JP3688434B2 - Mixing device for manufacturing inorganic foamable material, method for manufacturing inorganic foam cured body, and method for manufacturing wall panel - Google Patents

Description

【００８０】
《壁パネルの製造方法》
本発明に係る壁パネルの製造方法について実験を行った。
予め、表２の原料配合比になるよう、反応性無機質粉体、充填材、発泡助剤、補強繊維及び発泡剤、アルカリ金属珪酸塩水溶液を用意し、オムニミキサー（千代田技研工業株式会社製）にて混合した。
【表２】

※１：粉砕メタカオリンについて
メタカオリン(エンゲルハード社製ＳＡＴＩＮＴＯＮＥ ＳＰ ３３、平均粒径３.３μｍ、比表面積１３.９ｍ²/ｇ)１００重量部及びトリエタノールアミン２５重量部％とエタノール７５重量％の混合溶液０.５重量部をウルトラファインミルＡＴ−２０(三菱重工業社製、ジルコニアボール直径１０ｍｍ使用、ボール充填率８５％)に供給し２５ｋｗｈ/ｋｇの機械的エネルギーを作用させ、無機質粉体を得た。
※２：アルカリ金属珪酸塩水溶液について
所定量のｎＳｉＯ₂/Ｍ₂Ｏ(ｎ=１.５、Ｍ=Ｎａ,Ｋ;モル比１:１)をオートクレーブ中において１３０℃、７ｋｇｆ/ｃｍ²（０.７ＭＰａ）で所定量の水に溶解して得た。
【００８１】
これとは別に凹凸模様の深さを含む全深さが３１ｍｍで、幅方向９００ｍｍ、長さ方向３０００ｍｍの空間を有し、凹凸模様部はウレタンゴム（商品名：モールドスター、東海ゴム（株）社製）によってなりその他部分は金属によって構成される雌型と、それに合一する同じく金属製の雄型を用意した。
【００８２】
また、投入材料の均一分散の方法として、金属板によるスクレイパーを用意し、凹凸模様投影面積被覆率は、投入材料の投影寸法を図り、凹凸模様投影面積にて除することにて算出した。厚み分布率は、糸を用意し、その高さを基準として各所で厚みを測定し、その分布の最大幅を型の最大長さ寸法で除することにて算出した。
【００８３】
含水率はできた発泡硬化体を切り出し、２４時間放置して吸水させ、その後オーブンにて１０５℃にて３日で絶乾状態にし、その重量変化から算出した。実験結果の詳細を、実施例５と実施例６及び比較例６として表３に示す。
【表３】

【００８４】
【発明の効果】
以上説明したように、本発明の無機質発泡性材料製造用の混合装置によれば、反応性無機質粉体、アルカリ金属珪酸塩、水及び発泡剤からなる配合物を、短時間に連続的かつ充分に混合することができるので、安定した品質の無機質発泡硬化体を得ることができる。
【００８５】
また、本発明の無機質発泡硬化体の製造方法によれば、独立気泡を有しかつ外観の優れた無機質発泡硬化体を得ることができる。そして、得られた無機質発泡硬化体は建材等の用途に好適に用いることができる。
【００８６】
さらに、本発明の壁パネルの製造方法によれば、凹凸模様の転写に優れかつ意匠性が良く、壁として品質に優れた壁パネルを得ることができる。
【図面の簡単な説明】
【図１】本発明に係る無機質発泡性材料製造用の混合装置の断面図である。
【図２】本発明に係る壁パネルの製造方法の手順を示した図である。
【符号の説明】
１０ 外装容器
１１ 上板
１２ 下板
１３ 側壁
１４ 供給部
１４ａ 粉体供給部
１４ｂ 液体供給部
１４ｃ ノズル
１５ 排出口
２０ 内装回転体
２１ 上部回転面
２２ 側部回転面
２３ 突子
３０ 回転軸
３１ 軸受け
３２ 回転コーン
３３，３４ 伝動プーリ
３５ 伝動ベルト
４１ 一次混合室
４２ 二次混合室
５０ 駆動モータ
６０ 架台[0001]
BACKGROUND OF THE INVENTION
  The present invention relates to a mixing apparatus for producing an inorganic foamable material andNothing using itThe present invention relates to a method for producing a flexible foam cured body and a method for producing a wall panel.
[0002]
[Prior art]
2. Description of the Related Art Conventionally, there is known a method for producing an inorganic foamed cured product by mixing a composition composed of a reactive inorganic powder, an alkali metal silicate, water, and a foaming agent and foaming and curing. In this case, in order to cause foaming, a method of generating gas by adding metal powder as a foaming agent, a method of generating water vapor under heating without using a foaming agent, and the like have been proposed. For example, a method for adding metal powder as a foaming agent is described in JP-A-57-77062.
[0003]
By the way, when the reactive inorganic powder is cement-based, the mixing is generally performed by a batch mixer. However, when alkali metal silicate is contained, due to its high alkalinity, the time from the introduction of the foaming agent to the foaming is very short. Therefore, in a batch mixer that takes a long time to mix, foaming starts before a sufficiently mixed state is reached, and it is difficult to prepare an inorganic foamable material in a uniform foamed state. Variation in quality occurs. In addition, when fibers are added to improve the strength and the like, the mixing time cannot be made long, so that the fibers are not sufficiently dispersed and the strength quality varies.
[0004]
Thus, Japanese Patent Publication No. 6-15428 discloses that mixing is performed using a static mixer. If a static mixer is used, even if it is a compound containing an alkali metal silicate, it is possible to obtain an inorganic foam cured body having a certain quality.
