KR100760039B1 - Manufacture method of quick setting light weight bubble cement which superior to insulating effect - Google Patents

Abstract

A method for preparing fast setting low-weight aerated cement foam is provided to obtain cost-efficient aerated cement requiring no high curing temperature or long curing time and having excellent heat insulation and noise-protecting effects. A method for preparing fast setting low-weight aerated cement foam comprises the steps of: diluting and mixing an animal foaming agent or vegetable foaming agent in and with water to produce fine foam; adding cement and ceramic powder with the fine foam to obtain fine foamed cement slurry; introducing the slurry mixture into a structure or space having a desired shape for receiving low-weight aerated cement foam, and further introducing a fast setting agent thereto to perform casting of low-weight aerated cement foam; mixing the low-weight aerated cement foam with a water resistant reinforcing agent or an additive for improving water resistance; and heating the foam to perform coating of the agent or additive onto the foamed ceramic surface through heat fusion.

Description

Manufacture method of quick setting light weight bubble cement which superior to insulating effect.}

1 is a schematic process diagram for producing a lightweight foam cement for quick quenching through the cement quenching step of the slurry of cement comprising an aqueous solution and cement and an additive foamed by the foaming agent.

Figure 2 is a photograph taken after immersion in water for 30 days to confirm the water resistance and closed cells of the quick-bubble lightweight foam cement foam obtained through an embodiment of the present invention.

The present invention relates to a method for producing lightweight foam cement foam for fastening excellent heat insulation and soundproofing, and more specifically, to include a vegetable or animal foaming agent in an aqueous solution to foam first, by adding cement and additives to the microporous When the cement slurry is prepared, and a supply step for cement quenching is provided, the foam of slurry cement is quenched without disappearing to harden at room temperature while maintaining the original shape of the foam so that a large amount of fine foams are formed. It relates to a method for producing a cement-based light-weight foam cement foam.

Unlike the conventional foam ceramic or foamed cement (ALC) manufacturing method of the present invention, the foam ceramic manufacturing method does not require a long curing process or a very high temperature, and provides a lightweight foam cement of a constant shape in a very short time even at room temperature The present invention relates to a method for manufacturing a quick foaming foam article for foaming which can be replaced with a foamed resin such as a conventional styrofoam or a foamable polyurethane by obtaining an excellent foaming cement having excellent thermal insulation and sound absorption effect.

Energy is a necessity in almost all economic activities, of great importance for industrial production and transportation, commerce and household use. If the supply and demand of energy sources is not smooth, the ripple effect on the global and domestic economies will increase. For example, an increase in the price of oil spreads to all economic activities, slowing industrial activity and consequently slowing economic growth. In addition, the amount and amount of energy consumed in the country is large, and the energy-related industry accounts for a large portion of the industrial structure. And modern useful energy sources depend mainly on fossil fuels. Since these fossil fuels are limited, it is more important not only to save energy, but also to reduce energy losses through the use of good insulation methods.

Therefore, about 30% of Korea's total energy consumption is achieved through buildings, so thorough insulation construction is essential for eliminating energy waste factors through buildings, and noise is psychologically impaired in thinking capacity, disturbed in rest and sleep, and in dialogue. Obstruction, disruption of healthy daily life, physiologically increased fatigue, impatience, difficulty in mental concentration, increased energy consumption for work, decreased gastric juice secretion, cardiovascular effects, decreased salivation, As it may affect autonomic nerves, endocrine system and sleep disturbance, insulation and sound insulation are necessary to maintain comfortable and comfortable living space, and minimizing the heat energy required in the process of manufacturing insulation and sound insulation is Worth as.

Conventionally, in order to maximize the thermal insulation effect, ceramics or foamed polymer materials with fine porosity are used alone, or porous ceramics formed with air layers and sound absorbing materials that absorb noise are used together to increase the sound insulation effect. This is because the air layer itself formed on the foamable material has excellent heat insulation and sound absorption effects.

Conventional insulation and sound insulation materials use foamed polystyrene, glass wool, foamed polyethylene, polyurethane foam, vermiculite, perlite, urea foam, cellulose insulation, soft fiber board, phenol foam and aerogel and lightweight cement, but foamed In the case of polystyrene, it has high insulation and light weight, and has excellent transport and construction. However, it has a high risk of ignition or toxic gas in case of fire due to its high safety operating temperature of 70 ℃. In this case, the air layer sealed between the glass fibers is a heat insulating layer, which is excellent in incombustibility, sound absorption, workability, and transportability as well as heat insulation, and there is no fear of lowering the effective thickness due to compression or settlement, and lowering of heat insulation due to water, but there is no moisture permeability. Has the problem that installation is necessary, and in the case of expanded polyethylene The foamed and flame retardant is blended with the methylene resin and extruded and foamed, and then laminated with the cooled foamed laminating agent. The thermally conductive plate and thermostat are manufactured to be self-extinguishing.Then, the thermal conductivity at the average temperature is 0.039 kcal / mh ° C or lower. Although the effect is excellent, it has the problem that it can be fatal to human body due to the emission of toxic gas in case of fire at the maximum safe working temperature of 80 ℃.

In case of polyurethane, polyol, polyisocyanate, foaming agent, and additives for flame retardancy are the main raw materials.Thermal insulation and sound insulation of foamed polyurethane foam (independent bubble structure), heat resistance (highest safety use) It is suitable for cold insulation materials such as refrigeration equipment because it has better insulation than temperature (100 ℃), but it has the disadvantage of decreasing volume after construction and lowering thermal conductivity. Also, in case of fire, toxic gas is released like other foaming polymer materials. In the case of vermiculite, it is a mica-based ore that is a porous, mineral-fired mineral at temperatures above 1000 ° C. It has the advantage of insulation, insulation, non-combustibility, soundproofing, and condensation prevention. It is calcined and expanded by calcining at 1200 ℃, and it is composed of small particles of light spherical shape having micropores inside. It is used as light weight aggregate and insulation material, so it is effective for insulation, insulation, and sound absorption, but it has the problem that high energy of 1,000 ℃ or higher is required to foam minerals such as vermiculite and perlite. Phosphorus structures are entangled like cotton candy, so that the air hole occupies 95% of the total volume, so the insulation and soundproofing effects are very good, but they are very expensive and are limited in some high-tech industries.

