DE2248304A1 - PROCESS FOR MANUFACTURING NON-COMBUSTIBLE LIGHT ARTICLES - Google Patents

Description

VERF AH REN Z UR manuf RECOVERY NICHTBREtTITBARER, LIGHTER GEGEIT-

STÄL7DE

The invention relates to non-combustible, light objects, which are particularly suitable as building material.

Such items consist of a foamed and solidified one Mix that

a) - silicon powder or a powder of a silicon-containing Le alloy contains, '; .

b) inorganic powders that are porous or contain hollow browns and

c) V / asserglao, and furthermore, if desired

d) fiber material υηά / ofler

e) agents for improving fire resistance.

Neuerdinp «virdiPiP flour» emphasis on safety from building-1 .eraenten »and buildings placed against fire. By using of non-flammable building materials can occur and spread be prevented from fire. You also need

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light building materials for high-rise buildings.

Most of the building materials used so far are flammable, and the incombustible ones are heavy and require a great deal of labor to be built.

Good, non-flammable building materials have to be fireproof and also non-flammable themselves. The non-combustible building materials r.HRsen have a number of properties: they should not deform, "break or break out, when exposed to high temperatures, they should not form cracks through which flames can penetrate, and, if it is then extinguished, the flame on the materials should disappear within a short time. They are also supposed to be good be heat-insulating and, even if a surface of such a component is exposed to a high temperature, then the other surface remain at a relatively low temperature.

The usual, non-combustible components that are very fire-proof are, at the same time, are very heavy and are therefore not suitable for building very tall buildings. . .

According to the method according to the invention, non-combustible Molded articles are produced that are light and, nevertheless are mechanically strong, e.g. have high flexural or compressive strength in addition to good thermal insulation.

In addition, it is desirable that these components are also fireproof.

Such components should be manufactured continuously.

The method according to the invention by which non-flammable, lightweight molded articles are made consists in that

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a mixture is deformed which; -

a) a powder of silicon or a silicon alloy holds,. ■ ;. '.:

b) an inorganic powder containing porous or hollow spaces ver and

e) water glass,.

wherein the molded article is at a temperature between about 15 to 120 ° is held, .which causes foaming and solidification of the molded article is effected "

• If the object molded from the mixture has the features]; a, b and c and at a temperature between about 15 and 120 ° C is kept, then the alkali silicate is hydrolyzed by water that is contained in the water glass * and forms an alkali hydroxide, the Ä reacts and releases hydrogen.- This causes hydrogen the foaming and the resulting excessive reaction solidifies the molded article with evaporation of water. In this way a lightweight, non-flammable fitting is obtained.

In the component a the silicon content or the content of the silicon alloy is not very well defined, typically it is at 10 ^ renigstens Gew.?a however, _v preferably it is at least 50 wt.%. Examples of silicon alloys are ferrosilicon, calcium silicide, ferrosilicoaluminum, silicon manganese aluminum, calcium silicon manganese, silicon manganese or silicochrome. These substances are used either alone or in combination.

The metallic silicon or the silicon-containing alloy are used in granular or powder form. By-

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Particle size does not exceed 500 microns, preferably not over 100 microns. If the average size of the particles of powder of silicon or silicon alloy, tion is too large, then the total area of the particles that comes into contact with the water glass is reduced, which in turn the strength of the molded article is reduced, and the particles can no longer be fully dispersed in the water glass will.

The term "porous" or "containing voids" used here in connection with inorganic powders is intended to mean powders which have a pearlite structure, or hollow, spherical, inorganic powders, so-called microcapsules. These powders are made of a non-flammable, inorganic material that does not easily decompose or disintegrate even at high temperatures. The degree of porosity of such inorganic powders or of powders with a pearlite structure is not critical. Usual degrees of porosity are between 50 and 99 % i, preferably in the range of 6? up to 98%.

Examples of such porous or "hollow spaces" containing, inorganic Powders as used according to the invention are perlite rock, obnidian perlite, pumice stone microcapsules (Microcapsules made from volcanic ash and pumice stone), carbon microcapsules, glass microcapsules, powder made from foamed tinder, Pumice stone, gesch: i \ rmtcr clay and vemiculite. Preferably be Pearlite stone and glass microcups are used.

The particle size of the powders is not critical. Particles with a diameter of 10 to 1000 microns are preferred, and it is best to use particles with an average size of 50 to 500 microns. If you use particles with an average size of more than 1000 microns, then these particles contribute to the fact that the finished object is light, Fie _; . however, adversely affect its physical strength. On the other hand, particles with an average

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Size less than 10 microns used then is physical Strength of the manufactured item "better, however, it is then difficult to also make the object light.

