CA2144250A1 - Method for the manufacture of a porous, mineral lightweight insulating board - Google Patents
Method for the manufacture of a porous, mineral lightweight insulating boardInfo
- Publication number
- CA2144250A1 CA2144250A1 CA002144250A CA2144250A CA2144250A1 CA 2144250 A1 CA2144250 A1 CA 2144250A1 CA 002144250 A CA002144250 A CA 002144250A CA 2144250 A CA2144250 A CA 2144250A CA 2144250 A1 CA2144250 A1 CA 2144250A1
- Authority
- CA
- Canada
- Prior art keywords
- lightweight insulating
- insulating board
- boards
- foam
- water
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
- 238000000034 method Methods 0.000 title claims abstract description 27
- 229910052500 inorganic mineral Inorganic materials 0.000 title claims abstract description 12
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 12
- 239000011707 mineral Substances 0.000 title claims abstract description 12
- 239000004567 concrete Substances 0.000 claims abstract description 34
- 239000006260 foam Substances 0.000 claims abstract description 27
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicon dioxide Inorganic materials O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims abstract description 24
- 239000011230 binding agent Substances 0.000 claims abstract description 22
- 239000002002 slurry Substances 0.000 claims abstract description 22
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 22
- 229910001868 water Inorganic materials 0.000 claims abstract description 22
- 239000000126 substance Substances 0.000 claims abstract description 21
- AXCZMVOFGPJBDE-UHFFFAOYSA-L calcium dihydroxide Chemical compound [OH-].[OH-].[Ca+2] AXCZMVOFGPJBDE-UHFFFAOYSA-L 0.000 claims abstract description 12
- 239000004568 cement Substances 0.000 claims abstract description 10
- 239000000843 powder Substances 0.000 claims abstract description 10
- 239000010453 quartz Substances 0.000 claims abstract description 8
- 239000000084 colloidal system Substances 0.000 claims abstract description 7
- 238000002156 mixing Methods 0.000 claims abstract description 7
- 230000005070 ripening Effects 0.000 claims abstract description 6
- 238000005520 cutting process Methods 0.000 claims abstract description 5
- 230000015572 biosynthetic process Effects 0.000 claims abstract description 4
- 238000007599 discharging Methods 0.000 claims abstract description 3
- 238000005470 impregnation Methods 0.000 claims description 19
- 150000001875 compounds Chemical class 0.000 claims description 16
- 235000012239 silicon dioxide Nutrition 0.000 claims description 13
- 230000003068 static effect Effects 0.000 claims description 11
- 239000011148 porous material Substances 0.000 claims description 10
- 239000000377 silicon dioxide Substances 0.000 claims description 8
- 239000005871 repellent Substances 0.000 claims description 7
- 239000011152 fibreglass Substances 0.000 claims description 6
- 239000000969 carrier Substances 0.000 claims description 5
- 230000035515 penetration Effects 0.000 claims description 5
- 239000004890 Hydrophobing Agent Substances 0.000 claims description 3
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 claims description 3
- 239000006185 dispersion Substances 0.000 claims description 2
- 230000002209 hydrophobic effect Effects 0.000 claims description 2
- 239000003431 cross linking reagent Substances 0.000 claims 1
- 239000012530 fluid Substances 0.000 claims 1
- 235000019353 potassium silicate Nutrition 0.000 claims 1
- 230000000875 corresponding effect Effects 0.000 description 8
- 235000010755 mineral Nutrition 0.000 description 8
- 238000000465 moulding Methods 0.000 description 7
- 239000003795 chemical substances by application Substances 0.000 description 6
- 229960001866 silicon dioxide Drugs 0.000 description 5
- 238000010521 absorption reaction Methods 0.000 description 3
- 238000001035 drying Methods 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- 239000000203 mixture Substances 0.000 description 3
- ODINCKMPIJJUCX-UHFFFAOYSA-N Calcium oxide Chemical compound [Ca]=O ODINCKMPIJJUCX-UHFFFAOYSA-N 0.000 description 2
- 235000008733 Citrus aurantifolia Nutrition 0.000 description 2
- 239000004793 Polystyrene Substances 0.000 description 2
- 235000011941 Tilia x europaea Nutrition 0.000 description 2
- 229920004482 WACKER® Polymers 0.000 description 2
- 239000003513 alkali Substances 0.000 description 2
- 239000000835 fiber Substances 0.000 description 2
- 238000007667 floating Methods 0.000 description 2
- 230000001771 impaired effect Effects 0.000 description 2
- 238000009434 installation Methods 0.000 description 2
- 239000001034 iron oxide pigment Substances 0.000 description 2
- 239000004571 lime Substances 0.000 description 2
- 230000000149 penetrating effect Effects 0.000 description 2
- 229920002223 polystyrene Polymers 0.000 description 2
- 238000002791 soaking Methods 0.000 description 2
- 239000007787 solid Substances 0.000 description 2
- OYPRJOBELJOOCE-UHFFFAOYSA-N Calcium Chemical compound [Ca] OYPRJOBELJOOCE-UHFFFAOYSA-N 0.000 description 1
- 238000013459 approach Methods 0.000 description 1
- 239000012298 atmosphere Substances 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 238000007664 blowing Methods 0.000 description 1
- 230000001680 brushing effect Effects 0.000 description 1
- 239000011575 calcium Substances 0.000 description 1
- 229910052791 calcium Inorganic materials 0.000 description 1
- 239000000920 calcium hydroxide Substances 0.000 description 1
- 229910001861 calcium hydroxide Inorganic materials 0.000 description 1
- 235000011116 calcium hydroxide Nutrition 0.000 description 1
- 239000000292 calcium oxide Substances 0.000 description 1
- 235000012255 calcium oxide Nutrition 0.000 description 1
- 239000000378 calcium silicate Substances 0.000 description 1
- 229910052918 calcium silicate Inorganic materials 0.000 description 1
- OYACROKNLOSFPA-UHFFFAOYSA-N calcium;dioxido(oxo)silane Chemical compound [Ca+2].[O-][Si]([O-])=O OYACROKNLOSFPA-UHFFFAOYSA-N 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 238000004040 coloring Methods 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 230000001143 conditioned effect Effects 0.000 description 1
- 230000006378 damage Effects 0.000 description 1
- 238000000151 deposition Methods 0.000 description 1
- 230000002542 deteriorative effect Effects 0.000 description 1
- 238000009826 distribution Methods 0.000 description 1
- 238000004880 explosion Methods 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 230000001788 irregular Effects 0.000 description 1
- 238000011068 loading method Methods 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 230000004224 protection Effects 0.000 description 1
- 102000004169 proteins and genes Human genes 0.000 description 1
- 108090000623 proteins and genes Proteins 0.000 description 1
- 238000005086 pumping Methods 0.000 description 1
- 230000000284 resting effect Effects 0.000 description 1
- 229920006395 saturated elastomer Polymers 0.000 description 1
- 229910021487 silica fume Inorganic materials 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 239000004094 surface-active agent Substances 0.000 description 1
- 229920001187 thermosetting polymer Polymers 0.000 description 1
Classifications
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/009—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone characterised by the material treated
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/50—Producing shaped prefabricated articles from the material specially adapted for producing articles of expanded material, e.g. cellular concrete
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
