JPS6311306A - Manufacture of incombustible, light-weight and heat-insulating sizing - 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 [Objective of the Invention] (Industrial Application Field) The present invention is a non-flammable, lightweight, heat-insulating material that is continuously extruded by industrial production. 4
1. Regarding manufacturing method of noiding (prior art) In the conventional manufacturing method of siding with heat insulating material, the substrate can be continuously molded using a screw set extruder. After extrusion molding, curing at room temperature, followed by steam curing, and then leaving it in the air for a long time or curing it in a heated ole-crepe to obtain a hardened product, and then use synthetic resin foam (expanded polystyrene beads) as a heat insulating material. This must be foamed off-line using a pressure press or the like in a separate process, and then bonded to the substrate.

Additionally, off-line formation must be performed on an extremely long conveyor. Also in this case, legal issues regarding gas generation from synthetic resin foams must be taken into consideration. Moreover, the thing formed in this way is J
Even in the flame retardancy test for building materials according to IS 81321, it is considered to be a quasi-noncombustible material. In addition, there are cases where a cement molded body as a substrate is obtained by a pouring method, etc., and then the back side is filled with an inorganic lightweight material as a heat insulating material. The adhesion of the material is poor, and the water absorption is also poor (1,.

In addition, chemically foamed lightweight materials such as A, L, and C can be used for cement materials.
・There are examples of I-komono sliced into 501Nn etc. and used as exterior material for ceramics, but the specific gravity is 05-06.
Although it has good insulation properties, the open cell nature of foamed T culm means that it absorbs water easily, so it has weak resistance to freezing and thawing in cold regions, and there are no mechanical bullet holes on the surface. There are problems such as vulnerability.

(Problems that will be solved by the invention) As mentioned above, in the conventional siding with heat insulating material, even if the board is continuously molded for 1q, it is not possible to continuously mold the heat insulating material at the same time. 1b, which uses synthetic resin foam, is lightweight, but it has the problem of generating scum during manufacturing, and is also insufficient in terms of flame retardancy.
Even those that use lightweight inorganic materials as heat insulating materials have problems with adhesion and water absorption because they are molded using a separate culm and then filled into the substrate.

In view of the above-mentioned problems, the present invention simplifies the manufacturing method and improves adhesion by continuously extruding the substrate composition and transferring it while supplying the heat insulating material composition to the upper surface and curing it integrally. In addition, it is intended to use a hydraulic inorganic material It as the main ingredient of the heat insulating composition to increase the -C combustion efficiency, and to add expanded polystyrene beads and a foaming agent to achieve heat insulating properties and weight reduction.

[Structure of the invention]

(Means for Solving the Problems) The present invention provides a method for preparing a substrate composition consisting of a hydraulic inorganic material, an aggregate, a lightweight aggregate, a fibrous substance, a fluidity modifier, and water, after which a set of screws is completely emptied. A continuous substrate molded product is continuously extruded using an extrusion molding machine to form a continuous substrate molded product having a concave shape with a flat cross section in the width direction and integrally formed with connecting structure parts that are connected to each other on both sides in the +iJh direction. 100 parts of the molded product is fed and transferred to the continuously transferred pallet 1, and the following (F3) is added to 100 parts of the slurry having the following composition in the recess on the transported continuous substrate molded product. Insulating material composition mixed with foaming liquid 10-50 parts by weight Water 100 parts by weight Same hydraulic hardness as the substrate composition + 1 Inorganic material 50 300 horns Light weight siliceous bone 10-ioon primary foaming Polystyrene beads 1-10I! (B) Water 100
Single crop foaming agent to 001, 0
11I gas film stabilizer 1-5 JJ
Aqueous synthetic resin 1 to 5 11 is continuously supplied and filled, and then the continuous substrate molded product transferred is cut into a certain length together with the filled insulation material composition, and then steam-cured/1, A- -1 ~ By applying crepe treatment and integrally curing, expanded polystyrene beads are melted into GIJ.
Teλ'>II! ,! This person 9 changes into a shaped hollow balloon.
The membranes each have a hollow hole formed between each independent polystyrene waterproof membrane to provide insulation and freeze-thaw resistance. Then, the heat insulating material composition is continuously supplied to the substrate molded product which is continuously extruded and transferred from the extrusion molding machine, and the heat insulating material composition is integrated with the substrate molded product to avoid cutting and curing. Furthermore, the same hydraulic inorganic material as the substrate composition is added to the insulation material composition to strengthen the bond between the substrate and the insulation material, and polystyrene beads and foaming liquid are added to the insulation material composition to create an independent The aim is to increase the porosity to improve heat insulation and reduce weight.