The proportion of inorganic powders that are porous or have voids can vary within wide limits, usually it is between 100 and 2000 parts by weight, preferably between 200 Us 800 parts by weight per 100 parts by weight of the powder of silicon or a silicon alloy, if the Proportion of the inorganic powder is in this range, then the article produced therewith is light in weight and good physical strength. ·

The term "water glass" generally means water-free Water glass (solid alkali silicate) is understood, but in this application it is intended to be a concentrated, aqueous solution

of alkali silicate glass mean thus the hydrolysis of the alkali species Silicate can be exploited · Examples of water glass) that

% that can be used according to the invention are NapO

in aqueous solution (Japanese Industrial Standard No. 1), ₂ 2 in aqueous solution (Japanese Industrial Standard No. 3), O.3SiQ ₂ in aqueous solution (Japanese Industrial Standard No. 3) * ₂ O.4-SiOg in aqueous solution (Japanese Industry standard No. 4) _t an aqueous solution of sodium isquisilicate (3NapO.2SiO _p ),

an aqueous solution of sodium methasilicate _{(Na 2 CSiO 2} ), an aqueous solution of potassium silicate (K ₂ O.SiOp), and lithium waterglass * Among them, the types of waterglass shown in Nos. 2 and 3 of the Japanese Industrial Standard are particularly preferred because they are easily available are easy to process and cost little · * Contain common types of water glass. about 10 to 30 % water.

The proportion of the water glass to be added is not critical, but is preferably in the range of 100

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up to 1200 parts by weight, in particular between 200 to 800 parts by weight per 100 parts by weight of the silicon or silicon alloy powder. When the proportion of the water glass is less than 100 parts by weight, the physical strength of the molded article is insufficient and if the proportion exceeds 1200 parts by weight, then the physical strength of the molded article becomes lower.

To the composition containing a) silicon or a silicon alloy, b) void-containing or porous inorganic powder, and c) water glass, a fiber material d can be added to increase the strength of the article. For such reinforcement purposes, the length of the fibers of this material should preferably not be more than 5 nm, in particular in the range between 2 and 3 mm. If the fibers are longer than 5 mm in diameter, they will tangle up and become difficult to distribute evenly in the mixture. Very short fibers do not differ very much from powders and therefore cannot add anything to reinforcement. The fiber material should therefore have a length of at least 1 mm. Both organic and inorganic fibers can be used for reinforcement. Too much organic fibers should be avoided, however, since these lasers burn, decompose or melt when exposed to high temperatures. If the use of a large amount of fiber material is desirable, then only inorganic fibers should be used alone or in admixture. A small proportion of organic fibers is permissible since this does not adversely affect the non-combustibility of the molded article. It is preferred to use organic fibers which have been made non-combustible or non-flammable.

In general, however, inorganic fibers are recommended. Examples of such inorganic fibers are Chrysotilaabe,

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hard serpentine asbestos, antophyllite asbestos, amosite asbestos, tri r · ,, molitasbest, actinolite asbestos, ghrozidolite asbestos, rock wool, Slag wool, glass and metal fibers. Preferably one can use chrysothyl asbestos and amosite asbestos.

this can Gewichtεteile to 80 of the fiber material per 100 parts by weight of the sum of the constituents a, b, c are added to xrer. The fiber content of the fiber material is preferably 1 to 10 parts. The addition of the fibers improves the mechanical strength of the article, for example the flexural strength and compressive strength and also improves the resistance to cracking and disintegration.

If one adds an agent to increase the fire resistance, then the fire resistance and heat insulation of the article be improved.

One means of improving fire resistance is a non-combustible one Substance that ensures that the article does not deform, that it does not break or disintegrate when it is high Temperatures is exposed that also no cracks occur that allow the passage of flames when he high ■ Is exposed to temperatures that continue to extinguish the flames in a short time after the start of the extinguishing work and which ensure good thermal insulation and also have the consequence that an area is relatively lower Temperature can be maintained even if the opposite Surface is exposed to high temperatures. For example, Fweir.e inorganic powder used v / earth, the KristallwasF.er also contain inorganic powder, the. decompose when exposed to high temperatures, and thereby Consume heat.

Add this to the inorganic powder with water of crystallization higher temperature, and by the heat of evaporation of the water the fire resistance of the molded articles is increased. Ever

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The greater the proportion of crystal water, the cheaper it is. In general, it is expedient to use inorganic powders which contain at least 5%, preferably 10 to 65% by weight, of water of crystallization at room temperature.

Examples of such inorganic powders which improve fire resistance are powders made from aluminum hydroxide, calcium hydroxide, clays, alum, hydrogenated gypsum, sodium hydrate sulfate, disodium phosphate hydrate. These substances can be used alone or in combination. Aluminum hydroxide is preferred because it greatly improves fire resistance. These inorganic powders enter during the foaming and curing process no water _f freely eie set However, water-free and consume heat in the form of Verdampfungswänne when εο are exposed HO- _v hen temperatures as eie during a fire occur, whereby the fire resistance of the molded article is increased.

