed (Patent Documents 1 and 2, for example).
[0003] According to applications, biosoluble inorganic fibers are
not only used as the raw material of textiles such as a rope, a
yarn and a cloth, but also secondarily processed and used as a
formed product such as a blanket, a board and a felt or an unshaped
product such as a coating material and mortar.
[0004] Patent Documents 3 and 4 state that, in order to suppress
elution of fiber components, biosoluble inorganic fibers are
covered with a phosphate, a molybdenum compound, a zinc compound or
the like.
RELATED ART DOCUMENT
Patent Documents
[0005] Patent Document 1: Japan Patent No. 3753416
[0006] Patent Document 2: JP-T-2005-514318
[0007] Patent Document 3: JP-A-2007-197264
[0008] Patent Document 4: JP-A-2008-162853
SUMMARY OF THE INVENTION
[0009] An object of the invention is to provide biosoluble
inorganic fibers that can be easily processed and a method for
producing the same.
[0010] According to the invention, the following inorganic fiber
and method for producing the same can be provided. [0011] 1.
Inorganic fiber comprising biosoluble fiber and a cationic
surfactant adhering to the biosoluble fiber. [0012] 2. The
inorganic fiber according to 1, wherein the biosoluble fiber has
the following composition ratio: [0013] the total of SiO.sub.2,
Al.sub.2O.sub.3, ZrO.sub.2 and TiO.sub.2 50 to 82 wt %; and [0014]
the total of CaO and MgO 18 to 50 wt %. [0015] 3. The inorganic
fiber according to 1, wherein the biosoluble fiber has the
following composition ratio: [0016] SiO.sub.2 50 to 82 wt %; and
[0017] the total of CaO and MgO 10 to 43 wt %. [0018] 4. The
inorganic fiber according to 1, wherein the biosoluble fiber has
the following composition ratio 1 or 2: [0019] [Composition ratio
1] [0020] SiO.sub.2 70 to 82 wt %; [0021] CaO 1 to 9 wt %; [0022]
MgO 10 to 29 wt %; and [0023] Al.sub.2O.sub.3 less than 3 wt %
[0024] [Composition ratio 2] [0025] SiO.sub.2 70 to 82 wt %; [0026]
CaO 10 to 29 wt %; [0027] MgO 1 wt % or less; and [0028]
Al.sub.2O.sub.3 less than 5 wt %. [0029] 5. The inorganic fiber
according to any of 1 to 4, wherein the surfactant is a cationic
surfactant. [0030] 6. The inorganic fiber according to any of 1 to
5, wherein the surfactant is an alkyl amine acetate. [0031] 7. The
inorganic fiber according to any of 1 to 6, wherein the amount of
the surfactant is 0.01 to 2 wt %, based on 100 wt % of the whole
inorganic fiber comprising the surfactant adhered thereto. [0032]
8. A method for producing the inorganic fiber according to any of 1
to 7, comprising spraying a surfactant to biosoluble fiber or
impregnating biosoluble fiber with a surfactant.
[0033] According to the invention, biosoluble inorganic fiber that
can be processed easily and the method for producing the same can
be provided.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] FIG. 1 is a view for explaining the wetted state in Example
1; and
[0035] FIG. 2 is a view for explaining the settled state in Example
1.
MODE FOR CARRYING OUT THE INVENTION
[0036] The inorganic fiber of the invention is characterized in
that a biosoluble fiber is treated by a surfactant. Specifically, a
surfactant is adhered to a biosoluble fiber and they are
integrated. A surfactant is mainly adhered to the surface of a
fiber, and preferably covers the surface thereof.
[0037] If a surfactant is adhered to a fiber, friction among fibers
is suppressed to allow fibers to be soft. As a result, fibers are
hardly bent when processing. In addition, they can be easily mixed
uniformly with other components, whereby a secondary product can be
produced stably. For example, when a felt is produced, the fiber is
pricked with a needle, and when an unshaped product is produced,
the fiber is melt-kneaded with a solvent or the like. Due to the
adhesion with a surfactant, the fiber is hardly bent during such
processing. As a result, the strength can be increased.
[0038] Further, depending on the amount of a surfactant to be
adhered, hydrophilicity, hydrophobicity and water repellency of the
entire fiber can be adjusted in accordance with the
application.
[0039] For example, when an unshaped product such as a joint filler
is produced, a high hydrophilicity is required. When a textile is
produced, the fiber is required to have high flexibility or high
hydrophobicity.
[0040] The amount of a surfactant is normally 0.01 to 2 wt %,
preferably 0.01 to 1.5 wt %, and more preferably 0.01 to 1.0 wt %
relative to 100 wt % of the entire fiber with a surfactant being
adhered thereto. The amount may be 0.01 wt % or more and less than
0.25 wt % and may be 0.25 wt % or more and 1.0 wt % or less.
According to the application, the amount of a surfactant can be
increased or decreased within this range or exceeding this
range.