[0005]
Conventionally, in order to produce a wall panel using an inorganic foamable material, as described in the above Japanese Patent Publication No. 6-15428, after mixing with a batch mixer or the like, the mixture is predetermined. The male mold made in accordance with the female mold is attached to and merged with the female mold, then foam filled, hardened by applying thermal energy, and finally removed to remove the wall panel. The method of obtaining is known.
[0006]
[Problems to be solved by the invention]
However, as in the above prior art, when mixing using a static mixer, the inorganic foamable material containing the alkali metal silicate has a high viscosity, so it is difficult to sufficiently mix with the foaming agent in the static mixer, As a result, the resulting inorganic foamed cured product has a variation in quality. In addition, since the static mixer performs mixing by external power, it is necessary to increase the number of elements of the static mixer in order to increase the mixing capacity. However, as the number of elements increases, the pressure loss increases. It becomes necessary and causes difficulty in implementation. Moreover, since the mixing time becomes longer as the number of elements increases, foaming may start during mixing. Furthermore, when fibers are added, there is a problem in dispersibility, and since it has a large effect on pressure loss, the addition itself becomes a problem for operations that increase the mixing ability, and sufficient strength is required. I can't get anything.
[0007]
Moreover, when manufacturing an outer wall etc. using the said inorganic foamable material, depending on manufacturing conditions, only the foaming hardening body which has a bubble on the surface and lacks independence of a bubble is obtained, and quality is not enough. .
[0008]
In particular, when manufacturing wall panels, etc., if a wall panel with a concavo-convex pattern on the surface is made of a thermosetting compound containing alkali metal silicate and a material using a foaming agent as described above, it is simply put into a female mold. Only by doing this, the height of the material after charging will not be uniform. And if it is foamed and cured as it is, movement of the material during foaming due to the difference in height distribution will occur, and the foam that has been foam-grown neatly will be destroyed and cured as it is. There is a problem that it is continuous and lacks independence, and the performance as an outer wall is remarkably deteriorated. In addition, on the product surface, there is a problem that bubbles torn due to material movement appear on the surface layer in a single or a plurality of continuous forms, thereby ruining the design of the uneven pattern.
[0009]
An object of the present invention is to provide a mixing apparatus for producing an inorganic foamable material and a method for producing an inorganic foamed cured product, which can obtain an inorganic foamed cured product having stable quality.
Another object of the present invention is to provide a method for producing a wall panel having independent bubbles and having an excellent appearance.
[0010]
[Means for Solving the Problems]
In order to achieve the above object, the invention described in claim 1 is used when producing an inorganic foamable material, and a mixture comprising a reactive inorganic powder, an alkali metal silicate, water and a foaming agent is mixed. The mixing device includes an outer container fixed to a gantry, a rotatable container provided inside the outer container, a surface formed in a substantially similar shape to the outer container, and a large number of bar-like surfaces on the surface. An internal rotating body to which a member is attached, a drive unit that rotationally drives the internal rotating body, a supply unit that supplies the mixture into a space defined by the exterior container and the internal rotating body, and the space A discharge unit for discharging the mixture mixed therein, and the supply unit is provided with means for supplying a part of the liquid in the form of droplets in the form of droplets. .
[0011]
According to the said structure, the compound supplied in the space defined by an exterior container and an internal rotary body is continuously and fully mixed from a rod-shaped member with rotation of an internal rotary body. In particular, since a part of the liquid in the blend is supplied in the form of droplets, the viscosity of the blend can be lowered and the blend can be mixed in a short time.
[0012]
The invention according to claim 2 is characterized in that, in claim 1, the alkali metal silicate aqueous solution is supplied from the means for supplying a part of the liquid composition in the form of droplets. .
[0013]
  The invention according to claim 3 is to produce an inorganic foamed cured product by mixing and curing a compound comprising a reactive inorganic powder, an alkali metal silicate, water and a foaming agent.In the manufacturing method of an inorganic foaming hardening body, the said compound is mixed using the mixing apparatus of Claim 1 or 2.It is characterized byIt is a manufacturing method of an inorganic foaming hardening body.
[0014]
  When manufacturing an outer wall or the like, air that is entrained during mixing or casting becomes foam on the surface and impairs the appearance of the outer wall or the like, so that it is often performed to eliminate vibrations on the surface and improve the appearance. However, if the vibration is applied after the foaming starts, the independence of the bubbles is lost. ThereDepartApply vibration to the mixed formulation before starting to foam.If you sayMaintains independence of bubblesYou canIn addition, by applying vibration, the compound is easily filled in the concave and convex portions of the mold provided for decoration, and the patterning can be performed correctly. At this time, it is better to use vacuum in the mold together.
[0015]
  The invention described in claim 4 is a mixture of a reactive inorganic powder, an alkali metal silicate, water, and a foaming agent, and the mixed formulation is put into a female mold and matched to the female mold. A wall panel is manufactured by attaching a male mold and then curing by foaming.In the manufacturing method of a wall panel, the said compound is mixed using the mixing apparatus of Claim 1 or 2.It is characterized byIt is a manufacturing method of a wall panel.
[0016]
  The operation to make the height of the compound uniform is after mixing the thermosetting compound containing alkali metal silicate and the blowing agent., ArrangementIt is desirable to do this before the compound begins to foam. Preferably, it is a time earlier than the time when the upper surface height of the material obviously does not start to rise by visual observation.
