JP2882926B2 - Advanced blended inorganic lightweight foam - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a light-weight foam used as a heat insulating material or a sound absorbing material or a dew-condensing material for effective utilization of a building such as a house or a warehouse or a device using heat. It is an object of the present invention to provide a non-combustible or flame-retardant inorganic heat insulating material which is a two-part composition which can be easily sprayed or poured by mixing at the tip.

[0002]

2. Description of the Related Art In the field related to heat,
Numerous types of heat insulating materials have been developed and used in large quantities in order to save heat. In particular, as for buildings, such as houses, warehouses, factories, and the like, the frequency of use of insulating materials for walls, ceilings, floors, roofs, and the like tends to increase year by year as energy saving measures for heating and cooling. They may also be used as a dew-condensing material or as a sound-absorbing material by taking advantage of its porosity. When the type of the lightweight body is classified morphologically, a plate, sheet, or mat shaped article such as polystyrene foam, polyethylene foam, or glass wool mat is attached with an adhesive or attached with a pin. Or, it is supplied in the form of a so-called molded product, such as compounding and attaching other boards, and it is sprayed or poured into the construction site, such as in-situ foamed polyurethane foam or sprayed rock wool Insulation can be performed, so-called on-site spraying or on-site injection can be performed. From the standpoint of fire prevention performance, especially when applied to buildings, building standards require safety in the event of a fire in accordance with the Building Standards Law, and fire prevention performance standards such as non-combustible, semi-non-combustible, and flame retardant have been established. I have. For example, organic heat insulating materials such as polyurethane foam and polystyrene foam are flammable and are not preferable from the viewpoint of fire prevention. For it,
Inorganic materials such as glass wool and rock wool are inherently nonflammable, and each heat insulating material is classified from flammable to nonflammable depending on the raw material used.

[0003]

In the heat insulating material provided in the form of a molded product in the heat insulating material as described above, cutting, bonding, etc. are performed on a curved base or a complex-shaped portion. It is troublesome and cannot be applied in many cases, and joints are always formed at the abutting portions in a formed plate, so that the portions have a drawback that they become heat paths (thermal bridges). On the other hand, in order to avoid these drawbacks, a mixture of two liquids, such as polyurethane foam, at the tip and immediately spraying or injection foaming is used. Have been. However, this method itself is extremely effective, but at present, the materials that can be used for the method are limited to polyurethane foam. Moreover, in that case, the material itself is an organic flammable material, and it is necessary to respond to fire and harmful gas during construction work, and to make buildings that require fire protection more flame-retardant and non-flammable However, suitable materials have not yet been developed. In addition, from the viewpoint of recent global environmental conservation, since polyurethane foam uses fluorocarbon gas, which is said to destroy the ozone layer, as its foaming gas, urgent measures must be taken.

[0004]