It is advisable to use inorganic powders which, however, can only release crystal waters at temperatures above 120 ° C Powders can also be used, which the Krintal! water already has release below 120 ° C. In this case, the temperature at which the molded article is foamed and cured is lower than the temperature at which the KriGtallwaFier is released.

Inorganic powders which readily decompose at high temperature and consume VSfctne are those which exothermically decompose when exposed to high temperature such as fire, and due to heat absorption, the fire resistance of the molded article is improved. The amount of heat that is then consumed should be at least 100 kai./g, preferably 110 to 1000 kai./g. Inorganic powders, which decompose at least 120 ° C, in particular zwiechen etv ^r a 200, and preferably Verden 900 ° C. Such avenge at high temperature ζ err. ei i inorganic powder beef e.g. calcium carbonate, hagne egg carbonate, zinc carbonate, cadmium carbonate, sodium nitrate, lead oil rr-t,

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2241304

Aluminum sulfate, ammonium phosphate ,. Ammonium carbonate, ammonium, sulfate. They can be used either alone or in combination • Galcium carbonate is best because it is highly endothermic and MUiS,,,

Inorganic powders which decompose in the heat only then and only then take on Värrae ·. · ,. if the ■ pormartikel is exposed to a temperature such as, for example occurs wisely in a fire. They thus improve the fire resistance of the molded article, but should not decompose at the temperature at which it is foamed and hardened, i.e. in a temperature range of about 15 to 120 ° 0.

The inorganic powders, which decompose in the heat, should thus preferably have decomposition temperatures which Above 120 ° C are »Inorganic powders with a substitution temperature below 120 ° can also be used, depending on the quality the foaming and curing temperature of the molded article should then be below the temperature at which the inorganic Decompose powder.

Means that improve fire resistance can be used either alone or in combination, and the proportion of the fire resistance improving agent can be up to 80 parts by weight per 10 parts by weight of the sum of the weight of the constituents a, b and. "The proportion is preferably between about 10 and 5 parts by weight. ■ "- :

The mixture consisting of the ingredients given above can also contain various sub-sets, as they are usually used are used for non-flammable building materials, e.g. inorganic pigments or fillers (oil as pearls, borax pwiver and the like). .

The components are mixed with the usual equipment ^ to obtain the composition according to the invention. So

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can for example contain silicon or an alloy containing silicon, a 'light filler and. an agent which improves the firmness and, if necessary, a fiber substance can be mixed in a concrete mixer and water glass sprayed onto the minchung plodder · in processed deformation process at _t. where Bruck-Tcrlfte be exercised should be avoided if possible, that the forums or cavities of the inorganic powders are destroyed.

Bs has been shown that the mixture according to the invention so is compressed so that the density 1.5 to 12 times, as a precaution 2 to 10 times the density before compression is increased. Here, density is the ratio of the weight of the mixture to the volume occupied by the mixture ▼ be purchased.

The article formed by such compression with a density of 1.5 to 12 times the density before compression has high compressive strength, and it is not combustible unless the pores of the inorganic powders are noticeably destroyed . . ■■: ■■ '· ..;

Di * deformation of the mixture should preferably be done that way be that the deformed object has a density of 0.1 to 1, as a precaution has 0.3 to 0.8 · These figures refer to the density of the water, which is assumed here to be 1.0. However, the density range is not critical, it changes calibrate depending on the proportion of the various additives, the Faferraaterials and the refractory improving metal.

The shape of the article can be, for example, a plate, a rod or a cylinder, or any other shape

309BH / Q9SB

2-24830 «

to have"

[\ f ..- The molded article is foamed and cured while a temperature between 15 and 120 ° G held on \. The temperature suitable for foaming and curing depends on the composition, size, shape and the like, but is usually in the range of 20 to 5 ° C. When the fire resistance improving agent is added, the temperature should be be chosen so that the agent does not become dehydrated or decompose when exposed to heat.

When the molded article is at the above-mentioned temperature is held, then water glass is hydrolyzed in this molded article, being alkali hydroxide and a solar-like, acidic Alkali silicate are released. This alkali hydroxide reacts with the powders made of silicon or dem.in a silicon alloy existing silicon with the formation of water glass. At the same time, the hydrogen causes the foam to form. This reaction is exothermic, and the water glass becomes gradually evaporates, and the water vapor also contributes to the formation of foam. Then the molded article hardened. . .

-The time it takes after the start of the reaction described above depends on the density or shape, but in particular on the thickness of the molded article, it is usually at 90 minutes at 35 ° C, at 45 minutes at 45 ° C, at 20 minutes at 60 ° C, at 15 minutes at 80 ° C and about 10 minutes at 100 ° C. The reaction takes about 2 to 3 minutes. Since it is an exothermic reaction, εο spreads it accelerates itself, x \ running it once partially initiated ^ tet "is and will be ended soon thereafter.

