KR101236168B1 - Composite Insulation material using Porous Ceramic Ball and Natural Cellulose as a Core material and manufacturing method therof - Google Patents

Abstract

The present invention relates to an environmentally friendly composite insulating material using a porous ceramic ball and natural fiber as a core material, and an active ocher as a binder, and a method for manufacturing the same. As a composite heat insulating material using a natural fiber and a porous ceramic ball composed of 40 to 50 parts by weight of water and 26 to 38 parts by weight of a core material consisting of porous ceramic balls and natural fibers, based on 100 parts by weight of the binder prepared by mixing By using ocher, it improves the waterproofness of natural fiber and by using porous ceramic ball and natural fiber as the core material of insulation material, it has the effect of providing eco-friendly composite insulation material with excellent insulation and strength as a semi-combustible product and non-toxic to human body. .
Achievements of National R & D Projects
1) Research fund support department: Small and Medium Business Administration
2) Name of research project: Establishment of company affiliated research institute
3) Research title: Development of eco-friendly composite insulation
4) Organizer: Gongju University
5) Period: June 1, 2010-May 31, 2012
Outcome of National R & D Projects-1
1) Research fund support department: Korea Research Foundation
2) Research Project Name: Regional Base Research Group (Energy-Independent Green Village Core Technology Project Group)
3) Research title: Development of lightweight concrete insulation panel
4) Organizer: Gongju University
5) Research period: April 1, 2011-March 31, 2012

Description

Composite Insulation material using Porous Ceramic Ball and Natural Cellulose as a Core material and manufacturing method therof}

The present invention relates to a composite insulating material using a porous ceramic ball and a natural fiber as a core material and a method for manufacturing the same, and more particularly, using a porous ceramic ball and a natural fiber as a core material, and using activated ocher as a binder, strength and thermal insulation The present invention relates to an excellent eco-friendly composite insulating material and a method of manufacturing the same.

Insulation materials are classified into inorganic insulation materials and organic insulation materials. Inorganic insulation materials include asbestos, rock wool, glass wool, pearlite, and the like, and organic insulation materials include styrofoam, polyurethane foam, and urea foam. The insulation market accounts for 71% of organic insulation materials (55% styrofoam, 29% polyurethane, 6% compression boards, etc.) and 29% of inorganic insulation materials (glass, rock wool, asbestos, etc.). Such insulators have been relatively well insulated and chemically stable, and have been widely used for a long time due to their excellent performance in physical strength, absorbency, and workability.

However, these insulation materials have many problems in terms of human hazards and environmental pollution. The most commonly used organic insulation materials use petroleum as raw material, which causes serious resource damage as well as depletion of resources as well as polluting indoor air and toxic gases in case of fire. Inorganic insulation materials destroy nature in the process of obtaining raw materials, and materials such as asbestos are not used for general construction but are used for industrial purposes because of human health hazard.

Accordingly, the present inventors completed the present invention by developing a composite insulating material having excellent strength and thermal insulation by using activated clay, which is an eco-friendly product, as a binder, and using porous ceramic balls and natural fibers as core materials.

The present invention has been made in order to solve the above problems, by using a porous ceramic ball and natural fiber as a core material, using an active ocher as a binder to provide an environmentally friendly composite insulation and excellent manufacturing method with excellent strength and insulation properties For the purpose of

In order to achieve the above object, the composite insulating material using the porous ceramic ball and the natural fiber as a core material of the present invention is 100 parts by weight of a binder prepared by mixing the active ocher: cement is calcined raw clay in a weight ratio of 1: 1 40 to 50 parts by weight of water and a core material comprising 26 to 38 parts by weight of the core ceramic ball and natural fiber.

The core material is composed of 20 to 30 parts by weight of porous ceramic balls and 6 to 8 parts by weight of natural fiber with respect to 100 parts by weight of the binder, and the porous ceramic balls are A type porous ceramic balls having a diameter of 4.45 mm: B type porous having a diameter of 2.60 mm. Ceramic balls are composed of a weight ratio of 1: 1, and the natural fiber is wood chips: sawdust is composed of a weight ratio of 1: 1.

