JPH11302655A - Fireproof material and its production - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a fireproof material which has fire resistance, heat insulation properties, and sound insulation properties, has constant strength and the suitability for processing such as cutting, and can find various applications such as a building material as well as a member usable in the production of house fittings or furniture such as desks and chairs. SOLUTION: There is provided a process for producing a fireproof material, comprising: mixing a fireproofing fluid obtained by reacting potassium hydroxide, sodium carbonate (soda ash), metallic silicon, and water with each other with at least one member selected among paper, rice hulls, fibrous materials, wood chips, and sawdust; dehydrating the mixture; and pressing the dehydrated mixture.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a fireproof material which can be used for building materials, fittings, members used for manufacturing furniture such as desks and chairs, molds for home appliances such as refrigerators and televisions, and packaging materials. It relates to a material and its manufacturing method.

[0002]

2. Description of the Related Art Conventionally, various materials have been proposed as building materials having excellent fire resistance, heat insulation properties, and sound insulation properties. The present inventor uses a fire-resistant liquid which is an inorganic reaction product and has a high fire resistance. Has already proposed a refractory building material manufactured by the above method (1997 Patent Application No. 97697).

[0003]

The fire-resistant building materials proposed by the present inventor have exhibited excellent effects in terms of fire resistance, heat insulation and sound insulation, but are mainly used as building materials. It is intended to have not only fire resistance, heat insulation, and sound insulation, but also has a certain strength and is suitable for processing such as cutting. Components that can be used in the manufacture of furniture such as desks and chairs, forms for home appliances such as refrigerators and televisions, cardboard
A refractory material that can be used for various applications, such as a packaging material that can replace styrofoam or the like, has not yet been proposed.

[0004]

SUMMARY OF THE INVENTION The present invention relates to a refractory liquid obtained by reacting potassium hydroxide, sodium carbonate (soda ash), metal silicon and water with paper, rice husk, fibrous material, wood, etc. One or more kinds of chips and sawdust (sawdust) are mixed and press-formed to provide a refractory material that can be used for various applications.

[0005]

BEST MODE FOR CARRYING OUT THE INVENTION The invention of a refractory material and a method of manufacturing the same proposed by the present application is based on the fact that a refractory liquid obtained by reacting potassium hydroxide, sodium carbonate (soda ash), metal silicon and water is mixed with paper, A refractory material obtained by mixing one or more of rice hulls, fibrous materials, wood chips, and sawdust (sawdust) and press-molding the mixture, and a method for producing the same.

The refractory liquid is charged into a reaction tank with powdered or granular potassium hydroxide, powdered or granular sodium carbonate (soda ash), lump metal silicon, and water. In the tank, use what is produced by reacting naturally for 2 to 8 hours. Potassium hydroxide, sodium carbonate, metal silicon, etc., used in this reaction are in powder, granular, lump, etc.
A commercially available product in each state can be used. For example, 8 kg of powdered potassium hydroxide, 7 kg of granular sodium carbonate (soda ash), and 30 kg of lump of metal silicon are charged into a reaction tank, and then 60 liters of water is charged into the reaction tank, whereby the reaction occurs naturally. Is started,
After a reaction time of about 10 hours, the solid content is separated to obtain about 4 refractory liquids used for producing the refractory material of the present invention.
8 liters (about 70 kg) can be obtained.

The mixing ratio of the refractory liquid and the other components is preferably 5 to 15% by weight for the refractory liquid and 85 to 95% by weight for the other components. If the proportion of the refractory liquid is less than 5% by weight, the fire resistance is undesirably reduced. On the other hand, even if the ratio of the refractory liquid exceeds 15% by weight, there is no significant difference in fire resistance, and therefore, from the viewpoint of cost effectiveness, papers, rice husks, fibrous materials, wood chips, sawdust (sawdust) ), The proportion of the refractory liquid is preferably up to 15% by weight from the viewpoint of promoting the effective use of members having no other particularly effective use in industry.