■ .- ι, ■

The hardening of the molded article occurs quickly if one maintains a temperature in the range of 15 to 120 ° C. To this

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Way, nan gets a hardened * non-flammable, molded Item that looks good, no bumps or hoists which can be attributed to outbreaks of hydrogen glass would be ..

The foaming of the article proceeds without complications, and it hardly any control is necessary. If, however, the wetness of the foaming process should be monitored, then the temperatures lowered for foaming and hardening or shaping and foaming and curing are carried out in a press while the press pressure is monitored * Others Methods for controlling the extent of foaming are known to the person skilled in the art.

The production of a uniform mixture of its ingredients and the shaping of the mixture nowie the foaming and hardening of the articles can be continuous or batch-wise be carried out using a forming machine, e.g. Press used.

Εε has been shown that such a shaped, non-separable object can be produced continuously if one a special belt press is used.

According to another embodiment of the invention, a process for the continuous production of a non-flammable, lightweight, molded article is provided in which the deformation of the components a, b and c and, if necessary, also d and / or e is carried out under pressure by the shaped mixture is introduced into a pressure chamber. This pressure space is formed between an endless belt and a conveyor plate. The inner surface of the belt is ^{in contact with ni 4} "pressure rollers. The conveyor plate moves at about the same speed as the belt and in the same direction, the pressure ro being measured that the density of the

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compressed object reaches 1.5 to 12 times that of the same object before its compression, where- ^ at which time the molded article is placed in reaction chambers maintained at a temperature of about -15 "to 120 ° G thereby achieving the foaming and curing "of the article will. .

The continuous production of a non-inflammatory, lightweight, molded article according to the invention is preferred carried out in a device described in the attached Drawing is explained · -In this drawing shows:.

Fig. 1 such a device in section and '■

FIG. 2 shows a section along line II of FIG. 1.

The material 2 to be deformed is stored in a funnel 1. Pressure rollers 3 to 10 are in contact with the inner surface of the endless belt 11. The rollers are spaced from one another and are stored deeper and deeper as the distance from the funnel 1 increases. 12 and 13 are drive rollers and 14 to 16 are guide rollers. The pressure rollers 3 to 10, the drive rollers 12 and 13 and the belt guide rollers 14 to 16 all contact the inner surface of the endless belt 11. This endless belt 11 moves in the direction of the arrow shown in FIG. 1 by rotating the drive rollers 12 and I3. In the section where the rollers 3 to 10 are provided, the surface of the endless presses. Belt 11 gradually more and more strongly on the material 2 _% whereby this material is conveyed »The tension of the endless belt 11 is maintained by the guide rollers 14 to 16, whereby at the same time a zig-zag movement of the endless belt is prevented x-drd. Under the endless belt 11 lies a conveyor plate 17 which moves at approximately the same speed and in the same direction as the endless belt. The conveyor plate rests on several support rollers 18 and can through

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Drive roller 19 are moved.

The conveyor plate 17 can consist of a hard, flat plate, however, you can also use an endless belt that rests on several rollers. In this case it can be endless Belt, which instead of the conveyor plate 1? is used, in the same direction as the endless belt 11 in the printing roller

moved.
schnittV The conveyor plate 1? - Can also be made on several plates, and in this case the long plates are moved on support rollers.

From Fig. 2 it can be seen that side walls 20 are provided upright and opposite one another, the two side ends of the endless bando in the part where the DiPückwal »en J bit 10, the drive rollers 12 and 13 and the lateral ends of the lower part of the endless belt 11 and the two ends of the line parts 1 lie, creating a pressure space 21 between the endless belt 11, the guide plate 1? un4 the funnel 1 is formed.

The pressure chamber 21 gradually narrows from the funnel 1 as the rollers 3 ″ to 10 are arranged increasingly deeper.

■ ' ■ . ■ l |,

preferred ratio of the cross-sectional area of the pressure space 21 aft of the location of the pressure roller 10 to that at the location. de? Print roller 3 lies in the range from * 1/20 to 1 /% warpage? - in the range from 1/10 to 1/4. If the ratio of the cross-sectional areas becomes smaller than about 1/20, then the compressive forces become too great, and the ions of the inorganic powder in the molding compound collapse, and it is sometimes no longer possible to obtain a light object. If the ratio is more than 1/3, the compressive force is too small and the molded article may be destroyed if the impact occurs. The non-flammable molded article thus presented has

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- A3 - . . ■

low strength, and open pores occur, whereby the fire resistance is reduced. _.

If the aspect ratio is between 1/20 and 1/3, ■ then, the molding material can be deformed so much that the compressed material has a density which is 1.5 to 12 times is above the density before compression. ,

Bb it is necessary that the first pressure rollers at the funnel 1 are stored increasingly deeper in the direction of movement of the belt 11. The last pressure roller 10 and the pressure roller 9 lying next to it or also other pressure rollers which directly adjoin it can be arranged at the same height so that the material is deformed into a flat plate. In Fig. 1, the material to be deformed is pressed together by the pressure rollers 3 W. 8, and the shaping into a plate is carried out by the pressure rollers 9 and 10.

