JPH0341043B2 - - Google Patents

Description

[Detailed description of the invention]

(Field of Industrial Application) The present invention relates to a method for manufacturing an inorganic/organic composite foam heat insulating material that is nonflammable or quasi-nonflammable, lightweight, and has excellent heat insulation properties. Therefore, it can be used, for example, in the construction of a heat-insulating lining material for metal siding on internal and external walls of buildings. (Conventional technology) In recent years, many lightweight insulation materials have been used in the construction field from the perspective of energy conservation.
There are various manufacturing methods. For example, as an example of manufacturing urethane foam, a urethane resin main material containing an organic blowing agent and a urethane resin curing agent are sent out separately from two independent supply pipes quantitatively according to the composition, and after passing through a kneading section, 1
Simple products such as those that flow out from a supply pipe, and simple batch-type products such as those used in ALC manufacturing, where everything is kneaded in one kneading section and then poured into a mold and hydrothermally cured many times. It was something very simple. In this way, in the production of conventional foams, a simple method was sufficient, but in the production of the inorganic/organic composite foam shown in the present invention, the reactions are stepwise and intricately intertwined. Conventional manufacturing techniques such as these were not suitable for the actual situation. As a result of intensive research, the present inventors have completed the present invention. ``Object of the Invention'' The object of the present invention is to provide a method for producing an inorganic/organic composite foam insulation material that is nonflammable or quasi-nonflammable, lightweight, and has excellent heat insulation properties. (Problems to be Solved by the Invention) As mentioned in the section on the prior art, the reactions in the production of the inorganic/organic composite foam of the present invention are complex and rapid, and the conventional production method does not allow for mass production in factories. The problem was that it could not be adapted to the actual situation. The present invention is intended to enable mass production of the inorganic/organic composite foam insulation material referred to in the present invention at a factory. "Structure of the Invention" The structure of the present invention consists of a kneading procedure centered on time parameters such as flowable time, foamable time, and stabilization time after kneading of an inorganic/organic composite foamable composition. The kneading method was designed according to the To speed up understanding, the flow will be explained below with reference to Figure 1. The present inventors have energetically conducted various experiments and research, and have determined the stability time after kneading of the inorganic/organic composite foamable composition referred to in the present invention, the measurement of the foamable time,
Considering multi-stage split kneading from consideration of reaction mode, etc.
We have found that the division described below is most suitable for continuous production. That is, paste A is obtained by kneading (a) an inorganic filler, (d) a reaction rate regulator, (e) an additive, and (f) water in a mixer 1. The pot life of paste A varies depending on (a) the type of inorganic filler;
It lasted at least 4 hours. Stir and stock this. Paste A is quantitatively supplied by pump P ₁ 2. In a system independent from this, (b) the inorganic blowing agent is directly supplied in a fixed amount to the kneading section 6 in powder form, or the inorganic blowing agent and (f) water are kneaded and dispersed in the mixer 3 and then supplied in a fixed amount to the kneading section 6. do. The pot life of this dispersion B was at least 4 hours, although it differed depending on the type of inorganic blowing agent (b). Dispersion B
In this case, pump P ₂ 4 is used to supply a fixed amount. The pot life after kneading of paste A and inorganic blowing agent or dispersion B varies depending on the pot life of paste A, inorganic blowing agent or dispersion B.
It lasted at least 5 minutes. Therefore, a screw mixer or static mixer 6 or the like is used from the confluence point A5 to the confluence point B9 of the paste A and the inorganic foaming agent or dispersion liquid B, so that the passage time therein can be set within 5 minutes. . Next, (c) urethane prepolymer is supplied quantitatively from an independent tank 7 by a pump P ₃ 8, and the paste A and the kneaded inorganic blowing agent or dispersion B are combined at a confluence point RO 9. After that, the mixture is kneaded at high speed using a grooved screw mixer or a static mixer 10, and is extruded from the confluence point 9 to the outlet point 11 within 2 seconds. The extruded inorganic/organic composite foam kneaded material passes under the extrusion port through a steel plate coil 12 (in addition to aluminum coil,
surface material 13 (any of kraft paper, polyethylene kraft paper, asbestos paper, glass paper, etc.)
The inorganic/organic composite foam heat insulating material is formed into a shape with a constant thickness using a pressure roll 14 via a pressure roll 14, and then continuously cut into predetermined dimensions to obtain an inorganic/organic composite foam heat insulating material molded plate 15. (c) Since urethane prepolymer easily reacts with water, pump P ₄ cleaning thinner D from the cleaning thinner tank 16 when foam production is stopped.
17, paste A is supplied to the confluence point A5 through the discharge port 20, and pump _P5 is supplied from the water tank 18 to the confluence point I5, so that the inside of the static mixer 6 can be washed with water. and the inorganic blowing agent or dispersion B are discharged. In the manner described above, it has become possible to continuously produce an inorganic/organic composite foam insulation material. (Means/Features for Solving the Problems) The present invention solves the problem by dividing the kneading procedure into various ways for the inorganic/organic composite foamable composition referred to in the present invention, which has a complicated foaming reaction and is thought to be impossible to produce in a factory. While experimenting with pot life, foamability, etc., we discovered a practical dividing method and kneading procedure, and solved the problems by incorporating into the manufacturing process the most suitable kneading means and safety measures. That is, (a) the inorganic filler and (f) water, which are the largest in terms of weight in the formulation, are combined into one system. In this case, (b) an inorganic blowing agent cannot be used because it shortens the pot life.
