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
  • C04B26/00—Compositions of mortars, concrete or artificial stone, containing only organic binders, e.g. polymer or resin concrete
  • C04B26/02—Macromolecular compounds
  • C04B26/10—Macromolecular compounds obtained otherwise than by reactions only involving carbon-to-carbon unsaturated bonds
  • C04B26/12—Condensation polymers of aldehydes or ketones
  • C04B26/122—Phenol-formaldehyde condensation polymers
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
  • B29B—PREPARATION OR PRETREATMENT OF THE MATERIAL TO BE SHAPED; MAKING GRANULES OR PREFORMS; RECOVERY OF PLASTICS OR OTHER CONSTITUENTS OF WASTE MATERIAL CONTAINING PLASTICS
  • B29B7/00—Mixing; Kneading
  • B29B7/74—Mixing; Kneading using other mixers or combinations of mixers, e.g. of dissimilar mixers ; Plant
  • B29B7/7476—Systems, i.e. flow charts or diagrams; Plants
  • B29B7/7485—Systems, i.e. flow charts or diagrams; Plants with consecutive mixers, e.g. with premixing some of the components
• • 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
  • C04B2111/30—Nailable or sawable materials

Definitions

• the present invention relates to a process and an installation for obtaining a building material resistant to fire, cold, thermal shock, acids and bases and also relates to the building materials thus obtained.
• a building material on the market which is practically insensitive to fire, cold, thermal shock, acids and bases. None of the materials currently available meets all of the above conditions.
• the new process and installation according to the present invention lead to this surprising and perfectly unexpected result of making it possible to obtain a building material having these properties, but also making it possible to obtain a material further having the advantage of being homogeneous, of being easily machinable with tools used for woodworking, of being assembled by gluing or using cement, of being an excellent sound insulator and of being light while with a density lower than that of wood.
• this material is inert towards acids or bases.
• the present invention relates to a process for obtaining a building material consisting of: a.- mixing the phenolic resin and the pulverulent fillers by controlling the viscosity of the mixture obtained so as to obtain a viscosity mass constant; b.- discharge, under pressure by sucking in the occluded air, the mass of phenolic resin and of powdery fillers resulting from step a.-; c- introducing the mass obtained and the polymerization catalyst into a mixing and extrusion head; d.- extruding the mass resulting from step c- and adding it to the mixture of the expanded products or spheroid in an impregnator in which a homogeneous mixture of the mass and the mixture of expanded products or sphero mentioned above is formed; e.- send, via mobile distribution means, the mixture resulting from the aforementioned step d.- to a forming and setting zone.
• the pulverulent fillers are chosen from the group comprising magnesium silicate, aluminum silicate, TiO 4, talc, mica, phosphogypsum, aluminum sulphate, a mine, silica, shales, magnesia, magnesium sulfate.
• the expanded products or spheroids are chosen from a group comprising spheres of expanded clay, perli vermiculite, spherules of expanded glass or ceramic fibers.
• the total volume of the aggregates therefore of the pulverulent fillers and of the expsed products or spheroids incorporated in the composite product formed from 80 to 90% of the total volume of the said product and the “polymerization catalyst consists in that the polymerization catalyst consists of methanol and sulfuric acid or hydrochloride
• the installation for obtaining a building material comprising a mixing tank and a delivery block for products mixed in the tank to a mold formed from the building material, is characterized in that the mixing tank receives and mixes doses of phenolic res and pulverulent or weight products of various materials such as micas, shales, talc, etc., that a blowing screw blows pushes the kneaded products towards a intermediate temperature stabilization hopper fed to a discharge block which discharges into an extrusion mixture head into which also leads a discharge line of a curing catalyst and in that said installation comprises a mixer assembly of expanded charges or spheroids which pours these charges into a screw impregnator connected to a mixer of the mixing head capable of extruding the mixture of phenolic resin, of pulverulent products and of catalyst prepared in this head, the outlet of the impregnator being arranged above molding tanks receiving, before hardening, the pasty and sticky final product consisting of expanded fillers or spheroids impregna
• the mixing tank has at its base the screw delivery block connected to the intermediate hopper via a motorized cut-off valve and to a recirculation line via a motorized cut-off valve, these motorized valves being coupled via a regulating member to a tank temperature sensor and a pressure and / or tank discharge flow sensor.