[0017]
The invention according to claim 5 is the method according to claim 4, wherein the reactive inorganic powder is SiO 2.₂-Al₂O_ThreeBased inorganic powder comprising the SiO 2₂-Al₂O_ThreeThe inorganic inorganic powder is blended in 100 parts by weight, the alkali metal silicate in 0.2 to 450 parts by weight, and the water in 35 to 1500 parts by weight.
[0018]
In the present invention, an inorganic foamable material is prepared by mixing a reactive inorganic powder, an alkali metal silicate, water and a foaming agent using a continuous mixer.
[0019]
The reactive inorganic powder is not particularly limited, and examples thereof include cements, fluorides, acidic metal oxides, divalent or higher metal salts of higher fatty acids, and divalent or higher metal of water-soluble polymers having a carboxyl group. Salt, divalent metal sulfate, divalent metal sulfite and the like. In the present invention, SiO 2₂ -Al₂ O_Three A system powder is preferably used.
[0020]
SiO₂ -Al₂ O_Three As the system powder, SiO₂ 10 to 90% by weight, Al₂O_Three Those having a composition of 90 to 10% by weight are preferred. Examples of such materials include fly ash, corundum, and ash, metakaolin, pulverized and calcined bauxite of electrostatic precipitators that are generated during the production of mullite. It is not something. These powders may be used as they are, but in order to activate them, thermal spraying treatment, pulverization classification, and mechanical energy may be applied.
[0021]
As a thermal spraying method, a thermal spraying technique applied to a ceramic coating is applied. The thermal spraying technique is preferably such that the material powder is melted at a temperature of 2000 to 16000 ° C. and sprayed at a speed of 30 to 800 m / second, such as a plasma spraying method, a high energy gas spraying method, and an arc spraying method. Is possible. The specific surface area of the obtained powder is 0.1 to 100 m.²/ G is preferred.
[0022]
As a method of classification and pulverization, any conventionally known method is adopted, and classification by sieving, specific gravity, wind force, wet sedimentation, etc., pulverization by a jet mill, a roll mill, a ball mill and the like can be mentioned. These means may be used in combination.
[0023]
As a method for applying mechanical energy, a ball medium mill, a medium stirring mill, a roller mill or the like is used, and the mechanical energy to be applied is preferably 0.5 kwh / kg to 30 kwh / kg. When the mechanical energy is small, it is difficult to activate the powder, and when the mechanical energy is large, the load on the apparatus is large.
[0024]
The fly ash may be fired as necessary. When the firing temperature is low, fly ash black color remains, and when the firing temperature is high, the reactivity with the alkali metal silicate is low.
[0025]
The alkali metal silicate has the general formula: M₂ O · nSiO₂ (In the formula, M represents at least one selected from the group consisting of Li, K, and Na. N represents a positive rational number). In the present invention, among these, n is preferably from 0.05 to 8. When n is less than 0.05, the strength of the resulting inorganic foamed cured product is reduced. When n is more than 8, the viscosity of the aqueous alkali metal silicate solution is increased and mixed with the reactive inorganic powder. Becomes difficult. More preferably, it is 0.5 to 2.5.
[0026]
The addition amount of the alkali metal silicate is preferably 0.2 to 450 parts by weight with respect to 100 parts by weight of the reactive inorganic powder. If the amount is less than 0.2 parts by weight, the amount of alkali required for the reaction is too small, resulting in poor curing. If the amount exceeds 450 parts by weight, a problem arises in the water resistance of the resulting inorganic foam cured body. More preferably, it is 10-350 weight part, More preferably, it is 20-250 weight part.
[0027]
In the present invention, the alkali metal silicate is preferably added as an aqueous solution.
The concentration of the alkali metal silicate aqueous solution is preferably 10 to 60% by weight. When the amount is less than 10% by weight, the reactivity with the reactive inorganic powder decreases, and when it exceeds 60% by weight, a solid content tends to be generated.
[0028]
The alkali metal silicate aqueous solution can be prepared by dissolving the alkali metal silicate as it is in water under pressure and heating, but in the alkali metal hydroxide aqueous solution, silica sand, silica stone powder, etc. SiO₂ The component can also be prepared by dissolving under pressure and heating so that n is a predetermined amount.
[0029]
In the present invention, the water may be added as the alkali metal silicate aqueous solution, may be added independently, or these addition methods may be used in combination. The amount of water added is preferably 35 to 1500 parts by weight with respect to 100 parts by weight of the reactive inorganic powder. If it is less than 35 parts by weight, the resulting inorganic foamable material will not be sufficiently cured, and mixing will be difficult, and if it exceeds 1500 parts by weight, the strength of the resulting inorganic foamed cured product will be reduced. More preferably, it is 45-1000 weight part, More preferably, it is 50-500 weight part.
[0030]
The foaming agent is not particularly limited, and examples thereof include metallic foaming agents such as Mg, Ca, Cr, Mn, Fe, Co, Ni, Cu, Zn, Al, Ga, Sn, Si, and ferrosilicon; hydrogen peroxide , Peroxides such as sodium peroxide, potassium peroxide, and sodium perborate. Among these, an aluminum-based foaming agent and hydrogen peroxide are preferable from the viewpoints of cost, safety, availability, and ease of mixing, and Si and ferrosilicon are preferable from the viewpoint of controlling the foaming rate.
[0031]
When a metal foaming agent is used as the foaming agent, it is preferably dispersed and mixed in an appropriate amount of water. Moreover, you may mix a thickener, an emulsifier, etc. for dispersion stabilization.
[0032]
The amount of the foaming agent added can be appropriately determined according to the density of the target inorganic foam cured body. Moreover, you may add surfactant in order to refine | miniaturize a bubble as needed.
