JPS62207743A - Foam glass - Google Patents

Abstract

PURPOSE:To obtain the titled foam glass having excellent impact resistance and machinability and useful as a facing material and an external wall material by covering at least one surface of a foamed layer with a specified crust layer. CONSTITUTION:Fine foaming agent powder (e.g., limestone), an inorg. pigment, as required, and a binder such as water glass are added to colored or colorless fine glass powder (e.g., soda-lime glass) having <=150mum particle diameter and about 2.5 true sp. gr., and mixed. The mixture is granulated to obtain a foamed layer forming material having from 0.1 to several mm grain diameter. An inorg. pigment, as necessary, and fine foaming agent powder are added to the glass powder similar to that of the foamed layer forming material, and mixed. The mixture is granulated to obtain a crust layer forming material. The foamed layer forming material is charged into a mold made of steel in desired thickness and leveled, and the crust layer forming material is charged thereon in desired thickness. The materials are then heated at 700-1,000 deg.C, baked, and foamed to obtain foam glass of 30-125mm thickness with the crust layer having 0.8-1.7 bulk density and 1.5-20mm thickness integrally formed at least on one surface of the foamed layer having 0.3-0.6 bulk density.

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, and describes glass pieces that form a shell layer at the bottom of a mold and the space between the glass pieces. It is disclosed that glass fine powder is laid down, and a material to be formed into a foamed nozzle is filled thereon and heated to form foamed glass or ceramics.

In addition, in JP-A No. 60-166239, porosity l~30
A laminated foam glass is formed by integrally bonding a skin layer with VO 1% and a porous layer with a porosity of 70 to 95 VO 1%, 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 consisting of fine glass powder is formed by filling the space between the island-like parts in powder form.

[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 prior art, 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 VO1% or less, that is, the true specific gravity of the glass is 2.
5, while the apparent specific gravity is 1.75 or more, which also forms a dense skin layer.

By making the skin layer denser in this way, it is highly rigid, but if it receives a localized impact from the outside, a crack will occur in the core and develop around it, 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. Inadequate areas and cavities occur, which reduce the overall strength of the foam glass.

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

[Means to solve the problem]

The present invention is formed integrally with a foam layer and a shell 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 1.5. It provides a bubble glass consisting of 20 questions.

In the present invention, the raw materials for the foam layer include fine powders of colored or colorless ordinary glass with a particle size of 150 μm or less and a true specific gravity of around 2.5, such as soda lime glass, borosilicate glass, aluminosilicate glass, limestone, and dolomite. , a fine blowing agent powder such as carbon, and a mixture prepared with or without the addition of an inorganic pigment are used. These are further mixed with a binder such as water glass and processed by conventional granulation means to reduce the p particle size to 1 /
Pelletize to about 100 ml of IOH.

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 foam layers and shell layers depends on the type and amount of foaming agent,
It can be adjusted as appropriate within the scope of the present invention by selecting the softening temperature of the glass, the type and amount of inorganic pigment, 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 partially penetrating through the skin layer and being exposed on the surface, but such disadvantages can be eliminated by using granulated raw materials. be done. In addition, when non-granulated raw materials are used, the product has a strong tendency to form open cells, but when granulated raw materials are used, most of the cells become closed cells, which significantly improves water absorption and water permeability. .

For the same reason as mentioned above, when granulated raw materials are used in the shell layer, there are no locally weak spots due to non-uniform sintering, which is the case when non-granulated raw granules are used, and a homogeneous structure is created. A skin 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 charged into a mold or the like in a subsequent step and can easily form a flat layer.

In forming the shell layer, coarse granulated glass may be mixed with the granulation raw material to add elegance, 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. Pond 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 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 iomm-125ff1m. In other words, if it is less than 3 (1111111), the characteristic function of foam glass, that is, heat insulation, cannot be effectively expressed.If it is about 125cm, it is thick enough to block heat in ordinary buildings. It is not necessary to use more than that, and if it becomes thicker than that, even if it is foam glass, it will increase in weight, making it difficult to handle and construct, making it difficult to handle and construct.

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 internal, exterior, or exterior wall materials for buildings, and if it exceeds Q, 6, it will impair heat insulation, inhibit light weight, and be inferior in handling and construction. .

