JPH0222036A - Sound insulation molding - Google Patents

Abstract

PURPOSE:To obtain a molded item having excellent flexibility, processability and sound insulating property by preparing silicic acid iron oxide from a specified ratio of iron oxide and silica and kneading a filler wherein the content of an alkali metal oxide is low with a binder. CONSTITUTION:In a sound insulating molded item wherein a filler of an inorg. particle having a specified compsn. is incorporated, 50-90wt.% iron oxide and 10-30wt.% silica are incorporated therein and majority of the silica has a form of silicic acid iron oxide. In addition, the sum of the content of an alkali metal oxide or an alkali earth metal oxide is 10wt.% or less in the filler. 200-1,000pts. wt. this filler are compounded in 100pts.wt. binder consisting of a polymer resin and/or a petroleum asphalt and the mixture is kneaded and then molded. The thus obtd. molded item has excellent flexibility and processability, a large surface density and excellent sound insulating property.

Description

DETAILED DESCRIPTION OF THE INVENTION Field of Industrial Application The present invention relates to a sound-insulating molded product containing a filler of inorganic particles having a specific composition as a filler.

BACKGROUND OF THE INVENTION Conventionally, many types of sound insulating materials for preventing the intrusion of external noise or the emission of sound to the outside, or sound absorbing materials for weakening the reflection of sound, have been known.

These sound insulating or sound absorbing materials can be processed into seeds and laid on the floors and walls of automobiles, railway vehicles, buildings, etc., adhered to uneven or curved surfaces, or even laminated with copper plates, nonwoven fabrics, or boards. It is widely used as molded products. and,
In order to enhance the sound insulation effect of these molded products, it is considered desirable to fill the sound insulation material with as much high-density filler as possible.

However, when fillers are used in sound insulation materials, unless they are properly combined with a binder, a large amount of filler cannot be filled, the flexibility of the sound insulation materials cannot be obtained, and furthermore, the so-called plate-out phenomenon occurs during the molding process. There are problems such as a significant reduction in the surface finish of the product.

Incidentally, recently, a soundproofing material has been proposed in which a vinyl chloride resin containing a plasticizer is combined with iron oxide, which is produced as a by-product in the steel manufacturing process (Japanese Patent Application Laid-open No. 57-34064). It is emphasized that the oxide has excellent adhesive properties with vinyl chloride. However, the above-mentioned soundproofing material has poor releasability from the roll surface during molding and takes a long time to gel, so its mechanical properties when formed into a sheet are not satisfactory.

Problems to be Solved by the Invention The present invention has been made in view of the above-mentioned problems encountered with conventional sound insulating materials. An object of the present invention is to provide a sound-insulating molded product having sound-insulating properties.

The present inventor investigated sound-insulating molded products having the above characteristics and found that iron concentrate slag particles produced as a by-product in the copper refining process are extremely excellent as fillers for the above-mentioned sound-insulating molded products. As a result of investigating the composition of the filler and considering the results, it was found that an inorganic material containing iron oxide and silica as main components and having a specific composition can be effectively used as the filler, and the above problem can be solved. was successfully solved. The present invention will be explained in detail below.

Structure of the Invention The feature of the sound insulating molded product according to the present invention is that iron oxide is 50 to 90% iron oxide.
% by weight and 10-30% by weight of silica, with the majority of the iron oxide and silica being in the form of iron silicate oxide, and a content of alkali metal oxides or alkaline earth metal oxides. 200 to 100 parts by weight of a filler composition having a total of 10% or less of
It is kneaded and molded at a blending ratio of 1000 parts by weight.

Means for Solving the Problems The filler composition (filler) used in the sound-insulating molded product of the present invention is particularly important in its compositional component ratio,
50-90% by weight of iron oxide and 10-30% by weight of silica, while the total content of alkali metal oxides or alkaline earth metal oxides is less than 10% by weight, preferably 7% by weight, especially 5% by weight It is necessary to limit it to less than %.