[0033]
In the present invention, if necessary, a filler, a reinforcing woven fabric, a foaming aid and the like may be added. In this case, it is preferable to add the reactive inorganic powder after mixing it with a mixer or the like in advance.
[0034]
The filler is not particularly limited, for example, porous materials such as silica sand, silica powder, fly ash, slag, silica fume, mica, talc, wollastonite, calcium carbonate, aerosil, silica gel, zeolite, activated carbon, alumina gel, etc. Examples thereof include powders.
[0035]
The reinforcing fiber is not particularly limited, and examples thereof include vinylon, polypropylene, aramid, acrylic, rayon, carbon, glass, potassium titanate, alumina, steel, and slag wool.
[0036]
The foaming aid is not particularly limited, and examples thereof include porous powders such as silica gel, zeolite, activated carbon, and alumina gel; stearic acid metal salts such as zinc stearate, calcium stearate, and aluminum stearate; sodium oleate, olein Examples include oleic acid metal salts such as potassium acid; palmitic acid metal salts such as sodium palmitate and potassium palmitate; and surfactants such as sodium laurylbenzenesulfonate and sodium lauryl sulfate.
[0037]
Moreover, in the manufacturing method of the wall panel of this invention, it is desirable for the compound to be thrown in and deployed so that the predetermined uneven | corrugated pattern may cover the surface. Preferably, the covering area ratio is 95 to 100%, more preferably 100% of the projected area of the entire uneven pattern portion.
[0038]
Furthermore, it is desired that the thickness (height) distribution of the added composition is as small as possible. The absolute value varies depending on the thickness and specific gravity of the wall panel to be obtained, but the distribution ratio is 0 to 10% or less, preferably 0 to 5%, more preferably 0 to 1% with respect to the length. It should be within.
[0039]
  The inventions described in the above claims can be combined. For example, by mixing the formulation according to claim 5 using the mixing device according to claims 1 and 2, and applying the production method according to claim 3 to the mixed formulation, An inorganic foaming hardening body can be manufactured. In addition, for the above-mentioned blend mixed using claims 1 and 2, claim 3And 4Applying the manufacturing method described in 1), allowing the time from foaming the composition into a female mold until foaming, giving vibration during that time, and leveling it by applying vibrations. You can get a wall panel.
[0040]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, one embodiment of the present invention will be described with reference to the drawings.
FIG. 1 is a longitudinal sectional view of a mixing apparatus according to the present invention. As shown in FIG. 1, the mixing apparatus includes an outer container 10 and an inner rotating body 20. The exterior container 10 is an inverted frustoconical hollow body in which a side wall 13 is integrally provided between an upper plate 11 and a lower plate 12, and an interior rotary body 20 is provided therein. The internal rotary body 20 includes an upper rotary surface 21 and a side rotary surface 22, and the surface is formed in a substantially similar shape to the outer container 10. Connected to the center of the interior rotating body 20 is a rotating shaft 30 having a conical rotating cone 32 attached to the upper end. The rotating shaft 30 is rotatably supported by the gantry 60 via a bearing 31.
[0041]
A large number of protrusions 23 (rod-like members) made of short bars are implanted on the upper rotating surface 21 and the side rotating surface 22. As a method of planting the protrusion 23, for example, a method of fixing a short bar by stud welding or a method of fixing a short bar having a screw at an end by a nut can be employed. The tip of the implanted protrusion 23 may have a conical or hemispherical shape at the tip, depending on the physical properties of the raw material to be mixed. The arrangement state of the protrusions 23 is not particularly limited, and an arrangement such as a spiral shape or a radial shape around the rotation shaft 30 can be appropriately employed according to the physical properties of the materials to be mixed. The material used for the protrusion 23 is not particularly limited, and for example, a metal such as iron or stainless steel, or a metal coated with ceramics or resin is preferably used.
[0042]
A primary mixing chamber 41 is formed between the upper plate 11 and the upper rotating surface 21, and a secondary mixing chamber 42 is formed between the side wall 13 and the side rotating surface. A substantially central portion of the upper plate 11 is provided with a powder supply unit 14 a for introducing a powdery raw material into the primary mixing chamber 41 and a liquid supply unit 14 b for introducing a liquid raw material into the primary mixing chamber 41. In the lower part of the side wall 13, a discharge port 15 for taking out the mixture from the secondary mixing chamber 42 is provided. A nozzle 14c for supplying the liquid as droplets is provided in the powder supply unit 14a.
[0043]
The rotating shaft 30, the rotating cone 32, and the interior rotating body 20 are rotated by the drive motor 50 via the transmission pulleys 33 and 34 and the transmission belt 35. The number of rotations is not particularly limited, and can be appropriately determined according to the physical properties of the raw materials to be mixed. The drive motor 50 is preferably a variable speed motor so that the number of rotations of the internal rotating body 20 can be set as appropriate.
[0044]
In the present invention, a mixture of reactive inorganic powder, alkali metal silicate, water, foaming agent, and the like is mixed using the mixing device, so that the inorganic material is sufficiently mixed in a short time and continuously. A foamable material can be prepared.
[0045]
At the time of mixing, reactive inorganic powder, alkali metal silicate, water and blowing agent may be added to the mixing device independently and mixed, but they are premixed in an appropriate combination in advance. By doing so, a sufficiently mixed inorganic foamable material can be obtained in a shorter residence time. For example, the alkali metal silicate can be used after sufficiently dissolving the alkali metal silicate by adding it in advance as an alkali metal silicate aqueous solution. When a metal foaming agent is used as the foaming agent, the metal foaming agent and the reactive inorganic powder are premixed with a mixer or the like, and the metal foaming agent is sufficiently dispersed in the reactive inorganic powder. Then, if the obtained premix and alkali metal silicate aqueous solution are put into the above mixing device and mixed, the reactive inorganic powder and the alkali metal silicate aqueous solution are mixed, and at the same time, the blowing agent and the alkali metal silicate aqueous solution It is possible to prepare an inorganic foamable material capable of obtaining an inorganic foamed cured product having a stable quality in spite of the disadvantageous timing of foaming that is also mixed.
