JPH0433734B2 - - Google Patents

Description

[Detailed Description of the Invention] [Industrial Field of Application] The present invention relates to foam glass mainly used for interior, exterior, and wall materials of buildings, and particularly relates to foam glass that has excellent impact resistance and machinability. This relates to foam glass consisting of a shell layer and a skin layer.

[Conventional technology]

It is conventionally known to form a shell layer on the foam layer of foam glass. JP-A-50-123108 describes a method for producing foam glass and ceramics consisting of a glass or ceramic foam layer and a vitreous shell layer.
Glass pieces for forming a skin layer and glass fine powder to fill between the glass pieces are placed on the bottom of the mold, and a material to form a foam layer is filled on top of the mold and heated to form foam glass or ceramics. Disclosed.

In addition, in Japanese Patent Application Laid-open No. 60-166239, the porosity is 1 to 1.
A shell layer of 30 vol% and a porous layer with a porosity of 70 to 95 vol% are integrally bonded to form a laminated foam glass, and the skin layer is formed into an island shape by granulating a raw material mainly consisting of glass fine powder. On the other hand, it has been disclosed that another raw material mainly composed of fine glass powder is formed in a powdered state by filling the space between the island-like parts.

[Problem that the invention seeks to solve]

Generally, by forming a shell layer, strength such as bending and tensile strength can be increased. However, in the above-mentioned known technology, when attempting to divide or cut a foam glass body, the skin layer is formed so densely that the skin layer must be removed in advance along the line to be cut during foam glass production. The latter has a porosity of 30 vol% or less, that is, the true specific gravity of glass is 2.5, while the apparent specific gravity is
It also has a dense skin layer of 1.75 or higher.

By making the skin layer denser in this way, it is highly rigid, but if it receives a local impact from the outside, cracks will occur in that area and the cracks will develop in the surrounding area, sometimes resulting in bubble glass. leading to total collapse.

Needless to say, it is inferior in cutting workability, and cracks that deviate from the cutting line are likely to occur during the cutting process, significantly reducing production yield.

Furthermore, in these known examples, fine glass powder is used in its powder form as an essential ingredient for forming the skin layer, and is subjected to firing, but when the bulky fine powder is fired as it is, it often causes fusion and fusion. There are areas and cavities where the foam glass is insufficiently bonded, which reduces the overall strength of the foam glass.

The object of the present invention is to provide a new foam glass that solves these problems.

[Means to solve the problem]

The present invention provides foam glass that is integrally formed from a foam layer and a skin layer covering at least one side of the foam layer and having a bulk specific gravity of 0.8 to 1.7 and a thickness of 1.5 to 20 mm. It is something.

In the present invention, particle size 150 μm is used as the raw material for the foam layer.
Below, fine powder of a colored or colorless ordinary glass with a true specific gravity of around 2.5, such as soda lime glass, borosilicate glass, aluminosilicate glass, etc., is mixed with fine powder of a blowing agent such as limestone, dolomite, or carbon, and further an inorganic pigment. Mix and prepare with or without addition. These are further added with a binder such as water glass and processed by conventional granulation methods to produce particles with a particle size of 1/10 mm to 1/10 mm.
Granulate to a size of several mm.

Further, as a raw material for the shell layer, a mixture of the same glass powder as described above and an inorganic pigment and a fine foaming agent powder added thereto as required is used and granulated in the same manner as described above.

The bulk specific gravity of these foamed layers and shell layers can be appropriately adjusted within the scope of the present invention by selecting the type and amount of the foaming agent, the softening temperature of the glass, the type and amount of the inorganic pigment, the firing conditions, etc.

When a non-granulated raw material is used in the foam layer, it is extremely bulky and contains a large amount of trapped air, but during the firing process, the trapped air remains and expands, resulting in the formation of rough foam, cavities, and contact with the shell layer. There are disadvantages such as the interface being uneven and wavy, and the foam layer locally penetrating the skin layer and being exposed on the surface, but these disadvantages can be eliminated by using granulated raw materials. Ru. In addition, when non-granulated raw materials are used, products tend to form open cells;
When a granulated raw material is used, most of the cells become closed cells, which greatly improves water absorption resistance and water permeation resistance.

For the same reason as mentioned above, when a granulated raw material is used in the shell layer, there are no locally weak spots caused by uneven sintering that occur when non-granulated raw granules are used, and a homogeneous shell is created. A layer is formed, and the disadvantages of the previously mentioned known examples are solved.

Furthermore, since these granulated raw materials have high fluidity, they can be easily added to a mold in a subsequent process and can easily form a flat layer.

Incidentally, in forming the shell layer, applications such as mixing coarse granular glass with the granulation raw material to add elegance may be carried out as appropriate.