In the case of lightweight cement, it is possible to provide a foam with economical cost because cement is used as an inexpensive binder. However, in order to manufacture lightweight cement, it is necessary to cure in a high-temperature, high-pressure reactor (autoclave) to manufacture lightweight cement. In order to not only increase the economic burden on the installation cost but also high heat energy is required to cure the foamed cement, there is a problem that a long time is required for curing the cement. In particular, in the case of lightweight cement, when foamed cement in slurry state, which is not cured, is directly applied to the wall of a building structure such as an apartment, the cement foam that has already been foamed may take several days or tens of days. It is not only able to provide lightweight foam cement for insulation and sound insulation, but also has the disadvantage that the compressive strength is significantly lowered after complete hardening because the cement hardening and defoaming occur at the same time. .

As such, the foam material, which has been developed and provided as a heat insulating material and a soundproof material, has a high risk of causing fatal harm to the human body due to the release of toxic gases in the event of a fire, as well as accelerating environmental pollution. In the case of lightweight foam cement, large-scale facility system is needed, high temperature process is required or long-term treatment process is required in manufacturing process, and construction work for insulation and soundproofing is placed on the work site, so energy loss is not only high but also productivity is high. And workability is very poor.

In particular, in the case of foamed ceramics, a large amount of equipment cost is required for forming a mold in order to perform compression molding, or it has a disadvantage of using expensive raw materials such as aerogels. And as a soundproofing material is being applied to a limited number of fields.

In order to solve the above problems, the prior art data that have been researched to provide a porous lightweight structure for insulation and soundproofing materials have been studied. In Korean Patent Laid-Open No. 2006-0092782, pulverized foamed vermiculite, pearlite, obsidian, and pine stone Various foamed ceramic particles are included or mixed alone, one or more kinds of inorganic adhesives including gypsum, cement, clay, sodium silicate, unfinished gel silicate, sodium silicate cement, etc. are mixed. It is proposed a method of manufacturing ceramic foam moldings, which are manufactured by mixing fiber sulphate, paper crushed product (including powder type), glass wool (glass wool), or by attaching a wire mesh or synthetic resin network inside, and providing a durable ceramic foam molding. In 2003-0086955, natural vermiculite is heated at a high temperature to interface with expanded vermiculite formed with voids. Using airborne lauryl alkylbenzene sulfonate-based materials, the air density is controlled to about 40 to 50 kg / cm2, and the resulting bubbles, cement slurry, and expanded vermiculite are mixed so that they do not burn in the event of a fire. Non-combustible lightweight foam concrete sandwich panel is proposed considering the building's exterior wall finishing and heat insulation without release, and Korean Patent Publication No. 2000-0060707 is light weight obtained by curing with steam curing or high temperature and high pressure steam by adding foaming agent to cement, lime and siliceous fine powder. The soundproof panel which uses foamed concrete as a sound absorption material is proposed.

In Korean Patent Laid-Open Publication No. 2006-0092782 of the proposed patent publication, it is possible to provide insulation by air layers included in ceramics, but various rocks including natural materials, such as vermiculite, pearlite, obsidian, and pine stone, may be used to manufacture foamed ceramics. Grinding to the desired size, and the crushed particles must be heated to a high heat of 800 ~ 1400 ℃ high heat energy for producing a foamed ceramic, has a disadvantage in that a lot of equipment cost for manufacturing, also foaming Since the ceramic particles are only mixed with an inorganic adhesive including gypsum, cement, clay, sodium silicate, unfinished gel silicate, sodium silicate cement, etc., there is a problem in that it cannot be poured directly at the construction site.

Korean Patent Laid-Open Publication No. 2003-0086955 of the above patent provides excellent foaming power by surfactants and economics by using cement as an inorganic binder. Looking at the embodiment, curing time for forming a hardened body of lightweight cement is It takes a long time of 1 to 2 days, so the productivity is very low, and when it is placed on the wall of the building structure using the proposed method, it does not harden immediately. The problem is that it cannot be poured directly in the field.

Korean Patent Publication No. 2000-0060707 of the above patents can provide a light-weight concrete with a porosity can be excellent sound absorption effect, but because the foamed concrete must be cured by steam curing or steam of high temperature, high pressure The equipment cost and operating cost of equipment, and a lot of time during the curing process has the disadvantage of inadequate economics, and this also has a problem that can not be poured directly at the construction site because it does not harden immediately after pouring on the wall.

Therefore, the present inventors are products for replacing the foaming resin of petrochemical products with the conventional insulation and sound-absorbing material, in order to avoid fatal casualties due to the release of toxic gas in the event of fire, including the vegetable or animal foaming agent in an aqueous solution to foam first, By adding cement and additives to the cement slurry in the form of microporous cement, and providing a supplying step for cement quenching, the cement foam in the slurry state does not disappear and quenches and maintains the foamed shape. In order to provide a cement-based fastening lightweight foam cement foam having a large amount of micro-foam formed.

Lightweight foam cement foam for quenching of the present application does not require high temperature and high pressure steam curing and heating process as in the case of manufacturing conventional lightweight foam concrete, by providing a large amount of fine lightweight foam concrete of a certain form at room temperature Lightweight foam cement foam can be manufactured by simple manufacturing process with excellent insulation and soundproofing effect, and can be poured directly on the wall of building structure at work site. Has the purpose to provide.

The present application is more economical than the invention filed in the process of applying for the applicant's prior application (name of the invention: foamed ceramic manufacturing method and foamed ceramic manufacturing method with excellent insulation and sound insulation effect) in various fields. In order to improve the physical properties and confirm the results of the research to further increase the productivity, the present application, the present invention does not require high temperature and high pressure steam curing and heating process in the process of manufacturing lightweight cement, any other process It can be installed directly on the wall of the building without going through it, and it is confirmed that it is possible to obtain a lightweight foam cement foam for quick quenching with excellent heat insulation and sound insulation effect that can replace the foamable resin which is a conventional petrochemical product by a simple manufacturing process in a short time. Invention.

In addition, another object of the present invention has the object of using the quick-bubble lightweight foam cement foam of the present application in the construction field requiring a lightweight support while requiring the physical properties and thermal insulation and sound insulation of the ceramic.