In addition, the method of manufacturing a composite insulating material using the porous ceramic ball and the natural fiber as a core material of the present invention comprises the steps of: a) mixing the fired activated ocher: cement in a weight ratio of 1: 1 to prepare a binder; b) adding water to the binder of step a) to form a paste; And c) the core material consisting of a porous ceramic ball and a natural fiber in the binder of step b) is characterized in that it comprises a step of mixing.

The water is added 40 to 50 parts by weight based on 100 parts by weight of the binder, the core material is added to 26 to 38 parts by weight based on 100 parts by weight of the binder, 20 to 30 parts by weight of porous ceramic balls and 6 to 8 parts by weight of natural fiber It is composed.

The porous ceramic ball is a 4.45mm diameter A type porous ceramic ball: B type porous ceramic ball with a diameter of 2.60mm is composed of a weight ratio of 1: 1, the natural fiber is wood chips: sawdust 1: 1 weight ratio It consists of.

Hereinafter, the present invention will be described in detail.

The binder of the present invention is used by mixing the activated ocher made by firing fresh ocher at 800 ° C. in a weight ratio of active ocher: cement 1: 1 in order to enhance the flame retardant properties of the activated ocher and the binding force by the pozzolanic reaction. That is, when calcined raw ocher at 800 ° C., SiO ₂ and Al ₂ O ₃ were activated to cause a Ca (OH) ₂ and pozzolanic reaction, resulting in 3CaO · 2SiO ₂ · 3H ₂ O (CSH) phase and 2CaO · Al ₂ O ₃ · SiO ₂ · 8H ₂ O (CASH) phase crystals are generated to increase the bonding force.

The cement is preferably used commercial portland cement, but is not limited thereto.

In addition, for the strength and eco-friendliness of the composite insulation of the present invention, the mixing ratio of activated ocher: cement is preferably 1: 1.

Core material of the present invention is composed of a porous ceramic ball and a natural fiber for excellent heat insulation and strength, the porous ceramic ball is a 4.45mm diameter A type porous ceramic ball: B type porous ceramic ball with a diameter of 2.60mm 1: 1 The natural fiber is composed of wood chips: sawdust mixed with a weight ratio of 1: 1.

The porous ceramic ball type A has good pores and has good thermal insulation, but the strength is weak, and the porous ceramic ball type B has small pores, which have poor thermal insulation, but have strong strength. Therefore, the porous ceramic ball type A and the porous ceramic ball type B are 1: 1. When used by mixing in the weight ratio of to complement the disadvantages of each other it is possible to maintain the thermal insulation and strength of the insulation.

In addition, sawdust, which is a natural fiber, has a favorable effect in increasing the thermal insulation and compressive strength, and in the case of wood chips, the fiber is long, which has a favorable effect in increasing the insulation and bending strength. By using the mixture at a weight ratio of 1, it is possible to maintain high heat insulating properties and strength.

The core material is to add 26 to 38 parts by weight with respect to 100 parts by weight of the binder in consideration of the development of strength and workability according to the filling of the core material is composed of 20 to 30 parts by weight of porous ceramic ball and 6 to 8 parts by weight of natural fiber. desirable. That is, it is preferable to mix the porous ceramic ball and the natural fiber as described above to use as a core material when considering the heat insulation and strength of the heat insulating material as a whole.

When the water of the present invention is less than 40 parts by weight with respect to 100 parts by weight of the binder, there is a problem in that a dense specimen is not formed due to excessive workability of the mixed material due to an excessive amount of core material compared to the amount of water added, and 50 In the case of excess part by weight, the water used in excess remains in the molded body after completion of the hydration reaction of the binder to form bubbles, so the strength is lowered. Therefore, it is preferable to use 40 to 50 parts by weight of water with respect to 100 parts by weight of the binder. Do.

On the other hand, the composite insulating material using the porous ceramic ball and the natural fiber as a core material of the present invention to prepare a binder by mixing the calcined activated ocher and cement in a weight ratio of 1: 1. Then, 40 to 50 parts by weight of water is added to 100 parts by weight of the binder to form a paste.