On the other hand, the present inventors have obtained the workability of mixing the foam at the tip and immediately foaming it, as in the above-mentioned polyurethane foam, and have a nonflammable or difficult flame retarding performance. We have invented a flammable tip-mixed inorganic foam. That is, a mixture obtained by mixing an acidic stable emulsion with an aqueous solution of acidic phosphate as a main component at a solid content ratio of 100: 5 to 300 parts by weight is used as A.
An inorganic foamed lightweight body for mixing at the tip, characterized in that it comprises an agent B, and as a main component, an agent B containing 100: 5-300 parts by weight of a metal carbonate with respect to magnesium oxide. In the present invention, by applying such a composition, the A agent and the B agent are stably stored, respectively, and in use, the A agent and the B agent are respectively pumped by a constant pressure using separate pumps, and the mixing part at the tip of the hose is used. When the mixture is injected or sprayed, the mixture is foamed and hardened to form a lightweight heat insulating layer or a lightweight sound absorbing layer. As the acidic phosphate, for example, aluminum phosphate monobasic, magnesium phosphate monobasic, calcium phosphate monobasic, etc. can be obtained in the form of an aqueous solution or powder. In actual application, they can be used alone or as a mixture in the form of an aqueous solution. In general, among them, an aqueous solution of aluminum monophosphate is particularly easily available and easy to use. In the case of the agent A, the acidic phosphate is usually used after adjusting the solid concentration to about 5 to 40% by weight. If the solid content concentration is high, the strength of the heat insulating material after foaming and curing is enhanced, but on the other hand, the viscosity of the agent A becomes too high, which impairs the pumping property. Further, since the solid content may precipitate due to lack of storage stability as the agent A, the maximum concentration is naturally limited. On the other hand, when the solid content of the phosphate is reduced, the strength of the foam after reaction curing becomes weaker, and furthermore, depending on the mixing ratio with the emulsion, it may become insufficient to impart flame retardancy. That is, the object of the present invention cannot be achieved. In the present invention, one of the features is that an emulsion stable to acidity is blended. Incorporation of an emulsion particularly covers brittleness peculiar to inorganic substances. This may be mixed in advance with an aqueous acidic phosphate solution or may be mixed immediately before use. However, in terms of use, it is easier to use if they are mixed in advance because the packaging is simpler. The composition may be acryl, styrene or a copolymer thereof, but the composition is not particularly limited as long as it is an emulsion composition that does not immediately cause gelation in an acidic phosphate aqueous solution. The compounding amount thereof is desirably in the range of 100: 5 to 300 parts by weight of the emulsion which is stable to the acid with respect to the aqueous solution of the acidic phosphate in terms of the solid content ratio. When considered as a lightweight body after foaming and curing, it is desirable that the resin content of the emulsion falls within the range of 1 to 30% by weight based on the total solid content of the foamed cured body after mixing the agent A and the agent B. If the amount is too small, the flexibility of the resin is not exhibited, and the brittleness of the lightweight body after foaming cannot be improved. On the other hand, when the amount of the resin is increased, the flame retardancy, which is one of the objects of the present invention, is inferior, and the resin becomes flammable. As mentioned above, the agent A is adjusted to have a viscosity of 100 centipoise or more based on the above two components. However, if the viscosity is too high, a compound having a stable blending ratio with the agent B cannot be obtained. In addition, a fibrous substance may be put in this system for reinforcing the strength, or a viscosity modifier, a viscosity imparting agent, or the like may be added. On the other hand, in magnesium oxide to be blended as the B agent, magnesia raw materials such as magnesium carbonate and magnesium hydroxide are used as raw materials, and are calcined at relatively low temperatures, and are calcined magnesia or calcined at 1500 ° C. or more. Magnesia clinker (also called hard-burned, dead-burned, or over-burned magnesia) is included. In addition, minerals containing magnesium oxide as a main component, such as magnesite and serpentine, can be applied because they harden and react with an aqueous solution of acidic phosphate to form an insoluble hardened product. Among these, magnesia clinker is particularly preferred because the curing reaction rate is suitable for the present foamed cured product. In any case, these magnesium oxides are used in the form of powder once crushed. If the particle size is too coarse, sedimentation tends to occur in the case of the B agent slurry, and the strength of the foamed cured product tends to be inferior. Therefore, the particle size is desirably 1 mm or less. As the metal carbonate, a poorly soluble or insoluble carbonate such as magnesium carbonate, calcium carbonate and barium carbonate is selected.
When they are mixed with the agent A, they decompose on contact with the acidic phosphate of the agent A to generate carbon dioxide gas, thereby acting as a foaming gas source. After the reaction, an insoluble calcium salt is formed. If the particle size of the powder is too coarse, the reaction will slow down,
In addition, the strength after curing is poor. On the other hand, if it is too fine, the reaction is accelerated, the mixing time cannot be secured in the tip mixing section, and foaming occurs immediately, which hinders the operation. Therefore, the optimum use particle size is naturally defined. The range is desirably 0.001 mm to 1 mm. However, this does not prevent a small amount of particles having a particle size outside this range from being mixed. Examples of fibrous substances include mineral natural mineral fibers such as rock wool, wollastonite, asbestos, carbon fibers, ceramic fibers, and glass fibers and artificial fibers, and organic fibers such as pulp fibers, polypropylene fibers, vinylon fibers, and tetron fibers. Is mentioned. In addition, whiskers such as potassium titanate are also provided for the purpose of the present invention. The addition of these fibrous substances reinforces the strength of the foam. The length of the fiber used for the use can be several tens of mm.