In Fig. 2, the reference numerals 22 and 23 denote screws for Fixation of the wall panels 20, and the vertical position of the pressure roller 4 is adjusted by an adjusting device 24, can be moved up and down by the pressure roller 4. The power that is delivered by an engine is about a sprocket 2? transmitted that attached to a shaft 28 which in turn delivers the power to sprockets 25 and 26 to drive the endless belt. ■

The object that is pressed and formed between the conveyor plate 1? and the pressure rollers 3 to 10 manufactured in the printing room 21, is then introduced into reaction chambers 29, 30 and 31. Several conveyor rollers 32 are provided in each of these actuator chambers. Through the passage of the conveyor plate 17 through the Eealctionnkainriern 29, 3?> And .31 mediated by conveyor rollers 32, the shaped article, which is delivered from the pressure chamber 21, is successively through the reaction. ¹ ? Chambers

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guided. The reaction chambers 29 and 30 contain a tube 33 »

V by the one used for heating or cooling

LA medium is supplied, e.g. hot or cold air for adjustment the temperature of the chambers to a value of about 15 to 120 ° C.

In these reaction chimneys the alkali metal hydroxide reacts formed by the hydrolysis of the water glass in the molded article, with silicon or the silicon contained in the alloy, thereby releasing hydrogen which causes the molded article to foam. 'Through the Schäuraungs process and through the evaporation of water cures the molded article to form the desired non-flammable molded article.

The reaction chambers 29-30 and 3 " ^{1 also} contain outlets 35i 36 and 37 so that the risk of explosion by hydrogen is avoided. The molded article, which is foamed and cured, is delivered from the reaction chamber 31 to the conveyor roller 34-. The resulting, non-flammable, shaped article is then cut to the desired dimensions and forms the end product.

According to the invention, one can therefore use a non-flammable, light, obtained a molded article which has a high mechanical ability such as a flexural strength or a compressive strength, and which is heat-resistant and water-resistant, with Impact does not disintegrate, and the pores or voids of the inorganic Powder are not noticeably destroyed.

This article contains a fire resistance enhancer Medium, then not only is it light in weight and non-flammable, but also has excellent fire resistance. If the article is heated to a high temperature by a flame to test pure fire resistance, then its fire resistance or structure will not be adversely

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lig affects, for example, no deformation occurs, no Disintegration, no peeling or the like. There is also no cracking to be expected, through which the passage of flames would be borrowed. The temperature on the opposite of the heated surface The surface area does not increase so much, although the temperature increase depends on the thickness of the molded article, and the object therefore retains its resistance to fire. Flames or smoke are generated during heating not, and after heating, the fire goes out very quickly.

The article has. good looks and can be simple and continuous Working methods are produced.

The article can be machined with the saw, and it is. also nailable, so it can be used in the same way as wood. The article is therefore as a component that should not burn, for example as a material for roofs, ceilings, floors, interior and exterior walls, as well as very useful as a material for decorative purposes and furniture. .

The invention is illustrated below with the aid of examples, the proportions given being proportions by weight, if none other information can be provided. The properties given in the examples were illustrated by those explained below Procedure determined.

ITinflammable . ·

The sample was run for three minutes with a town gas burner erx-järnt, where 1.5 1 air per minute were supplied, then Additional heating was carried out with a heating furnace that contained nickel chromium wire as a heating element and had an output of 1.5 Kw / h would have. This additional heating lasted 17 minutes. Smoke, flame formation and continued burning was observed, and 'by a synthetic determination of all these phenomena the flame-retardancy of the sample is determined,

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Flexural strength. : JIS Α14Ό8
Compressive Strength: JIS A1108

Fire resistance ; JIS A1J04 · (Fire resistance test method for building elements); Heating time 1 or 2 hours.

Water resistance

The sample was immersed in hot water at 80 ° C for 48 hours. The flexural strength "of the sample before immersion was was compared with that after immersion, thereby determining the water resistance of the sample.

example 1
Ferrosilicon (grain size less than 325

Micron)
Pumice stone microspheres (smaller than 500

Micron)

Asbestos (fiber length less than 30 mra) Water glass (No. 3)

100 parts

300 parts 60 parts 200 parts

A mixture containing the above ingredients was placed in a kneading machine brought and kneaded well. The kneaded mixture was placed in a mold having a size of 150x150x50 mm had, it was then foamed and cured at a pressure of 50 kg / cm, which was done in a press, its pressure plate was heated to 100 ° G. The plate-shaped object that is so was then thoroughly dried, and then its flexural strength, its compressive strength and measured the density. The results are given below, and they show that the molded article has excellent flexural properties. and compressive strength and that it has a low weight and is not flammable.