- B28B11/04—Apparatus or processes for treating or working the shaped or preshaped articles for coating or applying engobing layers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B17/00—Details of, or accessories for, apparatus for shaping the material; Auxiliary measures taken in connection with such shaping
- B28B17/02—Conditioning the material prior to shaping
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28C—PREPARING CLAY; PRODUCING MIXTURES CONTAINING CLAY OR CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28C5/00—Apparatus or methods for producing mixtures of cement with other substances, e.g. slurries, mortars, porous or fibrous compositions
- B28C5/38—Apparatus or methods for producing mixtures of cement with other substances, e.g. slurries, mortars, porous or fibrous compositions wherein the mixing is effected both by the action of a fluid and by directly-acting driven mechanical means, e.g. stirring means ; Producing cellular concrete
- B28C5/381—Producing cellular concrete
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
- C04B38/10—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by using foaming agents or by using mechanical means, e.g. adding preformed foam
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/45—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements
- C04B41/50—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials
- C04B41/5076—Coating or impregnating, e.g. injection in masonry, partial coating of green or fired ceramics, organic coating compositions for adhering together two concrete elements with inorganic materials with masses bonded by inorganic cements
- C04B41/5089—Silica sols, alkyl, ammonium or alkali metal silicate cements
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B41/00—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone
- C04B41/60—After-treatment of mortars, concrete, artificial stone or ceramics; Treatment of natural stone of only artificial stone
- C04B41/61—Coating or impregnation
- C04B41/65—Coating or impregnation with inorganic materials
- C04B41/68—Silicic acid; Silicates
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/20—Resistance against chemical, physical or biological attack
- C04B2111/27—Water resistance, i.e. waterproof or water-repellent materials
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Structural Engineering (AREA)
- Materials Engineering (AREA)
- Organic Chemistry (AREA)
- Mechanical Engineering (AREA)
- Inorganic Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Manufacturing & Machinery (AREA)
- Porous Artificial Stone Or Porous Ceramic Products (AREA)
- Curing Cements, Concrete, And Artificial Stone (AREA)
- Building Environments (AREA)
Abstract
A method for the manufacture of a porous, mineral lightweight insulating board comprises the following steps:
producing a binder slurry from cement, quartz powder, lime hydrate and water, preferably in a colloid mixer;
producing a foam in a foam production unit from water, compressed air and an air entrainer;
mixing the binder slurry and the foam to form a porous concrete sub-stance;
homogenizing the porous concrete substance by means of a continuous mixer;
discharging the porous concrete substance into a mold for the formation of a molded cake for the lightweight insulating board;
initially stiffening the molded cake preferably in a ripening chamber;
cutting the molded cake into individual lightweight insulating boards;
and curing the lightweight insulating boards in an autoclave.
producing a binder slurry from cement, quartz powder, lime hydrate and water, preferably in a colloid mixer;
producing a foam in a foam production unit from water, compressed air and an air entrainer;
mixing the binder slurry and the foam to form a porous concrete sub-stance;
homogenizing the porous concrete substance by means of a continuous mixer;
discharging the porous concrete substance into a mold for the formation of a molded cake for the lightweight insulating board;
initially stiffening the molded cake preferably in a ripening chamber;
cutting the molded cake into individual lightweight insulating boards;
and curing the lightweight insulating boards in an autoclave.
Description
21~250 METHOD FOR THE MANUFACTURE OF A POROUS, MINERAL
LIGHTVVEIGHT INSULATING BOARD
BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION
The invention relates to a method for the m~mlf~ctllre of a porous, min-eral lightweight inslll~ting board, as it may for instance be used to re-10 place polystyrene boards or mineral boards as thermal building protec-tion.
BACKGROUND ART
15 It is known from the prior art to m~mlf~ct~lre so-called gas or porous concrete blocks, which have a density of some 100 kg/m3. Owing to their porous structure, these porous concrete blocks have excellent heat in-slll~tine properties.
20 Roughly outlined, these porous concrete blocks are made from a binder slurry (with lime or cement as a binder), which is expanded by the ad-dition of an expanding agent on the basis of an alnminllm compound.
This way of m~nllf~cture involves the problem that, as a rule, a density gradient from the bottom upwards as well as microcracks in the block 25 structure may occur as a result of the expansion. Moreover, the metered addition of the alllminnm compound is very critical. The m~nnf~cture of substances of extremely strong porosity having apparent densities of less than 200 kg/m3 is almost impossible.
30 Because of the above-mentioned circumstances it is not possible in pra.c-tice with the methods used for the m~nllf~cture of porous concrete blocks to m~nllf~cture mineral leight-weight ins~ ting boards that must have an apparent density of 100 to 200 kg/m3 and less in order to possess heat insulating properties comparable to polystyrene boards.
Tests have shown that in the case of a correspondingly increased expan-sion of the binder slurry, the method suitable for the m~nllf~chlre of po-rous concrete blocks results in lightweight insulating boards not having sufficient structural stability in the first place.
DE 41 18 537 C1 discloses a method for the manufacture of cement foam, by which, however, only foam densities of 250 to 400 kg/m3 are attain-able. As discussed, these foam densities are too high to achieve the desired heat insulating properties in the insulating board made from such lo a cement foam.
Further, DE 42 16 204 A1 discloses a porous, mineral lightweight insulat-ing board, which substantially consists of calcium silicate hydrate, silica and possibly a porous loading agent and which is prepared with such a 15 pore count and distribution as to have a weight per unit volume of less than 220 kg/m3 and a coefficient of thermal conduction below O.OS0 W/mK
As regards the components of this heat insulating board, the calcium si-licate hydrate component is explained to be preferably due to the pres-ence of slaked lime, silica and water in the basic m~nllf~cturing materi-20 al. Alternatively, a portion of burnt lime may be employed, which is hy-drated by water absorption during the m~mlf~cture. Preferably, the sili-con dioxide component of the heat insulating board according to the in-vention substantially consists of quartz powder and/or amorphous silicic acld.
As regards the formation of pores, it can be taken from DE 42 16 204 A1that water contained in the wet m~nllf~cturing material is evaporated during the curing or, respectively, that pores are formed with the aid of a pore forming agent in the manufacturing material and are then present 30 in the finished heat insulation boards. Preferred pore forrning agents are tensides, alnminllm powder or peroxo compounds. The problems mentioned at the outset should arise at least with the use of ahlminllm powder.