Various means can be employed for firing these foam glass raw materials. For example, the raw material for forming a foam layer is placed in a steel formwork to a desired thickness, then the raw material for forming a skin layer is filled on top of it to the desired thickness, and then heated in a heating furnace. Foamed glass can be simultaneously and integrally formed by firing and foaming at an appropriate temperature in the range of 700° C. to 1000° C., or by further applying appropriate pressure during or immediately after firing.

Alternatively, a foamed layer and a shell layer may be separately manufactured using the same heating means as described above, and then laminated and heat-fused to integrally form foam glass.

Furthermore, it is easy to do so by filling the lower part between the upper and lower running heat-resistant belts with the material for forming the foam layer, and filling the upper part with the raw material for forming the shell layer, and then continuously introducing the material into a heating furnace for firing and foaming. Foam glass can be formed economically, simultaneously, integrally and continuously.

The total thickness of the foam glass thus formed is preferably in the range of approximately 30 mm to 125 mm. That is, if the thickness is less than 30 mm, the characteristic function of foam glass, that is, the heat insulation property cannot be effectively exhibited. If it is around 125mm, it is thick enough to block heat in normal buildings, and no more than that is necessary.
If the thickness is greater than that, the weight increases even though it is foam glass, which goes against the trend of lighter and higher-rise buildings and makes handling and construction difficult.

The bulk specific gravity of the foam layer is preferably in the range of 0.3 to 0.6. If it is less than 0.3, it will be too weak to be used as interior, exterior, or exterior wall materials for buildings, and if it exceeds 0.6, it will impair heat insulation, reduce light weight, and be inferior in workability.

The bulk specific gravity of the skin layer is preferably in the range of 0.8 to 1.7, and the thickness is preferably in the range of 1.5 to 20 mm.

When the bulk specific gravity is less than 0.8, the density is poor and functional strength such as bending strength is insufficient, and in particular, chips and dents are likely to occur due to external impact.
When it exceeds 1.7, the rigidity improves, but cracks are likely to occur and grow from localized external impacts, which may induce collapse of the entire foam glass.

When using foam glass as exterior material, external wall material, etc., the impact strength P must be at least 1.0 kg, m.
Furthermore, it can be said that 1.3 kg, m or more is suitable. If the bulk specific gravity is within the above range, it will exceed 1.3 kg, m, which is fully satisfactory.

In addition, a material with a bulk specific gravity exceeding 1.7 impairs machinability, and is unsuitable because, for example, when cutting foam glass into a desired shape, multiple cracks deviate from the intended cutting line may occur.

In addition, related to the difference in bulk specific gravity between the foam layer and the shell layer, if the difference between the two layers is large, it is difficult to perform slow cooling uniformly, causing distortion between the two layers, which may be susceptible to external forces such as bending or impact. On the other hand, since cracks are likely to occur at the interface between both layers, the difference should preferably be within 1.2.

The total thickness of the skin layer is related to the total thickness of the foam glass,
The thickness should be 1/4 or less of the total thickness of the foam glass in order not to impair its insulation properties, light weight, ease of handling, etc. Although it is also related to the bulk specific gravity of the shell layer, for example, in the case of a shell layer with a bulk specific gravity of 1.2, a thickness of 4 mm or more has good impact resistance. If the bulk specific gravity is lower than that, the thicker the
If the bulk specific gravity is higher than that, the thinner the material tends to be, the more effective the impact resistance will be.In general, if it is in the range of 1.5 to 20 mm, the impact strength P will be 1.3 kg, m or more, which is satisfactory, and 2. A range of 9 mm to 9 mm is extremely good. Further, if it is within 20 mm, cutting is easy, and for example, no chips or cracks will occur during cutting.

Within the scope of the present invention, it is far superior to ALC of the same bulk specific gravity in terms of not only water absorption resistance and water permeation resistance, but also bending and compressive strength.
Since it has good impact resistance and machinability, it can be fully applied to interior, exterior, and exterior wall materials of buildings.

In one embodiment of the present invention, one or both of the shell layer and foam layer of the foam glass is reinforced with at least one of metal wire, metal mesh, punched metal, etc. coated with an adhesion promoter in advance. Effective. These metal materials can be placed in a formwork in advance when manufacturing foam glass, or they can be inserted into the raw material between the upper and lower belts during continuous manufacturing without the need for special means. can be easily integrated with foam glass.

Conventionally, when reinforcing foam glass with metal materials, it has been pointed out that mutual adhesion is poor due to differences in mutual thermal shrinkage or oxidation of the metal. By using a metal material coated with a resin such as silica-based oxide powder or the like, the adhesive force is greatly increased and the reinforcing effect is dramatically improved. Therefore, it is particularly suitable as an exterior wall material for buildings.