The present invention relates to a method for producing lightweight foamed concrete foams for quick quenching having excellent thermal insulation and soundproofing, and more specifically, to include a vegetable or animal foaming agent in an aqueous solution to foam first, and to add cement and additives to the microporous When the cement slurry is prepared, and a supply step for cement quenching is provided, the cement foam in the slurry state is rapidly removed and rapidly cured at room temperature while maintaining a foamed shape, thereby forming a large amount of fine foams. Has a technical idea of a method for manufacturing a cement-based light-weight foam cement foam.

One embodiment of the present invention for implementing the above technical concept is briefly mentioned, first of all, in order to prepare a foam, a mixture of vegetable or animal foam is mixed with water to dilute and disperse a large amount of the mixture in the mixture. A preliminary foaming step of forming microbubbles; Mixing cement and additives to the prefoam to obtain a foamed slurry cement mixture, wherein the mixture maintains the foam shape and provides cement quenching to prevent flow after a certain time; It characterized in that it comprises a light-bubble foam cement foam for excellent fast insulation excellent sound insulation and sound insulation effect.

Hereinafter, a detailed application example for implementing the technical idea of the present application will be described in detail.

The foaming agent used in the step of preparing the foam is diluted with water alone or after mixing a foaming agent based on an amino acid system called an animal foaming agent and an alkylbenzene sulfonate type or sodium lauryl sulfate and an ester thereof called a vegetable foaming agent. Can be used.

At this time, tap water, ground water, and industrial water can be used without special limitation, except for water containing a large amount of alkaline earth metals, which is the cause of hard water, in the mixing step of water and blowing agent.

The foaming agent may be advantageous to use an animal foaming agent in order to maintain the foamed foam for a long time without foaming, it may be advantageous to use a vegetable foaming agent to avoid the odor generated by the foaming agent itself during the foaming process.

The addition amount of the foaming agent may be added 0.1 to 10 parts by weight based on 100 parts by weight of water, preferably 0.25 to 8.5 parts by weight, more preferably from 0.5 to 7.5 parts by weight of the foaming agent When the content is less than 0.1 parts by weight, the foaming power is low, so it is unlikely that a fine porous bubble is formed. When the foaming agent is diluted to more than 10 parts by weight, a large amount of fine bubbles can be formed, but the foaming agent is Since it is composed of organic materials, not only the bonding strength with ceramic powder is lowered, but also a large amount of toxic gas may be generated due to thermal decomposition of the foaming agent in the event of a fire, and since the price is relatively high, it is preferable to add it in the above ratio.

The foaming step is not particularly limited, and it is irrelevant if the solution provided by the foaming agent dilution step can generate a fine amount of bubbles. The foaming step may use a foaming method using a dispersing force of the rotary blades mounted from the shaft of the motor or a foamer equipped with a compressor. If a small amount of foaming agent is required, foaming using the rotary blades mounted from the shaft of the motor is required. It is advantageous to use the process, and it is advantageous to use a foamer equipped with a compressor if a large amount of foaming agent is required.

When using the rotor blades mounted from the shaft of the motor can use the rotation speed of 500 ~ 12,000 rpm, it can be provided with a mixer (Mixer), a resolver (Dissolver), a Homer mixer (Homo mixer), the compressor ( When using a foaming machine equipped with a compressor, it is possible to use a large amount of uniform and fine air, which can be used by adjusting the density of air bubbles generated by applying air pressure by the compressor.

The cement and additive mixing step does not place a large limit except that the bubbles formed in the pre-expanding step is uniformly mixed with the cement and additives, and is uniformly mixed so as to remain in a slurry state by the mixer. Is a ceramic powder including silica sand, which is a bonding medium of cement, and includes sound absorbing material and water-resistance that combines a strength modifier to enhance strength of foamed light cement and admixture for improving workability and strength of foamed slurry cement. A water reinforcing agent may be included to increase.

The cement in the cement and additive mixing step is selected and used according to the use of the final lightweight foam cement foam, the cement used is portland-based cement (usually portland cement, medium heat Portland cement, crude portland cement, sulfate resistant portland cement) , White portland cement, oil well cement, colloid cement) or mixed cement (blast furnace cement, fly ash cement, silica cement, ultra low heat cement, geothermal cement, RCCP cement), alumina cement, super fast cement or GRC low alkali cement One or more kinds of cements can be mixed and used, and in order to provide for the strengthening of light foam cement for quick quenching, it is advantageous to use Portland-based cements having a specific surface area of 3,000 to 3,500 cm 2 / g. In order to have a specific surface area of 4,000 Crude steel portland cement with 4,600 cm 2 / g or crude steel portland cement with a specific surface area of about 6,000 cm 2 / g or more is used as a medium heat portland cement to obtain a dense hardened structure with a long-term strength of at least 1 year. In order to increase the long-term strength while increasing the expression of long-term strength, seawater resistance and chemical resistance, and blast furnace cement to minimize alkali and reactivity It is advantageous to use fly ash cement for this purpose. It is advantageous to mix 25 to 80 parts by weight of cement, based on 100 parts by weight of water formed in the foaming step, preferably 35 to 75 parts by weight, most preferably 45 to 65 parts by weight, Even if the cement content is less than 25 parts by weight, even if it is cured, the foam bonding strength of the final cement or concrete is likely to be low. If the cement content is more than 75 parts by weight, it is possible to provide a lightweight foam cement having excellent bonding strength. It is preferable to add it in the above ratio because the economy is poor due to mixing of cement.

The ceramic powder including silica sand, which is a bonding medium of cement in the cement and additive mixing step, is not particularly limited, and the bonding strength is increased by the cement hardening mechanism while being in contact with the cement, and does not affect the properties of the quick-bubble lightweight foam cement. If not possible. The binding medium of the cement is silica powder and ceramic powders, such as elvan, ocher, olivine, kaolin, silicate mineral, diatomite, wollastonite, pyrophyllite. , Dolomite, Lithium Minerals, Magnesite, Bauxite, Bentonite, Pumice, Borate, Serpentine, Acid clay ), Iron Oxide, Garnet, Carbonate Minerals, Attapulgite, Sepiolite, Nephrite, Apatite, Illite-Mica ), Feldspar, Pearlite, Vermiculite, Zeolite, Barite, Talc, Diatomaceous earth, Graphite, Hectorite, Clay Minerals, Zirconium Minerals, Titanium Minerals, Tours Lin (Tourmaine; tourmaline) may be configured to select a fume silica (Fume silica), aerogels (Aerogel), fly Ashton (Fly ash), blast furnace slag, at least one naejineun one kind of powder with mixing.

