JPS6354672B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to lightweight panels for use in building materials and the like. In the present invention, an inorganic foam is mixed into a kneaded mixture of an aqueous alkali silicate solution, silica powder, kaolin, white carbon, alkali silicofluoride, and a phenolic resin emulsion, which is then molded into a panel shape and heated. The first invention is a lightweight panel obtained by curing, and in this first invention, a sheet such as a thin iron plate, plywood, slate board, etc. is adhered to one or both sides of a molded panel, and this is heated. Two lightweight panels are placed in a furnace or high-frequency heating furnace, heat-cured, and molded into one piece.
This invention is intended to be provided as the second invention.

In this invention, the aqueous alkali silicate solution refers to sodium silicate, potassium silicate, etc., and the alkali silicate fluoride refers to sodium silicate, potassium fluorosilicate, etc.
Inorganic foam refers to foams such as perlite, vermiculite, and shirasu balloons.

It has been known to make lightweight panels by adding inorganic foam to water glass as the main material and heat-molding the mixture. However, this material is unsatisfactory as a building material because it has low strength, is susceptible to water, and causes efflorescence due to alkali elution over a long period of time, corroding other members.

The present invention eliminates the above-mentioned drawbacks, and the inorganic foam is mixed into a kneaded mixture of an aqueous alkali silicate solution, silica powder, kaolin, white carbon, alkali silicofluoride, and phenolic resin emulsion, and after panel molding, heating is performed. A lightweight panel is formed by firmly adhering the inorganic foams to each other.Furthermore, in order to give the surface of the lightweight panel a beautiful appearance and increase its strength, thin iron plates or plywood are applied to one or both sides of the panel after molding. , a lightweight panel is manufactured by bonding sheets such as slate boards and heating and curing them to form a single body.

In manufacturing this lightweight panel, appropriate amounts of the above inorganic and organic materials (the amounts are shown in the examples) are used.
A muddy slurry is obtained by mixing and kneading until it becomes homogeneous, but after forming this into a sheet or block shape and heating it in a heating furnace at 180℃ to 200℃ for 10 to 20 minutes, it becomes a slurry. acid alkali and silica powder,
The five components of kaolin, white carbon, and alkali fluorosilicate cause a complex chemical reaction to produce a ceramic-like compound, and the surface is coated with a thin film of phenolic resin emulsion, which unites the particles of the inorganic foam. As it grows, it eventually solidifies into one piece.

Therefore, the present invention has the following effects.

Since the main material is inorganic, it has excellent fire protection and fire resistance, and the presence of a small amount of organic matter further increases the strength, particularly the toughness. Therefore, damage during transportation is significantly reduced.

It has particularly excellent water resistance and prevents alkaline elution from the main material, so it will not cause any adverse effects such as corrosion on other components even after long-term use.

When a sheet is attached, the surface shape becomes beautiful and the strength increases.

The manufacturing method is simple, consumes little energy, and can be made using inexpensive materials and simple equipment, so it is suitable for mass production and can be manufactured at low cost.

[Example 1] Water glass No. 3 100 parts by weight Silica powder 10-20 Kaolin 5-10 White carbon 2-5 Soda silicofluoride 7-14 Phenol resin emulsion (Mitsui Petrochemical)
1-4 〃 Expanded pearlite (diameter 3 mm) 400-600 c.c. Thoroughly knead the above materials, make a muddy slurry, form it into a panel shape with a thickness of 3 cm, and then heat it in a heating furnace for 180 c.c.
A lightweight panel was obtained by heating and solidifying at ℃ for 10 minutes.

This panel has specific gravity 0.51~0.59 compressive strength 15~18
Kg/cm ² , there were no abnormalities in the 2-hour boiling test, and good results were shown in the freeze-thaw test.

[Example 2] A kneaded material with the same composition as in Example 1 was prepared, poured onto a thin iron plate (thickness 0.3 mm) whose back side was coated with emulsion and installed in a mold, and after pressure molding, It was taken out from the mold and heated and solidified in a heating furnace at 180°C for 10 minutes to obtain a lightweight panel. This panel has a strength of 18 to 23 kg/cm ² and a specific gravity of 0.70 to 0.72.
There were no abnormalities in the 2-hour boiling test, and good results were shown in the freeze-thaw test.

In addition, as another application example of the present invention, it is possible to make the following panel.

(1) After manufacturing this lightweight panel, a plastic foam such as urethane foam is attached to one side to a certain thickness. This material has particularly excellent heat insulation properties, and has excellent impact resistance and waterproof properties.

(2) The surface of the inorganic foam material is coated in advance with a plastic emulsion, and then a lightweight panel is produced in the same manner as in Example 1. This is particularly effective when the surface skin layer is a porous and brittle inorganic foam, the foam is strengthened, there is no slurry penetration, and an excellent panel can be obtained.

(3) A panel formed by inserting a wire mesh in the middle of the wall thickness when molding the same panel as in Example 1. This panel provides significantly increased flexural strength and impact resistance. Further, as an example of this application, a paper honeycomb may be inserted instead of the wire mesh, and the holes of each honeycomb may be filled with slurry, and the same effect can be obtained.

(4) Since the amount of phenolic resin emulsion mixed in the material is small, the amount of smoke emitted when the panel is scorched is very small. However, when using it for applications where smoke generation is particularly objectionable, fumaric acid, molybdenum powder, etc. It is only necessary to add a low-smoke agent of 100%, and the panel thus obtained will hardly emit smoke when exposed to fire.

(5) Mix a few percent of inorganic fibers such as asbestos and rock wool, or organic fibers such as cotton, linen, and nylon into the slurry. The resulting panels have bending strength,
A product with excellent impact resistance can be obtained.

(6) Even when the various application examples mentioned above are combined, panels with excellent characteristics can be obtained.

As described above, the lightweight panel of the present invention has excellent strength, impact resistance, water resistance, etc. due to the synergistic effect of the characteristics of the main inorganic material and the advantages of the phenolic resin. We can provide excellent building materials with unique characteristics.

Claims (1)

[Scope of Claims] 1. An inorganic foam is mixed into a kneaded product obtained by adding silica powder, kaolin, white carbon, alkali silicofluoride, and phenolic resin emulsion to an aqueous alkali silicate solution, and this is molded, A lightweight panel made by heating and curing. 2. At least one side of a panel made by mixing an inorganic foam into a kneaded mixture of an aqueous alkali silicate solution, adding silica powder, kaolin, white carbon, alkali silicofluoride, and a phenolic resin emulsion, and molding the mixture. A lightweight panel made by attaching a sheet such as a metal plate or plywood to a metal plate, heating and curing it and molding it into a single body.