In addition, 20 to 30 parts by weight of a porous ceramic ball mixed with a type A porous ceramic ball having a diameter of 4.45mm and a B type porous ceramic ball having a diameter of 2.60 mm in a weight ratio of 1: 1 with respect to 100 parts by weight of the binder and wood chips; Heartwood is prepared by mixing 6-8 parts by weight of natural fiber mixed with sawdust in a weight ratio of 1: 1.

The core material thus prepared is added by mixing 26 to 38 parts by weight based on 100 parts by weight of the binder on the paste.

The mixture is placed in a test body manufacturing mold and cured to prepare a composite insulating material using the porous ceramic ball of the present invention and natural fiber as a core material.

As described above, the present invention improves the waterproofness of natural fibers using activated ocher, and by using a porous ceramic ball and natural fibers as a core material, as well as excellent insulation and strength as a semi-non-combustible product, eco-friendly It is effective to provide a composite insulation.

1 is a graph showing the change in compressive strength when the water / binder (W / B) ratio of the composite insulating material using a porous ceramic ball and natural fiber as a core material is 40%.
Figure 2 is a graph showing the change in compressive strength when the water / binder (W / B) ratio of the composite insulating material using a porous ceramic ball and natural fiber as a core 45%.
Figure 3 is a graph showing the change in compressive strength when the water / binder (W / B) ratio of the composite insulating material using a porous ceramic ball and natural fiber as a core 50%.
Figure 4 is a graph showing the change in bending strength when the water / binder (W / B) ratio of the composite insulating material using a porous ceramic ball and natural fiber as a core material is 40%.
5 is a graph showing the change in flexural strength when the water / binder (W / B) ratio of the composite insulating material using a porous ceramic ball and natural fiber as a core material is 45%.
Figure 6 is a graph showing the change in bending strength when the water / binder (W / B) ratio of the composite insulating material using a porous ceramic ball and natural fiber as a core 50%.
Figure 7 is a graph showing the change in compressive strength after performing a hot water test for 28 days in hot water at 90 ℃ of the composite insulating material using a porous ceramic ball and natural fiber as a core material.
8 is a graph showing the change in flexural strength after performing a hot water resistance test for 28 days in hot water at 90 ℃ of the composite insulating material using a porous ceramic ball and natural fiber as a core material.
9 is a graph showing changes in total pore volume before and after 28 days of hot water resistance test in hot water at 90 ° C. for the composite insulating material test specimens of Examples 6 to 10 (water / binder ratio 45%).
10 is a graph showing changes in the average diameter of pores before and after a 28-day hot water resistance test in hot water at 90 ° C. for the composite insulating material test specimens of Examples 6 to 10 (water / binder ratio 45%).
FIG. 11 is a graph showing changes in density before and after 28 days of hot water resistance test in hot water at 90 ° C. for the composite insulating material test specimens of Examples 6 to 10 (water / binder ratio 45%). FIG.
12 is a graph showing changes in porosity before and after 28 days of hot water resistance test in hot water at 90 ° C. for the composite insulating material test specimens of Examples 6 to 10 (water / binder ratio 45%).
13 is a scanning electron micrograph of the composite insulating material specimen of Example 8.
14 is a graph showing the results of testing the thermal conductivity of the composite insulating material specimens of Examples 6 to 10.

Hereinafter, the present invention will be described in more detail with reference to Examples. However, the following examples are not intended to limit the scope of the present invention, and ordinary changes by those skilled in the art are possible within the scope of the technical idea of the present invention.

<Examples>

Preparation of Composite Insulation Material Using Porous Ceramic Ball and Natural Fiber as Core Material

The binder was prepared by mixing the activated ocher and portland cement produced by firing at 800 ° C. in a 1: 1 weight ratio.

Water was added to the binder to form a paste, followed by mixing core materials consisting of natural fibers and porous ceramic balls.

The mixture was placed in a test body preparation mold and cured to prepare a test body.

The mixing ratios of the water, the binder, the natural cellulose, and the porous ceramic ball are shown in Table 1 below.

Here, the natural fiber was prepared by mixing wood chips: sawdust in a 1: 1 weight ratio, and the porous ceramic balls were mixed in a 1: 1 weight ratio of A type (diameter 4.45 mm): B type (diameter 2.60 mm). It was prepared by.