The particle size of the silica sand and the ceramic mineral of the present invention has the advantage that can be used in a wide range of particles of 5 nm to 1.5 mm, unlike in the other ceramic field or construction field, preferably a particle size of 50 nm to 800 ㎛ It is advantageous, more preferably a particle size of 0.2 to 500 ㎛, most preferably 1.0 to 250 ㎛ is preferred, the size of 5 nm or less fine particles of several nm using a pulverizer except the airgel Not only is it unlikely to manufacture a product, but also has a disadvantage in that it can be used only in some special fields because of its low price competitiveness because the raw material cost is very high.The cement powder cured due to the small specific surface area of the ceramic powder having a size of 1.5 mm or more. While the bond strength is lowered and the formation rate of a large amount of fine foams between the powder and the powder is low Naejineun silica sand with a particle size of above, it is preferable to use a ceramic mineral.

The silica sand or ceramic powder is advantageously 50 to 750 parts by weight, preferably 75 to 600 parts by weight, and more preferably 100 to 500 parts by weight, based on 100 parts by weight of the cement included in the cement and additive mixing step. The addition is advantageous, and most preferably 300 to 500 parts by weight. When the silica sand or ceramic powder contains 50 parts by weight or less, the content of cement is relatively low because the content of silica sand or ceramic mineral, which is an inorganic oxide, is less than that of cement. Therefore, it is not only economically low but also can provide a low strength, and when it contains more than 750 parts by weight of silica sand or ceramic minerals, it is preferable to add it in the above ratio because it provides a cement or concrete having low bonding strength.

The admixture for improving the workability and strength of the foamed slurry cement is preferably 0.5 to 2.0 parts by weight based on 100 parts by weight of cement, and is selected from polycarboxylic acid series, melamine series or naphthalene series. It can be used mixed with one or more. In this case, when the admixture is out of the composition range, when the fine powders are generally mixed in the cement, it is difficult to obtain a homogeneous mixture due to separation in the mixing process of the product due to the difference in specific gravity or particle size with the cement. It is not desirable to be out of the composition range.

Among the lightweight foam cement additives, it may include a sound absorbing material having a strength reinforcing agent for increasing strength or a water reinforcing material for increasing water resistance, and a fiber may be used as a sound absorbing material having a strength reinforcing agent, and a water reinforcing material for increasing water resistance. Water dispersible polymer resin can be added.

Strength reinforcing agent in the present invention is because there is no big limitation except that the foam is formed and cured at room temperature to further increase the strength of the foam, it is possible to use any of natural fibers or artificial fibers, natural island Induced may include cellulose fibers (seedling fiber, bast fiber, salt fiber, fruit fiber), staples, filament-like protein fibers or mineral fibers, artificial fibers (regenerated fibers, semi-synthetic fibers, Synthetic fibers) or inorganic fibers (metal fibers, glass fibers, rock fibers, slag fibers, carbon fibers).

Fiber strength of the strength reinforcing agent is advantageously 3 to 50 μm, preferably 5 to 25 μm, and most preferably 5 to 10 μm, so that the fiber having a thickness of 3 μm or less is fibrous. In spite of its characteristics, the thinner and smoother the feel is, the better the physical properties and the higher the value of the use.In addition to glass fiber, most of the fiber produced from natural fiber and artificial fiber has a thickness of 3 ㎛ or more. It has the disadvantage of lacking the option to add the fiber, and the fiber having a thickness of 50 ㎛ or more is not smooth in appearance, and generally has a disadvantage that the strength is lower than the fine fiber, the fiber of the above range is used It is desirable to.

The fiber length of the strength reinforcing agent is advantageously 1 to 50 mm, more preferably 5 to 35 mm, and most preferably 10 to 25 mm, as the fiber length is 1 mm or less. The shortness of the fiber connection between the fine porous ceramic powders during the hardening step formed in the supply step for the fastening has a disadvantage in that the bonding force is not so large. In the mixing step, the fiber must be uniformly dispersed with the cement in the form of slurry. In the case of 50 mm or more, the fibers are entangled with each other, and rather, the physical properties of the foamed ceramics are inhibited.

Strength reinforcing agent of the foam ceramic is preferably 1 to 20 parts by weight based on 100 parts by weight of silica sand and ceramic powder, more preferably 2.5 to 15 parts by weight, and most preferably It is advantageous to include 5.0 to 10 parts by weight, the addition of less than 1 part by weight has the disadvantage that the reinforcing effect of the foamed ceramic structure is not high, and when more than 20 parts by weight added reinforcement effect is relatively large Although it is difficult to uniformly mix the silica sand powder, the ceramic powder and the fiber in the cement and additive mixing step, and the fiber is generally expensive, it is preferable to add the amount in the above range because it has the disadvantage of low economic efficiency. .

The water reinforcing agent to increase the water resistance can be used containing a water-dispersible polymer resin, water-dispersible polymer resin is that the polymer resin can be uniformly dispersed in water or soluble in water is coated on the surface of the cement foam particles There is no big limitation except to increase the water-resistant reinforcing agent may include acrylic, vinyl acetate, alkyd, melamine resin, styrene butadiene rubber (Solution Styrene Butadiene Rubber), epoxy resin, polyurethane, the water-dispersible polymer The amount of resin added is preferably 1.0 to 25 parts by weight, more preferably 2.5 to 25 parts by weight, most preferably 5.0 to 15 parts by weight based on 100 parts by weight of silica sand and ceramic powder. Advantageously, when added in an amount of 1.0 parts by weight or less, It has a disadvantage in that the water resistance is not large because it has a small role of covering the divided polymer film, and when it is added more than 25 parts by weight, the water resistance is considerably increased, but in case of fire, a large amount of toxic gas is released due to polymer decomposition. Since it has the disadvantage of being fatal, it is advantageous to add it at the appropriate concentration suggested above.