• the intermediate hopper comprises at least one level probe and one temperature probe and delivers, via a motorized valve, the mixture of phenolic resin and fillers maintained at suitable viscosity and temperature, at its base to the delivery block which is connected to a suction chamber for air and occluded gases and in which rotates a feeding screw at adjustable speed.
• the mixing and extrusion head is connected from upstream to downstream in the direction of its injection: a suction line for air and occluded gases, to the delivery block for the kneaded and conditioned mixture of phenolic resin and of pulverulent products, then to the pipe for discharging a curing catalyst and finally to a pipe for possibly supplying a liquid for rinsing the injector after stopping the injection of catalyst.
• the charge mixer assembly consists of a screw mixer connected from downstream to upstream, respectively a hopper for feeding large balls of expanded products or spheroids, to a hopper for feeding small balls of expanded products or spheroids, and finally to a hopper for supplying refractory cement intended to give cohesion to these products expanded.
• the screw impregnator and the injection head are preferably made integral and are carried by a mobile carriage on a rolling track in order to allow the final product to be output from the impregnator into a mold.
• the outlet nozzle of the screw impregnator is connected to an orifice for injecting cut son or filaments made of a material having good resistance. mechanical and heat.
• the building material according to the invention contains from 80 to 90% of its total volume of pulverulent fillers, of expanded products, of refractory cement, and possibly of son or filaments of fibers.
• this material contains from 25 to 125 volumes of mineral fillers and from 900 to 1275 volumes of pulverulent products.
• the powder fillers are chosen from the group consisting of magnesium silicate, aluminum silicate, TiO 2, talc, mica, phosphogypsum, aluminum sulphate, a mine, silica, shales, magnesia and magnesium sulfate.
• the expanded products or spheroids are chosen from the group comprising spheres of expanded clay, perli vermiculite, spherules of expanded glass or ceramic fibers.
• the son or filaments of fibers are chosen from the group comprising glass fibers, carbon fibers, metallic threads, flame-retardant threads, etc.
• the material is more often in the form of flat plates or suitable boards be sawn or machined by tools intended for working hardwood.
• FIG. 1 schematically shows an installation according to the present invention for obtaining the building material, object of the invention
• FIG. 2 is a schematic representation of another embodiment of the installation of Figure 1, in which the impregnator and the circuits which surround it have been modified.
• the installation represented in FIG. 1 comprises, as main elements arranged according to the order of their intervention in the process, a mixing tank 1, an inte cal hopper 2 a block for delivery and suction of occluded air 3 , a mixing and extrusion head 4, a mixer assembly of the expanded charges or spheroids 5 and, finally, an impregnator of these expanded products or spheroids 6.
• the mixing tank 1 receives, via a loading opening 7, doses of phenolic resin and pulverulent or weighty products of various materials such as micaceous minerals, expanded shales, silicates, magnesium sulphate, alumina, talc, etc.
• the mixing tank comprises a kneading assembly consisting of a paddle rotor 8 driven in rotation by an electric motor 8a and rotating in front of a finned stator 9, arranged in the bottom part of the tank and whose blades are oriented in the opposite direction to that of the blades of the rotor 8 located opposite.
• the bottom of the tank 1 of conical shape opens out through a connection tube 10 onto a screw delivery block 11 whose screw is rotated by an electric motor 12.
• the block 11 discharges, via a line 13, via a motorized valve 14 for regulation and cut-off and a flowmeter 15 coupled with a pressure indicator, into the intermediate hopper Upstream of the motorized valve 14, a recirculation line 16 on which is interposed a motorized valve 17 of regulation and cutoff, allows the return or recycling to the tank 1 of all or part of the mixture of resin and filler.
• a temperature probe 18 is immersed in the mass at the neck of the mixture inside the tank 1 and is electrically coupled, via a regulating member 19, to the motorized valves and 17 and to the flow meter 15.
• the hopper 2 is provided with an agitator, not shown, driven by a motor 20 and includes various monitoring probes: a high level probe 21, a low level probe 22 and a temperature probe 23.
• the hopper 2 delivers to its base, via a motorized valve 24, the mixture of phenolic resin and fillers, maintained at the appropriate viscosity and temperature.