Note that there are no particular restrictions on the composition of the remainder. Iron oxide is Fe01
Fe203, Fe3O4, FeO-Fe2O3, nFe
o ・5iOz, nFe0 ・FezO3-5i02(
n is an integer of 1 to 3). Among these forms, those in the form of iron silicate oxide have particularly excellent adhesion with resins as binders, and n
Feo・SiO□ and nFeo・Fe203H5iOz
Iron oxide existing in the form (n is the same as above) is Fe
Compared to a simple physical mixture of iron oxide particles in the form of O or Fe2O3 and SiO The sheet surface of the sound-insulating molded product obtained by using this method has a good finish.

Therefore, in the filler composition used for the sound-insulating molded article of the present invention, most of the iron oxide and wrinkle strength must be present in the form of iron silicate oxide, and the iron oxide must be present in an amount of at least 50% by weight. is nFeo-3i02 and nFe0 ・Fe
It is preferable that it is 2O3.5i02 (n is an integer of 1 to 3).

Furthermore, it should be noted that if the content of iron oxide in the filler composition as a whole is less than 50% by weight, a molded product obtained using the filler composition will not be able to exhibit sufficient sound insulation properties.

Note that the upper limit of the content of iron oxide is determined by the required amount of silica to be included, which will be described below.

Silica, which is another essential component of the filler composition used in the sound-insulating molded product of the present invention, has a bulk density of 0.3 to
It is around 1, which is smaller than 4 to 6 for iron oxide, so it is not useful for improving the areal density when used in sound-insulating molded products, but the presence of this silica significantly reduces the amount of iron oxide packed. It also has the effect of improving the surface smoothness of products. Thus, it is important to have at least 10% by weight of silica in the filler composition in order to increase the loading of iron oxide into the sound-insulating molding. However, as mentioned above, silica itself has a low density, so it is not preferable to have a large amount of silica present in the filler because it will suppress the amount of high-density filling.
0% by weight is the limit.

In addition to 5i02, the silica used here is nFe0.
Although it may be in the form of 5i02, nPeo-Fe2O:+H5iOz (n is an integer of 1 to 3) or silica alumina, as described above, the form of iron silicate oxide is preferable.

Therefore, in the filler composition used in the present invention, it is preferable that the iron oxide or silica present in the form of iron silicate oxide is about 50 to 100% by weight of the total iron oxide or the total silica.

Furthermore, in the filler composition used in the present invention, an alkali metal oxide or an alkaline earth metal oxide, such as N
It is preferable that the content of a2O, MgO, CaO, etc. is small, and as mentioned above, it is necessary to limit the total amount to 10% by weight or less, preferably 7% by weight or less, especially 5% by weight or less. be.

The presence of these oxides causes a plate-out phenomenon on the roll metal surface during the molding process of sound-insulating moldings and causes a delay in gelation time, and as the content increases, the above phenomenon becomes more severe. As mentioned above, the content is preferably as low as possible.

The filler composition used in the present invention has the above-mentioned composition, and as an example of one that satisfies such composition, mantle obtained from a flash furnace in the copper refining process is mixed with SiO□ and oxygen in a converter. The so-called iron ore slag is obtained by adding silicate and oxidizing, subjecting the resulting slag to magnetic separation, flotation of the obtained slag, and dehydrating the residue after recovering copper concentrate. I can do things.

That is, the main component of this iron concentrate slag is 2FeO・S
Approximately 50 to 80% by weight (740 to 50% as FeO)
wt%, Sin□715-30wt%), Fe5
O4 is 10 to 30 M%, Fe2O3 is 5% by weight, MgO is 5% by weight or less, and CaO is hardly contained. Moreover, this slag is crushed particles with a particle size of about 30μ that has undergone flotation, has a bulk density of 3 to 4, and a true specific gravity of 5 to 5.
5.5, it is suitable as a filler of the present invention, especially nFeo-5iOz (n is 1 to 2) and n
Iron concentrate slag produced as a by-product in the copper refining process and containing Feo-Fe203Si02 (n is 1 to 3) as a main component is the most preferable example of the filler.

Now, in order to use this iron concentrate slag as a filler composition in the present invention, it should be noted that its moisture content must be dried to 2% by weight or less, preferably 1% by weight or less, particularly 0.5% by weight or less. It is.

This is because a high moisture content may cause foaming during the molding process when used as a filler composition in a sound-insulating molded product.