Slurry cement up to the cement and additive mixing step is advantageous to maintain a viscosity of 5,000 to 200,000 cps, for this purpose can be adjusted by adding a thickener. Cement viscosity in slurry state is preferably 15,000 to 180,000 cps, more preferably 35,000 to 160,000 cps, most preferably 50,000 to 150,000 cps is advantageous, the viscosity is low when the viscosity is 5,000 cps or less Finely foamed cement slurry has the advantage that it is more likely to flow into a mold having a complicated shape, but since the viscosity is low, it is highly likely to be defoamed, so it is not close to the technical idea of the present invention, and when the viscosity is 200,000 cps or more, fluidity It is preferable to keep the above range of viscosity because the problem of not being able to provide a slurry mixed at such a small corner of the mold shape and not being able to provide a large amount of micro-foams.

The supplying step for cement quenching is not subject to a large limit, and the curing starts in a few seconds to several ten minutes when the fine foamed cement slurry already made in the cement and additive mixing step and the fastening agent provided in the supplying step for cement quenching are mixed. It is advantageous to carry out the pouring step as soon as possible, since anything may be possible and hardening may begin during or before the pouring process after supplying the quickener. Quickeners are admixtures that greatly accelerate the solidification and hardening of cements, including aluminum salts (aluminum sulfate, aluminum chloride, aluminum nitrate, aluminum acetate), carbonates (sodium bicarbonate, potassium bicarbonate, ammonium bicarbonate, sodium carbonate, potassium carbonate, ammonium carbonate, Calcium carbonate) silicate, silica sol (silica sol), glyoxal, ethylene glycol diacetate may be selected from one or more selected from one or more selected and mixed, and the cement configured in the cement and additive mixing step When it is based on 100 parts by weight it is advantageous to comprise 5 to 70 parts by weight, preferably 5 to 35 parts by weight, and most preferably 10 to 25 parts by weight, in the case of complete curing after a few minutes, In the case of the fastening (fastening) to cure in seconds, preferably 35 to 70 parts by weight is advantageous, and most preferably 45 to 60 parts by weight. Advantageously, if the fastener contains less than 5 parts by weight of the curing is very slow because already foamed bubbles are deflected, which departs from the technical idea of the present invention, if exceeding 70 parts by weight of curing before pouring at a very high speed It is advantageous to maintain the concentration range because it can not provide a lightweight foam cement for insulation and sound insulation.

Aluminum salts and carbonates, glyoxal and ethylene glycol diacetate in the fasteners are advantageously used after dissolving in water and diluting. In particular, bicarbonates in carbonates are more likely to be converted to carbonates after dissolution. It is advantageous to use.

The silicate in the fastener is not particularly limited except that it is dissolved or uniformly dispersed in water and reacts with cement to cause a quenching reaction. One to four kinds of solution sodium silicate or powdered sodium silicate and silicate At least one selected from potassium, lithium silicate, and sodium aluminum silicate is selected, and it is advantageous to use at least one type of solution sodium silicate, potassium silicate, or sodium aluminum silicate. More preferably, one to four kinds of sodium silicate and sodium aluminum silicate are advantageous, and most preferably three kinds of sodium silicate are used. Potassium silicate and lithium silicate are the final lightweight foam cement of the present invention. When manufactured, it is possible to provide foam ceramic having excellent bonding strength and excellent water resistance, but the price is high. In the case of sodium aluminum silicate, the price is generally inexpensive, but since silica and aluminum are combined together and silica content is reduced, the silica content of the present invention is excellent. Somewhat insufficient, powdered sodium silicate requires a heat source or a long time dissolution time in order to dissolve clearly in water, and one type of sodium silicate (SiO ₂ / Na ₂ O) The mole ratio of 2.1 to 2.3) has a disadvantage that the binding strength may be relatively low as water must be supplied in order to adjust the slurry state because the viscosity is very high at a viscosity of 100,000 cps or more. There is a disadvantage that the workability is very high due to the high probability of solidification, such as sodium silicate 2 The species (mole ratio of SiO ₂ / Na ₂ O: 2.4 to 2.6) can provide more silica sol than the one, but the two species are also highly accurate silicates because of the high viscosity of 10,000 to 50,000 cps. If the inflow is difficult to control, and the four types of sodium silicate (mole ratio of SiO ₂ / Na ₂ O: 3.4 to 3.6) can generate a large amount of three-dimensional silica network, and the viscosity of the ceramic mineral is relatively low It is very convenient to control, but it is difficult to purchase because it does not produce domestic demand because it is generally low, and the unit price is expensive. Sodium silicate species (SiO ₂ / Na ₂ O mole ratio: 3.15 ～ 3.30 ), The viscosity is not so high, but the price is low and it is convenient to purchase because it is the silicate most produced by domestic silicate manufacturers. It is most preferable to use thrium.

Silica sol (colloidal silica) of the fastener may be used to directly prepare a chemically labile silica sol by commercially available colloidal silica having a size of 10 to 110 nm or the silicate reacts with an acid. In the case of using a commercially available silica sol as a fastener, the smaller the particle size, the faster the curing rate of the cement. Therefore, it is advantageous to use a silica sol having a size of 10 to 30 nm when curing is required in a few seconds. If desired, it is advantageous to use a silica sol having a size of 30-100 nm. When the silicate is reacted with acid to produce a chemically unstable silica sol, it is possible when the pH range of the acid-silicate mixed solution is 2-9, and when the pH of the acid-silicate mixed solution is low Since the pH has a strong alkali, it is preferable to maintain the pH in the range of 4 to 9 because the strength of the cement can be significantly reduced while being neutralized. At this time, the acid (acid) is advantageously diluted acid, hydrochloric acid, nitric acid, sulfuric acid, phosphoric acid, hydrofluoric acid, formic acid, acetic acid, citric acid, maleic acid, oleic acid is selected from one or more acids (acid), Preferably, it is advantageous to use sulfuric acid, acetic acid, citric acid which is inexpensive and can minimize environmental pollution, and the dilution amount of the acid is preferably 10 to 75 parts by weight based on 100 parts by weight of water. Diluted acids are advantageous, more preferably 25 to 50 parts by weight, most preferably 30 to 45 parts by weight, and when acid is diluted to 10 parts by weight or less, chemically when mixed with silicate and acid The disadvantage is that it takes a long time to provide an unstable silica sol, and if the acidity is higher than 25 parts by weight, a chemically unstable silica sol may be produced. Silica gel is formed during the lifting process, so that it does not play a role of quenching can be described as deviating from the technical idea of the present invention.

