KR101056699B1 - Lightweight ceramic board for construction - Google Patents

Abstract

The present invention relates to a lightweight ceramic board for construction. More specifically, the present invention relates to a magnesium-based construction lightweight ceramic board having excellent weight, weight, and incombustibility compared to conventional ceramic boards or gypsum boards.

The light weight ceramic board for building according to the present invention is a building ceramic board having a core layer and surface layers formed on both surfaces thereof, wherein the core layer is made of magnesium oxide (MgO) -based inorganic 80 to 40% by volume and light chip 20 to 60% by volume. Characterized in that made.

Therefore, the light weight ceramic board for building according to the present invention improves on-site cutting performance by 20% or more of board weight reduction and cutter knife by adding lightweight foam chips while maintaining strength, water resistance, and the like of magnesium-based ceramic board, and incombustibility and dimensions Other properties such as stability, heat insulation, sound insulation, etc. are also inferior.

Ceramic Board, Gypsum Board, Magnesium Oxide, Foam, Binder

Description

Lightweight ceramic board for building {A lightweight ceramic board for building}

 1 is a cross-sectional view of a lightweight ceramic board for construction according to an embodiment of the present invention.

 Figure 2 is a process diagram schematically showing a manufacturing process according to an embodiment of the present invention

Description of the Related Art

110: upper glass fiber reinforced layer 120: core layer

121: light weight chip 130: lower glass fiber reinforced layer

201: lower glass fiber fabric 202: raw material for forming the surface layer

203: core layer forming material 204: upper glass fiber fabric

301: plate-shaped mold 311,312,313: pressure roller

The present invention relates to a lightweight ceramic board for construction. More specifically, to provide a lightweight ceramic board for magnesium-based construction, in particular, the weight of the weight compared to the conventional ceramic board or gypsum board and excellent in the field cutting.

The present invention is a ceramic ceramic board having a core layer and a glass fiber reinforced inorganic layer formed as a surface layer on both sides thereof, characterized in that the core layer is composed of 80 to 40 volume percent of magnesium-based inorganic and 20 to 60 volume percent of lightweight chips It is characterized by.

In general, building interior materials such as gypsum board or ceramic board is manufactured to make gypsum into a plate shape and attach paper to front and back sides to maintain the structure and to withstand shear strength.

Such a gypsum board is excellent in heat insulation and flame retardancy, but there is a problem in that the joint is easily relaxed by moisture, and thus the structure is easily broken when the structure is broken or the strength is weak.

Republic of Korea Patent Application Publication No. 10-2004-0099709 is a magnesium-based coagulation composed of magnesium oxide and magnesium chloride after mixing a calcium material consisting of quartz powder and diatomaceous earth and a calcium material consisting of limestone and white cement, which is a lightweight material with flame retardancy in the center BACKGROUND ART A siliceous layer formed by stirring with water together with a binder and a building plate having a glass fiber embedded in upper and lower surfaces of the siliceous layer to improve shear strength and a manufacturing process thereof are known.

Korean Patent Laid-Open No. 10-2003-2960 discloses a method for forming a dry material using magnesium oxide, which is composed of 30 to 70 parts by weight of magnesium oxide powder and 30 to 70 parts by weight of vegetable material or mineral material powder. There is a problem of poor tailorability.

In addition, Japanese Patent Laid-Open No. 2001-279860 discloses a mixture of 30 to 65 parts by weight of magnesium oxide as a main component, which is a water-soluble inorganic oxide such as silica, aluminum, calcium, and the like, followed by stirring and continuously expanding a mixture including bubbles. Lightweight non-combustible board manufactured by thermoforming into a plate shape while maintaining the swelling state of the insert material while inserting it to the maximum and cooling and curing has been proposed. have.

Existing magnesium oxide (MgO) -based building plate as described above has excellent water resistance and strength compared to gypsum board, but has a heavy weight, poor on-site cutting properties and large dimensional change rate has been limited in its use.

The present invention is to solve the problems of the prior art as described above to provide a lightweight ceramic board for magnesium-based construction excellent in weight reduction effect and field cutting by adding 20 to 60% by volume of light foamed chip in the core layer.

