DK172004B1 - Fiber-reinforced mold body and method for its manufacture - Google Patents

Abstract

The shaped article of hydraulic binder contains, as reinforcing fibres, birch pulp fibres alone or together with other fibre materials and, if appropriate, fillers. The shaped article is especially suitable as a building component, for example as a building panel, and shows particularly good material properties.

Description

in DK 172004 B1

The invention relates to a molding body of hydraulic binder and fibers as well as fillers, pigments and additional additives, as appropriate.

Replacement of asbestos cement products with similar but asbestos-free building components has in recent years become increasingly important in the construction industry. Firstly, in the case of improper manufacture and processing of asbestos cement, hazardous dust occurs, secondly, the decline in available 10 natural asbestos deposits is sought for alternative raw materials, which can be used without problems in previous applications of asbestos.

For this purpose, it has already been proposed to replace asbestos with other natural and synthetic fibers or mixtures made therefrom in the manufacture of fiber-reinforced, inorganic, hydraulically bonded mold bodies.

It is also known instead of asbestos to use cellulose fibers, alone or mixtures of cellulose fibers with synthetic organic fibers as reinforcing material for concrete or cement products.

However, such known working materials, especially asbestos cement, still have manufacturing disadvantages and technical disadvantages. They can only be manufactured at high costs, especially as a result of the preparation of raw materials or raw material mixtures, and have relatively low bending and impact strength, so that they do not meet the application requirements, for example due to building standards.

30 Recent proposals envisage the use of hemp fibers (DE patent 24 63 044) and eucalyptus fibers (DE patent application 29 40 623) as reinforcing fibers for cement. However, compared to asbestos cement, these working materials have a markedly poorer strength, especially for non-pressed products. An obvious disadvantage of these fiber cements is their very poor impact resistance and breaking strength, respectively. In addition, profiled products such as corrugated sheets of such mixtures cannot be made due to their completely unsatisfactory malleability and plasticity, respectively. Further, according to the aforementioned patents, the use of bleached cellulose fibers is indispensable, which in addition to higher raw material costs also has the disadvantage of reducing the service life. In addition, the cellulose species proposed there as eucalyptus cellulose or fibers are only limitedly available and not as domestic raw material.

Thus, the prior art provides no satisfactory solution for the production of fiber-reinforced asbestos-free inorganic working materials which can be used in place of asbestos cement with good material properties and can also be produced economically.

This problem is solved by fiber-reinforced moldings according to the invention by inserting bleached or unbleached birch cellulose fibers alone or together with other fibrous materials such as reinforcing fibers.

By virtue of the invention, economical preparation of a working material of fiber-reinforced inorganic binder is possible without the above disadvantages.

The mold body according to the invention is distinguished by high bending and impact strength or by a high tensile strength, so that it can be used in an excellent way instead of asbestos cement products as a building part.

It is surprising to those skilled in the art that bleached and especially unbleached birch cellulose is as excellent as fibrous reinforcement for working materials made of hydraulic binder. Hereby it must be emphasized the fact that the inventive use of birch cellulose leads to an unexpectedly good combination of manufacturing and utility properties. In contrast to eucalyptus cellulose, the good dewatering ratio and good formability of blends made with birch cellulose allow the manufacture of pressed or pressed corrugated sheets which, in addition to the required high bending strength, are also distinguished by high tensile strength, impact resistance and frost resistance. .

With birch cellulose, vapor-cured products containing quartz flour with lime hydrate as a binder can also be produced better than with other fiber types known in this context, and which can be used especially as corrugated sheets, but also in areas of the construction industry with higher fire protection requirements, such as for the coating of 10 steel carriers. or to the refractory lining of vents.

The inventive moldings are made with bleached or unbleached birch cellulose, alone or blended with other natural and / or synthetic fibers, whereby also primarily a blend of birch cellulose and cellulose or cellulose hard fibers such as palm, flax, manila hemp, spruce, pine. -, and / or sisal fibers meet expectations.

Some of the many possible embodiments of the invention are given below.

Example 1

Ca. 2,500 parts by weight (VD) of water are placed in a solution container and 90 VD of unbleached (16 degree SR) in 25 leaf form is added. After an opening time of approx. 30 minutes at approx. At 800 rpm the fabric suspension is dripped and mixed in a mixer with 1,000 VD portland cement.

The aqueous fiber cement suspension is fed to a mixing vessel and from there - with the addition of 30 polyelectrolytes (0.001 to 0.25% by weight of polyacrylamide relative to the cement content) - fed to a direct run machine (direct-flow machine) in which the suspension is processed into a tube or tube. plate-shaped mold body through deposition and dewatering processes analogous to the Hatschek or Magnani method.

The flexural strength and tensile strength of the moldings are examined after 28 days of air stacking.

4 DK 172004 B1 (Bending tensile strength and breaking strength, measurement data in attached table 1).

Example 2 Birch cellulose is suspended in water as above.

The dipped cellulose suspension is mixed with 600 VD portland cement and 400 VD quartz flour (fineness approx. 5,000 Blaine) and the mixture is processed into a plate mold body in a direct run machine.