The pouring step does not place any limitation, and any one can be sprayed in molds, walls, floors, ceilings within seconds after the supply step for cement quenching. In case of curing by heating device in the following drying step, it is advantageous to spray on the mold. In case of curing by room temperature curing, it is for a long time at room temperature for the purpose of insulation and sound insulation of wall, ceiling and floor of building structure. When left unattended, it is advantageous to pour, and at this time, it is advantageous to install and spray a mold-shaped housing as much as possible in order to maintain the precise thickness of the lightweight foam cement and to further strengthen the strength.

The heating step goes through a supply step for cement quenching, and after the completion of the pouring step, removes moisture as quickly as possible without physical change of the foam, and the water-dispersible resin has a surface between the light-bubble cement particles and the particles for improved water resistance. There is no particular limitation except that it is fused to to increase the water resistance and to further increase the strength.

The lightweight bubble cement that has been processed in the pouring stage can be dried by air at room temperature, by hot air heating by oven, or by rapid heating drying by microwave (aka: microwave oven). It is advantageous to use in places where the thickness of lightweight foam cement is thin or irrelevant even if it is sprayed on building structures and left for a long time. It is advantageous to remove the moisture.

The microwave heating method has the advantage that when water of 2,450 MHz is applied, the water molecules with polarity rise in temperature by vibrating heat as much as microwave, and the moisture contained in the object can be removed at a high speed. However, since it has a disadvantage that a lot of equipment cost is required to dry a large material such as insulation, it is advantageous to use the hot air heating method by the oven which is most used in the industrial field when heating method is used, and microwave or hot air heating The heating temperature using the method is preferably heated to a temperature of 80 to 250 ° C, more preferably 90 to 220 ° C, most preferably 100 to 200 ° C, preferably 80 ° C When heated, not only does the removal rate of water contained in the foaming step be very high, The water-dispersible polymer resin for improving aqueous property has the disadvantage that it cannot be thermally fused by the heat source on the surface of the lightweight bubble cement. When the heating temperature exceeds 250 ℃, the water can be rapidly increased and the water-dispersible polymer Since it is much higher than the melting point of the resin, it has the advantage of being easily thermally fused to the ceramic surface in a short time, so that the water resistance is greatly increased.However, the heat energy loss due to the high temperature is increased and the economic efficiency is lowered. It is preferable to maintain the above proposed heating temperature because it has disadvantages, and more preferably, drying at room temperature.

Hereinafter, the present invention will be described in more detail with reference to the following examples, which are not intended to limit the present invention.

Example 1

As a foaming agent, 2% of water weight is added to the animal foaming agent purchased from Korea Industrial Co., Ltd., a foamed aqueous solution is prepared by using a homomixer, and 1 liter is prepared. 500 g of Portland general cement (Hanil Cement) and silica sand powder (No. 5) 1.5 kg, blast furnace slag powder 20 g and naphthalene series admixture 1 g were mixed to prepare a foamed cement slurry. To this, 50 g of three types of water glass of Yeongilhwa were added as a fastener, and as soon as they were uniformly mixed, they were put into a mold to prepare a lightweight foam cement foam and allowed to stand at room temperature to cure.

Example 2

As a foaming agent, add 2% of the water foam of Hanilcon's vegetable foaming agent (trade name Infomer), prepare a foaming solution using a homomixer, and prepare 1 liter of Portland General Cement (Hanil Cement) 500 g, ocher powder 1.5 kg, blast furnace slag powder 20 g, naphthalene series admixture 1 g was mixed to prepare a foamed cement slurry. 100 g of sodium bicarbonate was added thereto as a fastener, and as soon as it was mixed uniformly, it was put into a mold to prepare a lightweight foam cement foam, which was left to stand at room temperature to cure.

Example 3

As a foaming agent, 2% of the weight of water is added to the animal foaming agent purchased from Korea Industrial Co., Ltd., a foaming solution is prepared using a bubble generator, and 1 liter is prepared. Here, 500 g of Portland general cement (Hanil Cement) and silica sand 1.5 kg of powder (No. 5), 20 g of blast furnace slag powder, 20 g of epoxy resin of Kukdo Chemical (trade name: KEM-128-70), and 1 g of admixture of naphthalene series were mixed to obtain a foamed cement slurry. Prepared. 100 g of collidal silica (trade name: YGS-20) of Yeongil Chemical Co., Ltd. was added thereto as a fastener, and as soon as it was uniformly mixed, it was put into a mold to prepare a lightweight foam cement foam and allowed to stand at room temperature to cure.

Example 4

As a foaming agent, 2% of the weight of water is added to the animal foaming agent purchased from Korea Industrial Co., Ltd., a foaming solution is prepared using a bubble generator, and 1 liter is prepared. Here, 500 g of Portland general cement (Hanil Cement) and silica sand 1.5 kg of powder (No. 5), 20 g of blast furnace slag powder, 20 g of epoxy resin of Kukdo Chemical (trade name: KEM-128-70), and 1 g of admixture of naphthalene series were mixed to obtain a foamed cement slurry. Prepared. Add three kinds of water glass of Yeongilsung Co., Ltd. and 50% sulfuric acid to make pH 3.5, and prepare chemically unstable colloidal silica and add it to foamed cement slurry and mix it uniformly. As soon as it was put in the mold to prepare a light-foamed cement foam and cured by heating in an oven at 100 ℃ for 3 hours.

Example 5

As a foaming agent, 2% of the weight of water is added to the animal foaming agent purchased from Korea Industrial Co., Ltd., a foaming solution is prepared using a bubble generator, and 1 liter is prepared. 500 g of portland cement (Hanil Cement) for crude steel is added here. 800 g of powder (No. 5), 500 g of fly ash, 200 g of fume silica, 20 g of blast furnace slag powder, 20 g of fiber purchased from Dintex Korea as a strength enhancer and to improve water resistance A foamed cement slurry was prepared by mixing 20 g of latex of Kumho Petrochemical (trade name: KTR 101; a copolymer of butadiene and styrene) and 1 g of a naphthalene-based admixture. Add three kinds of water glass of Yeongilsung Co., Ltd. and 50% sulfuric acid to make pH 3.5, and prepare chemically unstable colloidal silica and add it to foamed cement slurry and mix it uniformly. As soon as it was put in the mold to prepare a lightweight foam cement foam and cured by heating in a microwave for 30 minutes.