The substrate composition usually has a cement-based or hydraulic inorganic material such as silica stone, lime, or gypsum slag as a main component, and also contains aggregates such as silica stone, lightweight aggregates such as perlite, and inorganic materials such as asbestos.
H or synthetic fibers, a fluidity modifier such as Medilcel [1-S], and water, and a conventional two-stage screw set vacuum extrusion 1
1, which is blended with an extrudable blending ratio, is as follows.

Formulation example of substrate composition Cement l-100/E Okabe silica sand 10
0〃Ballai 1~301I Asbestos 5
Weight part synthetic fiber Q, 5
n Medyl cellulose 1 water
38
As shown in Fig. 1, the above composition except for water is sequentially charged into a dry disintegration device 1, and after thorough mixing, the composition is dropped into a kneader 2 such as a kneader, and water is added at the same time. After sufficient cross-mixing, extrude the cross-wire material using a two-stage screw set 11
When fed to the upper hopper 4 of 3, the supplied material is 1
It is pumped by the stage screw 5, degassed in the empty chamber 6, and continuously extruded through the die part 8 by the second stage screw 7. As shown in FIG. 2, the extruded continuous substrate molded product 9 has a concave shape with a flat cross section in the width direction, and connecting structure parts 11 and 12 such as solid parts and recessed parts are integrally formed on both sides in the 1] direction. It is formed. This molded product 9 is moved on an inclined conveyor 10 to pallets 1 to 1 on which separately supplied molded products 9 are loaded.
Transferred to 13. The molded products 9 move on the conveyor 14 while being continuously loaded on pallets [13]. During this continuous movement, a heat insulating material composition 17 is supplied from above to the recess 16 on the upper surface of the molded article 9 from the heat insulating silk composition supplying device 15. After filling the recess 16 of the molded product 9 with the heat insulating material composition 17, the molded product 9 and the filled insulating material composition 17 are cut into the cutting machine 1.
After being cut to a predetermined length by 8, the pallets 17 are stacked together by a stacking device 19. The molded product 9 is put into a pallet together with the heat insulating material composition 13 at room temperature or at 50~50℃.
After being pseudo-condensed to a state where it can be demolded by steam curing at around 70°C, the pallet 13 is separated and subjected to a curing reaction in an autoclave 20 at 120 to 165°C under heating and pressure, and then taken out. The temperature, pressure, and time are controlled by the composition of the heat insulating material composition 11, which will be described later, and especially by the heat decomposition resistance and humidity of the synthetic resin liquid. Desirably, a temperature of about 165° C. gives favorable results in terms of manufacturing strength and the like.

As described above, the recess 1 of the substrate 9a is formed as shown in FIG.
Product a 19 is obtained by integrally bonding a heat insulating material 17a to 6a. Furthermore, coupling structures 11a and 12a are integrally formed on both sides of the substrate 9a in the 1] direction.

The surface of the substrate 9a may be patterned with a pattern 31 as shown in FIG. 4, or the substrate 9a may be formed into a hollow body.

The heat insulating material composition 17 supplied from the supply device 15 consists of a slurry and a foaming liquid, and an example of the composition of the slurry is as follows.

Water 100 parts by weight Cement 1~200 Silicon das 1~
50〃-Subexpanded polystyrene beads (60
3 times the foaming) The above-mentioned formulation is operated in a conventional mixer 21 as shown in FIG. 1 to form 1 q of slurry.

This slurry is mortar-like,
Coupled with the addition of the foaming liquid described later, the continuous substrate molded product 9
The ratio of each component is adjusted to maintain the fluidity of the surface leveling bamboo after filling the molded product 9, such as the supply pressure from the supply device W 15 during the taking process. 12 is made variable. t17
When the straw moisture content is more than 3.0 parts, the slurry loses its shape.
When the foaming liquid described later is mixed, it is filled into the recess 1G of the molded product 9 and used for leveling.
Bubbles tend to disappear.