[0046]
On the other hand, when the above peroxide is used as the foaming agent, the reactive inorganic powder, the alkali metal silicate aqueous solution, and the foaming agent are independently and simultaneously added to the mixing device, despite the short time until foaming. Even in a short time, a sufficiently mixed inorganic foamable material can be obtained before the foaming agent starts foaming.
[0047]
Moreover, after mixing a reactive inorganic powder and alkali metal silicate aqueous solution with a batch mixer etc., it can also be thrown into the said mixing apparatus with a foaming agent.
[0048]
Since the inorganic foam hardened | cured material obtained by hardening the inorganic foamable material manufactured with the said mixing apparatus of this invention has stable quality, it can be used suitably for uses, such as building materials.
[0049]
The method of curing the inorganic foamable material to obtain an inorganic foamed cured product is not particularly limited, but for example, it is cured after being shaped into a desired shape by a known method such as casting or press molding. Can be performed.
[0050]
An aqueous alkali metal silicate solution is charged from the liquid supply unit 14b. For charging, for example, a gear pump (GX-12SKKC-04G3, manufactured by Iwaki), a plunger pump (V-10G100C, manufactured by Iwaki), or the like can be preferably used.
[0051]
At the same time, an alkali metal silicate aqueous solution is sprayed from the nozzle 14c. When spraying, an air gun, an airless gun or the like normally used for painting can be suitably used as the nozzle. The size and the like of the droplet are not particularly limited, and can be suitably used depending on the thickness, length, and amount of the fiber to be added. When it is desired to increase the amount of droplets, it may be possible to increase the injection amount itself or increase the number of nozzles.
[0052]
On the other hand, a mixed powder composed of a reactive inorganic powder, a filler, a foaming aid, a reinforcing fiber, and a foaming agent premixed in advance is charged from the powder supply unit 14a. For charging, for example, a constant spiral feeder PSF-65 (manufactured by Taiheiyo Kiko Co., Ltd.) or the like can be suitably used.
[0053]
The alkali metal silicate aqueous solution supplied in a droplet state reaches the upper rotating surface 21 while being mixed with the charged mixed powder.
[0054]
On the other hand, the charged mixed powder also scatters in the circumferential direction on the upper rotating surface 21 due to centrifugal force, so that the mixed metal powder and the alkali metal silicate aqueous solution scattered in a thin film form merge on the upper rotating surface 21. Furthermore, the joined alkali metal silicate aqueous solution and mixed powder are sheared and mixed by the protrusions 23 to form a mixture. In this way, the mixture that is sheared and mixed in the primary mixing chamber 41 is sequentially transferred to the secondary mixing chamber 42 by centrifugal force in accordance with the rotation of the rotating mixture 20.
[0055]
In the secondary mixing chamber 42, the mixture mixed in a shearing manner in the primary mixing chamber 41 is allowed to stay for a certain period of time to perform further sufficient mixing.
The mixture conveyed to the secondary mixing chamber 42 receives a force in a direction away from the rotating shaft 30 due to centrifugal force. However, since the side wall 13 exists, as a result, the mixture gradually rises on the side wall 13 surface. Accordingly, in the secondary mixing chamber 42, sufficient mixing is achieved by further combining the above-mentioned mixture rising along the surface of the side wall 13 in accordance with the centrifugal force and the new mixture conveyed from the primary mixing chamber 41. Kneading is performed.
[0056]
As described above, the above mixed powder comprising the alkali metal silicate aqueous solution and the reactive inorganic powder, the filler, the foaming aid, the reinforcing fiber and the foaming agent is sufficiently mixed and kneaded continuously and in a short time. Therefore, an inorganic foamable material capable of obtaining an inorganic foamed cured product with stable quality can be prepared. The obtained inorganic foamable material is sequentially discharged from the discharge port 15.
[0057]
The discharged inorganic foamable material is manufactured as a base plate such as an outer wall by the procedure shown in FIG. That is, the inorganic foamable material discharged from the mixing device 1 is put into the female mold 2 (FIG. 1A), and then the male mold 3 is mounted in accordance with the female mold 2 (FIG. 2B). )). Then, before the start of foaming, vibration is applied and the height is leveled. Note that the vibration is preferably 12 Hz rather than 60 Hz, the amplitude is preferably 2 mm rather than 0.2 mm, the vertical vibration is small, and the horizontal vibration may be mainly from the viewpoint of filling the decorative surface. At this time, if vacuuming is used in combination, a better pattern can be formed.
[0058]
Next, pre-cure and after-cure are performed, and further dried and cured ((c) to (e) in the figure). The curing temperature may be room temperature, but by curing at 50 to 110 ° C. for 30 minutes to 8 hours, the curing reaction can be promoted and the mechanical properties can be improved. Finally, the base plate 4 is completed ((f) in the figure). If the female mold 2 and the male mold 3 are for wall panels, the base plate 4 is a wall panel.
[0059]
【Example】
Next, examples of the present invention will be described, but the present invention is not limited to only these examples.
《Mixing device for manufacturing inorganic foamable materials》
First, an experiment was performed using a mixing apparatus for producing an inorganic foamable material according to the present invention.