Comparative Example 1

500 g of Portland general cement (Hanil Cement), 1.5 kg of silica sand powder (No. 5), 20 g of blast furnace slag powder, and 1 g of naphthalene-based admixture are mixed to prepare a cement slurry, which is placed in a mold and left to stand at room temperature for curing. It was.

Comparative Example 2

As a foaming agent, 2% of water weight is added to the animal foaming agent purchased from Korea Industrial Co., Ltd., a foamed aqueous solution is prepared by using a homomixer, and 1 liter is prepared. 500 g of Portland general cement (Hanil Cement) and silica sand powder (No. 5) 1.5 kg, blast furnace slag powder 20 g, naphthalene series admixture 1 g was mixed to prepare a foamed cement slurry, and put it in a mold to prepare a light foam foam cement foam, which was left at room temperature to cure.

According to Comparative Examples 1 and 2 and Examples 1 to 5, the results for examining the effect of the lightweight foam cement foam having excellent heat insulation and soundproofing effect of the present invention are shown in Table 1, in particular, after rapid curing with a fastener, In spite of not undergoing the treatment process, porous lightweight foam cement foam having a large number of fine closed cell structures having high water resistance was able to be produced, and as shown in FIG. Lightweight foam cement foam for quenching was immersed in water for 30 days.

TABLE 1

As shown in Table 1, the cement structure without foaming in Comparative Example 1 had no thermal insulation and soundproofing effect, and immediately subsided in water, and in Comparative Example 2, even though fine foaming was performed, Since the initial curing time is more than 8 hours, most of them are defoamed by large silica sand and cement during the process, so that the foam of lightweight cement is not made. Turned out to be absent. On the other hand, as shown in Examples 1 to 5, the cement slurry containing the appropriate cement additive is quenched before being defoamed, so that a large amount of closed cells can be provided even at room temperature, Since the flow can be prevented, even if the wall or upper part of the building structure is directly placed, it can be confirmed that it can provide excellent workability of the lightweight foam cement foam by preventing it from falling to the bottom of the upper part during the construction process. Also, compared to Comparative Examples 1 and 2, a large amount of fine closed cell air layers having excellent water resistance and low thermal conductivity while providing excellent results equal to or more than those of Comparative Examples 1 and 2 can be formed to provide a lightweight cement foam having excellent heat insulation and soundproofing effects. It could be confirmed.

The present invention is not limited to various shapes and thicknesses, and can be manufactured in a large amount of fine high-strength lightweight foam cement foam even if it is cured at room temperature by placing directly on a construction site for thermal insulation and soundproofing or by de-molding in a mold of a certain form, and thus insulate effect. In order to obtain excellent foaming ceramic foam for quick quenching with excellent heat insulation and sound insulation effect to minimize the damage to life caused by the emission of toxic gas in the event of fire and minimize the manufacturing process and expenses, it provides environmentally sound insulation and sound insulation. It is.

By using the technical idea of the present application, a high heat source of 900 to 1,300 ° C. is not required to manufacture a foamed ceramic as in the case of a conventional foamed ceramic, and a mold and pressure for maintaining a constant shape for extrusion and molding It does not require many facilities such as equipment, and it is not necessary to cure the foamed concrete with steam curing or steam of high temperature and high pressure as in the case of the conventional lightweight foam cement (ALC; Autoclaved Lightweight Concrete). In addition, it can overcome the disadvantage that can not be directly poured in the construction site, it can provide a lightweight foam cement foam with excellent insulation and sound insulation effect while minimizing the manufacturing process and construction process, as well as shorten the manufacturing and construction process. Insulation material and sound absorption material of styrofoam and foamed polyurethane which are conventional petrochemical products An effect that can provide a lightweight foam cement foam can.

As described above, in the case of manufacturing the conventional foamed ceramic, a high temperature of 1,000 ° C. or more is required for sintering, and huge equipment by extrusion and molding is required, and thus, workability and economic efficiency are very low.

In addition, in the case of manufacturing conventional AAC (Autoclaved Lightweight Concrete), the foamed concrete needs to be cured by steam curing or steam of high temperature and high pressure for a long time. The disadvantage is that the foamed cement slurry cannot be placed directly on the walls or ceiling of building structures.

On the other hand, according to the present invention, the animal or vegetable foaming agent is diluted and mixed in water, and a large amount of micro bubbles are formed therein, and cement and additives are added thereto to prepare a microporous cement slurry, and at this time, a feeding step for cement quenching. When providing the foam foam of the cement of the slurry does not disappear, it is quickly cured at room temperature while maintaining the original shape of the foamed form to provide a quick foaming foam foam for fastening to form a large amount of high-strength micro-foam, so that the thermal insulation and sound absorption effect It can replace foamable polymer resins such as styrofoam or foamable polyurethane, which has excellent economical efficiency and workability, and can produce lightweight foam cement foam with excellent insulation and soundproofing effect. Even though it is poured directly at room temperature Nevertheless, it is possible to provide a high-strength, lightweight foam cement foam, there is a very large construction advantages.

Claims (18)