Moreover, tests of Applicant have shown that the application of generally known m~nllf~cturing methods for heat insulating boards according to DE 42 16 204 A1 gives rise to practical problems of obtaining heat insu-lating boards of the indicated weight per unit volume and heat conduc-tivity which exhibit the structural stability necessary for reliable use at site. Any approaches to the solution of these problems cannot be taken 5 from DE 42 16 204 A1.
Another problem with the heat ins~ ing boards according to this docu-ment resides in the water absorption of these heat insulating boards dur-ing transport, storing and when used in building. It can be taken from 10 the document that the surface of the heat in~ ting boards is provided with a water-repellent agent applied by brushing or spraying. But there is the fundamental requirement that heat insulating boards fixed to the wall of a building must be floated prior to the application of a layer of cast, thin as a rule, on their surface, so as to compensate any differ-15 ences in height where the boards join. During this floating operation, forinstance by means of a so-called float, the top layer of the heat in-sulating boards and thus the water-repellent agent on the surface are removed, so that the board can take up humidity where it has been floated. This means that the boards take water from the layer of cast 20 subsequently applied, which results in inhomogeneities within the layer of cast and in a humidification of the board, deteriorating the heat insulat-ing capacity. Humidification will also impair the frost resistance of the boards.
25 The older patent application P 43 27 074.3 deals with a method for the m~nllf~c~lre of a mineral lightweight insulating board, in which a binder slurry of the conventional components of water, quartz powder, lime hy-drate and cement is prepared in a so-called paddle agitator and into which a foam produced in a foam production unit is subsequently stirred 30 The porous concrete thus produced allowed the manufacture of mineral lightweight inslllating boards of a density ranging from 100 to 200 kg/m3 and a specific thermal conductivity of approximately O.OS, and of im-proved structural stability and homogeneity to a limited degree, but these boards still did not exhibit the properties, needed for the reliable use in ~ ~1442~0 practice, as to strength, heat inclllating power and water-repellent be-havior.
SUMMARY OF THE INVENTION
It is accordingly the object of the invention to specify a method for the m~nllf~ct~lre of a porous, mineral lightweight insulating board, which will comply with the practical requirements in building as a result of its high degree, conditioned by the m~nllf~ctllre, of strength and heat insu-10 lating properties.
This object is solved by a method comprising the following steps: pro-ducing a binder slurry from cement, quartz powder, lime hydrate and water, preferably in a colloid mixer; producing a foam in a foam pro-15 duction unit from water, compressed air and an air entrainer; mixing thebinder slurry and the foam to form a porous concrete substance; homo-genizing the porous concrete substance by means of a continuous mixer;
discharging the porous concrete substance into a mold for the formation of a molded cake for the lightweight ins~ ting board; initially stiffening 20 the molded cake preferably in a ripening chamber; cutting the molded cake into individual lightweight insulating boards; and curing the light-weight insulating boards in an autoclave. The outstanding features of the invention are considered to be the individual production of a binder slurry and a foam, the mixing of these two components to form a porous 25 concrete substance, and in particular the latter's homogenizing by means of a continuous mixer. Test have shown that the use of this process se-quence serves to form an especially homogeneous porous concrete of fine air pores, which will give an especially solid and high-temperature insu-lating board after the autoclaving. The reason for this is considered to 30 be the particularly gentle homogenizing in the continuous mixer used, which preferably is a so-called static mixer as used for many applica-tions in chemical industry. Such continuous or static mixers are charac-terized by the fact that there are no rotating parts, by their momentum exercising forces on the porous concrete that might lead to a destruction ~144250 of the pores. Rather, in the continuous or static mixer, the homogenizing is caused by static guiding elements leading to turbulences in the porous concrete when it is pumped through. Obviously, this constitutes an espe-cially gentle way of homogenizing, resulting in excellent properties in 5 the lightweight insulating boards thereby produced.
The preferred mixing of the binder slurry and the foam with the aid of a mixer tube branched in the form of a Y is technically particularly simple on the one hand, but on the other hand it results in a preliminary mix-10 ing of the porous concrete components sufficient for the further homo-genizing in the continuous or static mixer.
Further preferred embodiments of the method according to the invention relate to a finishin~ treatment of the autoclaved lightweight insulating 15 boards, according to which the latter are provided with a water-repellent and/or hardening impregnation. This impregnation is characterized by the fact that the depositing of the impregnation takes place in such a way that, proceeding from the board surface, the impregnation extends in-wardly by a certain depth of penetration - at least 1.5 cm are consider-20 ed to be advantageous. Different effects are achieved with the aid of thispreferred impregnation, which are directed to the lightweight insulating board itself:
- Because of the penetrating depth of the impregnation, the lightweight25 insulating boards can be floated on their surface without the water-re-pellent qualities of the impregnation being impaired. Consequently, the cast layer to be applied after the mounting of the lightweight insulat-ing boards to the wall of a building meets with water-repellent proper-ties constant over the surface of the boards, so that no irregular water 30 absorption from the cast layer by the insulating board can take place and the frost resistance will not be impaired.
- Because of the impregnation layers on all its surfaces, the insulating board is excellently protected against penetrating water so that even - ~144250 when the boards are stored in the open at site, humidification is not to be expected. The lightweight in~ ting boards according to the in-vention do not make any special demands of protected storing.
5 - Because of the hardening of their surfaces, the boards are very well protected against being impressed so that no special care must be taken when the boards are handled at site.
- Because of the impregnation of the board all over, rigid layers includ-10 ing between them a layer of reduced strength form in the vicinity ofboard faces turned away from each other. The lightweight insulating board has a structural design similar to that of a multilayer composite board. In the manner known from the latter, this results in a substan-tial increase in the strength of the board, in particular the bending 15 tensile strength increasing.
- Because of the hardening of a surface zone of the board, plugs can be anchored especially reliably in the board.
20 - Because of the coloring of the impregnating layer for instance by iron oxide pigment, optimal controllability of the boards is ensured to the effect that board zones not impregnated, which appear during the floating for the board joints to be levelled or when the boards are cut to size for instance in the case of window bays, are recognized imme-25 diately and can then be impregnated subsequently.
Fundamentally, the impregnating compound is applicable by overpressureor partial vacuum for soaking into the board. In particular, the over-pressure method is known from the pressure impregnation of wooden com-30 ponents. When applied to the lightweight insulating boards according tothe invention, the pressure impregnation may be applicable if certain limits of m~xim~lm pressure and of the rapidity, by which pressure actu-ation and relief will take place, are observed, but it is not without problems. For instance, the impregnating compound soaked into the boards - ~14 12~0 by the application of pressure in a dip tank may be expelled again dur-ing pressure relief by re-expansion of the air in the pores inside the boards, so that the impregnation leaves much to be desired. Also, in particular in the case of too rapid a pressure relief, the boards tend to 5 be destroyed like in an explosion, because the pores of the boards have a strong tendency towards expansion in the case of pressure relief. Last but not least, the apparatus requirements for overpressure impregnation are very complicated, because overpressure values of several bars must be dominated.