• the mixture is brought to the inlet connection of the discharge and suction block 3 provided with a solid body capable of withstanding the high discharge pressure and inside which a booster screw 25 rotates. After the connection inlet, the interior space with the booster screw 25, leads to a chamber 26 for suction of the air occluded in the mixture of phenolic resin and fillers.
• the chamber 26 is connected, via a cut-off valve 27, to a suction line 28 connected to a vacuum pump with low depression, for example of the order of 6 to 7 mbar and not likely to suck the mixture based on phenolic resin.
• Booster screw 25 is rotated by means of a speed controller 29, so as to allow its speed to be adapted to the discharge flow rate required for the mixture based on phenolic resin and to the viscosity of this mixture.
• the discharge block 3 discharges under pressure, via a fixed pipe 30 and a flexible connector 31 via a cut-off valve 31a, the mixture based on phenolic resin in the mixing head 4 in the form of a column and which has several (four in the experimented embodiment) rotors provided with cutting blades in the shape of plowshares and driven in rotation by a motor 4a_.
• Downstream of the entry of the mixture into the body of the mixing head 4, via a cut-off valve 32a opens a supply line 32 of a discharged catalyst by a recovery pump 33, from an intermediate catalyst reservoir 34 equipped with level and temperature detection probes 34a and supplied via a pump 34b with a motorized valve 34c of catalyst taken from a reservoir see main 34d.
• the mixing head 4 arranged vertically, ends at its lower part with an injector 35 and is carried by a carriage 36 movable on a rolling track 37.
• a complementary vacuum suction pipe 38 sucks in the upper part of the mixing head 4 the gases occluded in the phenolic-based mixture being extruded.
• the mixing head 4 is integral with the impregnator 6 which includes a small hopper 39 for receiving the extruded mass of resin, fillers and catalyst, available just below the injector 35.
• the small hopper 39 che on a mixing and propulsion screw 40, upstream of which is introduced by a supply line 41 a homogeneous mixture of expanded products of spheroid form coming from the mixer 42 of the mixer assembly 5.
• the homogeneous mixture of expanded products or spheroids is brought into the screw mixer 42 from feed hoppers 43, 44, 45 loaded, respectively from downstream to upstream of the mixer: large balls of expanded products, small balls of expanded products, and a refractory cement intended to give cohesion to these expanded products.
• L 1 impregnator 6 is integral with the carriage 36 which rolls in the plane of the figure on the raceway 37, carrying with it the mixing and extrusion head 4.
• An outlet opening 46 of the impregnator 6 pours the product final composite obtained generally containing less than 20% of phenolic resin coming from head 4 and injector 35 and more than 80% of charges consisting on the one hand of pulverulent products or spheroids coming from the tank and , on the other hand, of expanded products from the mixer assembly 5.
• Mixing tank 1 is supplied with phenolic resin and the aforementioned pulverulent products such as micaceous ores, expanded shales of silicates, magnesium sulphate, alumina, tal in predetermined proportions for which the percentage of phenolic resin is significantly lower than that powdery products.
• the kneading assembly 8, 9 in the lower part of the tank ensures good impregnation of powdered products with phenolic resin and these impregnated powdered products are poured into the bottom of the tank at the inlet of the screw delivery block 11 which conveys via line 13 to the inlet of the intermediate hopper 2 where the pulverulent products impregnated with phenolic resin are brought to and maintained at a suitable viscosity and temperature * -.
• the still insufficiently impregnated pulverulent products are brought back by the recirculation line 16 to the mixing tank 1 to perfect their impregnation.
• the motorized regulating valve 17 opens to allow recycling to the tank 1 of impregnated powdery products which are discharged at flow rate. almost cons ⁇ by the screw delivery block 11 operating in volumetric pump.
• the intermediate hopper 2 delivers at its base a controlled flow of impregnated pulverulent products which enters the high-pressure delivery block 3 where the air and the occluded gases are sucked by the suction line 28.
• the impregnated pulverulent products discharged by the loading screw 25 of the delivery block 3 are brought to the appropriate viscosity, by means of any thermal source, via flexible connector 31 at the upper part of the mixing head 4 in which the rotors have blades plowshares.
• Line 32 leads into the mixing head 4, downstream of the arrival of the pulverulent products impregnated with phenolic resin, a catalyst discharged by the recovery pump 33.