Alternatively, it can be said that a length of about 5 mm or less is desirable in consideration of the mixing property at the tip. Those having a size of 1 mm or less are also used. Alternatively, fibers having different lengths or fibers of different materials may be mixed and used. In particular, short fibrous substances such as whiskers are often used in such a form. If the added amount is small, the desired reinforcing effect cannot be obtained, while if it is too large, the viscosity is too high at the time of addition, which hinders pumping or clogging due to fiber entanglement at the tip mixing section. Is naturally limited. Although it depends on the type of the fiber to be used, usually, the range is preferably 0.5 to 40 parts by weight based on 100 parts by weight of the final foamed cured product. The fibrous substance may be added to either the A agent or the B agent. However, which one to mix is determined by which one can be stored stably when put in each, and does not cause a reaction. From the viewpoint of actual workability, agent A,
It is important to adjust the viscosity and difference in viscosity of the B agent so that they do not greatly differ. For these compositions, by adjusting the viscosity and foaming speed at the time of mixing, curing time and the like, it is possible to form a foamed lightweight body,
Furthermore, by adding a foam stabilizer, further foam stabilization,
It is desirable to make the air bubbles uniform. As an example,
In the case of inorganic powders, so-called foaming of porous inorganic powders such as silica gel, activated carbon, zeolite and carbon black and mineral powders having layered crystals such as mica, talc, sepiolite and palygorskite, and in the case of organic materials, surfactants and the like Stabilizers can be incorporated at appropriate times. The compounding amount is preferably in the range of 100: 0.1 to 60 parts by weight of the cell stabilizer with respect to the solid content of the lightweight body after foaming and curing. One with a large amount of addition also acts as a bulking agent, so it may be added in a considerably large amount.However, if it is added more than this, the viscosity of the liquid before mixing becomes too high, or the lightweight body after curing The strength is low and it is not practical. Naturally, even if the addition amount is too small, uniform stabilization of bubbles to be added cannot be obtained.
Like the fibrous substance, this may be added to either the A agent or the B agent as long as the stability of the system is not impaired.
In addition, as in the case of the agent A, an anti-settling agent, a fluidizing agent, and the like can be further added to the agent B. As described above, the main component of the agent B is mixed with water and adjusted to have a viscosity of at least 100 centipoise or more. If the viscosity is set too low with too much water, the powder in the agent B separates and precipitates, and a stable blending ratio with the agent A cannot be obtained. Naturally, if the amount of water to be mixed is small, the viscosity of the entirety of the B agent becomes high, and the pumpability becomes poor,
It may become impossible to mix at a fixed ratio, so it is necessary to keep it at least 800 poise or less. In addition, other powders such as talc, bentonite, clay minerals, or lightweight aggregates such as expanded pearlite, expanded vermiculite, microballoons, and shirasu balloons can be added within a range that does not impair the object of the present invention. As described above, based on the composition of the present invention prepared into two parts of agent A and agent B, each liquid or slurry is separately pumped through a hose using a pump or the like, and is applied to the tip of the hose. A mixing section is provided, and after mixing the agent A and the agent B guided therein, the mixture is applied to a predetermined location by means such as pouring, pouring, or spraying. At this time, it is desirable that the mixing ratio of the A agent and the B agent is such that the magnesium oxide in the B agent is 100: 10 to 1000 parts by weight based on the acidic phosphate solid content in the A agent. When the amount of magnesium oxide is less than 10 parts by weight, the acidity of the foamed cured product is high and the water resistance is poor.
On the other hand, when the amount is more than 1000 parts by weight, the weight of the foamed cured product increases, and a lightweight body which is one of the objects of the present invention cannot be obtained. When these compositions are mixed, they begin to react in a short time, foam and harden, and further increase their strength as the water evaporates and dries. As the pump to be used, a pump of a type capable of pressure-feeding the compound containing powder in particular, such as a plunger type, a snake type, a squeeze type, and a diaphragm type, is selected. In addition, since the liquid itself is acidic with respect to the agent A, it is necessary to consider an acid-resistant material such as stainless steel and acid-resistant rubber at the liquid contact portion. For the mixing part at the end of the hose, a method of mechanical mixing using an air motor or the like, or a method of blowing out from separate nozzles A and B to mix in the air or on the surface of the object to be coated can be applied. In the case of the composition, the viscosity is high to some extent, so that if a more uniform mixing is to be performed, a static mixer is more appropriate from the viewpoint of maintenance. The mixing time is desirably within a few seconds to at most a few tens of seconds from the foam hardening time of the present invention. Otherwise, it will harden and clog in the mixing section. The composition thus mixed is poured or poured as it is,
Alternatively, a spray nozzle can be attached to the outlet of the mixing section, and the composition immediately after mixing can be sprayed to a predetermined site with air. After foaming and curing after mixing in this manner, a lightweight, flame-retardant foam having a dry bulk density of 0.6 to 0.05 g / cm3 was formed.