In addition, silicon dust 1~ (or silica top 1~), etc.
Si 92 min is 95% or more, and since it is pumice, amorphous, and fine powder, its reactivity with cement is extremely rapid, and when heated and cured in an autoclave, 5iQ2 is quickly supplied to the CaO content of cement 1. , which plays the role of creating a strong calcium silicate salt.

Usually silicon dust during ferrosilicon production is Si
02 minutes is 98% or more, and fiff against cement
The i ratio is approximately 20%, and the amount added is determined by the content of 5iQ2 in the composition. S i like crystalline silica sand
Although 95% or more of 02 min is supplied on the market, it has a heavy specific gravity of 27, which increases the specific gravity of the composition, which goes against the weight reduction that is the objective of the present invention. Furthermore, the addition of silicone dust helps to adjust the viscosity of the slurry, and also has the effect of preventing the foamed polystyrene beads added later from floating due to the difference in specific gravity.

For expanded polystyrene beads, the diameter of the primary expanded beads is 3#.
I#I or less is desirable, and a high-magnification foam is selected for weight reduction. Normally, primary foam beads have a diameter of 3# and a maximum secondary foaming ratio of approximately 70 to 80 times.
With foamed beads of size M or higher, the beads swell up after being filled with the composition, making it difficult to form a flat shape, and many pores are formed on the surface due to the molten foamed polybrene pieces.
2E, l-Disturbance occurs in appearance.

Examples of the formulation of the foaming liquid to be added to the above slurry are as follows.

Water 100 parts by weight Foaming agent (radium polyol-1-diethylene alkylene-1-)
Q, i in gas film stabilizer (methylpropylethylcellulose)
15 n Aqueous synthetic resin (acrylic resin emulsion solid content 30%) 5
I+ The above composition is mixed in the mixer 22 shown in FIG. 1, and then this mixed liquid is sufficiently foamed in the air-entraining foaming machine 23 to produce a creamy foamed liquid. Various types of foaming machines are used as the foaming machine 23, and the foaming machine shown in FIG. From the pressurized air supply hole 27, the foaming liquid is in the form of fine bubbles (average diameter is about 20 μm).
It is extracted as a cream.

As foaming agents, among the usual various surfactants, polyoxy-blene alkyl ether or polyethylene glycol fatty acid ether sodium salt, sodium alph-7 olefin sulfonate, etc. are used, and they have as few double bonds as possible and are resistant to It needs to be an alkaline compound.

In addition, to prevent these fine bubbles from combining and forming large bubbles, a gas film stabilizer such as C, M, C, methylcellulose, methylpropylcellulose, casein, gum arabic, etc. is added. . The amount added is limited to 5 parts by weight,
If it is more than this, the connection of air bubbles will be promoted and dispersion will be impaired. Furthermore, a water-soluble or emulsion type water-bearing synthetic resin such as alkali-resistant acrylic, urethane, or PVA is added to strengthen the gas film and improve the waterproof property of the gas film after curing. This resin liquid mixes with the gas film and has the role of maintaining the waterproof property of the cured foam. However, this addition amount is also 5
The limit is about 1 part by weight of melon; adding more than this increases the viscosity, does not increase the effect, and is economically disadvantageous. Usually, by adding these foaming agents, foaming stabilizers, and waterproofing agents, the raw foaming liquid is foamed into a foam cream that is 10 to 20 times finer in the foaming process. This was added to 100 parts by weight of the slurry,
Approximately 50 parts by volume are mixed in with the mixer 18. Fill the voids between the secondary foamed polystyrene balloons with approximately 50 parts of this mixed volume. enough to do.

The heat insulating material composition 11 made of this slurry and foaming liquid is fed to the heat insulating material composition supplying device 15 in FIG. 1 by a method such as air pressure feeding.
The composition 17 in the form of a slurry may be supplied using a single shaft or parallel multi-shafts and smoothed into a flat surface as the molded product 9 advances using a metal spatula, rotating roller, or the like. At this time, the molded product 9 is also in a moist state, and the heat insulating material composition 17 is also an aqueous fluid, so it blends well, and since both are based on the same type of hydraulic inorganic material, they become one solid body after curing. Glue.