By reason of the above described circumstances, partial vacuum impreg-nating is to be preferred, the boards being impregnated in a manner gentle to the structure. More detailed explanations of this will become apparent from the exemplary embodiment, to which reference is made to 15 avoid unnecessary repetition.
According to further embodiments of the invention, additional silicon dioxide carriers or, respectively, additional fiber glass may be mixed into the binder slurry. The additional silicon dioxide carriers may for 20 instance be so-called "micro-silica" particles as they are commercially available as concrete adn~ixLures. The fiber glass, which may optionally be mixed in for further increasing the strength of the in.cul~ting board, is alkali resistant and has a preferred fiber length ranging between 6 mm and 12 mm.
Further features, details and advantages of the invention will become apparent from the ensuing description of exemplary embodiments of the method according to the invention as well as the insulating board ac-cording to the invention, taken in conjunction with the drawing.
BRIEF DESCRIPTION OF THE DRAWING
Fig. 1 is a diagr~mm~tic partial illustration of an installation using the m~nllf~cturing method according to the invention, and -- 21442~0 ig. 2 is a diagr~mm~tic section through a lightweight insulating board according to the invention.
ESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to Fig. 1, the production of the porous concrete for the light-weight ins~ ing board is explained first. A binder slurry of cement, quartz powder, lime hydrate and water is produced in a conventional colloid mixer, which is for instance provided with a paddle agitator.
10 Being supplied from corresponding silos 2, 3, 4 via conveying means (not shown), such as feed screws, the solid components, while being weighed, can be automatically added to the colloid mixer 1 together with a corre-sponding quantity of hot water (of a temperature of approxim~tely 40 to 50C). Additionally, fiber glass and/or special silicon dioxide carriers 15 can be mixed in. The following basic recipe can be used for the binder slurry:
30 kg cement 15 kg lime hydrate 20 50 kg quartz powder 2 kg alkali-resistant fiber glass (fiber length ranging from 6 mm to 12 mm) 60 l water.
25 This mixture is mixed in the colloid mixer 1 while being simultaneously transferred by pumping via the return pipe 5, which is connected with the output of the colloid mixer 1 by way of the three-way valve 6, so that the binder slurry is discharged into the tundish 7.
30 In a parallel branch of the installation, water, protein-composition air entrainer and compressed air are supplied from corresponding reservoirs 12, 13, 14 via metering valves 9, 10, 11 to a conventional foam gun 8.
The foam gun 8 is for instance of the type SG-E2 of the company of Wur-schum, Ostfildern, Germany, producing a highly fine-pored protein foam.
- 21~2~0 g A first supply line 16 branches from the tundish 7 with a feed pump 15 being interconnected, and a second supply line 17 branches from the foam gun 8. These supply lines 16, 17 are united by way of a rnixer tube 18 branched in the form of a Y, the connecting branch 19 of which is dis-5 posed on the side of the output; a static mixer 20 is connected with thisconnecting branch 19. The mixer tube 18 serves to mix the flow of binder slurry in the supply line 16 with the flow of foam in the supply line 17, the flow of binder slurry being produced by the feed pump 15 and the flow of foam by corresponding actuation of the metering valves 9, 10, 11.
10 The porous concrete substance produced by the mixing of the two mention-ed components in the mixer tube 18 is further conveyed through the static mixer 20, where a thorough homogenizing of the porous concrete substance takes place.
15 On the side of its output, the static mixer 20 is connected with a dis-charge tube 21, in which a valve 22 is inserted for the control of the discharge of the porous concrete substance.
By corresponding selection of the conveying ratio of the flow of binder 20 slurry and the flow of foam, this porous concrete substance is adjusted such that, in its dry final state, the lightweight insulating board thus produced has a density of approximately 100 kg/m3.
The static mixer 20 may for instance be a mixer of the type 25 SMF-DM50/3-674.9i34 of the company of Sulzer AG, Winterthur, Switzerland.
Other types of mixers may be employed as well, such as for instance the SNX-mixer of the above-mentioned company. When selecting the mixer, at-tention must be paid to the fact that the diameter of the static mixer is matched for the flow rates in the mixer tube. The correct design of the 30 continuous mixer can be found by simple tests.
Molding boxes 23 can be filled with the porous concrete substance via the discharge tube 21. The molding boxes 23 serving as so-called "ripening molds" are conceived in the way of a springform, consisting of a bottom -~ 21 ~250 and four displaceable side walls.
By way of a conventional traverser, the molding boxes 23 filled with the porous concrete substance are conveyed into a ripening chamber, where 5 they dwell at approxim~tely 50C for 6 to 12 hours. As a result, the po-rous concrete substance starts to stiffen, so that the molded cake formed by the molding box 23 will subsequently be stable without the aid of the molding box 23.
10 In a further process line subsequent to the ripening chamber, the mold-ing boxes 23 are removed by a special grab opening the mold, in which case all the four side walls spread apart from the sides of the initially set molded cake to a distance of about 1 cm. The side walls thus opened are lifted, moved to the side, cleaned, lubricated and again united with 15 the mold bottoms.
The molded cake resting free on the bottom plate of the molding box 23 is transported to the cutting station in the process line. In the cutting station, a first rough blank of the molded cake is effected by oscill~ting 20 wires in the vicinity of the upper and the lower side of the molded cake.
When the excess cake has been removed from the upper side, the remain-ing molded cake has a smooth surface. As a result of the cut in the vi-cinity of the lower side, the molded cake or, respectively, the slabs cut from it will more readily come off the bottom plate.
Then the molded cake cut to size is further conveyed to the so-called harp, where the cake is cut into single slabs by oscill~ting wires. This is realized in that the wire harp moves through the standing cake from the top to the bottom.
By means of a vacuum grab the slabs are lifted off the bottom plate and placed on a hardening carriage, where they are placed at a distance of 3 to 5 mm from each other by a corresponding grab control. This distance ensures a more rapid and more uniform hardening and drying of the .~ 214~2~0 boards during and after the autoclaving.
Once the hardening carriages thus occupied have been moved into an au-toclave, the boards are hardened in a saturated steam atmosphere of ap-5 proxim:~tely 16 bar and 220C for a period of few hours, subsequent towhich they are again removed.
The hardened boards can then again be cut to size - for instance with the aid of a band saw.
This is followed by the impregnation of the boards. To this end, a set of for instance 15 boards is placed by corresponding grabs into a dip tank, which is filled with an impregnating compound. The boards are entirely dipped into the impregn~ting compound. Then the dip tank is closed her-15 metically and acted upon by partial vacuum. As a result, the air in theopen-cell structure of the boards escapes and is sucked of When the dip tank is again vented and set to normal pressure, the impregnating com-pound surrounding the boards is soaked into the boards. Thus, an im-pregn~ting layer forms, proceeding from all the surfaces of the board 20 and having an inward depth of penetration d of approxim~tely 2 cm in-ward. Entire soaking of the boards is possible, too.