Incidentally, iron oxide 25%, silica 12wt% and Ca037w described in the above-mentioned Japanese Patent Application Laid-Open No. 57-34064
Converter slag (generated in the steel manufacturing process) with a composition containing approximately t% has a composition different from that of the above-mentioned iron concentrate slag in terms of wood quality, and has a different composition due to its affinity with polymer resins and molding process. Also in terms of properties, as shown in the examples below, it is significantly inferior.

Next, the sound-insulating molded article of the present invention obtained by utilizing the characteristics of the filler composition described above will be described.

The sound-insulating molded product according to the present invention is obtained by kneading the above-described filler composition and a polymer resin and/or petroleum asphalt as a binder, and then molding the mixture. Here, the filler is mixed as fine particles of 200 to 1000 parts by weight with respect to 100 parts by weight of the binder, heated to a temperature of about 100 to 150°C, and mixed with a Hanhari mixer. Thoroughly knead using a mixing roll or the like.

In addition, the polymer resin used as a binder here includes soft polyvinyl chloride, a copolymer of vinyl chloride and vinyl acetate, ethylene-vinyl acetate resin, acrylic resin,
Urethane resin, polypropylene resin, natural rubber, butadiene rubber, styrene rubber, styrene-butadiene rubber,
Examples include waste tires, and plasticizers, stabilizers, etc. are added as appropriate during use. Moreover, it is preferable to use petroleum asphalt in combination with the above resin.

The material kneaded as described above is usually molded into a thickness of 0°2 to 5 m using a calendar molding machine or an extrusion molding machine.
It is molded into a sheet shape with a thickness of about 1.5 m and used as a sound-insulating molded product as it is, or by pasting it onto metal materials, nonwoven fabrics, or even plate materials.

As mentioned above, the sound insulating molded product according to the present invention uses a filler composition having excellent properties, so it has excellent moldability compared to conventionally proposed sound insulating materials. It retains excellent flexibility even when filled with a large amount of material, making it highly practical as a sound insulating material.

EXAMPLES The present invention and its effects will be explained in more detail with reference to Examples below.

Examples and Effects Example 1 Vinyl chloride resin (average degree of polymerization 800) 100 parts by weight,
600 parts by weight of each filler having the composition shown in Table 1 was mixed and kneaded with 165 parts by weight of a compound consisting of 60 parts by weight of DOP as a plasticizer and 5 parts by weight of a tin-based stabilizer. Each of the obtained kneaded products was formed into sheets 1 with a thickness of 1 and 0 mm using 8 inch x 20 inch two-wood rolls, respectively. The processability of each sheet obtained was examined and evaluated. The results are shown in Table 2. Note that, as Comparative Example 1, a sheet formed using a filler different from the filler of the present invention in the same manner as above was also evaluated for its workability, and the results are also shown in Table 2.

As shown in Table 2, when Comparative Examples F-2 and F-3 fillers containing large amounts of alkaline earth metal oxides such as CaO were used, the plate-out phenomenon was significant and the gelation time was 2. It will take almost twice as long. Furthermore, it is recognized that the present invention has higher bending strength and greater flexibility than the comparative example.

Example 2 The same procedure as described in Example 1 was followed except that the amount of filler composition F-1 used in Example 1 was changed to obtain a material with a thickness of 2.0.
A sheet of mm was molded and its workability was evaluated in the same manner.

As Comparative Example 2, sheets were molded in the same manner as in Comparative Example 1, except that the amount of filler F-2 used was changed, and the processability was evaluated in the same manner.

The results are shown in Table 3.

table (unit parts by weight)

Claims (1)

[Claims] (1) In a molded product having sound insulation properties obtained by kneading and molding a binder made of a polymer resin and/or petroleum asphalt and a filler of inorganic particles, (a) the filler of the inorganic particles is iron oxide 50; ~90% by weight and 10-30% by weight of silica, with most of the iron oxide and silica being in the form of iron silicate oxide, and containing alkali metal oxides or alkaline earth metal oxides. Particles having a composition in which the total amount is 10% by weight or less,
and (b) a sound insulating molded article, characterized in that the filler is contained in a blending ratio of 200 to 1000 parts by weight per 100 parts by weight of the binder.