[0008] In the above, the refractory liquid, paper,
When the rice hull and the fibrous material are mixed to form a refractory material, the refractory liquid is 5 to 15% by weight, the paper is 75 to 85% by weight, the rice husk is 3 to 7% by weight, the fibrous material is 3 to 7%. It is preferable to mix at a ratio of weight%. The reason why the mixing ratio of the refractory liquid is preferably 5 to 15% by weight is as described above. If the mixing ratio of papers is less than 75% by weight, the flexibility of the refractory material as a product is undesirably reduced. On the other hand, if it exceeds 85% by weight, the fire resistance decreases, which is not preferable. If the mixing ratio of the rice hulls is less than 3% by weight, the elasticity of the refractory material as a product is undesirably reduced.
On the other hand, if it exceeds 7% by weight, the elasticity becomes too strong, which is not preferable. 3% by weight of fiber material
If the amount is less, the fire resistance and flexibility of the refractory material as a product are undesirably reduced. On the other hand, if it exceeds 7% by weight, the flexibility becomes too strong, which is not preferable.

[0009] Even if only papers (85 to 95% by weight) are mixed with the refractory liquid (5 to 15% by weight), a refractory material can be produced in the same manner. However, if the rice hulls are also mixed, the silica content (silicon (Si) component) contained in the rice hulls will be added to the production of refractory material, so that the fire resistance and water resistance of the refractory material as a product will be enhanced, It is preferable in adjusting the flexibility of the refractory material as a product. The fibrous material is mixed for the purpose of reducing the generation of smoke even when the refractory material as a product is burned, and can also be used for adjusting the flexibility of the refractory material as a product. When the fibrous material is mixed, the amount of smoke generated when the refractory material as a product is burned is reduced by about 80% as compared with the case where the fibrous material is not mixed.

In the above, any used paper such as old newspapers and old magazines can be used as the paper, and the used paper is cut into a mixture with a refractory liquid to form a uniform mixture. It is only necessary to mix them, and there is no need to remove stapler needles from old magazines or to remove ink. As described above, old newspapers, old magazines, and the like can be used without any processing other than cutting, which is useful for effective use and recycling of used paper.

Further, since the rice husk is mixed with the silica content (silicon (Si) component) in the rice hull for use in the production of the refractory material of the present invention, even if it is other than rice husk, the silica content ( Any plant seeds or shells containing silicon (Si) component) can be used.

As the fibrous material, Chinese cotton, glass cotton, stainless steel cotton, ceramic cotton, rock wool, asbestos, cellulose fiber, ceramic fiber and the like can be used.

The refractory material of the present invention can be produced by mixing only the rice husk with the refractory liquid. However, in this case, in consideration of the strength and flexibility of the refractory material as the product, the mixing ratio of the rice hulls is set to 70 to 90% by weight (if the mixing ratio is less than 70% by weight, the strength of the refractory material as the product is reduced). On the other hand, if the content is more than 90% by weight, the refractory material as a product becomes hard and poor in flexibility, which is not preferable.) The mixing ratio of the refractory liquid is preferably 10 to 30% by weight. . However, as described above, in manufacturing the refractory material of the present invention, from the viewpoint of fire resistance, it is sufficient to mix the refractory liquid at 5% by weight or more. The mixing ratio (refractory liquid: 10 to 30% by weight, rice hull: 70 to 90% by weight) is appropriately corrected, and in addition to the refractory liquid and the rice hull, papers,
One or more of fibrous materials, wood chips, and sawdust (sawdust) are mixed, fire resistance, non-combustibility, performance to prevent smoke when burned, water resistance, rigidity, flexibility, elasticity, etc. Can be modified.

Further, the refractory material of the present invention can be produced by mixing only wood chips with a refractory liquid. However, in this case, it is preferable to mix wood chips of 65 to 85% by weight with the refractory liquid of 15 to 35% by weight. If the mixing ratio of the wood chips exceeds 85% by weight, the weight of the refractory becomes heavy and the product becomes hard. Therefore, it is not preferable from the viewpoint of workability. This is because it is unfavorable because it decreases. In this case, instead of or together with the wood chips,
Sawdust, sawdust, fallen leaves and cedar leaves can also be used. Whichever one is used, wood chips, sawdust (sawdust), etc., which have no other uses, can be effectively used. Here, as described above, in producing the refractory material of the present invention, from the viewpoint of fire resistance, it is sufficient to mix the refractory liquid at 5% by weight or more. While mixing, the mixing ratio (refractory liquid: 15 to 35% by weight, wood chips and / or sawdust (sawdust): 65 to 85% by weight) is appropriately corrected, and the refractory liquid and the wood chips and / or sawdust (sawdust) ) In addition, one or more of papers, rice hulls, and fibrous materials are mixed to provide fire resistance, non-combustibility, smoke prevention when baked, water resistance, rigidity, flexibility,
The elasticity can be modified.