The impregn~ting compound may be a mix on the basis of modified water glass, of a hydrophobing agent and water according to the following 25 recipe:
99 I modified water glass type 14 of the company of Wollner GmbH of D-67065 Ludwigshafen, Germany 1 l hydrophobing agent type BS 1306 of the company of Wacker Chemie of D-80538 Munich, Germany, and 200 I water.
By alternative, the impregnating compound may also be produced on the basis of thermoset hydrophobic plastics dispersions. The corresponding product "Vinapas" (R) of the company of Wacker Chemie of D-80538 Munich, Germany, is cited by way of example.
The impregnated boards can be dried by hot air in a drying station, in 5 which case it must be preferred that the boards are exposed to blowing by hot air from below, the coating then drying from the underside, which prevents any sticking of the boards to the pallets on which they will be placed.
10 As seen in Fig. 2, a lightweight insulating board according to the in-vention may consist of an open-cell porous concrete body 24 of a flat, parallelepiped shape, produced in the manner described above. The po-rous concrete body 24 has an impregn~ting layer 26 extending inwards all over from its surface, for hardening and achieving a water-repellent 15 effect. The impregn~ting layer has a depth of penetration d of approxi-mately 2 cm. The impregn~ting compound being colored by iron oxide pig-ment, the impregn~ting layer is set off the rem~ining board material.
Further, fiber glass 27 and so-called silicon dioxide carriers 28 are placed into the lightweight insul~ting boards.
LIGHTVVEIGHT INSULATING BOARD
BACKGROUND OF THE INVENTION
FIELD OF THE INVENTION
The invention relates to a method for the m~mlf~ctllre of a porous, min-eral lightweight inslll~ting board, as it may for instance be used to re-10 place polystyrene boards or mineral boards as thermal building protec-tion.
BACKGROUND ART
15 It is known from the prior art to m~mlf~ct~lre so-called gas or porous concrete blocks, which have a density of some 100 kg/m3. Owing to their porous structure, these porous concrete blocks have excellent heat in-slll~tine properties.
20 Roughly outlined, these porous concrete blocks are made from a binder slurry (with lime or cement as a binder), which is expanded by the ad-dition of an expanding agent on the basis of an alnminllm compound.
This way of m~nllf~cture involves the problem that, as a rule, a density gradient from the bottom upwards as well as microcracks in the block 25 structure may occur as a result of the expansion. Moreover, the metered addition of the alllminnm compound is very critical. The m~nnf~cture of substances of extremely strong porosity having apparent densities of less than 200 kg/m3 is almost impossible.
30 Because of the above-mentioned circumstances it is not possible in pra.c-tice with the methods used for the m~nllf~cture of porous concrete blocks to m~nllf~cture mineral leight-weight ins~ ting boards that must have an apparent density of 100 to 200 kg/m3 and less in order to possess heat insulating properties comparable to polystyrene boards.
Tests have shown that in the case of a correspondingly increased expan-sion of the binder slurry, the method suitable for the m~nllf~chlre of po-rous concrete blocks results in lightweight insulating boards not having sufficient structural stability in the first place.
DE 41 18 537 C1 discloses a method for the manufacture of cement foam, by which, however, only foam densities of 250 to 400 kg/m3 are attain-able. As discussed, these foam densities are too high to achieve the desired heat insulating properties in the insulating board made from such lo a cement foam.
Further, DE 42 16 204 A1 discloses a porous, mineral lightweight insulat-ing board, which substantially consists of calcium silicate hydrate, silica and possibly a porous loading agent and which is prepared with such a 15 pore count and distribution as to have a weight per unit volume of less than 220 kg/m3 and a coefficient of thermal conduction below O.OS0 W/mK
As regards the components of this heat insulating board, the calcium si-licate hydrate component is explained to be preferably due to the pres-ence of slaked lime, silica and water in the basic m~nllf~cturing materi-20 al. Alternatively, a portion of burnt lime may be employed, which is hy-drated by water absorption during the m~mlf~cture. Preferably, the sili-con dioxide component of the heat insulating board according to the in-vention substantially consists of quartz powder and/or amorphous silicic acld.
As regards the formation of pores, it can be taken from DE 42 16 204 A1that water contained in the wet m~nllf~cturing material is evaporated during the curing or, respectively, that pores are formed with the aid of a pore forming agent in the manufacturing material and are then present 30 in the finished heat insulation boards. Preferred pore forrning agents are tensides, alnminllm powder or peroxo compounds. The problems mentioned at the outset should arise at least with the use of ahlminllm powder.
Moreover, tests of Applicant have shown that the application of generally known m~nllf~cturing methods for heat insulating boards according to DE 42 16 204 A1 gives rise to practical problems of obtaining heat insu-lating boards of the indicated weight per unit volume and heat conduc-tivity which exhibit the structural stability necessary for reliable use at site. Any approaches to the solution of these problems cannot be taken 5 from DE 42 16 204 A1.
Another problem with the heat ins~ ing boards according to this docu-ment resides in the water absorption of these heat insulating boards dur-ing transport, storing and when used in building. It can be taken from 10 the document that the surface of the heat in~ ting boards is provided with a water-repellent agent applied by brushing or spraying. But there is the fundamental requirement that heat insulating boards fixed to the wall of a building must be floated prior to the application of a layer of cast, thin as a rule, on their surface, so as to compensate any differ-15 ences in height where the boards join. During this floating operation, forinstance by means of a so-called float, the top layer of the heat in-sulating boards and thus the water-repellent agent on the surface are removed, so that the board can take up humidity where it has been floated. This means that the boards take water from the layer of cast 20 subsequently applied, which results in inhomogeneities within the layer of cast and in a humidification of the board, deteriorating the heat insulat-ing capacity. Humidification will also impair the frost resistance of the boards.
25 The older patent application P 43 27 074.3 deals with a method for the m~nllf~c~lre of a mineral lightweight insulating board, in which a binder slurry of the conventional components of water, quartz powder, lime hy-drate and cement is prepared in a so-called paddle agitator and into which a foam produced in a foam production unit is subsequently stirred 30 The porous concrete thus produced allowed the manufacture of mineral lightweight inslllating boards of a density ranging from 100 to 200 kg/m3 and a specific thermal conductivity of approximately O.OS, and of im-proved structural stability and homogeneity to a limited degree, but these boards still did not exhibit the properties, needed for the reliable use in ~ ~1442~0 practice, as to strength, heat inclllating power and water-repellent be-havior.
SUMMARY OF THE INVENTION
It is accordingly the object of the invention to specify a method for the m~nllf~ct~lre of a porous, mineral lightweight insulating board, which will comply with the practical requirements in building as a result of its high degree, conditioned by the m~nllf~ctllre, of strength and heat insu-10 lating properties.