In order to effectively achieve the above object, the present invention provides a ceramic ceramic board having a core layer and a glass fiber reinforced inorganic layer formed on both sides thereof, wherein the core layer is 80-40 volume percent of the magnesium-based inorganic material and 20-60 volume percent of the lightweight chip. Characterized in that consisting of.

The lightweight ceramic board for magnesium-based construction according to the present invention is characterized in that the core layer is made of 99 to 90 weight percent of the magnesium-based inorganic material and 1 to 10 weight percent of the light weight chip.

The magnesium-based mineral may be selected from magnesium oxide (MgO), magnesium chloride or a mixture thereof.

The lightweight chip may be one or two or more blends selected from expanded polystyrene (EPS), expanded polypropylene (PP), expanded polyethylene (EPE), and aerogel granules. It may be spherical or amorphous, the size of which is preferably smaller than the thickness of the core layer, and chips of approximately 0.1 to 3 mm are preferred.

The lightweight foaming chip used has a foaming ratio of about 15 to 70 times for EPS, EPP, and EPE, and the density is 0.05 ~ 0.015 g / cm3, and its particle size is 3mm in diameter or less, especially 0.1 To 3 millimeters (mm) is preferred. If the foaming ratio is less than 15 times or the content is less than 20% by volume (or 1% by weight), the weight reduction effect is small, and the foaming ratio is more than 70 times or the content is more than 60% by volume (or 10% by weight) , The strength of the light weight chip itself is too low, there is a problem that the shape can be deformed when mixing.

 If the particle size is more than 3mm (mm), the board thickness is 3 ~ 15mm (mm), there is a high possibility that there is a part where the strength is weak.

The silane-based coupling agent (coupling agent) is, for example, a binder such as amine (Amin) silane (acryl), acrylic (silane) based (silane), the surface treatment is spray coating, Dip coating method Etc. can be processed by conventional methods.

The glass fiber reinforced inorganic layer formed on both sides of the core layer is a glass fiber fabric made of glass woven or non-woven fabric (glass paper) or a combination of fabric and non-woven fabric as a surface layer is impregnated or coated with magnesium-based inorganic Buried to reinforce the strength of the board.

The woven fabric or nonwoven fabric of the glass fiber is preferably 20 grams (g) to 200 grams (g) per square meter, and the magnesium-based inorganic material impregnated in the glass fiber fabric may be selected from magnesium oxide, magnesium chloride or a mixture thereof. Preferably, it is a mixture of magnesium oxide and magnesium chloride, and this mixture can be kneaded with an appropriate amount of water.

The magnesium-based inorganic mixture for forming the surface layer and the core layer used in the present invention may be added with wood powder, expanded pearl rock, or a small amount of a foaming agent or a curing regulator for the purpose of improving strength.

  In the building ceramic board of the present invention, a fabric layer made of fabric may be added to one surface or both surfaces. By adding a fabric layer it is possible to increase the bonding with other interior materials or to enhance the strength or decorative effect.

The lightweight ceramic board for building according to the present invention can be manufactured by conventional techniques that can be easily carried out by those skilled in the art.

Hereinafter, the manufacturing process of the present invention will be described in detail with reference to the accompanying drawings.

1 is a cross-sectional view of a lightweight ceramic board for construction according to the present invention, Figure 2 is a process diagram schematically showing a manufacturing process according to the present invention.

The lightweight ceramic board for building according to the present invention

Preparing a core layer-forming material kneaded with magnesium-based inorganic powder and lightweight foam chips with water and a surface layer-forming material kneaded with magnesium-based inorganic powder with water; Stacking (or applying) the surface layer forming material on a plate-shaped mold; Stacking a glass fiber fabric made of glass fiber woven or nonwoven fabric prepared separately from the surface layer forming material or a combination of a glass fiber fabric and a nonwoven fabric; Pressing the glass fiber fabric to form a glass fiber reinforced inorganic layer as a surface layer; Stacking (or applying) a core layer forming material on the surface layer; Compressing the stacked core layer-forming raw materials to form a core layer; Stacking a glass fiber fabric comprising a glass woven fabric or a nonwoven fabric of glass fiber or a combination of a glass fiber fabric and a nonwoven fabric on the core layer; Stacking (or applying) the surface layer forming material on the glass fiber fabric; Pressing the surface layer forming material to form a glass fiber reinforced inorganic layer as a surface layer;

In the manufacturing process, a fabric layer lamination process may be added before and / or after forming the glass fiber reinforced inorganic layer to form the fabric layer on the outer surface of the surface layer.