(d) reaction rate modifier, (e) additives are included. The kneaded paste A thus obtained had the lowest pot life of 4 hours. Next, (b) the inorganic blowing agent was kneaded in a quantitative manner as it was with paste A, or (f) it was dispersed in water to facilitate further kneading, so that it could be supplied in a quantitative manner. The pot life of this inorganic blowing agent was ∞ hours, and the pot life of Dispersion B was 4 hours at the lowest. Furthermore, when the pot life of paste A and an inorganic blowing agent or dispersion B dispersed in water was kneaded and the pot life was measured, the minimum time required to form a stable foam was 5 minutes. Furthermore, when paste A, an inorganic foaming agent or its aqueous dispersion B, and urethane prepolymer C were kneaded, the foaming start time was the shortest, 2 seconds. After finding the stability time for each system as described above, we assembled a flow sheet and adopted a format appropriate for each process, making continuous production of foam possible. Note that (a) inorganic fillers mentioned here include hydraulic cements (a ₁ ) group, Portland cement, alumina cement, blast furnace cement, fly ashes cement, silica cement, etc., as well as other inorganic filler components. a Group ₂ , dihydrate gypsum, silica powder, calcium carbonate,
There are clay, talc, aluminum hydroxide, shirasu balloon, perlite, alumina powder, etc., and it is one type or a mixture of two or more selected from these. (c) Urethane prepolymer is a compound having an isocyanate group such as tolylene diisocyanate, One or more urethane prepolymers obtained by reacting with polyols having 2 or more OH groups and containing oxyethylene content of 5% by weight or more; in some cases, isocyanate compound monomers such as TDI, MEK, etc. (d) A reaction rate modifier is a retarder such as broom or sodium citrate when using cements of group (a ₁ ), or an accelerator such as calcium chloride. , carbonated soda, etc. However, when an accelerator is used in the present invention, it is kneaded into the inorganic blowing agent or its aqueous dispersion B. (e) Additives are mainly organic surfactants such as foam stabilizers, and foam enhancers, flame retardants, etc. may also be used. (f) Water may be groundwater, tap water, or industrial water. (Function) According to the manufacturing method of the present invention, an inorganic/organic composite foam insulation material can be manufactured continuously in a factory production manner from the inorganic/organic composite foamable composition to which the present invention is applied. It can be poured onto the back side of steel plates to create insulation panels such as heat-insulating and fire-retardant metal siding. (Example) A detailed explanation will be given below using an example. (Example 1) Inorganic/organic composite foamable composition (i) 80 parts by weight of Portland cement, 20 parts by weight of dihydrate (ii) 2 parts by weight of hoshiya (iii) Product name: SN-FORM200 (San Nopco Co., Ltd.) Make paste A by kneading 1 part by weight of (iv) 50 parts by weight of water. Next, (v) 4 parts by weight of potassium hydrogen carbonate and (vi) 4 parts by weight of water were kneaded to form an inorganic blowing agent dispersion B.
make. A+B is kneaded at regular intervals, and the kneaded product is further mixed with (vii) (c) urethane prepolymer [i.e., trade name here: Polygrout W-1 type (manufactured by Dai-ichi Kogyo Seiyaku Co., Ltd.) 40% by weight, trade name: Hisel OH-IA
(Manufactured by Toho Chemical Co., Ltd.) 40% by weight and 20 parts by weight of tolylene diisocyanate were kneaded and foamed in several test pieces at separate intervals. At that time, the pot life, time for fluidity, time for normal foaming, etc. were measured. (Example 2) As an inorganic/organic composite foamable composition, (i) 50 parts by weight of Portland cement, 50 parts by weight of calcined gypsum, (ii) 2 parts by weight of hoshiya, (iii) Product name: SN-FORM200 (Sannopco) Make paste A by kneading 1 part by weight (iv) and 54 parts by weight of water. Next, (v) 4 parts by weight of potassium hydrogen carbonate and (vi) 4 parts by weight of water are kneaded to prepare an inorganic blowing agent dispersion B. (If the amount of inorganic blowing agent is large, use the direct kneading method.) Knead A+B at regular intervals, and add (vii) urethane prepolymer (Example 1) with the same composition to the kneaded product. The mixture was kneaded and several test pieces were foamed at separate intervals. At that time, the pot life, fluidity time, and normal foaming time were measured. (Comparative Example 1) The composition ratio of Example 1 was placed in the state of a kneaded product of paste A + dispersion B, and while stirring at low speed, the time was divided into various intervals to mix paste A + aqueous dispersion of inorganic blowing agent B. A certain amount of the intermediate kneaded material was extracted, and (vii) urethane prepolymer was added and kneaded so as to match the composition ratio, and the state of foaming was measured. The urethane prepolymer used had the same formulation as in Example 1. (Comparative Example 2) The composition ratio of Example 2 was placed in the state of a kneaded product of paste A + aqueous dispersion B of inorganic foaming agent, and paste A + dispersion B inorganic foaming was carried out at various intervals while stirring at low speed. Extract a certain amount of the intermediate kneaded material consisting of the aqueous dispersion B of the agent, and add (vii) urethane prepolymer (Example 1) to match the composition ratio.
The foaming state was measured by adding and kneading a mixture (with the same formulation as the above). The above results are shown in Table 1.