This object is solved by a method comprising the following steps: pro-ducing a binder slurry from cement, quartz powder, lime hydrate and water, preferably in a colloid mixer; producing a foam in a foam pro-15 duction unit from water, compressed air and an air entrainer; mixing thebinder slurry and the foam to form a porous concrete substance; homo-genizing the porous concrete substance by means of a continuous mixer;
discharging the porous concrete substance into a mold for the formation of a molded cake for the lightweight ins~ ting board; initially stiffening 20 the molded cake preferably in a ripening chamber; cutting the molded cake into individual lightweight insulating boards; and curing the light-weight insulating boards in an autoclave. The outstanding features of the invention are considered to be the individual production of a binder slurry and a foam, the mixing of these two components to form a porous 25 concrete substance, and in particular the latter's homogenizing by means of a continuous mixer. Test have shown that the use of this process se-quence serves to form an especially homogeneous porous concrete of fine air pores, which will give an especially solid and high-temperature insu-lating board after the autoclaving. The reason for this is considered to 30 be the particularly gentle homogenizing in the continuous mixer used, which preferably is a so-called static mixer as used for many applica-tions in chemical industry. Such continuous or static mixers are charac-terized by the fact that there are no rotating parts, by their momentum exercising forces on the porous concrete that might lead to a destruction ~144250 of the pores. Rather, in the continuous or static mixer, the homogenizing is caused by static guiding elements leading to turbulences in the porous concrete when it is pumped through. Obviously, this constitutes an espe-cially gentle way of homogenizing, resulting in excellent properties in 5 the lightweight insulating boards thereby produced.
The preferred mixing of the binder slurry and the foam with the aid of a mixer tube branched in the form of a Y is technically particularly simple on the one hand, but on the other hand it results in a preliminary mix-10 ing of the porous concrete components sufficient for the further homo-genizing in the continuous or static mixer.
Further preferred embodiments of the method according to the invention relate to a finishin~ treatment of the autoclaved lightweight insulating 15 boards, according to which the latter are provided with a water-repellent and/or hardening impregnation. This impregnation is characterized by the fact that the depositing of the impregnation takes place in such a way that, proceeding from the board surface, the impregnation extends in-wardly by a certain depth of penetration - at least 1.5 cm are consider-20 ed to be advantageous. Different effects are achieved with the aid of thispreferred impregnation, which are directed to the lightweight insulating board itself:
- Because of the penetrating depth of the impregnation, the lightweight25 insulating boards can be floated on their surface without the water-re-pellent qualities of the impregnation being impaired. Consequently, the cast layer to be applied after the mounting of the lightweight insulat-ing boards to the wall of a building meets with water-repellent proper-ties constant over the surface of the boards, so that no irregular water 30 absorption from the cast layer by the insulating board can take place and the frost resistance will not be impaired.
- Because of the impregnation layers on all its surfaces, the insulating board is excellently protected against penetrating water so that even - ~144250 when the boards are stored in the open at site, humidification is not to be expected. The lightweight in~ ting boards according to the in-vention do not make any special demands of protected storing.
5 - Because of the hardening of their surfaces, the boards are very well protected against being impressed so that no special care must be taken when the boards are handled at site.
- Because of the impregnation of the board all over, rigid layers includ-10 ing between them a layer of reduced strength form in the vicinity ofboard faces turned away from each other. The lightweight insulating board has a structural design similar to that of a multilayer composite board. In the manner known from the latter, this results in a substan-tial increase in the strength of the board, in particular the bending 15 tensile strength increasing.
- Because of the hardening of a surface zone of the board, plugs can be anchored especially reliably in the board.
20 - Because of the coloring of the impregnating layer for instance by iron oxide pigment, optimal controllability of the boards is ensured to the effect that board zones not impregnated, which appear during the floating for the board joints to be levelled or when the boards are cut to size for instance in the case of window bays, are recognized imme-25 diately and can then be impregnated subsequently.
Fundamentally, the impregnating compound is applicable by overpressureor partial vacuum for soaking into the board. In particular, the over-pressure method is known from the pressure impregnation of wooden com-30 ponents. When applied to the lightweight insulating boards according tothe invention, the pressure impregnation may be applicable if certain limits of m~xim~lm pressure and of the rapidity, by which pressure actu-ation and relief will take place, are observed, but it is not without problems. For instance, the impregnating compound soaked into the boards - ~14 12~0 by the application of pressure in a dip tank may be expelled again dur-ing pressure relief by re-expansion of the air in the pores inside the boards, so that the impregnation leaves much to be desired. Also, in particular in the case of too rapid a pressure relief, the boards tend to 5 be destroyed like in an explosion, because the pores of the boards have a strong tendency towards expansion in the case of pressure relief. Last but not least, the apparatus requirements for overpressure impregnation are very complicated, because overpressure values of several bars must be dominated.
By reason of the above described circumstances, partial vacuum impreg-nating is to be preferred, the boards being impregnated in a manner gentle to the structure. More detailed explanations of this will become apparent from the exemplary embodiment, to which reference is made to 15 avoid unnecessary repetition.
According to further embodiments of the invention, additional silicon dioxide carriers or, respectively, additional fiber glass may be mixed into the binder slurry. The additional silicon dioxide carriers may for 20 instance be so-called "micro-silica" particles as they are commercially available as concrete adn~ixLures. The fiber glass, which may optionally be mixed in for further increasing the strength of the in.cul~ting board, is alkali resistant and has a preferred fiber length ranging between 6 mm and 12 mm.
Further features, details and advantages of the invention will become apparent from the ensuing description of exemplary embodiments of the method according to the invention as well as the insulating board ac-cording to the invention, taken in conjunction with the drawing.
BRIEF DESCRIPTION OF THE DRAWING
Fig. 1 is a diagr~mm~tic partial illustration of an installation using the m~nllf~cturing method according to the invention, and -- 21442~0 ig. 2 is a diagr~mm~tic section through a lightweight insulating board according to the invention.
ESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to Fig. 1, the production of the porous concrete for the light-weight ins~ ing board is explained first. A binder slurry of cement, quartz powder, lime hydrate and water is produced in a conventional colloid mixer, which is for instance provided with a paddle agitator.
10 Being supplied from corresponding silos 2, 3, 4 via conveying means (not shown), such as feed screws, the solid components, while being weighed, can be automatically added to the colloid mixer 1 together with a corre-sponding quantity of hot water (of a temperature of approxim~tely 40 to 50C). Additionally, fiber glass and/or special silicon dioxide carriers 15 can be mixed in. The following basic recipe can be used for the binder slurry:
30 kg cement 15 kg lime hydrate 20 50 kg quartz powder 2 kg alkali-resistant fiber glass (fiber length ranging from 6 mm to 12 mm) 60 l water.
25 This mixture is mixed in the colloid mixer 1 while being simultaneously transferred by pumping via the return pipe 5, which is connected with the output of the colloid mixer 1 by way of the three-way valve 6, so that the binder slurry is discharged into the tundish 7.