[0060]
Example 1
Classified fly ash as reactive inorganic powder (new Onoda fly ash, 5 μm under, manufactured by Onoda Cement) 40.0 parts by weight, alumina filler as filler (Alumina cement No. 1, manufactured by Asahi Glass) 10.0 parts by weight 40.0 parts by weight of finely divided silica sand (M-100, average particle size 65 μm, manufactured by Repco), 20.0 parts by weight of wollastonite, 1.0 part by weight of zinc stearate as a foaming aid, vinylon ( RM182 × 3 mm (manufactured by Kuraray Co., Ltd.) 1.0 part by weight, and aluminum powder (350F, manufactured by Minalco Co., Ltd.) 0.08 part by weight as a foaming agent were mixed for 3 minutes with an Eirich mixer, This was referred to as “mixed powder (I)”.
[0061]
The continuous mixer was driven so that the rotating mixture and the rotating cone were rotated at 1730 rpm.
The mixed powder (I) was charged into a continuous mixer at 1.67 kg / min by a constant spiral feeder (PSF-65, manufactured by Taiheiyo Kiko Co., Ltd.).
Moreover, alkali metal silicate aqueous solution (water: 58.8%, SiO₂ : 24.4%, Na₂ O: 16.8%, manufactured by Nippon Kagaku Kogyo Co., Ltd. (hereinafter referred to as “alkali metal silicate aqueous solution”), gear pump (GX-12SKKC-04G3, manufactured by Iwaki Co., Ltd.), and air spray gun as a nozzle Two (Microace AGB20, manufactured by Asahi Osumi Sangyo Co., Ltd.) were charged into the continuous mixer at 0.969 kg / min.
[0062]
From the outlet of the continuous mixer, the inorganic foamable material was continuously discharged at 2.639 kg / min for 1 hour. The density and bending strength of the discharged inorganic foamable material were measured by the following evaluation methods. The measurement results are shown below.
result
Density: 0.75 ± 0.01 g / cm^Three
Bending strength: 84 ± 0.2 kgf / cm² (8.2 ± 0.02 MPa)
[0063]
Evaluation methods
After 5 minutes from the start of mixing by the continuous mixer, the discharged inorganic foamable material was sampled 12 times every 5 minutes for 10 seconds and cured at 85 ° C. for 12 hours to obtain an inorganic foam cured body. The obtained inorganic foam cured body was cut into three 30 × 30 × 30 mm test pieces to obtain a total of 36 test pieces.
The density of the test piece was measured by dividing the weight of the test piece by the volume, and the compressive strength was measured according to JIS A1408, and the average value and the standard deviation were obtained.
[0064]
(Example 2)
The inorganic foamable material was continuously discharged at 2.639 kg / min for 1 hour in the same manner as in Example 1 except that the number of nozzles was changed to 4. The evaluation results are shown below.
result
Density: 0.75 ± 0.01 g / cm^Three
Bending strength: 96 ± 0.2 kgf / cm² (9.4 ± 0.02 MPa)
[0065]
(Comparative Example 1)
A mixed powder (hereinafter referred to as “mixed powder” in the same manner as in Example 1 except that no foaming agent was added and 1.0 part by weight of vinylon (RM182 × 3 mm, Kuraray) was added as a reinforcing fiber. (II) ”. Also, a suspension in which aluminum powder is mixed and dispersed in water as a foaming agent (aluminum powder: water = 0.08: 4 (weight ratio) (hereinafter, this is referred to as “foaming agent solution (I)”)) Was prepared.
[0066]
112 kg of the mixed powder (II) and 65 kg of the alkali metal silicate aqueous solution were mixed and kneaded with an omni mixer (150 liter, manufactured by Chiyoda Giken Kogyo Co., Ltd.) to obtain a kneaded product. The obtained kneaded material was transferred to a static mixer (N-60 type, outer diameter 65.9 mm, total length 630 mm, Noritake Company Limited) at 2.638 kg / min with a tube pump (KB-12, manufactured by Kawaki Kogyo Co., Ltd.). Into the injection port. Further, the blowing agent solution (I) was injected from the vicinity of the injection port at 61 g / min to obtain an inorganic foamable material, which was evaluated in the same manner as in Example 1. The results are shown below.
result
Density: 0.75 ± 0.05 g / cm^Three
Bending strength: 62 ± 0.5 kgf / cm² (6.1 ± 0.05 MPa)
[0067]
(Comparative Example 2)
An inorganic foamable material was obtained in the same manner as in Comparative Example 1 except that the foaming agent solution (II) was used instead of the foaming agent solution (I) and the supply rate was 167 g / min. And evaluated. The results are shown below.
result
Density: 0.75 ± 0.05 g / cm^Three
Bending strength: 53 ± 0.5 kgf / cm² (5.2 ± 0.05 MPa)
[0068]
(Comparative Example 3)
112 kg of the mixed powder (II) and 65 kg of the alkali metal silicate aqueous solution were mixed for 3 minutes with an omni mixer (150 liter, manufactured by Chiyoda Giken Kogyo Co., Ltd.), and 4080 g of the blowing agent solution (I) was further added and mixed for 30 seconds. .
The obtained inorganic foamable material had already started foaming, did not flow, was difficult to inject into a mold, and a test piece could not be produced.
[0069]
(Comparative Example 4)
Mixed powder (hereinafter referred to as “mixed powder (III)”) in the same manner as in Example 1 except that 2.0 parts by weight of vinylon (RM182 × 3 mm, manufactured by Kuraray) was added as a reinforcing fiber. Got.