[0015] As described above, the refractory material of the present invention is obtained by adding 5 to 15% by weight of a refractory liquid obtained by reacting potassium hydroxide, sodium carbonate (soda ash), metal silicon and water to a final product. Various performances required for refractory materials (fire resistance, non-flammability, ability to prevent smoke when burned,
Considering water resistance, rigidity, flexibility, elasticity, weight, hardness, etc.), one or more of papers, rice husks, fibrous materials, wood chips, sawdust (sawdust) It can be produced by appropriately selecting an appropriate amount, setting the total to 85 to 95% by weight, adding to the 5 to 15% by weight of the refractory liquid, mixing, dehydrating, and pressing.

In the method for producing a refractory material according to the present invention, one or more of papers, rice husks, fibrous materials, wood chips, sawdust (sawdust) and a refractory liquid are mixed with a known kneader. After mixing using a mixer or the like, the obtained mixture is subjected to dehydration treatment by compression or the like, and is subjected to pressure molding by hot pressing or extrusion molding to produce a refractory material as a product.

In the above, after mixing the materials and before performing the dehydration treatment, the mixture is heated at 100 ° C. to 170 ° C. for 3 hours.
A step of boiling (boiling) for 0 to 90 minutes can be added. By adding a boiling (boiling) process,
The penetration of the refractory liquid into paper and the like is promoted, and the mixing state becomes better. In addition, when the boiling (boiling) step is added, the workability in the pressure forming step by a hot press or the like is improved, and the refractory material as the final product formed is compared with a case where the boiling (boiling) step is not added. The surface is glossy and the finish is beautiful. If the boiling (boiling) temperature (100 ° C. to 170 ° C.) in the above is lower than this temperature range, the time required for the boiling (boiling) step will be long. boiling)
This is determined because it is not preferable because the mixed substances are agglomerated during the process. In addition, boiling (boiling) time (30 minutes to 90 minutes)
If the time is shorter than this time range, the desired effect (enhancement of penetration of refractory liquid into paper etc.) by adding boiling (boiling) is not sufficiently achieved, while the time longer than this time range However, this is determined because there is no significant difference in the effects.

The dehydration treatment in the above manufacturing process is performed for the purpose of removing excess liquid before the molding process and improving the finish of the heat-resistant material as a product. However, if dewatering is performed by pressing, the squeezed liquid (the first mixture of the refractory liquid and the components such as paper mixed therein) is dissolved into the next refractory material manufacturing process Since it can be used repeatedly, refractory fluid can be saved. In this dehydration treatment, the liquid content in the mixture is from 40% by weight to 5% from the viewpoints of workability in the subsequent molding step and good finish of the refractory material as a product.
It is preferred to carry out until it becomes 0% by weight.

In the case where the pressure molding in the manufacturing process is performed by a hot press, at 150 ° C. to 180 ° C.
It is desirable to carry out for 30 to 90 minutes. In this pressure molding step, various pressure molding methods known in this field can be used in addition to hot press, roll molding, and extrusion molding.

[0020] The refractory material of the present invention comprises a refractory liquid obtained by reacting potassium hydroxide, sodium carbonate (soda ash), metal silicon and water, paper, rice hull, fibrous material, wood chips, sawdust. (Sawdust) is manufactured by mixing one or more of them and press-molding them. Various shapes such as plate, column, and rod are produced by hot pressing, rolling, extrusion, etc. Can be molded. This molded refractory material not only has fire resistance, but also has a certain strength and can be easily processed by cutting or the like.
Components that can be used in the manufacture of furniture such as chairs, refrigerators,
It can be used for various purposes, such as molds for home electric appliances such as televisions, and packaging materials that can replace cardboard and styrofoam. As an example, it can be used as a component of ventilation ducts for kitchens and the like, which were conventionally manufactured from stainless steel, beer case frames, pachinko machine frames, cartons (payment at banks and shops, etc.). It can also be used for the production of trays for changing and the like).