Apparent density

Flexural strength

Compressive strength

0.95

105 kg / cm *

180 kg / cm ²

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Water resistance

Non-combustibility thermal resistance ■

105 kg / cm (before treatment with hot water). · · '

102 kg / cm (after treatment with hot water)
excellent

thermally stable up to 750 ° C.

• Example 2

Each of the following mixtures (samples 1, 2 and 3) was treated in the same way as in Example 1. The physical properties of the molded articles thus obtained are in Table 1 below.

Sample # 1

Calcium silicide (grain size less

than 325 microns) 100 parts

Obsidian pearlite (grain size less than ^ than 500 microns) 300 parts

Asbestos (fiber length less than

30 min) 90 parts

Water glass (Mr. 3, JIG standard,
Japanese industry standard) 300 parts

Rehearsal Fr. 2

Ferrosilicon (grain size smaller

'than 325 microns) 100 parts

Ferlite rock (grain size less than 500 microns) 150 parts

Asbestos (fiber length less than

30 mm) 60 parts

Water glass (ITr. 3, JIo Borm) '100 parts

I "robe ITr. 5

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Ferrosilicon (grain size smaller than 325 microns) pumice stone microspheres (smaller than 500 micron) water glass (No. 3 »JIS standard)

100 parts

300 parts 200 parts

TABLE 1

properties Sample # 1 Sample # 2 Frobe No. 3 apparent density 1.0 0.8 0.8 Flexural strength
(kg / cm) 89 68 38 Compressive strength (kg / cm2) 185 99 140 Water resistance (kg / cm2) before treatment lung with hot water 89 68 38 after the treatment lung with hot ' water 87 66 35 ITflammability excellent excellent excellent Thermal cons stand (thermal st » bil up to the specified
benen temperature; 710 ° σ 710 ° c 1150 ° c

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Example 3

Ferrosilicon (grain size smaller than

325 microns) 100 parts

Perlite rock (grain size 100 "to

1000 microns) '. '600 parts

Water glass' (No. "3" JIS ITorm) "5OO 0? Hurry

Asbestos (fiber length less than 30 mm) 60 parts

0 9 8 14/095

22A830A

a mixture with the above-mentioned ingredients was sufficiently kneaded in a kneading device. The mixture had an apparent density of 0.116.

The mixture obtained in this way was processed continuously, using a device as shown in FIG. 1 and FIG. 2 is shown.

The mixture was continuously poured from the funnel 1 into a Brought pressure space, which is formed between the endless belt 11 and the conveyor plate 17, which extends in the direction of movement of the belt moves at substantially the same speed as this. The aspect ratio from the narrowest point of the pressure chamber to the furthest point of the pressure chamber was open Adjusted 1: 8 and the mixture was set to an apparent Density of 0.61 compressed to form a plate-like article with a thickness of 31.5 mm.

The molded article was introduced into reaction chambers into which hot air at about 80 ^° C. was blown. The water glass in the molded article was hydrolyzed and the sodium hydroxide formed reacted with silicon and released hydrogen, which in turn caused foaming in the molded article. The molded article was then cured in the reaction chambers.

The hardened article had excellent non-flammability

2 speed and a flexural strength of 32 kg / cm, a compressive strength

speed of 30 kg / cm and an apparent density of 0.55. He had also very good thermal properties and was waterproof.

for

The molded article thus formed was useful for walls and ceilings.

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Example 4

Each of the blends (Examples 4 to 6) were the same Processed in the same way as in Example 3, with the exception of the shaping conditions, which were chosen as shown in Table 2 is specified. The properties. Of the molded, in this way obtained articles are shown in Table 2.

Example No. 4

Ferrosilicon (grain size less than 325

Micron)

Obsidian perlite (500-1000 micron) water glass (No. 3, JIS standard)

100 parts

700 parts 200 parts

Example No. 5 .. '* ...

Metallic silicon powder (grain size

smaller than 325 microns) 100 parts

Perlite rock (grain size 100 - 1000 microns) 1300 parts Water glass (No.3, JIS standard) - 1200 pieces

Example No. 6 .

Ferrosilicon (grain size smaller than

Micron)

Glass microspheres (50-100 microns) water glass (No. 3, JIS standard)

Asbestos fibers (average fiber length 20 mm)

100 parts

Parts 500 parts 100 parts

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- 24 Table 2

Sample No. 4 Sample No. 5 Sample No. 6

Forming conditions

Apparent density of the mixture before molding

Ratio of the cross-sectional area in the pressure chamber at the pressure roller 3 in proportion to the point at the pressure roller 10 according to FIG. 1

Apparent density of the mixture after deformation

Molded Article Thickness (mm)

Temperature of the reaction chambers (0)

Properties of the molded article

0.250

1/6

0.75

30.5

80

0.10

1/6

0.45

31

18th

0.20

0.45

30th

80

Apparent density 0.68 0.41 0.66 ο
Flexural strength (kg / cm) 50 25th 60 'ο
Compressive strength (kg / cm) 90 25th 90 NON-BURNABILITY excellent excellent excellent Water resistance
(kg / cm) 45 20th 56 Thermal strength
(thermally stable up to
at the specified tempe
rature) 750 ⁰ C. 750 ⁰ C. 750 ^Q C.