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

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 easily generated due to external impact.

When it exceeds 1.7, the rigidity improves, but cracks are likely to occur and grow from the core due to localized impact from the outside, leading to the collapse of the entire foam glass.

When foam glass is used as exterior material, exterior wall material, etc., the impact strength (P) must be at least 1.0#, ? 7Z is necessary, but also 1,3/1. It can be said that it is suitable if it is ff1 or more. If the bulk specific gravity is within the above range, it will exceed 1.3140 m and be fully satisfactory.

In addition, materials with a bulk specific gravity exceeding 1.7 impair machinability, and for example, when cutting foam glass into a desired shape, multiple cracks deviate from the planned cutting line may occur, making it unsuitable. be.

In addition, related to the difference in bulk specific gravity between the foam layer and the skin layer, if the difference between the two layers is large, it is difficult to maintain the cold uniformly, and distortion occurs between the two layers, resulting in resistance to external forces such as bending or impact. Since cracks are likely to occur at the interface between both layers, it is preferable to reduce the difference by 1.
．． It should be within 2.

The total thickness of the skin layer is related to the overall thickness of the foam glass, and should be 1/4 or less of the total thickness of the foam glass in order not to impair the insulation, lightness, handling workability, etc. of the foam glass. . 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 4M or around 4M has good impact resistance. If the bulk specific gravity is lower than that, the thicker one tends to be more effective, and if the bulk specific gravity is higher than that, the thinner one tends to be more effective for impact resistance.In general, it is 1.5 to 201 KI.
If it is in the range of l, the impact strength (P) is 1.3J4. A value of m or more is satisfactory, and a range of 2 to 9 is extremely good. Moreover, if it is within 2Cllll1, cutting is easy, and, for example, no chips or cracks will occur during cutting.

Within the scope of the present invention, for example, not only water absorption resistance and water permeation resistance, but also bending and compressive strength, etc., are far superior to ALC of the same bulk specific gravity, and impact resistance and cutting workability are also good. Therefore, it can be fully applied to the interior, exterior, and 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 requiring any 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. That is, 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 raw materials are introduced and laminated in the order of lower order. By applying the above-mentioned manufacturing means, it is possible to obtain a foam glass integrally formed from these three layers, 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.

In addition, if narrow 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. If used as an outer 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〕

As an example, the bulk specific gravity of the foam layer is 0.4 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 30M, and the total thickness is 50 and 100M. The results of various tests on the bubble glass of the cabinet are explained in detail.

Sample: Ordinary soda-lime glass waste crushed to a particle size of 150 μm or less, mixed with calcium carbonate as a blowing agent.
0.7 wt% of powder with a particle size of 50 μm or less was added and mixed, and a small amount of water glass as a binder was added and mixed, and the mixture was transferred and granulated to obtain a granulated raw material for a foam layer with a particle size of 0.5 to 2 ffll11. .

Next, 1 wt% 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 specific gravity, and water glass as a binder is added. A small amount of the mixture was added and mixed, and granulated by rolling to obtain a shell layer phase granulated raw material having 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 for 20 to 60 minutes. By appropriately firing or further pressing and slow cooling, foamed glass having a foam layer with a bulk specific gravity of 0.4 and 0.5 and a skin layer with a bulk specific gravity of 0.6 to 2.0 was obtained.

The resulting foam glass was subjected to the following tests.

Bending strength test: width 15B, length 20crrL1 thickness 50
Prepare a 1111 foam glass test piece, support it at two points,! The bending fracture strength was measured under the conditions of a point load, a support span of 15 cm and 17 m, and a loading rate of 1 wn and 1 minute, with the skin layer on the support side.

Impact strength test: A glass test piece with a width of 40 cm, a length of 40 cm, and a thickness of 50 cm was placed with the skin layer on top, and a steel ball weighing 1# was dropped from a height of 1. The impact fracture strength was measured.

Cutting test; width 40mm, length 40mm, thickness 50mm and 1
Cut 00MIIL foam glass test pieces using a resinoid cutting wheel with corundum abrasive grains, observe the occurrence of chips and cracks, and grade A from good to bad.
- Graded to D.