[0005]

【Example】

Example 1 8 kg of an emulsion of an acrylic styrene copolymer having a solid content of 50% and 0.6 kg of vinylon fiber having a length of 2 mm were mixed with 10 kg of an aqueous solution of monobasic aluminum phosphate having a solid content of 40%. Agent. Even when mixed, it was stable without producing any gel. The viscosity is B
It was 53 poise when measured by a mold viscometer. On the other hand, magnesia clinker powder 5 having an average particle size of 100 microns 5
kg and calcium carbonate powder with an average particle size of 300 microns 6
kg and 4 kg of talc powder were each weighed, and the powders were sequentially charged and mixed into 6 kg of water prepared in a container with stirring to finally obtain a B agent. Its viscosity was 26 poise. These Agent A and Agent B were transferred to the hopper of the pump. Two stainless steel plunger pumps were prepared as metering pressure pumps, and each was adjusted to match the mixing ratio. A static mixer was attached to the end of two hoses 10 m in length, and a spray nozzle was also attached to the tip. At the same time, when the pump was switched on, the mixture coming out of the mixer end was uniformly mixed, and the time from when it came out until the foaming was measured. became. Further, a spray nozzle was attached to the end of the mixer and sprayed on the wall surface together with air. The coating material started foaming on the surface, and foamed and cured to a thickness of about 30 mm in one application. The bulk density was measured after placing such a lightweight body in a dryer at 50 ° C. and drying for 2 days.
/ Cm3. The fragility of the surface was good as compared with the sprayed rock wool surface. In addition, 100
Two pieces were cut out to a size of × 100 × 30 mm and subjected to a hot wire thermal conductivity measuring device manufactured by Kyoto Electronics Industry Co., Ltd.
A value of 5 kcal / m.hr. ° C. was obtained. Also, JIS A 1321
A surface heating test was performed in the fire prevention performance test specified in the above, and the second class performance of flame retardancy was obtained from numerical values such as exhaust temperature and smoke generation coefficient. (Example 2) 1 kg of an emulsion of an acrylic styrene copolymer having a solid content of 50% and a length of 0.3 mm was added to 10 kg of an aqueous solution of monobasic aluminum phosphate having a solid content of 40%.
3 kg of glass fiber and 3 kg of water were added and mixed to obtain an agent A. When the viscosity was measured with a B-type viscometer, 10
Poise. On the other hand, 6 kg of magnesia clinker powder, 3 kg of magnesium carbonate powder, 10 kg of talc powder, amphoteric ionic surfactant (Viscol N:
Daiichi Kogyo Pharmaceutical Co., Ltd.) 0.2 kg and hydroxyethyl cellulose (HEC) 0.1 kg were weighed, and the above-mentioned powders and the like were successively charged and mixed into 10 kg of water prepared in a container while stirring. Agent B was obtained. Its viscosity was 8 poise. When these agents A and B were mixed and sprayed in the same manner as in Example 1, foaming started 2 seconds later, and soon hardened to obtain a lightweight body. The bulk density of the thus obtained light body was even lighter at 0.10 g / cm3. The fragility of the surface was inferior to Example 1. The thermal conductivity was 0.037 kcal / m.hr. ° C. In addition, when a surface heating test was performed, first-class flame retardant performance was obtained. (Comparative Example 1) A cylinder in which a liquid A and a liquid B of a polyurethane foam were set was attached to a dedicated nozzle for spraying and sprayed on a wall surface to obtain a lightweight body. Example 1
The measurement was performed on the same items as in Example 1.
Was obtained. In particular, in the fire prevention performance test, the test started burning immediately after the start of the test, and the test was stopped due to danger. (Comparative Example 2) Rock wool and cement milk (mixed liquid of cement powder and a large amount of water) were separately prepared, separately pumped by a special machine, and sprayed on the wall while mixing at the tip, and 30 mm
Was obtained. During the operation, considerable scattering of dust was observed. When they were measured for the same items as in Example 1, the values of Comparative Example 2 in Table 1 were obtained. In particular, the fragility of the sprayed surface was conspicuous, and the fibers were peeled from the tatters and the surface when rubbed by hand.