The glass fiber reinforced inorganic layer, which is the surface layer on both sides, may be configured by using a glass fiber reinforced inorganic sheet prepared by impregnating or coating a magnesium-based inorganic material on a glass fiber fabric in advance.

The lightweight ceramic board for building according to the present invention manufactured as described above may prevent cracking due to excessive curing and add an immersion curing process for the discharge of harmful components.

The lightweight ceramic board for building according to the present invention may be manufactured by any process such as a continuous process or a batch process.

Hereinafter, the present invention will be described in detail with reference to Examples and Comparative Examples.

Raw Material Mixing Example 1

[ Preparation of Magnesium-Based Mineral Mixture for Surface Layer Formation]

A magnesium-based inorganic mixture 202 for forming a surface layer was prepared by uniformly mixing 10 kg of magnesium oxide (kg), 10 kg of magnesium chloride (kg), and 4 kg (kg) of water.

The volume of the mixture of 10 kg (kg) of magnesium oxide and 10 kg (kg) of magnesium chloride was 18 liters (L).

Raw Material Mixing Example 2

[Preparation of Raw Material Mixture for Core Layer Formation]

6 kg (kg) of the magnesium-based inorganic mixture for surface layer formation prepared in Mixture Example 1 was taken, and then the density was A raw material mixture 203 for core layer formation was prepared by uniformly adding 250 grams (g) of amorphous expanded polystyrene (EPS) chips having a diameter of 0.03 g / cm 3 and a particle size of 0.01 to 3 mm. .

The volume of the 250 grams of amorphous expanded polystyrene (EPS) chip was 4.5 liter (L).

Raw Material Mixing Example 3

[Preparation of Raw Material Mixture for Forming Core Layer Containing Surface-treated Foam Chip]

6 kg (kg) of the surface-based magnesium-based inorganic mixture prepared in Mixture 1 of the raw materials, an amorphous foam having an EPP density of 0.02 g / cm 3 and a particle size of 0.01-3 mm in diameter, treated with 50 g of expanded pearl rock and Amin-based Silane. 250 grams (g) of polystyrene (EPS) chips were added and mixed uniformly to prepare a raw material mixture 203 for core layer formation.

Example 1

The magnesium-based inorganic mixture 202 for surface layer formation prepared in Mixture 1 of the above-described raw materials was applied (stacked) to a thickness of 3 mm on the plastic plate 301, and a glass fiber nonwoven fabric 201 having a thickness of 50 g / m 2 prepared in advance was laminated thereon. Then, by pressing the ring 311 on it to form a surface layer 130, and then to the core layer of the core layer forming material mixture 203 prepared in the raw material mixing example 2 to a thickness of 8mm (lamination) Thereafter, a pressure rolling 312 was formed thereon to form a core layer, and a glass fiber nonwoven fabric 204 having a thickness of 50 g / m 2 was laminated on the core layer, and the magnesium system for forming a surface layer of the raw material mixing example 1 thereon. The inorganic mixture 202 was applied (stacked) to a thickness of 1 mm, and then press-rolled 313 thereon to form a smooth surface layer 110 and a lightweight ceramic board having a thickness of 9 mm was prepared.

The lightweight ceramic board was cured at 40 ° C. for 24 hours, dried at 50 ° C. for 3 days, cured in air for 3 days, and then cut into a size of 450 cm × 450 cm to test its physical properties. Table 1 Shown in

[Example 2]

The raw material for core layer formation was the same as that of Example 1 except that the mixture of the raw material mixing example 3 was used and a glass woven fabric was additionally laminated inside the glass paper for the purpose of improving the strength. The lightweight ceramic board was manufactured by the method, and the physical properties thereof were tested, and the results are shown in Table 1.

[Comparative Examples 1 and 2]

MgO boards (comparative example 1) and gypsum boards (comparative example 2) were purchased commercially. And the physical properties were measured and shown in Table 1.