In the manufacturing method of the lightweight foam cement foam for fastening which does not require a long curing process, Foam foam forming step of diluting and mixing animal foam or vegetable foam in water to form a large amount of fine foam foam (foam); A slurry mixture forming step of obtaining a finely foamed cement slurry mixture by mixing cement and ceramic powder with the fine bubble foam mixture prepared in the foam forming step; An injection step of injecting the slurry mixture into a structure or a space having a predetermined shape provided to accommodate the lightweight foam cement foam, and injecting a fastener into the slurry mixture and pouring the lightweight foam cement foam; Mixing a water reinforcing agent or an additive to remove water or improve water resistance of the poured and injected lightweight foam cement foam; A heating step for coating the ceramic surface foamed by thermal fusion; Method for producing a lightweight foam cement foam for fastening characterized in that it comprises a. The method of claim 1, The foaming agent used in the foam forming step is used by using an animal-based foaming agent of the amino acid or selected from the vegetable foaming agent based on alkylbenzene sulfonate or sodium lauryl sulfate or esters thereof, based on 100 parts by weight of water A method for producing a lightweight foam cement foam for fastening, characterized in that 0.1 to 10 parts by weight of the foaming agent is included. The method of claim 1, In the foamed foam forming step, the foaming agent is dispersed in water at high speed, using a dispersing device selected from a mixer, a dissolver, a homo mixer, and a foamer equipped with a compressor. A method for producing a quick foamed light foam cement foam, characterized by obtaining a large amount of fine bubbles by applying a rotational speed of 500 to 12,000 rpm. The method of claim 1, The cement used in the slurry mixture forming step is selected from portland cement, mixed cement, alumina cement, ultrafast cement, and low alkali cement for GRC, and based on 100 parts by weight of water used in the foam forming step A method for producing a quick foamed foam foam for fastening, characterized in that 25 to 80 parts by weight of cement is used. The method of claim 1, The ceramic powder used in the slurry mixture forming step is Silica, Elvanite, Ocherite, Olivine, Kaolin, Silica Mineral, Diatomite, Wollastonite, Pyrophyllite, Dolomite, Lithium Minerals, Magnesite, Bauxite, Bentonite, Pumice, Borate, Serpentine, Acid clay, Iron Oxide, Garnet, Carbonate Minerals, Attapulgite, Sepiolite, Nephrite, Apatite, Illite-Mica, Feldspar, Perlite, Vermiculite (Vermiculite, Zeolite, Barite, Talc, Diatomaceous earth, Graphite, Hectorite, Clay Minerals, Zirconium Minerals, Titanium Minerals, Tourmaine (Tourmaline), Fume silica, Aerogel (Aerog) el), Fly ash, blast furnace slag powder is selected in the particle size range of 5 nm ~ 1.5 mm, when the ceramic powder is used based on 100 parts by weight of 50 ~ 750 parts by weight Method for producing a lightweight foamed cement foam for fastening. The method of claim 1, In addition to the cement and ceramic powder used in the slurry mixture forming step, admixture for improving workability of the foamed slurry state or A method for producing a quick foamed light foam cement foam, characterized in that an additive selected from a strength reinforcing agent for enhancing the strength of the foamed lightweight cement or a water reinforcing agent for increasing the water resistance is further used. The method of claim 6, The strength enhancer used in the additive addition step is selected from natural fibers or artificial fibers having a thickness of 3 to 50 μm and a length of 1 to 50 mm, and the strength enhancer is 1 to 20 based on 100 parts by weight of ceramic powder. Method for producing a lightweight foam cement foam for fastening characterized in that the weight part is included. The method of claim 6, The admixture used in the additive addition step is selected from dicarboxylic acid series, melamine series, naphthalene series, light weight for quick quenching, characterized in that the admixture is provided with 0.5 to 2.0 parts by weight based on 100 parts by weight of cement Method of manufacturing foam cement foam. The method of claim 6,  Water-resistant reinforcing agents used in the additive addition step It is selected from acryl, vinyl acetate, alkyd, melamine resin, styrene butadiene rubber, epoxy resin and polyurethane resin, and the water reinforcement agent is 1.0-25 parts by weight based on 100 parts by weight of ceramic powder. Method for producing a lightweight foam cement foam. The method of claim 1, In the slurry mixture forming step, the slurry mixture is prepared to have a viscosity of 5,000 ~ 200,000 cps, the manufacturing method of the light-weight foam cement foam for fastening. The method of claim 1, The fasteners used in the lightweight foam cement foaming step are aluminum sulfate, aluminum chloride, aluminum nitrate, aluminum acetate, sodium bicarbonate, potassium bicarbonate, ammonium bicarbonate, sodium carbonate, potassium carbonate, ammonium carbonate, calcium carbonate, silicate, commercial silica sol ( silica sol; colloidal silica), chemically labile silica sol, glyoxal, ethylene glycol diacetate is selected from the use, based on 100 parts by weight of the fastener, characterized in that 5 to 70 parts by weight of the fastener is used Method for producing lightweight foam cement foam. The method of claim 11, The silicate of the fastener is a method for producing a light-weight foam cement foam for fastening, characterized in that selected from one to four types of solution sodium silicate or powdered sodium silicate, potassium silicate, lithium silicate, sodium aluminum silicate. . The method of claim 11, Commercially available silica sol among the quickener is a manufacturing method of a light-weight foam cement foam for fastening, characterized in that consisting of a size of 10 ~ 110 nm. The method of claim 11, In the case where the silicate is reacted with an acid in the fastener to prepare and use a chemically labile silica sol directly, Based on 100 parts by weight of water, dilute acid selected from hydrochloric acid, nitric acid, sulfuric acid, phosphoric acid, hydrofluoric acid, formic acid, acetic acid, citric acid, maleic acid, and oleic acid diluted to 10 to 75 parts by weight is used, and the pH of the aqueous solution is mixed by mixing the silicate. Method for producing a lightweight foam cement foam for fastening characterized in that for use in the range of 2 to 9 adjusted. The method of claim 1, Light-weight foam cement foam The step of placing a structure having a predetermined shape in the form of a mold (mold), the method of manufacturing a lightweight foam cement foam for fastening, characterized in that placed on the wall surface, floor surface or ceiling surface of the building structure. The method of claim 1, The heating step is a method for producing a quick foamed light foam cement foam, characterized in that selected from the room temperature drying with air, hot air drying with an oven, drying method using microwaves. The method of claim 16, A method for producing a quick foamed light foam cement foam, characterized in that the heating temperature is 80 to 250 ℃ in the hot air drying by oven or drying using microwaves. Lightweight foam cement foam for fastening that does not require a long curing process, Foam foam forming means for diluting and mixing animal foam or vegetable foam in water to form a fine amount of foam foam; Slurry mixture forming means obtained by mixing cement and ceramic powder in the foam foam mixture prepared in the foam foam forming step to obtain finely foamed cement slurry; Means for pouring the slurry mixture into a structure or space having a predetermined shape provided to accommodate the lightweight foam cement foam, wherein the slurry is poured into the slurry mixture by means of additionally injecting a fastener into the slurry mixture; Means for adding a water reinforcement agent to remove water or improve water resistance of the poured lightweight foam cement foam; Heating means for coating the ceramic surface foamed by thermal fusion; Drying means selected from room temperature drying with air, hot air drying with an oven, or drying using microwaves; Lightweight bubble cement foam for fastening, characterized in that provided to have a thermal insulation and soundproofing effect.

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