[Table 1]

[0006]

By applying the above-mentioned components and the method of the present invention, the following effects which have not been obtained before can be obtained. 1. Until now, combustible organic foams typified by polyurethane foams have been the main heat-insulating materials of the tip-mixed, short-time foaming type. On the other hand, it has become possible to obtain a flame-retardant tip-mixed foam that can be efficiently worked in the same manner. 2. In addition, in the case of polyurethane foam, the foaming gas uses Freon gas, which is said to destroy the ozone layer surrounding the earth, whereas the present invention uses carbon dioxide gas as the foaming gas, which is extremely effective in protecting the global environment. is there. 3. Naturally, unlike a molded heat insulating material such as polystyrene foam, a construction method that does not cause a seam, which is a weak point of heat insulation performance, can be taken, which is effective in heat insulation. 4. Unlike fibrous heat insulating materials such as rock wool and glass wool, there is no scattering of fibers from the surface, and the indoor environment is not polluted.

Continuation of front page (58) Field surveyed (Int.Cl. ⁶ , DB name) C04B 38/02

Claims (5)

(57) [Claims] An agent A is prepared by mixing an acidic stable aqueous emulsion with an aqueous solution of an acidic phosphate as a main component at a solid content ratio of 100: 5 to 300 parts by weight as an A agent. Agent B containing 100: 5-300 parts by weight of a metal carbonate with respect to magnesium was added to A
A tip-mixing type inorganic foam produced by mixing the acidic phosphate solids in the agent with the magnesium oxide in the agent B in an amount of 100: 10 to 1000 parts by weight. Light body. 2. The fibrous substance is contained in an amount of 100: 0.5 to 40 parts by weight or a foam stabilizer in an amount of 100: 0.1 to 60 parts by weight based on the solid content of the lightweight body after foaming and curing. 2. The tip-mixing inorganic foamed lightweight body according to claim 1, wherein each of the ingredients is blended in advance with the agent A or the agent (and) the agent B. 3. 3. An inorganic foam lightweight body with a mixed tip according to claim 1, wherein the acidic phosphate aqueous solution is an aqueous aluminum phosphate solution. 4. The lightweight inorganic foam according to claim 1, wherein the magnesium oxide is a magnesia clinker. 5. An emulsion which is acid-stable as an active ingredient with respect to an aqueous solution of acidic phosphate at a solid content of 1%.
The agent A is a mixture prepared by mixing 00: 5 to 300 parts by weight, and the acid phosphate in the agent A is obtained by mixing the agent B as a main component with 100: 5 to 300 parts by weight of a metal carbonate to magnesium oxide. A method for constructing a lightweight foam body, characterized in that magnesium oxide in the B agent is mixed at a tip of 100: 10 to 1000 parts by weight with respect to a solid content.