That is, not only members conventionally made of wood, but also members made of metal, synthetic resin, etc., which are required to have fire resistance, all of the refractory materials of the present invention are used. Can be used as an alternative.

[0022]

Example 1 Refractory liquid 1 obtained by reacting potassium hydroxide, sodium carbonate (soda ash), metal silicon and water
0% by weight, 80% by weight of used waste paper (old newspaper), 5% by weight of rice hulls, and 5% by weight of Chinese cotton are put into a production tank and mixed well.

Thereafter, the mixture was pressed to obtain a water 4
It is dehydrated until it becomes about 5% by weight, and this is pressed with a hot press at about 180 ° C. for about 60 minutes to obtain a plate-like refractory material of the present invention (length: 30 cm, width: 30 cm, thickness: 1.5 cm) , Weight: 2 kg). It can be said that it is lightweight as it has fire resistance and is of such a size.

[0024]

Example 2 Refractory liquid 1 obtained by reacting potassium hydroxide, sodium carbonate (soda ash), metal silicon and water
0% by weight, 80% by weight of used waste paper (old newspaper), 5% by weight of rice hulls, and 5% by weight of Chinese cotton are put into a production tank and mixed well.

After mixing as described above,
Boil for approximately 60 minutes at 0 ° C. Room temperature (20 ℃
), The mixture was pressed and dehydrated until the water content reached about 45% by weight.
Pressed for about 60 minutes with a hot press at ℃ for 30 minutes, plate-shaped refractory material of the present invention (length: 30cm, width: 30cm, thickness: 1.5c)
m, weight: 1.5 kg). This refractory material also has fire resistance, and it can be said that it is lightweight when it has such a size.

A comparison between the refractory material of the present invention molded in Example 1 and the refractory material of the present invention molded in Example 2 shows that the refractory material of Example 2 has a glossier surface. Yes,
The finish was beautiful.

[0027]

Example 3 Refractory liquid 2 obtained by reacting potassium hydroxide, sodium carbonate (soda ash), metal silicon and water
0% by weight and 80% by weight of the rice husks are charged into the production tank and mixed well.

Thereafter, the mixture was pressed to obtain a water 4
It is dehydrated until it becomes about 0% by weight, and this is used as a rod-shaped refractory material of the present invention (diameter: 1.
0 cm, length: 30 cm, weight: 0.6 kg).

[0029]

Example 4 Refractory liquid 2 obtained by reacting potassium hydroxide, sodium carbonate (soda ash), metal silicon and water
0% by weight and 80% by weight of the rice husks are charged into the production tank and mixed well.

After mixing as described above,
Boil for approximately 60 minutes at 0 ° C. Room temperature (20 ℃
After cooling to about 40% by weight, the mixture was pressed and dehydrated until the water content reached about 40% by weight, and the mixture was extruded into a bar-shaped refractory material of the present invention (diameter: 2.0cm, length: 30cm, weight: 1.2k
g) was obtained.

[0031]

Example 5 Refractory liquid 2 obtained by reacting potassium hydroxide, sodium carbonate (soda ash), metal silicon and water
5% by weight and 75% by weight of wood chips are charged into the production tank and mixed well.

Thereafter, the mixture was pressed to obtain a water 4
It is dehydrated until it becomes about 5% by weight, and it is pressed with a hot press at about 180 ° C. for about 60 minutes to form a columnar refractory material of the present invention (length: 30 cm, width: 2.0 cm, thickness: 3. 0cm,
(Weight: 0.8 kg).

[0033]

Example 6 Refractory liquid 2 obtained by reacting potassium hydroxide, sodium carbonate (soda ash), metal silicon and water
5% by weight and 75% by weight of wood chips are charged into the production tank and mixed well.