The mold body is aerated for 3 days, then autoclave at 6 bar and 3 38 K for 16 hours and its strength is tested after another 3 days of aeration storage as in Example 1.

(Bending tensile strength and tensile strength, measurement data in attached table 3).

Examples 3 20 to 80 parts by weight of birch cellulose and 70 to 10 parts by weight of flax and / or sisal cellulose are dissolved as above in the solution container and processed - alternatively - as in Example 1 with Portland cement as an adhesive to an air-curing molding body or as in Example 2 with Portland cement and quartz as a binder for a vapor-curing mold body.

The strength is tested on the air-dried formal body as in Example 1 after 28 days or 3 days.

(Bending tensile strength and tensile strength, measurement data in attached table 3).

Example 4

A cellulose suspension similar to the above examples is mixed in a mixer with approx. 800 parts by weight of portland cement or a mixture of portland cement / quartz according to Example 2 as well as up to 300 parts by weight of perlite and / or mica and / or vermiculite and processed into a mold body in a direct run machine.

5 DK 172004 B1 On the - alternatively - 28 days aeration-stored or vapor-cured molding, as in example 1, the tensile strength and breaking strength are examined.

(Bending tensile strength and tensile strength, measurement data in Appendix Table 4).

Example 5

A cellulose suspension similar to the above examples is mixed in a mixer with 550 parts by weight of fine quartz flour (Blaine> 5,000) as well as 300 to 450 parts by weight of lime hydrate and processed into a plate mold.

The body is autoclaved at a steam pressure of 16 bar for approx. 8 hours or at 8 bar water vapor pressure for approx.

15 for 20 hours and then aerated for 3 days.

Then the strength is examined as in the previous examples.

(Bending tensile strength and tensile strength, measurement data in attached table 5).

20

Example 6

A cellulose / binder suspension of Examples 1 to 5 is adjusted in a mixer to a solids content of 4 to 10% by weight by adding water and processed according to the known Hatschek method to a plate or tubular body.

At the same time as the functional test carried out on the inventive mixture, a molding body of known cellulose / binder mixtures 30 as disclosed, for example, in DE patent application 29 40 523, was prepared and these were included in comparative strength studies (measurement data, see attached table 6).

From the majority of test series in the above examples for which extracts and exemplary 35 material test results are given in attached Table 6a, it is seen that the use of birch cellulose and / or mixtures of birch cellulose with cellulose or cellulose hard fibers according to the invention is proposed. for everything with sisal fibers, enables the production of asbestos-free molding bodies of hydraulic binder and 5 fibers whose material values and properties are superior to material values and properties of older known proposals.

In addition, there is the special economic advantage of using a domestic or European and thus easily and cheaply and sufficiently available raw material in the future.

Example 7

The following listed mixtures were adjusted to a solids content of 4 to 10% by weight by adding water in a mixer and corrugated sheets were prepared on a Hatschek machine according to profile 7 of 6 mm thickness. The freshly made plates were placed between oiled corrugated iron for 3 days to cure. Then, the plates were autoclaved in an autoclave for 16 hours at 6 bar. Of the mixture 1, unpressured and pressed variants were prepared (30 minutes, 180 bar).

Of the blends Nos. 1-4 of Attachments Table 7, the waveformability of the blends Nos. 1 to 3 was fully satisfactory. In mix # 4, numerous cracks occurred in the wave course. Particularly optimally, the wave ratio appeared at mixtures 2 and 3, which also showed satisfactory results at small wave radii.

The properties of the corrugated sheets thus prepared are set out in attached Table 8.

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Claims (8)

1. Form body which can be used as a building element, of hydraulic binder and natural and / or synthetic, inorganic and / or organic fiber materials and, where applicable, fillers, characterized in that bleached and / or unbleached birch cellulose fibers are used as reinforcing fibers alone or with other fiber materials. Mold body according to claim 1, characterized in that the proportion of the reinforcing fibers of the mixture of 10 fibers, binder and, where appropriate, fillers and dyes as well as further addition is 1-15% by weight. Mold body according to claim 1 or 2, characterized in that portland cement and / or clay soil cement and / or blast furnace cement and / or puzzolane are used as hydraulic binder. Mold body according to one of claims 1-3, characterized in that quartz and lime hydrate and / or cement are used as hydraulic binder. 5. Form body according to any one of claims 1-4, characterized in that the mixture is added to mica and / or vermiculite and / or perlite and / or pumice and / or color pigment and, where appropriate, bentonite, spiolite, amorphous silicic acid , kaolin, wollastonite and ball clay. 6. The molding body according to any one of claims 1-5, characterized in that polyelectrolyte such as polyacrylamide and / or alkylsulfonate and / or alkylcellulose ether is added. Process for preparing a molding body according to any one of claims 1-6, characterized in that the mixing components are randomly mixed with the excess water or the dry mixture produced therefrom and that the aqueous mixture is subjected to a molding process, for example according to " Hatschek "process. DK 172004 B1 16 Process according to claim 7, characterized in that the molding body is subjected to atmospheric pressure and / or a water vapor cure at higher pressure and higher temperature during the quenching and / or thereafter.