30 In a parallel branch of the installation, water, protein-composition air entrainer and compressed air are supplied from corresponding reservoirs 12, 13, 14 via metering valves 9, 10, 11 to a conventional foam gun 8.
The foam gun 8 is for instance of the type SG-E2 of the company of Wur-schum, Ostfildern, Germany, producing a highly fine-pored protein foam.
- 21~2~0 g A first supply line 16 branches from the tundish 7 with a feed pump 15 being interconnected, and a second supply line 17 branches from the foam gun 8. These supply lines 16, 17 are united by way of a rnixer tube 18 branched in the form of a Y, the connecting branch 19 of which is dis-5 posed on the side of the output; a static mixer 20 is connected with thisconnecting branch 19. The mixer tube 18 serves to mix the flow of binder slurry in the supply line 16 with the flow of foam in the supply line 17, the flow of binder slurry being produced by the feed pump 15 and the flow of foam by corresponding actuation of the metering valves 9, 10, 11.
10 The porous concrete substance produced by the mixing of the two mention-ed components in the mixer tube 18 is further conveyed through the static mixer 20, where a thorough homogenizing of the porous concrete substance takes place.
15 On the side of its output, the static mixer 20 is connected with a dis-charge tube 21, in which a valve 22 is inserted for the control of the discharge of the porous concrete substance.
By corresponding selection of the conveying ratio of the flow of binder 20 slurry and the flow of foam, this porous concrete substance is adjusted such that, in its dry final state, the lightweight insulating board thus produced has a density of approximately 100 kg/m3.
The static mixer 20 may for instance be a mixer of the type 25 SMF-DM50/3-674.9i34 of the company of Sulzer AG, Winterthur, Switzerland.
Other types of mixers may be employed as well, such as for instance the SNX-mixer of the above-mentioned company. When selecting the mixer, at-tention must be paid to the fact that the diameter of the static mixer is matched for the flow rates in the mixer tube. The correct design of the 30 continuous mixer can be found by simple tests.
Molding boxes 23 can be filled with the porous concrete substance via the discharge tube 21. The molding boxes 23 serving as so-called "ripening molds" are conceived in the way of a springform, consisting of a bottom -~ 21 ~250 and four displaceable side walls.
By way of a conventional traverser, the molding boxes 23 filled with the porous concrete substance are conveyed into a ripening chamber, where 5 they dwell at approxim~tely 50C for 6 to 12 hours. As a result, the po-rous concrete substance starts to stiffen, so that the molded cake formed by the molding box 23 will subsequently be stable without the aid of the molding box 23.
10 In a further process line subsequent to the ripening chamber, the mold-ing boxes 23 are removed by a special grab opening the mold, in which case all the four side walls spread apart from the sides of the initially set molded cake to a distance of about 1 cm. The side walls thus opened are lifted, moved to the side, cleaned, lubricated and again united with 15 the mold bottoms.
The molded cake resting free on the bottom plate of the molding box 23 is transported to the cutting station in the process line. In the cutting station, a first rough blank of the molded cake is effected by oscill~ting 20 wires in the vicinity of the upper and the lower side of the molded cake.
When the excess cake has been removed from the upper side, the remain-ing molded cake has a smooth surface. As a result of the cut in the vi-cinity of the lower side, the molded cake or, respectively, the slabs cut from it will more readily come off the bottom plate.
Then the molded cake cut to size is further conveyed to the so-called harp, where the cake is cut into single slabs by oscill~ting wires. This is realized in that the wire harp moves through the standing cake from the top to the bottom.
By means of a vacuum grab the slabs are lifted off the bottom plate and placed on a hardening carriage, where they are placed at a distance of 3 to 5 mm from each other by a corresponding grab control. This distance ensures a more rapid and more uniform hardening and drying of the .~ 214~2~0 boards during and after the autoclaving.
Once the hardening carriages thus occupied have been moved into an au-toclave, the boards are hardened in a saturated steam atmosphere of ap-5 proxim:~tely 16 bar and 220C for a period of few hours, subsequent towhich they are again removed.
The hardened boards can then again be cut to size - for instance with the aid of a band saw.
This is followed by the impregnation of the boards. To this end, a set of for instance 15 boards is placed by corresponding grabs into a dip tank, which is filled with an impregnating compound. The boards are entirely dipped into the impregn~ting compound. Then the dip tank is closed her-15 metically and acted upon by partial vacuum. As a result, the air in theopen-cell structure of the boards escapes and is sucked of When the dip tank is again vented and set to normal pressure, the impregnating com-pound surrounding the boards is soaked into the boards. Thus, an im-pregn~ting layer forms, proceeding from all the surfaces of the board 20 and having an inward depth of penetration d of approxim~tely 2 cm in-ward. Entire soaking of the boards is possible, too.
The impregn~ting compound may be a mix on the basis of modified water glass, of a hydrophobing agent and water according to the following 25 recipe:
99 I modified water glass type 14 of the company of Wollner GmbH of D-67065 Ludwigshafen, Germany 1 l hydrophobing agent type BS 1306 of the company of Wacker Chemie of D-80538 Munich, Germany, and 200 I water.
By alternative, the impregnating compound may also be produced on the basis of thermoset hydrophobic plastics dispersions. The corresponding product "Vinapas" (R) of the company of Wacker Chemie of D-80538 Munich, Germany, is cited by way of example.
The impregnated boards can be dried by hot air in a drying station, in 5 which case it must be preferred that the boards are exposed to blowing by hot air from below, the coating then drying from the underside, which prevents any sticking of the boards to the pallets on which they will be placed.
10 As seen in Fig. 2, a lightweight insulating board according to the in-vention may consist of an open-cell porous concrete body 24 of a flat, parallelepiped shape, produced in the manner described above. The po-rous concrete body 24 has an impregn~ting layer 26 extending inwards all over from its surface, for hardening and achieving a water-repellent 15 effect. The impregn~ting layer has a depth of penetration d of approxi-mately 2 cm. The impregn~ting compound being colored by iron oxide pig-ment, the impregn~ting layer is set off the rem~ining board material.
Further, fiber glass 27 and so-called silicon dioxide carriers 28 are placed into the lightweight insul~ting boards.
Claims (14)
1. A method for the manufacture of a porous, mineral lightweight insulat-ing board comprising the following steps:
producing a binder slurry from cement, quartz powder, lime hydrate and water, preferably in a colloid mixer (1);
producing a foam in a foam production unit (8) from water, compressed air and an air entrainer;
mixing the binder slurry and the foam to form a porous concrete sub-stance;
homogenizing the porous concrete substance by means of a continuous mixer (20);
discharging the porous concrete substance into a mold (23) for the formation of a molded cake for the lightweight insulating board;
initially stiffening the molded cake preferably in a ripening chamber;
cutting the molded cake into individual lightweight insulating boards;
and curing the lightweight insulating boards in an autoclave.
producing a binder slurry from cement, quartz powder, lime hydrate and water, preferably in a colloid mixer (1);
producing a foam in a foam production unit (8) from water, compressed air and an air entrainer;
mixing the binder slurry and the foam to form a porous concrete sub-stance;
homogenizing the porous concrete substance by means of a continuous mixer (20);
discharging the porous concrete substance into a mold (23) for the formation of a molded cake for the lightweight insulating board;
initially stiffening the molded cake preferably in a ripening chamber;
cutting the molded cake into individual lightweight insulating boards;
and curing the lightweight insulating boards in an autoclave.