[Table] *Pot life here refers to the time during which a constant foaming state is obtained.
(Effect of the invention) As is clear from the above test results, in the production of inorganic/organic composite foams in the present invention, as shown in Examples 1 and 2 of the experimental results, inorganic/organic composite foamable compositions are Of these, the parts that have a high composition ratio and require a lot of time to knead (a) inorganic filler + (d) reaction rate regulator + (e) additive + (f) water are kneaded and kept for more than 4 hours. It has become possible to make actual production a reality.

[Brief explanation of the drawing]

FIG. 1 is a process diagram showing an embodiment of the present invention. 1 is (a) an inorganic filler, (d) a reaction rate regulator, (e)
3 is a mixer for kneading additives and (f) water, and 3 is a mixer for kneading (b) an inorganic foaming agent and (f) water. Paste A kneaded in step 1 and paste B kneaded in step 3
are supplied by pumps 2 and 4, pump P ₁ and pump P _2, respectively, and sent to kneading section 6. The urethane prepolymer sent out from the urethane prepolymer tank 7 by the pump _P3 8 is mixed at high speed with the kneaded pastes A and B in the mixer 10, and is caught on the steel plate coil 12. . 1
The sheet material No. 4 is press-formed from the top of the sheet material No. 13 using a pressing roll No. 4 to form a molded plate No. 15. Thinner is supplied from the 16 cleaning thinner tanks and used for cleaning the 10 mixers. Water is supplied from the water tank 18 and used for cleaning the kneading section 6.

Claims (1)

[Scope of Claims] 1 Composition used for production and composition ratio (a ₁ ) Hydraulic cements (a ₂ ) Hydraulic gypsum, silica powder, aluminum hydroxide,
Inorganic filler selected from ingredients (a ₁ ) and (a ₂ ) such as whitebait balloons and alumina powder
(a) 100 parts by weight (b) 1 to 40 parts by weight based on inorganic blowing agent (a) (c) 2 to 40 parts by weight based on urethane prepolymer (a) (d) Reaction rate modifier a ₁ When using ingredients: (a ₁ ) 0.1 to 20 parts by weight (e) Additives such as foam stabilizers, thickeners, flame retardants, etc. to (a) 0 to 20 parts by weight (f ) 10 to 200 parts by weight based on water (a), and the kneading procedure during production includes (i) (a) inorganic filler, (d) reaction rate regulator, (e) additive, (f) Water is kneaded into a paste to form independent channels. (ii) Either (b) create a path to supply a fixed amount of the inorganic blowing agent in its powder state, or (f) knead water and (b) the inorganic blowing agent to form a dispersed state and form an independent flow path. Make it. (iii) Depending on the composition ratio, (i) and (ii) are supplied independently and then combined into one, kneaded with a screw mixer or static mixer and sent out, or can be consumed within 5 minutes. Two kneaders with a capacity are installed, and after continuous batch-type kneading is repeated alternately, (iv) urethane prepolymer and screw-type kneading or screw-type kneading or All the material that has been kneaded once in a short time (about 2 seconds) by impact kneading or spray kneading is allowed to flow out of the kneading section, and is continuously formed into a foam while being pressed with a roll through a face material such as kraft paper. A method for producing an inorganic/organic composite foam insulation material. 2. A method for manufacturing an inorganic/organic composite foam insulation material, characterized in that the kneading section of the urethane prepolymer and paste described in claim 1 (iv) is washable with a solvent if necessary. .