• the mixture of impregnated pulverulent products and catalyst is discharged by the injector 35 provided at the base from column 4, in the form of an extrusion, into the small hopper 39 which introduces it inside the screw 40.
• the mixer for expanded products or spheroid assembly introduces, via the supply line 41, the homogeneous mixture of the expanded products made coherent by a refractory cement, at the inlet of the screw 40 where it meets the mixture of pulverulent products impregnated with phenolic resin and added with catalyst.
• the screw 40 ensures the mixing of impregnated powder products and expanded or spheroid products and pours through the outlet opening 46 the final composite product obtained.
• the outlet opening 46 in the form of a sleeve moves alternately in the plane of the figure and pours this pasty and sticky final product into a mold pan 47 which moves perpendicularly in the plane of the figure, the length of a pass by any appropriate means such as rollers or slides after each pass for discharging this opening 46.
• a mold pan 47 which moves perpendicularly in the plane of the figure, the length of a pass by any appropriate means such as rollers or slides after each pass for discharging this opening 46.
• the tank 47 there is obtained in the tank 47 the juxtaposition of several adjacent "strips" of final product pasty, the outer surface of which becomes substantially flat at rest to give a rectangular or square slab shape to the final product which hardens after polymerization of the phenolic resin.
• 47a and 47b other molding tanks intended for molding slabs of composite product respectively thinner or thicker.
• the hardening of the slabs or other forms of molding filled by regular distribution of the pasty final product in a mold can be obtained in a few minutes by polycondensation of the phenolic resin after the triggering of the exothermic physico-chemical phenomenon causing the solidification
• the mixing head 4 is connected to its lower part via a cut-off valve 48a pa a flexible pipe 48 and a pump 49 to a rinsing tank equipped with level and temperature probes 50a and supplied with products rinsing by a pump 51 from a reser ⁇ see 52 of rinsing products.
• a cut-off valve 48a pa a flexible pipe 48 and a pump 49 to a rinsing tank equipped with level and temperature probes 50a and supplied with products rinsing by a pump 51 from a reser ⁇ see 52 of rinsing products.
• the mixture of phenolic resin and fillers present in the delivery block 3 remains liquid on the other hand during the shutdown of the installation due to the absence of catalyst and only requires reheating at the time of restarting the installation when the rinsing products are discharged from the mixing head 4, followed by the reopening of the respective motorized valves 31a, 32a, of the connector 31 and of the pipe 32 and of the closing of the motorized valve 4 controlling the flow of rinse aid.
• FIG. 2 shows a different embodiment of the final mixer of the expanded or spherical products and of the pulverulent products impregnated with phenolic resin.
• a hopper 60 for supplying expanded mineral spherules is connected via a solenoid valve with adjustable opening 61 to a propulsion screw 62 driven in rotation by a motor with adjustable speed 63.
• the hopper 60 which can replace the three hoppers 43 44, 45 represented in FIG. 1 receives a mixture of expanded mineral products or spheroids and of a refractory cement giving cohesion to these mineral products.
• the propulsion and mixing screw 62 is surrounded by a cylindrical casing or casing 64 open at its upper part on the outlet of a funnel 65 for receiving impregnated pulverulent products delivered by the injector 35 the mixing head 4.
• the mixture kneaded by the screw 62, of expanded or spheroid products, of refractory cement and of impregnated pulverulent products is poured through an outlet nozzle 66 of the impregnator 6 contained in the casing 64.
• An orifice 67 for injecting cut threads or filamen opens laterally into the wall of the outlet nozzle 66 11
• coils 68 e 69 of different threads for example textiles but more generally non-combustible, the threads 70 and 71 of which are brought "by unwinding in a device 72 for cutting and injecting threads comprising for example, rotary knives and a blowing injection fan as wires or filaments for reinforcing the final product 67 hardened into plates in the molding trays 47.
• a device 72 for cutting and injecting threads comprising for example, rotary knives and a blowing injection fan as wires or filaments for reinforcing the final product 67 hardened into plates in the molding trays 47.
• Various shades and varieties of textile or other yarns or fibers can be used.
• non-combustible or flame retardant such as fire-retardant treated threads, but also carbon, glass, high-resistance synthetic fibers and also for certain applications.
• Example 1 Eight samples of the composite material according to the invention were prepared and which substantially present the following compositions, expressed in volume parts. Example 1