2. A method according to claim 1, wherein the mixing of the binder slurry and of the foam takes place by uniting a flow of binder slurry guided in first pipe (16) and a flow of foam guided in a second pipe (14) by way of a mixer tube (18) branched in the form of a Y.
3. A method according to claim 1, wherein the homogenizing of the porous concrete substance is effected by the porous concrete substance being pumped through a continuous mixer in the form of a static mixer (20).
4. A method according to claim 1, wherein the autoclaved lightweight insulating boards are provided with a water-repellent and hardening impregnation (26), which, proceeding from the surface (25) of the lightweight insulating boards extends inwards by a depth of penetration (d) of preferably at least 1.5 cm.
5. A method according to claim 4, wherein the impregnating compound is placed into the lightweight insulating board by means of overpressure or partial vacuum.
6. A method according to claim 5, wherein, for partial vacuum impreg-nating, the lightweight insulating board is placed into a dip tank filled with a fluid impregnating compound and disposed in a pressure-sealed vessel, and wherein the vessel is acted upon by partial vacuum to re-move the air from the pores of the board and is then again vented to place the impregnating compound into the lightweight insulating board.
7. A method according to claim 4, wherein after the impregnation, the boards are dried by means of hot air.
8. A method according to claim 1, wherein silicon dioxide carriers (28) are additionally mixed into the binder slurry.
9. A method according to claim 1, wherein fiber glass (27) is addition-ally mixed into the binder slurry.
10. A porous, mineral lightweight insulating board consisting of a hy-draulically cured porous concrete of cement, quartz powder, lime hydrate and water on the one hand and foam on the other, wherein at least the zones adjacent to surface (25) of the lightweight insulating board are provided with a hydrophobic and hardening impregnation (26).
11. A lightweight insulating board according to claim 10, wherein the impregnation (26) covers a depth of penetration (d) of at least 1.5 cm.
12. A lightweight insulating board according to claim 10, wherein an im-pregnating compound forming the impregnation (26) consists of water glass, a dispersion, a cross-linking agent, water and a hydrophobing agent.
13. A lightweight insulating board according to claim 12, wherein the impregnating compound is pigmented.
14. A lightweight insulating board according to claim 10, wherein the lightweight insulating board has a density of maximally 150 kg/m3 and a coefficient of thermal conduction of maximally 0.05.
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
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DEP4408088.3 | 1994-03-10 | ||
DE4408088A DE4408088A1 (en) | 1994-03-10 | 1994-03-10 | Process for the production of a porous, mineral lightweight insulation board |
Publications (1)
Publication Number | Publication Date |
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CA2144250A1 true CA2144250A1 (en) | 1995-09-11 |
Family
ID=6512416
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
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CA002144250A Abandoned CA2144250A1 (en) | 1994-03-10 | 1995-03-09 | Method for the manufacture of a porous, mineral lightweight insulating board |
Country Status (4)
Country | Link |
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EP (1) | EP0673733A3 (en) |
JP (1) | JPH08319180A (en) |
CA (1) | CA2144250A1 (en) |
DE (1) | DE4408088A1 (en) |
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US6033591A (en) * | 1997-02-26 | 2000-03-07 | E. Schwenk Dammtechnik Gmbh & Co. | Cellular thermal insulating material based on diatomaceous earth and method for its production |
US6780230B2 (en) | 2000-09-04 | 2004-08-24 | W.R. Grace & Co. -Conn. | Foamed fireproofing composition and method |
US7427321B2 (en) | 2001-09-03 | 2008-09-23 | W.R. Grace & Co. -Conn. | Foamed fireproofing composition and method |
WO2013190184A1 (en) * | 2012-06-21 | 2013-12-27 | Coligro Oy | Method of processing porous article |
US9725368B2 (en) | 2012-06-14 | 2017-08-08 | Geolyth Mineral Technologie Gmbh | Self-setting cement foam |
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WO1997015727A1 (en) * | 1995-10-25 | 1997-05-01 | Ed. Züblin Ag | Sound-absorbent and sound-damping structural element |
DE59700038D1 (en) * | 1996-07-04 | 1999-01-07 | Hebel Ag | Process for producing a light, open-pore, mineral insulation board |
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AT509012B1 (en) * | 2009-10-15 | 2011-10-15 | Geolyth Mineral Technologie Gmbh | INSULATION |
AT509011B1 (en) * | 2009-10-15 | 2011-10-15 | Geolyth Mineral Technologie Gmbh | MINERAL FOAM |
WO2012116380A1 (en) * | 2011-03-03 | 2012-09-07 | Geolyth Mineral Technologie Gmbh | Composite body and method for production |
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DE102016207858A1 (en) * | 2016-05-06 | 2017-11-09 | Baustoffwerke Löbnitz GmbH & Co. KG | insulation |
DE102017205822A1 (en) * | 2017-04-05 | 2018-10-11 | Baustoffwerke Löbnitz GmbH & Co. KG | Method and device for producing porous mineral building material |
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-
1994
- 1994-03-10 DE DE4408088A patent/DE4408088A1/en not_active Withdrawn
-
1995
- 1995-03-07 EP EP95103205A patent/EP0673733A3/en not_active Withdrawn
- 1995-03-09 CA CA002144250A patent/CA2144250A1/en not_active Abandoned
- 1995-03-09 JP JP7050041A patent/JPH08319180A/en active Pending
Cited By (5)
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US6033591A (en) * | 1997-02-26 | 2000-03-07 | E. Schwenk Dammtechnik Gmbh & Co. | Cellular thermal insulating material based on diatomaceous earth and method for its production |
US6780230B2 (en) | 2000-09-04 | 2004-08-24 | W.R. Grace & Co. -Conn. | Foamed fireproofing composition and method |
US7427321B2 (en) | 2001-09-03 | 2008-09-23 | W.R. Grace & Co. -Conn. | Foamed fireproofing composition and method |
US9725368B2 (en) | 2012-06-14 | 2017-08-08 | Geolyth Mineral Technologie Gmbh | Self-setting cement foam |
WO2013190184A1 (en) * | 2012-06-21 | 2013-12-27 | Coligro Oy | Method of processing porous article |
Also Published As
Publication number | Publication date |
---|---|
DE4408088A1 (en) | 1995-11-09 |
JPH08319180A (en) | 1996-12-03 |
EP0673733A2 (en) | 1995-09-27 |
EP0673733A3 (en) | 1996-06-19 |
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