Also, a suspension in which aluminum powder is mixed and dispersed in water as a foaming agent (aluminum powder: water = 0.08: 4 (weight ratio) (hereinafter, this is referred to as “foaming agent solution (I)”)) Was prepared.
[0070]
An attempt was made to obtain an inorganic foamable material in the same manner as in Comparative Example 1 except that this mixed powder (III) was used. However, due to pressure loss, the material was clogged and the inorganic foamable material could not be obtained.
[0071]
In the test pieces in Examples 1 and 2, it was clear that both the density and the compressive strength of the test pieces in Comparative Examples 1 and 2 were reduced by a fraction of each test piece. It was. In Comparative Examples 3 and 4, foaming started during mixing, and in particular, Comparative Example 4 could not produce a test piece due to material clogging.
[0072]
<< Method for producing inorganic foam cured body >>
An experiment was conducted on a method for producing an inorganic foamed cured product according to the present invention.
100 parts by weight of metakaolin (SAINTONE SP 33 manufactured by Engelhard, average particle size of 3.3 μm, specific surface area of 13.9 m 2 / g) and 0.5 parts by weight of a mixed solution of 25 parts by weight of triethanolamine and 75% by weight of ethanol Was supplied to Ultra Fine Mill AT-20 (manufactured by Mitsubishi Heavy Industries, Ltd., zirconia ball diameter 10 mm, ball filling rate 85 volume%), and mechanical energy of 25 kwh / Kg was applied to obtain inorganic powder. The mechanical energy applied was expressed as the electric power supplied to the ball mill per unit weight of the processed powder.
[0073]
(Example 3)
A predetermined amount of nSiO₂ / M₂ O (n = 1.5, M = Na, K; molar ratio 1: 1) in an autoclave at 130 ° C., 7 kgf / cm² (0.7 MPa) dissolved in a predetermined amount of water, wollastonite, vinylon fiber (manufactured by Kuraray, trade name: RM182 × 3), silica powder, No. 8 silica sand SiO₂―Al₂O_ThreeThe inorganic inorganic powder 1, aluminum hydroxide (particle size of 100 μm or less), and zinc stearate were mixed with an omni mixer (manufactured by Chiyoda Giken Co., Ltd.) to obtain a uniform paste. To this paste, an aluminum powder containing 90% by weight or more of a powder having a particle size of 70 μm or less was added and stirred for 40 seconds to obtain a curable inorganic composition. While pouring this into the mold, vibration (frequency of 30 Hz) was applied for 1 minute, and after applying vibration, foaming started after 1 minute, and after completion of foaming, it was demolded to obtain an inorganic foam cured body.
[0074]
The appearance of this inorganic foam cured body was excellent with few bubbles, and further, it was confirmed that it was an inorganic foam cured body inorganic having closed cells when observed with a microscope.
[0075]
Example 4
A predetermined amount of nSiO₂ / M₂ O (n = 1.5, M = Na, K; molar ratio 1: 1) in an autoclave at 130 ° C., 7 kgf / cm² (0.7 MPa) dissolved in a predetermined amount of water, wollastonite, vinylon fiber (manufactured by Kuraray, trade name: RM182 × 3), silica powder, No. 8 silica sand SiO₂―Al₂O_ThreeThe inorganic inorganic powder 1, aluminum hydroxide (particle size of 100 μm or less), and zinc stearate were mixed with an omni mixer (manufactured by Chiyoda Giken Co., Ltd.) to obtain a uniform paste. To this paste, Si powder having a particle size of 70 μm or less (# 600 manufactured by Kinsei Matec Co., Ltd.) was added and stirred for 40 seconds to obtain a curable inorganic composition. This was poured into a mold, and vibration (frequency 30HZ) was applied for 1 minute. After applying vibration, foaming started 12 minutes later, and after completion of foaming, it was cured and demolded to obtain an inorganic foam cured body.
[0076]
The appearance of this inorganic foam cured body was excellent with few bubbles, and further, it was confirmed that it was an inorganic foam cured body having closed cells when observed with a microscope.
[0077]
(Comparative Example 5)
A predetermined amount of nSiO₂ / M₂ O (n = 1.5, M = Na, K; molar ratio 1: 1) in an autoclave at 130 ° C., 7 kgf / cm² (0.7 MPa) dissolved in a predetermined amount of water, wollastonite, vinylon fiber (manufactured by Kuraray, trade name: RM182 × 3), silica powder, No. 8 silica sand SiO₂―Al₂O_ThreeThe inorganic inorganic powder 1, aluminum hydroxide (particle size of 100 μm or less), and zinc stearate were mixed with an omni mixer (manufactured by Chiyoda Giken Co., Ltd.) to obtain a uniform paste. To this paste, an aluminum powder containing 90% by weight or more of a powder having a particle size of 70 μm or less was added and stirred for 40 seconds to obtain a curable inorganic composition. This was poured into a mold, and after foaming started, vibration (frequency 30 Hz) was applied for 1 minute, and after completion of foaming, it was cured and demolded to obtain an inorganic foam cured body.
[0078]
The appearance of this inorganic foamed cured body was deteriorated due to the collapse of bubbles, and further, it was an inorganic foamed cured body with few closed cells when observed with a microscope.
[0079]
In addition, the compounding weight part in Example 3, Example 4, and Comparative Example 5 is collectively shown in Table 1.
[Table 1]

[0080]
《Wall panel manufacturing method》
An experiment was conducted on a method for manufacturing a wall panel according to the present invention.