[0041] Preferable surfactants in respect of performance are a
cationic surfactant such as alkylamine (primary, secondary,
tertiary, diamine, triamine) acetate, alklyldimethyl betaine,
polyoxyethylene alkylamine lactate, an alkylamideamine derivative
and alkyltrimethylammonium chloride. As for an alkyl group, one
derived from beef tallow (C8 to C18) is preferable, with alkylamine
acetate being more preferable.
[0042] In ethylenediamine tetraacetic acid (EDTA), a salt portion
is Na.sup.+(sodium salt) or NH.sub.3.sup.30(ammonium salt).
Further, since the terminal group of EDTA has a structure of acetic
acid (CH.sub.3COO.sup.-), it does not become acetate as a salt
(counter ion). Therefore, alkylamine acetate does not include in
EDTA. Normally, a surfactant does not include such a chelating
agent.
[0043] The biosoluble fiber is a fiber having a physiological
saline dissolution ratio of 1% or more at 40.degree. C.
[0044] The physiological saline dissolution ratio is measured by
the following method, for example. Specifically, first, 1 g of the
sample obtained by pulverizing inorganic fibers to 200 meshes or
less and 150 mL of physiological saline are put in a conical flask
(volume: 300 mL). This flask is placed in an incubator of
40.degree. C., and a horizontal vibration (120 rpm) is continuously
applied for 50 hours. Thereafter, the concentration (mg/L) of each
element contained in a filtrate obtained by filtration is measured
by an ICP emission spectrometry apparatus. Based on the measured
concentration of each element and the content (wt %) of each
element in inorganic fibers before dissolution, the physiological
saline dissolution ratio (%) is calculated. That is, if the
measurement elements are silicon (Si), magnesium (Mg), calcium (Ca)
and aluminum (Al), the physiological saline dissolution ratio C(%)
is calculated in accordance with the following formula:
C(%)=[Amount of filtrate (L).times.(a1+a2+a3+a4).times.100]/[Weight
(mg) of inorganic fibers before
dissolution.times.(b1+b2+b3+b4)/100]. In this formula, a1, a2, a3
and a4 are respectively the measured concentration (mg/L) of
silicon, magnesium, calcium and aluminum and b1, b2, b3 and b4 are
respectively the content (wt %) of silica, magnesium, calcium and
aluminum in the inorganic fibers before dissolution.
[0045] As the biosoluble fiber, the following composition ratio can
be specifically given: [0046] Total of SiO.sub.2, Al.sub.2O.sub.3,
ZrO.sub.2 and TiO.sub.2: 50 to 82 wt % [0047] Total of CaO and MgO:
18 to 50 wt %
[0048] In addition, the following composition ratio can be given:
[0049] SiO.sub.2: 50 to 82 wt % [0050] Total of CaO and MgO: 10 to
43 wt %
[0051] The biosoluble fibers can be roughly divided into
Mg-silicate fibers containing a large amount of MgO and Ca-silicate
fibers containing a large amount of CaO. As the Mg-silicate fibers,
the following composition ratio can be exemplified. [0052]
SiO.sub.2: 66 to 82 wt % [0053] CaO: 1 to 9 wt % [0054] MgO: 10 to
30 wt % [0055] Al.sub.2O.sub.3: 3 wt % or less [0056] Other oxides:
less than 2 wt %
[0057] As the Ca-silicate fibers, the following composition ratio
can be exemplified. The fibers having this composition ratio have
excellent biosolubility and fire resistance after heating. [0058]
SiO.sub.2: 66 to 82 wt % (it can be 68 to 80 wt %, 70 to 80 wt %,
71 to 80 wt % or 71 to 76 wt %, for example) [0059] CaO: 10 to 34
wt % (it can be 20 to 30 wt % or 21 to 26 wt %, for example) [0060]
MgO: 3 wt % or less (it can be 1 wt % or less, for example) [0061]
Al.sub.2O.sub.3: 5 wt % or less (it can be 3.5 wt % or less or 3 wt
% or less, for example, or it can be 1 wt % or more or 2 wt % or
more) [0062] Other oxides: less than 2 wt %
[0063] If SiO.sub.2 is in the above range, the fibers have
excellent heat resistance. If CaO and MgO are in the
above-mentioned range, the fibers have excellent biosolubility
before and after heating.
[0064] The content of Al.sub.2O.sub.3 can be 3.4 wt % or less or
3.0 wt % or less, for example. Further, it can be 1.1 wt % or more
or 2.0 wt % or more. It is preferably 0 to 3 wt %, more preferably
1 to 3 wt %. If Al.sub.2O.sub.3 is included within this range, the
strength is increased.
[0065] The above-mentioned inorganic fiber may or may not include,
as other oxides, one or more selected from alkali metal oxides
(K.sub.2O, Na.sub.2O or the like), Fe.sub.2O.sub.3, ZrO.sub.2,
P.sub.2O.sub.5, B.sub.2O.sub.3, TiO.sub.2, MnO, R.sub.2O.sub.3 (R
is selected from Sc, La, Ce, Pr, Nd, Sm, Eu, Gd, Tb, Dy, Ho, Er,
Tm, Yb, Lu, Y or a mixture thereof). The amounts of other oxides
may be 0.2 wt % or less or 0.1 wt % or less. As for the alkali
metal oxides, the amount of each oxide may be 0.2 wt % or less, and
the total of the alkali metal oxides may be 0.2 wt % or less.