< Table 1 >

Item Example 1 Example 2 Comparative Example 1 Comparative Example 2

Thickness (mm) 9mm 9mm 9mm 9.5mm

Thread Bearing Capacity (kgf / cm) 38 39 39 6

Density (g / cm3) 0.78 0.80 1.15 0.9 Flexural Strength (kgf / mm2) 0.9 1.6 1.2 0.57 Submersion Flexural Strength (kgf / mm2) 0.7 1.5 0.9 0.08 Dimensional Stability (%) 0.25 0.25 0.55-

Flame retardant 1 1 1 2

Very good Good Bad Good

Surface texture Good Good Bad-

* The screw bearing capacity was tested by KS F 2214, bending strength KS F 2263, density KS F 2518, dimensional stability KS M 3802 and flame retardancy KS F 2271.

From the above table, the lightweight ceramic board according to the present invention has a weight reduction effect of more than 30% (0.78 / 1.15 to 0.80 / 1.15) compared to the existing magnesium board, and for forming a core layer containing foam chips surface-treated with a silane-based binder. In the case of Example 2 composed of a core layer of the raw material mixture and reinforced with a glass fiber fabric, adhesion to the magnesium-based inorganic material was improved, so that some separation of the lightweight chip did not occur during cutting, and the board strength was greatly improved.

In addition, it can be seen that the luxurious surface texture and the field cutting property are improved.

 The present invention can improve the on-site cutting properties by the cutter knife with 30% or more board weight compared to the existing magnesium board by adding a light weight chip while maintaining the insulation, sound insulation, water resistance, dimensional stability, etc. of the advantages of the magnesium-based ceramic board As well as the effect, there is an effect that can improve the strength.

Claims (9)

In the building ceramic board having a core layer and a glass fiber reinforced inorganic layer formed on both surfaces thereof, the core layer is composed of 80 to 40 volume percent of magnesium-based inorganic and 20 to 60 volume percent of the light weight chip, wherein the light weight chip is a silane Lightweight ceramic board for construction, surface-treated with a series of coupling agents. The lightweight ceramic board for building according to claim 1, wherein the core layer is made of 99 to 90 weight percent of magnesium-based inorganic material and 1 to 10 weight percent of light weight chip. [Claim 2] The lightweight ceramic board for building according to claim 1, wherein the magnesium-based inorganic material is magnesium oxide (MgO), magnesium chloride or a mixture thereof. The mixture of claim 1, wherein the light weight chip is one or a mixture of two or more selected from expanded polystyrene (EPS), expanded polypropylene (EPPP), expanded polyethylene (EPE), or aerogel granules. Lightweight ceramic board for construction, characterized in that. delete The light weight of claim 1, wherein the light weight chip has a density of 0.05 to 0.015 grams per cubic centimeter (g / cm 3), and the particle size is spherical or amorphous having a diameter of 0.01 to 3 mm (mm) or less. Ceramic board. 7. The glass fiber of any one of claims 1 to 4 and 6, wherein the glass fiber of the glass fiber reinforced inorganic layer is formed of a glass woven or nonwoven fabric of glass fiber or a nonwoven fabric of glass fiber. Lightweight ceramic board for construction, characterized in that the glass fiber fabric made of a combination. Preparing a core layer-forming material for kneading the magnesium-based inorganic powder and lightweight foam chips with water and a surface layer-forming material for kneading the magnesium-based inorganic powder with water; Laminating (or applying) the surface layer forming material on a mold; Stacking a glass fiber fabric made of glass fiber woven or nonwoven fabric prepared separately from the surface layer forming material or a combination of a glass fiber fabric and a nonwoven fabric; Pressing the glass fiber fabric to form a glass fiber reinforced inorganic layer as a surface layer; Stacking a core layer forming material on the surface layer; Compressing the stacked core layer-forming raw materials to form a core layer; Stacking a glass fiber fabric comprising a glass woven fabric or a nonwoven fabric of glass fiber or a combination of a glass fiber fabric and a nonwoven fabric on the core layer; Stacking (or applying) the surface layer forming material on the glass fiber fabric; And pressing the surface layer forming material to form a glass fiber-reinforced inorganic layer as a surface layer. The method of claim 8, further comprising the step of immersion curing after the step of forming the glass fiber reinforced inorganic material layer.

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