Further, as another embodiment of the present invention, a shell layer may be formed on both sides of the foam layer of the foam glass.
In other words, when producing foam glass, the raw materials for forming the shell layer, the raw materials for forming the foam layer, and then the raw materials for forming the shell layer are introduced into the mold in this order, or in continuous production, the above raw materials are introduced and layered in that order from the lowest level. By applying the above-mentioned manufacturing method, a foam glass integrally formed from these three layers can be made, which is particularly suitable as an exterior wall material.

It will be readily understood that, as a further embodiment of the present invention, the entire surface of the foam layer of the foam glass may be covered with a shell layer.

That is, for example, a foam glass body covered with a skin layer on both sides is first manufactured by the above-mentioned method, and then the surfaces on which the skin layer is not formed are held vertically and the raw material for forming the skin layer and the foam are placed in the mold. The glass body and then the raw material for forming the shell layer are charged in this order and fused together in a heating furnace, and this operation is repeated on other surfaces to coat the entire surface with the shell layer.

In the continuous production of foam glass, a similar method is used to first produce a foam glass body covered with a skin layer on both sides, and then to cover the surface of the foam glass body with no skin layer formed between the upper and lower heat-resistant belts. Holding them above and below, the raw material for forming the shell layer, the foam glass body, and the raw material for forming the shell layer are successively introduced from the bottom in this order, heated and fused together, and this operation is repeated for other surfaces as well. By repeating this process, the entire surface is covered with a shell layer, resulting in an extremely strong foam glass body.

Furthermore, if surface irregularities are provided on at least one of the shell layer and the foam layer, the adhesive area will increase and the effect will be enhanced when adhering to a wall surface as an exterior material, and the surface irregularities can be formed into a geometric pattern. If used as an external surface, it will be aesthetically pleasing.

These surface irregularities can be carved by placing irregularities on the bottom of the mold in advance, or by using a mesh-like heat-resistant belt to form mesh marks during continuous manufacturing, or by placing irregularities on the press lid surface. This can be done very easily by keeping it in place.

〔Example〕

The bulk specific gravity of the foam layer is 0.4 as an example of implementation below.
and 0.5, the bulk specific gravity of the skin layer is 0.6 to 2.0, the thickness of the skin layer is 1 to 30 mm, and the results of various tests on foam glass with a total thickness of 50 mm and 100 mm are detailed.

Sample: Regular soda lime glass waste with particle size
0.7wt% of calcium carbonate powder of 150μm or less as a blowing agent is added to the powder crushed to 150μm or less, and a small amount of water glass is added as a binder.The mixture is rolled and granulated to have a particle size of 0.5. A granulated raw material for a foam layer of ~2 mm was obtained.

Next, 1wt% of Bengara as a coloring agent is added to and mixed with soda lime glass waste crushed to a particle size of 150 μm or less, calcium carbonate is added as appropriate to obtain the desired bulk density, and water glass as a binder is added. A small amount of the following ingredients were added and mixed, and granulated by rolling to obtain a granulated raw material for the shell layer with a particle size of 0.5 to 2 mm.

Furthermore, the granulated raw material for the foam layer and the granulated raw material for the shell layer were placed in a steel mold to the desired thickness, and then heated in a heating furnace at 750 to 1000°C.
The bulk specific gravity of the foam layer is 0.4 and
0.5, and the bulk specific gravity of the skin layer was 0.6 to 2.0.

The resulting foam glass was subjected to the following tests.

Bending strength test: Prepare a foam glass test piece with a width of 15 cm, a length of 20 cm, and a thickness of 50 mm. Two-point support, one-point load,
The bending fracture strength was measured under the conditions of a support span of 15 cm and a loading rate of 1 mm/min, with the skin layer on the supporting side.

Impact strength test; Width 40cm, length 40cm with sand as the base
Foam glass specimens with a thickness of 50 mm and 100 mm were placed with the skin layer on top, and a steel ball weighing 1 kg was dropped from various heights to measure the impact fracture strength.

Cutting test; width 40cm, length 40cm, thickness 50mm and
A 100 mm foam glass test piece was cut using a resinoid cutting wheel with corundum abrasive grains, and the occurrence of chips and cracks at that time was observed and graded from A to D from good to bad.

Heat insulation test: 30mm × 50mm, 30mm for the main foam glass with thickness of 50mm and 100mm respectively.
An average of 50℃ using a prismatic shape of 100 mm and a steady method.
Thermal conductivity in the thickness direction λ (Kcal/m.hr.℃)
Very good X; λ≦0.12, good Y; 0.12<λ≦0.16, poor Z; λ>
It was graded at 0.16.

The results are shown in Figures 1 to 3 and Table 1.