&Lt; Test Example 1 >

Compressive strength test according to water / binder ratio

The compressive strength test was performed by the KS F 2405 for the composite insulating material test specimens of Examples 1 to 15.

Table 2 and Figs. 1 to 3 show changes in compressive strength of 3 days, 7 days and 28 days when the water / binder (W / B) ratio is 40, 45 and 50%, respectively.

As can be seen in Table 2 and FIGS. 1 to 3, in the case of water / binder ratio of 40% in FIG. 1, the compressive strength was slightly increased at 29% in the core / binder ratio, but the compressive strength was slightly increased in the core / binder ratio more than that. It was found to decrease by. This is considered to have the highest compressive strength because 40% water / binder (W / B) ratio and 29% core / binder ratio were able to make the compact specimen with the best filling effect and workability. On the whole, the compressive strength is gradually decreased as the core / bond ratio is increased due to the excessive amount of core material compared to the amount of added water, and thus the workability of the mixed material is not formed to form a dense specimen.

In FIG. 2, when the water / binder ratio was 45%, the core material / binder ratio was 32%, indicating that the compressive effect of the core material was excellent and the workability was made, resulting in a compact specimen, thereby indicating the maximum compressive strength.

In FIG. 3, when the water / binder ratio is 50%, the compressive strength gradually decreases as the core / binder ratio increases. It is thought that the water / binder ratio is increased rather than the reinforcement effect of the core material, so that the excess used water forms voids in the matrix, and thus the compressive strength is reduced because the bonding force between the matrix and the core material is reduced.

In summary, the higher the water / binder ratio, the better the workability and the easier it is to mold the specimens. However, the excess water remains in the molded body after the hydration reaction of the binder, forming a bubble, thus compressing strength. Since the amount of water used is reduced, it is thought that it is good to maintain high strength physical properties if the minimum amount is used within a range that does not interfere with molding.

&Lt; Test Example 2 &

Flexural strength test according to water / binder ratio

The flexural strength test was performed by the KS F 2408 for the composite insulating material test specimens of Examples 1 to 15.

Table 2 and Figures 4 to 6 show the changes in bending strength of 3 days, 7 days and 28 days when the water / binder (W / B) ratio is 40, 45, 50%, respectively.

As can be seen in Table 2 and FIGS. 4 to 6, regardless of the increase in water / binder ratio, the flexural strength was continuously increased as the core / binder ratio was increased. This is thought to be because the reinforcing effect on flexural strength is much greater than the reinforcing effect on compressive strength as the amount of natural fiber used as core material increases.

In addition, the flexural strength was much higher in the flexural strength as the water / binder ratio was lower than the compressive strength.

<Test Example 3>

Hot water resistance test

The composite insulating material test specimens of Examples 1 to 15 were subjected to a hot water test for 28 days in hot water at 90 ° C., and then compression and bending strength were measured and compared with the strength before the test.

The results are shown in Table 2 and FIGS. 7 to 8.

As can be seen from Table 2 and FIGS. 7 to 8, the compressive strengths measured after the heat resistance test are lower than the compressive strengths measured before the water resistance test regardless of the water / binder ratio change in Tables 2 and 7. I could see the result. This is due to the fact that activated ocher, which is a component of the binder, is promoted by the hydration reaction in hot water, so that the strength decreases because natural fiber, which is one component of the core, expands and expands in hot water for a long time. I think.

In Table 2 and FIG. 8, the bending strength measurement results showed that the bending strength was significantly reduced than that of the compressive strength. This is because the reinforcing effect of natural fiber is greater in flexural strength than compressive strength, and it is considered that the reduction of flexural strength is greater than compressive strength because the reinforcing effect is decreased by expanding in hot water.

<Test Example 4>

Pore analysis

Total pore volume measurement

The total pore volume of the composite insulation specimens of Examples 6 to 10 (water / binder ratio 45%) was measured before and after the hot water resistance test as in Example 3, and the results are shown in FIG. 9.

As can be seen in FIG. 9, the total pore amount was decreased as the core / binder ratio was increased, and the total pore amount measured after the heat resistance test was decreased compared to the total pore amount measured before the heat resistance test.