Reactive inorganic powder, filler, foaming aid, reinforcing fiber and foaming agent, and alkali metal silicate aqueous solution are prepared in advance so that the raw material mixing ratio shown in Table 2 is obtained. Omni mixer (manufactured by Chiyoda Giken Co., Ltd.) And mixed.
[Table 2]

* 1: About ground metakaolin
Metakaolin (SAINTONE SP 33 manufactured by Engelhard, average particle size 3.3 μm, specific surface area 13.9 m²/ g) 100 parts by weight and 0.5 parts by weight of a mixed solution of 25 parts by weight of triethanolamine and 75% by weight of ethanol, Ultra Fine Mill AT-20 (manufactured by Mitsubishi Heavy Industries, Ltd., using zirconia ball diameter of 10 mm, ball filling rate of 85 %) And mechanical energy of 25 kwh / kg was applied to obtain an inorganic powder.
* 2: About alkali metal silicate aqueous solution
A predetermined amount of nSiO₂/ M₂O (n = 1.5, M = Na, K; molar ratio 1: 1) in an autoclave at 130 ° C., 7 kgf / cm²(0.7 MPa) was obtained by dissolving in a predetermined amount of water.
[0081]
Apart from this, the total depth including the depth of the concavo-convex pattern is 31 mm, it has a space of 900 mm in the width direction and 3000 mm in the length direction, and the concavo-convex pattern portion is urethane rubber (trade name: Mold Star, Tokai Rubber Co., Ltd.) The other part was made of metal and the other part was made of metal.
[0082]
Further, as a method for uniformly dispersing the input material, a scraper using a metal plate was prepared, and the uneven pattern projected area coverage was calculated by measuring the projected size of the input material and dividing by the projected uneven pattern area. The thickness distribution ratio was calculated by preparing a yarn, measuring the thickness at various points based on the height, and dividing the maximum width of the distribution by the maximum length of the mold.
[0083]
The moisture content of the foamed cured product was cut out, allowed to stand for 24 hours to absorb water, then dried in an oven at 105 ° C. for 3 days, and calculated from the change in weight. Details of the experimental results are shown in Table 3 as Example 5, Example 6, and Comparative Example 6.
[Table 3]

[0084]
【The invention's effect】
As described above, according to the mixing apparatus for producing an inorganic foamable material of the present invention, a compound comprising a reactive inorganic powder, an alkali metal silicate, water and a foaming agent can be continuously and sufficiently obtained in a short time. Therefore, it is possible to obtain an inorganic foamed cured product having a stable quality.
[0085]
Moreover, according to the manufacturing method of the inorganic foaming hardening body of this invention, it has an independent cell and can obtain the inorganic foaming hardening body excellent in the external appearance. And the obtained inorganic foaming hardening body can be used suitably for uses, such as building materials.
[0086]
Furthermore, according to the method for producing a wall panel of the present invention, it is possible to obtain a wall panel that is excellent in transferring a concavo-convex pattern and good in design, and excellent in quality as a wall.
[Brief description of the drawings]
FIG. 1 is a cross-sectional view of a mixing apparatus for producing an inorganic foamable material according to the present invention.
FIG. 2 is a view showing a procedure of a method for manufacturing a wall panel according to the present invention.
[Explanation of symbols]
10 Exterior container
11 Upper plate
12 Lower plate
13 Side wall
14 Supply section
14a Powder supply unit
14b Liquid supply unit
14c nozzle
15 outlet
20 Interior rotating body
21 Upper rotating surface
22 Side rotation surface
23
30 Rotating shaft
31 Bearing
32 Rotating cone
33, 34 Transmission pulley
35 Transmission belt
41 Primary mixing chamber
42 Secondary mixing chamber
50 Drive motor
60 frame

Claims (5)

A mixing device used when producing an inorganic foamable material and mixing a composition comprising a reactive inorganic powder, an alkali metal silicate, water and a foaming agent,
The mixing device includes an outer container fixed to a gantry, an inner container that is rotatably provided inside the outer container, the surface is formed in a substantially similar shape to the outer container, and a large number of rod-shaped members are attached to the surface. A body, a drive unit that rotationally drives the interior rotator, a supply unit that supplies the mixture into a space defined by the exterior container and the interior rotator, and a mixture mixed in the space. A discharge section for discharging, and the supply section is provided with means for supplying a part of the liquid in the form of droplets in the form of droplets. Mixing equipment. In the mixing apparatus for producing the inorganic foamable material according to claim 1,
The mixing device for producing an inorganic foamable material, wherein the alkali metal silicate aqueous solution is supplied from a means for supplying a part of the liquid in a droplet state. In the method for producing an inorganic foam cured body, a mixture comprising a reactive inorganic powder, an alkali metal silicate, water and a foaming agent is mixed and foamed and cured to produce an inorganic foam cured body.
The manufacturing method of the inorganic foaming hardening body characterized by mixing the said compounding using the mixing apparatus of Claim 1 or 2 . Mixing a compound composed of reactive inorganic powder, alkali metal silicate, water and a foaming agent, putting the blended compound into a female mold and attaching a male mold to the female mold, then foaming In the manufacturing method of a wall panel for manufacturing a wall panel by curing ,
A method for producing a wall panel, wherein the compound is mixed using the mixing apparatus according to claim 1 . In the manufacturing method of the wall panel of Claim 4,
The reactive inorganic powder is a SiO ₂ —Al ₂ O ₃ inorganic powder, the SiO ₂ —Al ₂ O ₃ inorganic powder is 100 parts by weight, and the alkali metal silicate is 0.2 to 450. A method for producing a wall panel, characterized in that 35 parts by weight and the water are mixed in 35 to 1500 parts by weight.

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