• test pieces with a surface area of 53.3 cm 2 are formed by cutting from molded blocks of the aforementioned samples and the compressive strength measurements are carried out. The results obtained are recorded in Table I.
• Expanded clay spherules 800 Expanded glass spherules 8/12 ...
• Phosphogypsum 30 Alumina globular silicate .... - 100 80
• the flexural strength (in daN / cm 2 ) is measured using a mobile punch moving at 10 mm / m nute.
• W is a heat flux expressed in watts.
• K ° expresses Kelvin or centigrade degrees The thermal resistance and thermal conductivity measurements were carried out for an average temperature of around 20 ° C.
• Pipes are prepared having the following composition (expressed in volume parts): a) pipes: resin 100, roving wire 3 thicknesses, powdery minerals 22, for each pipe; b) insulation between pipes: resin 100, powdery minerals 40, ceramic fibers 5.
• Insulation between Fenotubes Resin -. 100
• Powdered aluminum silicate 10 (._ Mica 5)
• Carbon powder 5 (Ceramic fibers 5
• the composite product according to the invention prepared with the aid of the installation described above has, in cut test pieces, a mechanical resistance close to that of common molded concretes, excellent cold behavior and good thermal insulation properties.
• the fire behavior of the composite material according to the invention intended in particular to constitute a sound insulator and to the flame was tested on samples of the material according to the invention composed of micaceous minerals, expanded wart, expanded shales with phenolic binder, silicates , sulphates of magnesia and alumina having, for a thickness of 70 mm, a total surface mass of approximately 5000 g / m 2 .
• the composite material according to the invention turns out to be an excellent material for protection against flames accidental heating both by its qualities of resistance to flame and to thermal shock as by its qualities of thermal insulation.
• the composite material according to the invention obtained in the installation which has just been described is thus formed from a thermosetting organic resin charged with incombustible powdery mineral products, mainly of micaceous type and at high melting temperature.
• the resin thus obtained from a mixture of liquid and solid constituents in substantially equal amounts has a very high viscosity and serves as a binder to a saturated agglomerate of spherical aggregates of clay or of expanded glass or other products, even organic .
• the volume of the aggregates, therefore of the pulverulent fillers and of the expanded or spheroid products, thus incorporated into the final molded composite product can reach 80 to 90% of the total volume of the product, while the specific specific weights of these aggregates vary between 15 and 1 700 g / dm 3 .
• the specific mass of the molded composite product varies between 350 and 740 kg / m 3 depending on the proportions of the various aggregates used.
• the thickness of the slabs obtained by molding the composite material according to the invention varies between 80 and 800 and it has already been possible to mold slabs reaching 3 per side.
• the blocks molded in “ composite product according to the invention have a texture allowing them to be machined by cutting tools under conditions close to those of hard boils, that is to say preferably using tungsten carbide tools or similar.
• the materials according to the invention have been found to be practically insensitive to the aggression of all alkaline or acid bases. Their behavior in cold or fire is remarkable and they remain inert and without apparent disorder after being subjected to the greatest thermal shocks while being considered as non-freezing. Their natural color, after exposure to the solar spectrum, and close to dark mahogany. All coatings and paints can be applied without precaution on the raw surface of these materials, the behavior and duration of which have not revealed any failure so far.

Landscapes

• Chemical & Material Sciences (AREA)
• Engineering & Computer Science (AREA)
• Ceramic Engineering (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Materials Engineering (AREA)
• Structural Engineering (AREA)
• Organic Chemistry (AREA)
• Mechanical Engineering (AREA)
• Compositions Of Macromolecular Compounds (AREA)

Applications Claiming Priority (2)

Publications (1)

Family

ID=9363180

Family Applications (1)

Country Status (4)

Families Citing this family (2)

Family Cites Families (11)

• 1988
  • 1988-02-11 FR FR8801625A patent/FR2627177A1/fr active Pending
• 1989
  • 1989-02-13 EP EP19890902525 patent/EP0387306A1/fr not_active Withdrawn
  • 1989-02-13 AU AU30677/89A patent/AU3067789A/en not_active Abandoned
  • 1989-02-13 WO PCT/FR1989/000054 patent/WO1989007518A1/fr not_active Application Discontinuation

Non-Patent Citations (1)

Also Published As

Similar Documents

Legal Events