The substrate molded product 9 filled with these heat insulating material compositions 17 is left at room temperature together with the loaded pallet 13, or
After curing and curing in steam at ℃ and pseudo-condensation, pallet 1
3 is removed, and the molded product 9 is subjected to a curing reaction together with the heat insulating material composition 17 in O-1 to crepe 20 at high temperature and high pressure. As mentioned above, the temperature and pressure of this Ohmy crepe 20 are controlled by the heat resistance of the waterproof resin liquid in the foaming liquid, but the pressure increases from 120 to 165 at 6.5 atmospheres to increase the strength of the molded product 9.
C. melon is preferred.

At this time, the primary foamed porous foamed polystyrene beads 28a as shown in FIG.
As shown in the figure, the closed-cell balloon 28 is made of a waterproof membrane and has the functions of being waterproof, insulating, and lightweight. The waterproof property of the balloon 28 prevents the product from cracking due to freezing and thawing of water. 30 are fine bubbles formed by the foaming liquid.

(Function) In the present invention, the same hydraulic inorganic material is used for the substrate composition and the heat insulating material composition, and the wet molded product formed by molding the board composition is filled with the slurry-like heat insulating material composition. The bond between the insulation materials becomes stronger.

In addition, by blending primary foamed polybream peas and a foaming liquid in the heat insulating material composition, the foaming liquid uniformly disperses fine bubbles in the slurry, and the slurry becomes cream-like with a light viscosity, Works to uniformly disperse expanded polystyrene beads without lifting them. The uniformly dispersed polystyrene foam beads are heated and melted into a balloon, forming a hollow body that covers the polystyrene waterproof membrane, giving the product lightweight, heat insulation and waterproof properties. This waterproof property prevents the infiltration of moisture and prevents the occurrence of cracks due to freezing and thawing of moisture. The slurry of the thermal insulation composition contains 50 to 300 parts by weight of a hydraulic inorganic material to 100 parts by weight of water to maintain fluidity and prevent bubbles from disappearing when mixing the foaming liquid. 10 to 100 parts by weight of bone-containing particles are suitable for reacting with inorganic materials to produce calcium silicate, and 1 to 10 parts by weight of primary foamed polystyrene beads are used to fill the recesses of the substrate with the heat insulating material composition. The mixing ratio is such that the beads do not protrude from the heat insulating layer. Regarding the foaming liquid, if the film stabilizer exceeds 5 parts by weight, the dispersibility of the bubbles will be impaired, and if the aqueous synthetic resin exceeds 5 parts by weight, the viscosity of the foaming liquid will increase and the foaming performance will be hindered. Ru.

(Example) A substrate composition having the following composition was prepared by Mikami T-gyo Co., Ltd.
A die was attached to an IT 200 type extrusion machine, and after extrusion molding at a rate of 6 m, a continuously moving stainless steel pallet was taken up.

Wed 30 Jumonbu Port 1
Helland Cement 35! I silicon sand
35 II Pepperite 25 n Asbestos Cotton
5 rr Methyl cellulose 111-17 = Synthetic fiber H, 0.5 parts by weight Paddle Me 1-(, J-T- A slurry as a heat insulating material composition of the following composition was prepared in a similar manner to υ11.

water ioo heavy goods port]・
Landsemen h 230 no! Silicon Hicom Das 10.1 Primary expanded polystyrene beads (expanded 60 times) 10, Water reducing agent (polycarboxylate) 1.

Next, a foaming liquid-C with the above formulation was prepared.

water 10
0 Φ Placement foaming agent 01
n Mebruzel [1-s 1 Acrylic resin emulsion (30% solids) (solids)
15JJ) Polydynylfurnyl 1-l (10% solid content) I (solid content Q, !l IT) To Melmen 1 (melamine resin cotton mixture) 2 jtiJi part This foaming liquid is foamed 15 times through a foaming device. At least 50 parts by volume are added to 100 parts by weight of the slurry and stirred to produce a heat insulating material composition. This heat insulating material composition is poured into a recess on the upper surface of a molded substrate that is being picked up and transported and cut into an appropriate length. After leaving at room temperature for 6M and curing in steam at 50°C for 6 hours, the molded product filled with the heat-insulating composition was placed in an autoclave for 140C.
A zaiding product was obtained by curing at ℃. This product is JIS
It passed the first grade (noncombustible material) after testing in the flame retardant test method for building interior materials and construction methods of ^1321. Also J I
Passed the second class heating test (fireproof structure) according to SA1301 fire prevention test method for wooden parts of buildings.

Also, the weight, nailing properties, and sawing properties were all good.