[0066] In the biosoluble fibers, the total of SiO.sub.2, CaO, MgO
and Al.sub.2O.sub.3 may be larger than 98 wt % or larger than 99 wt
%.
[0067] Next, an explanation will be made on the method for allowing
a surfactant to be adhered to the fiber.
[0068] As for the method for allowing a surfactant to be adhered to
the fiber, no specific restrictions are imposed as long as an
adequate amount can be adhered. For example, a surfactant can be
blown from the surrounding area immediately after the formation of
a biosoluble fiber. Alternatively, a surfactant can be blown before
secondary processing; i.e. before the fibers are assembled in the
form of a bulk and a blanket. A surfactant may be adhered by
impregnation. A surfactant can be used after diluting with an
adequate solvent. Dilution can be conducted appropriately by using
water or an organic solvent as the solvent. pH adjustment can be
conducted with acetic acid, nitric acid, hydrochloric acid,
sulfuric acid, ammonium or the like. Normally, taking equipment,
safety or the like into consideration, it is preferable to adjust
with water, acetic acid, ammonium or the like. pH is not
particularly restricted, but a pH of about 6 to 8 is preferable in
respect of safety.
[0069] Further, heating and drying may be conducted at a
temperature range in which a surfactant does not totally disappear
or its effects are exhibited.
[0070] The fiber of the invention to which a surfactant is adhered
can be used as it is as a textile and a bulk. In addition, they can
be processed into a formed product such as a blanket, a board and a
felt or an unshaped product such as a coating material, mortar or
the like.
[0071] The fiber of the invention may have a configuration in which
only a surfactant is adhered. Within a range that does not impair
the effects of the invention, other materials may be adhered. The
fiber of the invention may have a configuration in which
phosphates, molybdenum compounds, zinc compounds, polyamidine
compounds, ethyleneimine compounds, aluminum compounds,
nitrilotriacetic acid, ethylenediaminetetraacetic acid, a
hydrophobic agent (silicone or the like). antiseptics (natural)
starch, (natural) starch sulfamate or sulfamic acid or the like are
not adhered.
EXAMPLES
Examples 1 and 2
[0072] A raw material containing 73 mass % of SiO.sub.2, 24 mass %
of CaO, 0.3 mass % of MgO and 2 mass % of Al.sub.2O.sub.3 was
heated to produce a molten solution. Next, when the molten solution
was formed into fiber, an alkyl amine acetate (surfactant) was
sprayed from the side to produce inorganic fiber. The amount of
surfactant attached to the fiber was varied as shown in Table
1.
[0073] The fiber obtained was lightly rubbed with both hands and
made into a ball to prepare a sample. The sample was dropped into a
200 ml measuring cylinder containing 200 ml of tap water. The time
taken until the sample became wet and the time taken until it
settled were measured continuously. The results are shown in Table
1.
[0074] The wetting time means the time taken from a point in time
at which the sample is dropped to the measuring cylinder to a point
in time at which the entire sample sinks under the water as shown
in FIG. 1. The settling time means the time which has passed from a
point in time when the sample is dropped to a measuring cylinder to
a point in time when the sample settles at the bottom of the
measuring cylinder shown in FIG. 2.
Comparative Example 1
[0075] Fiber was produced and evaluated in the same manner as in
Example 1, except that a surfactant was not attached. The results
are shown in Table 1.
TABLE-US-00001 TABLE 1 Water Attached amount Flexibility repellency
Hydrophilicity Wetting time Settling time Example 1 Less than 0.01
to .smallcircle. .smallcircle. x Not wetted Not settled 0.25%
Example 2 0.25 to 1.0% .smallcircle. .DELTA. .DELTA. 10 to 25 sec
Within 60 sec Com. Ex. 1 None x x .smallcircle. Within 3 sec Within
4 sec
[0076] The fiber in Example 1 is suited for a bulk of textile
products. Also, it can be used as a joint filler which is used in
an atmosphere with high humidity and thus requires to have high
water repellency.
[0077] The fiber in Example 2 has good flexibility, and moderate
hydrophilicity and water repellency (i.e. hardly settle down in
water but not completely float), and is easily stirred
homogeneously without being broken. Therefore, it is suited for an
unshaped heat insulating material.
INDUSTRIAL APPLICABILITY
[0078] The inorganic fiber of the invention can be used for various
applications as a heat insulator and an alternative to
asbestos.
[0079] Although only some exemplary embodiments and/or examples of
this invention have been described in detail above, those skilled
in the art will readily appreciate that many modifications are
possible in the exemplary embodiments and/or examples without
materially departing from the novel teachings and advantages of
this invention. Accordingly, all such modifications are intended to
be included within the scope of this invention.
[0080] The documents described in this specification and the
Japanese application specification claiming priority under the
Paris Convention are incorporated herein by reference in its
entirety.
* * * * *