Heat insulation test: 3oM1n' x 50 for the main foam glass with thickness sot+m and toofi respectively
Thermal conductivity in the thickness direction at an average temperature of 50℃ λ(
Kcal/m, hr, 'C) were measured and were very good <'x>; λ≦0.12, good O(Y);
0.12 (λ≦0.16, bad (7) (Z); λ
) 0.36.

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

The overall thickness is 50cm, the bulk specific gravity of the foam layer is 0.4 and 0.
In the foam glass shown in No. 5, the bulk specific gravity of the entire foam glass changes by changing the bulk specific gravity and thickness of the skin layer.
The graph shows the relationship between this and the impact strength.

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.

Since it is the bulk specific gravity of ten foam layers, the total thickness (50Tr
alL) and the bulk specific gravity of the foam layer (0, when ri is 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". Therefore, the maximum value indicates that it exists within the specified range of "thickness of the skin layer x difference in specific gravity between the skin layer and the foamed layer".Generally speaking, when the bulk specific gravity of the skin layer is small, the skin layer When the bulk density of the shell layer is large, it exhibits good impact strength when the shell layer is thin.

As an example, Figure 2 shows a total thickness of 50 ml, a bulk specific gravity of the skin layer of 1.0, and! , 3, bulk specific gravity of foam layer 0.4
This is a graph showing the bending and impact strength when the thickness of the skin layer is changed in foam glass.The bending strength increases as the thickness of the skin layer increases, while the impact strength increases when the thickness of the skin layer increases. It shows the maximum in the thickness range.

As another example, Figure 3 shows 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 fi, and a foam layer bulk specific gravity of 0.4. The graph shows that 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 shell layer is 0.8 to 1.7 and the thickness is 1.5 to 20 m11, 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 with a thickness of 50 m and 100 m, respectively, according to the rankings appended to the tables.

It is natural that as the bulk specific gravity and thickness of the skin layer increase, the cuttability and insulation properties become poorer, but in Table 1, for foam glass with a thickness of 50 mm, the skin layer If the bulk specific gravity of the layer is 1.7 or less and the thickness is 12.5M or less (1/4 or less of the total thickness), both cuttability and heat insulation properties can be satisfied.

Also, in Table 2, the thickness of bubble glass is 10011111
0, 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, the impact resistance is determined by the bulk specific gravity of the skin layer being 0.6 and 2.
0, and those with a skin layer thickness exceeding tin and 20 mm are all defective, regardless of the overall thickness of the foam glass.
The bulk specific gravity of the skin layer is 0.8-1.7, the thickness is 2-2 (h+0
11 is good.

If we combine these results with the results shown in Figures 1 to 3, the bulk specific gravity of the skin layer is 0.8 to 1.7, and the thickness is! , 5 to 20 layers is preferable, but 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 ALO, 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]

1-3 are graphs of impact strength and bending strength showing an example of the implementation of the present invention. Table 1 Note) Cutting performance evaluation A: Very good (almost no chips) B: Good (there are some minute chips, but no problems in appearance) C;
Slightly poor (cracks occur when chips are noticeable) D: Poor (cracks often occur) Y: Good (0, 12 (λ≦0.
16) 2; Defective (λ) 0.16. ) L; Good (1,3≦P(1,7) M; Bad (P<1.3) *λ; Kcal/m, hr, ℃P; kf
, m Table 2 Note) Evaluation symbols follow Table 1.

Claims (1)

[Scope of Claims] 1) A foamed layer and a shell layer covering at least one side thereof and having a higher bulk specific gravity, the shell layer having a bulk specific gravity of 0.8 to 1.7 and a thickness of 1. A foam glass characterized by having a thickness of .5 to 20 mm. 2) The foam glass according to claim 1, wherein the foam layer has a bulk specific gravity of 0.3 to 0.6. 3) Foam glass according to claims 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 each glass fine powder are used as the foam layer forming raw material and the shell layer forming raw material. . 5) 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 metal net coated with an adhesion promoter in advance.
Bubble glass as described in section. 6) Foam glass according to any one of claims 1 to 5, characterized in that the shell layer covers both sides or the entire surface of the foam layer. 7) Claim 1 characterized in that unevenness is provided on the surface of at least one of the shell layer and the foam layer.
Bubble glass according to items 6 to 6.