Thickness (mm)

30th

30th

29.5

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Example 5

Ferrosilicon (grain size less than 100 parts

325 microns),.

Pe rlite (less than 500 microns) 660 pieces

Aluminum hydroxide. 600 parts

Water glass (No. 3, JIS standard) "540 parts

Asbestos (fiber length less than 30 mm). 100 parts

A mixture containing the above ingredients (apparent density 0.24) was placed in a mold whose dimensions 900 ram 900 mm 47 mm. The mixture was at a

2
Deformed pressure of 27 kg / cm. The molded article had an apparent density of 0.79. The molded article was taken out of the mold. The sodium hydroxide formed upon hydrolysis of the water glass reacted with the silicon contained in the ferro-silicon, releasing hydrogen gas, and curing the molded article at 45 ° C. The molded article had an apparent density of 0.71. The article was excellently non-flammable, "no smoke, no flame, and no residual flame formation was observed."

The article has been tested for fire resistance. When it was heated for two hours and the temperature of the molded article was the 1010 ⁰ C, the maximum temperature at the opposite rear surface at 245 ° C. In addition, no deformation, destruction or degradation was observed when heated, and no cracks occurred. After warming up, the flame went out immediately. An analysis of the sample after the test showed that the aluminum hydroxide had been converted to aluminum oxide by dehydration »

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The article had an apparent density of 0.65, a flexure

2 2

strength of 22 kg / cm and a compressive strength of 28 kg / cm. It was also very waterproof and suitable as a building material for ceilings or walls.

Example 6

Each of the following mixtures (Sample Nos. 7 through 11) were also made treated as in Example 5, except that the deformation conditions set out in Table 3 were used. The properties of the articles thus obtained are shown in Table 3 compiled.

Sample # 7

Ferrosilicoaluminium (grain size less than 325 microns)

Obsidian pearlite (grain size less than 500 microns)

Calcium silicate hydrate (grain size less than 100 microns)

Water glass (No. 3, JIS standard) Asbestos (fiber length less than 31 mm)

100 parts 600 parts 320 parts

500 parts 80 parts

Sample # 8

Ferrosilicon (grain size less than 325 microns)

Perlite rock (grain size smaller than 500 microns)

Disodium phosphate hydrate (grain size less than 100 microns)

Water glass (No. 3, JIS standard) rock wool (fiber length less than 30 mm)

100 parts 540 parts 290 parts

430 parts 70 parts

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Sample No. 9

Calcium silicide (grain size smaller than 325 microns)

Pumice microspheres (smaller than 500 microns)

Potassium carbonate (grain size less than 100 microns)

Amosite asbestos (fiber length less than 10 mm)

Water glass (No * 3, JIS standard) 100 parts 300 parts 175 parts 100 parts 200 parts

Sample no.

Metallic silicon powder (grain size less than 325 microns)

Obsidian pearlite (grain size less than 500 microns)

Hydrogenated gypsum (grain size smaller than 100 microns) water glass (No. 2, JIS standard) 100 parts 400 parts 200 parts 300 parts

Sample No. 11

Metallic silicon powder (grain size less than 325 microns)

Obsidian pearlite (grain size less than 500 microns)

Ammonium phosphate (grain size smaller than 100 microns)

Water glass (No. 3, JIS standard) 100 parts

500 parts 250 parts 400 parts

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Table 3

Deformation conditions 7th Sample no. 9 10 11 Apparent density of the mixture
before deforming 8th Shape size (mm) 0.21 0.19 0.22 0.21 Compressive force during the
Deformation. (Kg / cm) 900x900x38 0.13 900x900x40 900x900x35 900x900x40 O
to Apparent density of deform
ten mixture 26th 900x900x37 15th 30th 35 OO
—J
* ■> Reaction stone door (O ⁰ C) 0.70 20th 0.68 0.71 0.81 to Properties of the ver 45 0.63 45 45 45 at molded article 45 Apparent density Flexural strength (kg / cm ² ) 0.64 0.60 . 0.65 0.70 Compressive strength (kg / cm ² ) 20th 0.57 14 " - 20 '.'., - Non-combustibility 28 26, 15th 2% 30- out
draws 31 ■ out
draws excellent
draws excellent
draws out
draws

Continue! Ünc [the. Table 3

Water resistance (kg / cm ") Thermal insulation (kcal / m h ° C)

18 0.13

Refractory

Duration of heating (hours)

* £ ί temperature of the heated 3 surface (C)

2.3 0 * 10

10

.