Overall thickness 50mm, bulk specific gravity of foam layer 0.4 and
0.5, the bulk specific gravity of the entire foam glass changes by changing the bulk specific gravity and thickness of the skin layer, and Figure 1 shows the relationship with bending and impact strength with the overall bulk specific gravity as the horizontal axis. is shown in the graph. The bending strength increases with the increase in overall bulk specific gravity. On the other hand, although there is some variation in impact strength, on average it shows a maximum in a specific range of overall bulk specific gravity. In addition, since the overall bulk specific gravity = thickness of the skin layer x difference in specific gravity between the skin layer and the foam layer/total thickness + bulk specific gravity of the foam layer, the overall thickness (50
mm) and the bulk specific gravity (0.4) of the foam layer are constant, the overall bulk specific gravity is in a proportional relationship with "thickness of the skin layer x difference in specific gravity between the skin layer and the foam layer". This indicates that the maximum value exists within the specific range of "thickness of the shell layer x difference in specific gravity between the shell layer and the foamed layer". Generally speaking, when the bulk specific gravity of the shell layer is small, good impact strength is exhibited when the shell layer is relatively thick, and conversely, when the bulk specific gravity of the shell layer is large, good impact strength is exhibited when the shell layer is thin.

Figure 2 shows, as an example, the bending and impact strength when the thickness of the skin layer is changed for foam glass with a total thickness of 50 mm, bulk specific gravity of the skin layer of 1.0 and 1.3, and bulk specific gravity of the foam layer of 0.4. The graph shows that the bending strength increases as the thickness of the skin layer increases, while the impact strength shows a maximum within a certain thickness range of the skin layer.

As another example, Figure 3 is a graph showing the bending and impact strength when the bulk specific gravity of the skin layer is changed in a foam glass with a total thickness of 50 mm, a skin layer thickness of 5 mm, and a foam layer bulk specific gravity of 0.4. However, the bending strength increases as the bulk specific gravity of the skin layer increases, while the impact strength shows a maximum in a certain bulk specific gravity range of the skin layer.

As is clear from these Figures 1 to 3, when the bulk specific gravity of the skin layer is 0.8 to 1.7 and the thickness is 1.5 to 20 mm, the shell layer has good impact resistance and other properties.

Tables 1 and 2 show the results of a cutting test, a heat insulation test, and an impact resistance test for foam glass having a thickness of 50 mm and 100 mm, respectively, according to the rankings appended to the tables.

It is natural that as the bulk specific gravity and thickness of the shell layer increases, the cuttability and insulation properties become poorer, but Table 1 shows that the thickness of the foam glass is 50 mm. If the specific gravity is 1.7 or less and the thickness is 12.5 mm or less (1/4 or less of the total thickness), both cutting performance and heat insulation properties will be satisfactory. Furthermore, in Table 2, for the foam glass having a thickness of 100 mm, it is equally satisfactory if the bulk specific gravity of the skin layer is 1.7 or less and the thickness is 25 mm or less (1/4 or less of the total thickness).

On the other hand, impact resistance is poor for those with bulk specific gravity of the skin layer of 0.6 and 2.0, and those with a skin layer thickness of more than 1 mm and 20 mm, regardless of the overall thickness of the foam glass. Specific gravity 0.8-1.7, thickness 2
~20mm is good.

Combining these results and the results in Figures 1 to 3, we get
The bulk specific gravity of the skin layer is preferably 0.8 to 1.7 and the thickness is preferably 1.5 mm to 20 mm, however, it is more preferable that the thickness of this skin layer is 1/4 or less of the total thickness of the foam glass.

〔Effect of the invention〕

As described above, the present invention has sufficient bending strength compared to ALC, and also has excellent impact resistance, cutting workability, heat insulation properties, etc., and can be effectively applied as interior, exterior, and exterior wall materials of buildings. This has the effect of making it possible.

[Brief explanation of drawings]

1 to 3 are graphs of impact strength and bending strength showing an example of the implementation of the present invention.

【table】

【table】

【table】

【table】

【table】

Claims (1)

[Scope of Claims] 1. It is integrally formed of a foam layer and a shell layer with a higher bulk specific gravity covering at least one side of the foam layer, and the shell layer has a bulk specific gravity of 0.8 to 1.7 and a thickness of 1.5 to 20 mm. Bubble glass featuring 2. The foam glass according to claim 1, wherein the foam layer has a bulk specific gravity of 0.3 to 0.6. 3. The foam glass according to claim 1 or 2, characterized in that the shell layer and the foam layer are formed integrally at the same time. 4. Foamed glass according to any one of claims 1 to 3, characterized in that granules mainly composed of glass fine powders are used as foam layer forming raw materials and shell layer forming raw materials. 5. The foam according to claims 1 to 4, characterized in that one or both of the shell layer and the foam layer is reinforced with a metal wire or a metal net coated with an adhesion promoter in advance. glass. 6. Foam glass according to claims 1 to 5, characterized in that the shell layer covers both sides or the entire surface of the foam layer. 7. The foam glass according to any one of claims 1 to 6, characterized in that the surface of at least one of the shell layer and the foam layer is provided with irregularities.