After mixing as described above,
Boil for approximately 60 minutes at 0 ° C. Room temperature (20 ℃
After cooling to about 45% by weight, the mixture was dehydrated until the water content reached about 45% by weight, and the mixture was pressed with a hot press at about 180 ° C. for about 60 minutes to form a columnar refractory fire of the present invention. Material (length: 30cm, width: 3.0cm, thickness:
3.0 cm, weight: 1.3 kg).

[0035]

Test Example 1 Using the refractory material of the present invention obtained in Examples 1 to 6, various tests were performed on the performance.

First, the flame of a gas burner at 1500 ° C. was brought close to the surface of the refractory material and observed for 30 minutes. At the time when 10 minutes had elapsed, the surface of any of the refractory materials became ceramic. After a lapse of 30 minutes, each refractory material was cut and the interior was observed. As a result, it was confirmed that all refractory materials had turned into ceramics from the surface near the flame of the gas burner to about 0.8 mm. did it. In the case of the plate-like refractory material of Example 1 and Example 2 having a thickness of 1.5 cm, fire did not pass through to the back surface.

When the plate-shaped refractory material manufactured in Example 1 or 2 was placed on the floor and the golf ball was allowed to fall naturally from about 80 cm above, the golf ball that collided with the refractory material on the floor almost rebounded. Did not. It was also confirmed that the refractory material of the present invention had excellent shock absorbing ability.

Further, a box was made using the plate-shaped refractory material of the present invention manufactured in Example 1, and a radio with sound (with the switch turned on) was sealed therein.
Outside the box, almost no sound could be heard from the radio. From this, it was also confirmed that the refractory material of the present invention had excellent sound insulation.

Next, the refractory material of the present invention obtained in Examples 1 to 6 was nailed, screwed in, and cut with a saw / knife to examine workability. Example 1
When the nail was driven into the refractory material of the present invention obtained in Example 6 and observed, no loosening of the nail occurred after the driving. Further, any of the refractory materials of the present invention obtained in Examples 1 to 6 could be screwed.

Further, any of saws and knives could be easily cut or processed. Therefore, the refractory material of the present invention obtained in the above-mentioned Examples 1 to 6 is made into various shapes by using a saw and a knife to form a frame of a home refrigerator, a form of a television (chassis), a conventional thick cardboard. It could be easily processed into various housing materials in addition to packaging materials and materials used in the manufacture of desks and chairs in place of polystyrene foam and the like.

[0041]

According to the present invention, it has not only fire resistance, heat insulation and sound insulation, but also has a certain strength and is suitable for processing such as cutting. , Fittings,
Components that can be used in the manufacture of furniture such as desks and chairs, refrigerators,
It is possible to provide a refractory material that can be used for various uses such as a form of a home appliance such as a television and a packaging material. That is, not only members conventionally manufactured from wood, but also members manufactured from metal, synthetic resin, and the like, which are required to have fire resistance, are all replaced with the fire-resistant material of the present invention. Can be used.

The refractory material proposed by the present invention is manufactured using paper, rice husk, fibrous material, wood chips, sawdust (sawdust), etc., and can be provided at extremely low cost. Also, by using these,
It can contribute to the promotion of waste use and recycling.

If the refractory material of the present invention is buried in the ground after use, it returns to the soil in about 10 years and does not have a harmful effect on the human body.

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁶ Identification code FI E04B 1/94 E04B 1/94 Q // B27M 3/00 B27M 3/00 K

Claims (2)

[Claims] 1. A refractory liquid obtained by reacting potassium hydroxide, sodium carbonate (soda ash), metal silicon and water, in paper, rice husk, fibrous material, wood chips, sawdust (sawdust). A refractory material obtained by mixing any one or more of the above, and molding the mixture under pressure. 2. A refractory liquid obtained by reacting potassium hydroxide, sodium carbonate (soda ash), metal silicon and water, in paper, rice husk, fibrous material, wood chips, sawdust (sawdust). A method for producing a refractory material, comprising mixing one or more of the above, subjecting the mixture to a dehydration treatment, and then performing pressure molding.