0.11

• i--

0 · 13

«« J Maximum temperature of the

O opposite, back

«Ö western surface (C)

925 ■ 255

Deformation, destruction, degradation and cracks

Results of the analysis after the fire resistance test

no

Calcium silicate hydrate was made in potassium silicate converted

.925 256

no

925
250

\ 925

no

Disodium phosphate hydrate was in Dina'triüffipho sphat converted

Calcium carboriate would
decomposed to kai-aium oxide

no

Hydrogenated plaster of paris has been dehydrated into plaster of paris

0.12

925

IFo "

no

Ammonium phosphate would become ammonium salt 'decomposes

From the table above it can be seen that the objects
would not be flammable and neither smoke, flames nor the rest! Flames developed and had excellent fire resistance. Extinguished during the fire resistance test
the flame on the article immediately after switching off the flames used for heating.

The articles had good water resistance and were suitable
as building materials, e.g. for blankets and winches.

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Claims (14)

Godfather. NT ANS PROBLEMS 1. A method for producing a non-flammable, lightweight, molded article, characterized in that a mixture was formed which contained a) powder of silicon or a silicon-containing alloy, b) inorganic powders which were porous or contained voids and c) Water glass, with the resulting ^ shaped article on. a temperature between 15 and 120 ⁰ C was kept, whereby it is foamed and hardened. 2. The method according to claim 1, characterized * in that During the deformation, a pressure is exerted on the mixture until the apparent density of the shaped Article increased to 1.5 to 12 times the density of the article before deformation. 3. The method according to claim 1, characterized in that the Mixture 100 parts by weight of a) a powder of silicon or a silicon alloy, b) 100-2000 parts by weight an inorganic powder which was porous or contained voids and c) contains 100-1200 parts by weight of water glass. * 4. The method according to claim 1, characterized in that the Silicon alloy ferrosilicon, calcium silicide, ferrosilicoaluminum, Silicomanganaluminiüm, Kelziumsilicomengan, Contains silicomanganese or silicochrome. 5. The method according to claim 1, characterized in that the porous or 'cavities containing, inorganic ■ Powder Powder made of pearlite stone, pumice stone microspheres, carbon microspheres, glass microspheres, foamed pumice stone, foamed clay or vermiculite. 3098U / 0959 6. The method according to claim 1, characterized in that the mixture also contains fiber material. 7. The method according to claim 6, characterized in that Fiber material is used in an amount »that is not is over 80 parts by weight per 100 parts by weight of the total from aj, b) and c). 8. The method according to claim 6, characterized »that the fiber material chrysotile asbestos, hard serpentine asbestos, Anthophyll asbestos, amosite asbestos, tremolite asbestos, Actinolite asbestos, crocidolite asbestos, rock wool, flaky wool, Glass fiber or metal fiber is " 9. The method according to claim 1, characterized in that the mixture also e) a fire resistance improving Contains funds. 10. The method according to claim 9, characterized in that the fire resistance improving agent in an amount is used that is no longer 80 parts by weight per 100 parts by weight of the total from a), b) and c) contains. 11. The method according to claim 9, characterized in that the fire resistance improving agent? Us i) a inorganic powder that contains water of crystallization and releases it in the form of water vapor at high temperature, the i) an inorganic powder that decomposes and consumes heat at high temperature, and the ii) contains a mixture of these powders. 3098U / 0959 - -33 - 12. The method according to claim 11, characterized in that - that the inorganic powders i) powders of aluminum hydroxide, calcium hydroxide, clays, alum, hydrogenated gypsum, sodium sulphate hydrate or disodium phosphate hydrate are * 13. The method according to claim 11, characterized in that the inorganic powder ii) powder of calcium carbonate, magnesium carbonate, zinc carbonate, cadmium carbnate, sodium nitrate, Are lead nitrate, aluminum sulfate, ammonium phosphate, ammonium carbonate or ammonium sulfate. 14. A method for the continuous production of a non-flammable, light, molded article, characterized in that a mixture is deformed under pressure, the a) powder of silicon or a silicon-containing alloy, b) inorganic powders \ which are porous or have cavities, and c) water glass, and if desired d) fiber material and / or e) a fire resistance enhancing agent is fed into a pressure space formed between an endless belt and a conveyor plate, the inner surface of the endless belt opposite the pressure space in contact stands with pressure rollers and the conveyor plate is moved at about the same speed and in the same direction as the endless belt, the compression deformation being continued until the apparent density of the compressed article is 1.5 to 12 times the density that comprising the mixture of the article to be molded prior to the pressure treatment, wherein The molded article is then introduced into reaction chambers maintained at a temperature of 15-12 ° C., whereby foaming and hardening of the molded article occur. 3 09814/0959