〔Effect of the invention〕

According to the present invention, the substrate composition is continuously extruded, and after filling the transitional continuous substrate molding with the insulation composition, the continuous substrate molding is cut together with the insulation composition, and then steam-cured. Since the substrate molded product is not cured together with the heat insulating material composition by autoclaving, the manufacturing method can be greatly simplified and the manufacturing time can be shortened compared to the method of molding and curing the board and the heat insulating material separately.

In addition, since the base material of the heat insulating material composition is made of the same hydraulic inorganic material as the base material of the substrate composition, the adhesion between the two is good. Because it contains liquid, it prevents the foamed polystyrene beads from rising, and the foamed polystyrene beads expand when heated to form an independent waterproof balloon. 1!7 can be done.

[Brief explanation of the drawing]

Fig. 1 shows an embodiment of the present invention, and Fig. 2 is a sectional view of the same substrate molded product, and Fig. 3 is a perspective view of a part of the product produced by the method of the present invention. , FIG. 4 is a perspective view of a part of a product according to another example, FIG. 5 is a side view of a foaming machine used in the method of the present invention, and FIG. 6 is a view of one of the insulation compositions of the present invention. FIG. 7 is an enlarged view of a part of the heat insulating material obtained by the method of the present invention. 2... Extrusion molding machine, 9... Substrate molded product, 13... Pallet, 16... Recess, 17... Heat insulating material composition, 20... Autoclave, 28a... Expanded polystyrene beads,
28. Polystyrene balloon. 1N Opened in 1982-1130G (7) Tewa ° C Neyama i Ding Invitation (Voluntary) OO month 19, 1985 1, Display of the case Showa 61 Nail Patent Application No. 157131 2, Name of the invention Nonflammable, lightweight, Insulation Redding Manufacturing Method 3, Relationship with Person Making Amendment F1 Special II'r Applicant NE1BELLENTER 4 Co., Ltd. Agent Totaku 4-1 Shinjuku, Shinjuku-ku, Tokyo] 3-22 (Ando Building) Telephone 03-3! 12-15 (ii (generation) 5, Amendment Order Roy-, 1 to 6, Subject of Amendment Specification Yamanaka [Detailed Description of the Invention] σ
) column. 7. Contents of the amendment <1) The word "silica stone" on page 7, line 9 of the specification has been replaced with [
"Silica (amorphous fine grain)" is corrected. (2) On page 7, line 11 of the specification, 1 silica stone 1 is corrected to ``silica stone (silica sand).'' (3) "Maintain fluidity" on page 10, line 16 of the specification
Masa Tomari says, ``Maintain liquidity.'' (4) On page 10, line 18 of the 11th Meiji edition, there is “fluid state”.
Correct the statement to read "liquidity". (5) In the first line of page 19 of the specification, the phrase "1 melamine resin line mixture" is corrected to read "melamine resin condensation material." . (6) In the first line of page 19 of the specification, the phrase ``In order to include 1'' should be revised to ``In order to include.''

Claims (1)

[Claims] (1) Hydraulic inorganic materials, aggregates, lightweight aggregates, fibrous materials,
After kneading a substrate composition consisting of a fluidity modifier and water, the substrate composition is continuously extruded using a screw-type vacuum extruder, and the cross section in the width direction is flat and concave, and the connections are bonded to each other on both sides in the width direction. A continuous substrate molded product having a structural part integrally formed therein is formed, and this continuous substrate molded product is fed onto a pallet that is continuously transferred and transported, and the following is placed in a recess on the transported continuous substrate molded product. A heat insulating material composition prepared by mixing 10 to 50 parts by volume of a foaming liquid of the following formulation (B) with 100 parts by weight of the slurry of the formulation (A) (A) Water 100 parts by weight Same hydraulic inorganic as the substrate composition Material 50-300 Lightweight siliceous aggregate 10-100 Primary expanded polystyrene beads 1-10 parts by weight (B) Water 100 Parts by weight Foaming agent 0.01-0.1 Film stabilizer 1-5 〃 Aqueous synthetic resins 1 to 5 〃 are continuously supplied and filled, and then the continuous substrate molded product transferred is cut into a certain length together with the filled insulation material composition, and then subjected to steam curing and autoclave treatment. A method for manufacturing non-combustible, lightweight, heat-insulating siding, which is characterized by integrally curing and melting primary expanded polystyrene beads to form balloons.