JPS6177683A - Manufacture of lightweight foamed body - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) The present invention relates to a method for producing lightweight foams useful as filters, soil conditioners, and aggregates.

In particular, the present invention relates to a method for producing a lightweight foam that is fire resistant, can be molded into any shape, and is easily recyclable.

(Prior art) Methods for producing porous lightweight foam include: - Mixing flammable substances such as sawdust and coke with inorganic substances and burning them to form voids; - Expanded vermiculite. , A method of binding lightweight grains such as pearlite grains with inorganic materials,■
A method in which bubbles are chemically generated in a slurry of clay or other refractory composition powder and then fired; ■ A method in which a foaming agent is added to an inorganic composition in advance; ■ A method in which a foaming agent such as naphthalene is sublimated to an inorganic composition. A method is known in which a porous, lightweight foam is produced by blending solid particles with a porous material and heating them to exhibit their properties.

(Problems to be Solved by the Invention) In the above-mentioned method for producing a porous lightweight foam, the combustible material cannot be uniformly mixed into the inorganic composition in (2), It is difficult to manufacture plates, etc., and they often lose their shape. With ■, there are no continuous holes and there is no suitable binder. In the case of ■, cracks appear when fired and often result in destruction.

■ and ■ have restrictions on the shape. There were drawbacks such as. In this type of method, since the shape is formed using a mold material, the manufacturing process is large-scale, and there are disadvantages in that it requires a long time due to shape retention. (Means for Solving the Problems) The present invention impregnates an arbitrary amount of clay in the shape of a clay into the cells of a plastic open-cell foam that has shape-retaining properties to further strengthen its shape-retaining properties. The purpose is to incinerate the plasti components at the bottom to produce a lightweight foam with an open cell structure consisting only of viscosity.

(Function) In the present invention, the size and density of the cells in the plastic open-cell foam can be arbitrarily selected at the time of forming the foam, and the shape can be formed into the final product shape. The density of the lightweight foam can be selected depending on the size, grain size, and soil conditions.

(Example) Below, the manufacturing method of the lightweight foam according to the present invention will be described in detail using the drawings. That is, the present invention provides a method for producing a lightweight foam by impregnating clay in the form of clay into a plastic foam having an open-cell foam structure, pre-drying the clay, incinerating the plastic foam, and then firing the clay. It is. To explain further, the plastic foam l used in the present invention is illustrated in FIG.
It is molded into the shape shown in 1, and mainly functions as a shape forming material, shape retaining material, and impregnating material.

Furthermore, the plastic foam 1 is capable of impregnating clay 3 into the cells 2, and is formed into an open cell structure, as shown in FIG. The size of the bubble 2, the film thickness,
The degree of distribution of air bubbles can be arbitrarily set at the time of forming the plastic foam. In other words, the physical properties and shape of the lightweight foam are mostly determined by the plastic foam l. The clay used in the present invention may be any material that can be used to make pottery or porcelain, such as Kibushi clay, Frogme clay, pottery stone, Rouseki, Shigaraki clay, etc.
It is made of one type of clay produced in various places, or a mixture of two or more types. The particle size of the clay is 0.01 m or less, and the clay is in a muddy state to be impregnated into the plastic foam 1. Therefore, to explain the manufacturing process, first, as shown in Fig. 1(a), plastic foam 1 (thickness 5
A plate with a length of 10 cm x foci and an open cell structure with a bubble diameter of 1 mm was impregnated with mud. In this case, the plastic foam 1 has flexibility and cushioning properties, and is impregnated by rubbing the plastic foam 1 in mud. Of course, the amount of clay 3 impregnated varies depending on the number of times of rolling, and the bulk specific gravity after firing also corresponds to the amount of impregnation. Note that when the bubbles 2 of the plastic foam 1 are impregnated with mud, the amount of impregnation is such that the plastic foam (2) can recover. next,
The plastic foam 1 impregnated with this clay is forcibly heated in a microwave oven for 5 to 10 minutes to dry the plastic foam 1 containing the clay 3. In this case, even with rapid heating, no cracks or destruction were observed in the porous clay plate. Next, the clay plate is heated to 200-350°C to incinerate the plastic foam, and then heated to 1000-120°C.
It is baked at a temperature of 00°C for 30 minutes, and then slowly cooled to form a lightweight foam. The lightweight foam thus formed has the same shape as the plastic foam 1, is an inorganic porous body with open cells, and is hard and cured without cracks or damage.

What has been described above is only one example of the method for producing a lightweight foam according to the present invention, and the clay is made by adding silicic acid, alumina, organic polymers (CMC, MC), etc. It is also possible to strengthen the viscosity of the material, improve shape retention and moldability, and make it more porous and lightweight. Alternatively, the lightweight foam can be treated with a dehydrating agent to make an oil-absorbing filter.

(Effect of the invention) When a lightweight foam is manufactured through such a process, the outer shape can be formed using a plastic foam that is easy to mold and process.
It is characterized by the ability to produce lightweight foams of arbitrary shapes such as cylinders, spheres, honeycombs, net-like objects, prisms, columns, etc. In addition, since the clay is impregnated into the open cell structure in the form of a slurry, it is extremely easy to impregnate the clay. Furthermore, even if the clay-impregnated plastic foam is forcibly dried in a microwave oven, the clay itself can be dried in a short time without cracking or breaking because the plastic foam itself has open air bubbles. In addition, since the amount of clay impregnated can be arbitrarily selected depending on the size and density of the cells in the plastic foam and the impregnation process, it is possible to easily produce lightweight foams with arbitrary bulk density and hardness.

[Brief explanation of the drawing]

Figures 1 (a) to (e) are explanatory diagrams showing an example of the shape of the plastic foam used in the present invention, and Figure 2 is an explanatory diagram showing an enlarged part of the plastic foam impregnated with clay. , FIG. 3 is a process diagram showing a method for manufacturing a lightweight foam according to the present invention. 1...Plastic foam, 2...Bubble, 3...
·clay.

Claims (1)

[Claims] (1) A plastic foam with an open-cell foam structure is impregnated with clay slurry, and then the clay content of this foam is dried by high-frequency heating.
1. A method for producing a lightweight foam, which comprises heating the plastic foam component to 00°C to incinerate the plastic foam component, and then firing the clay component at 800 to 1200°C.