The total pore volume decreases as the core / binder ratio increases, so that the excess water is absorbed by the natural fiber and the porous ceramic ball to ensure fluidity as the amount of the natural fiber and the porous ceramic ball used as the core increases. It is thought that the amount of excess water that can exist as pores after the hydration of activated ocher, one component of, is reduced.

In addition, the decrease in total pore volume after the hydrothermal resistance test is thought to be a result of the formation of dense tissues by promoting the hydration reaction of activated ocher, a component of the binder in the hydrothermal water.

Measurement of average diameter of pores

The average diameter of the pores before and after the hot water resistance test was measured for the composite insulation specimens of Examples 6 to 10 (water / binder ratio 45%) as in Test Example 3, and the results are shown in FIG. 10.

As can be seen in Figure 10, the average diameter of the pores according to the core / binder ratio was found to be almost unchanged, but the diameter of the pores measured after the hydrothermal resistance test compared to the diameter of the pores measured before the hydrothermal resistance test It was found to be close to 50%. This is thought to be the result of hydration reaction of activated ocher which is one component of binder in hot water, which is transformed into dense tissue.

Measurement of density

Density was measured before and after the hot water resistance test as in Example 3 for the composite insulating material test specimens of Examples 6 to 10 (water / binder ratio 45%) and the results are shown in FIG.

As can be seen in Figure 11, as the core / binder ratio is increased, the density tends to increase slightly, and the density measured after the hydrothermal resistance test is slightly increased compared to the density measured before the hydrothermal resistance test. Is showing.

The increase in density as the core / binder ratio increases is thought to be due to the formation of dense tissue due to the absorption of excess water from natural fibers and porous ceramic balls.

In addition, the increase in density by the hydrothermal resistance test is thought to be a result of the formation of dense tissues by promoting the hydration reaction of activated ocher, a component of the binder, in the hydrothermal water.

Porosity measurement

The porosity was measured before and after the hot water resistance test as in Test Example 3 with respect to the composite insulating material test samples of Examples 6 to 10 (water / binder ratio 45%) and the results are shown in FIG.

As can be seen in FIG. 12, the porosity tends to decrease slightly as the core / bond ratio increases, and the porosity measured after the hydrothermal resistance test is slightly decreased compared to the porosity measured before the hydrothermal resistance test. Is showing.

The decrease in porosity with increasing core / binder ratio is thought to be a result of dense structure due to absorption of excess fiber by natural fiber and porous ceramic balls, and the decrease in porosity by hot water resistance test. It is thought to be the result of the formation of dense tissues by promoting the hydration reaction of activated ocher which is one component of the binder.

&Lt; Test Example 5 >

SEM analysis

Example 8 The composite insulation specimen was washed with acetone, dried, and then examined for microstructure of the specimen using a scanning electron microscopy (SEM).

The results are shown in Fig.

As can be seen in Figure 13, it can be observed that acicular hydrate crystals are well grown in the hydrate of activated ocher. These results indicate that the raw ocher has no component which can cause the pozzolanic reaction, but the activated ocher is prepared by calcining the raw ocher at 800 ° C. and quenching the raw ocher to produce a component that can cause the pozzolanic reaction. As these acicular crystals grow, bonds are formed between the materials and strength is expressed.

<Test Example 6>

Thermal conductivity measurement

ASTM C518, ISO 8301 and KS M 3809, KS with composite (300mm) × length (300mm) × thickness (20mm) of composite insulation material specimens of Examples 6 to 10 to examine the characteristics of thermal conductivity according to the addition rate of core material The thermal conductivity test was carried out according to the measurement method of M 9016.

The results are shown in FIG.

As can be seen in Figure 14, as the addition rate of the core material consisting of natural fibers and porous ceramic balls is increased, the thermal conductivity was significantly reduced to show excellent performance as a heat insulating material.

In general, considering that the thermal conductivity of concrete is 1.74 W / m · K, the thermal conductivity of the composite insulating material of the present invention is about 0.2 to 0.17 W / m · K, so it can be seen that the thermal insulation is excellent at about 1/10 of the thermal conductivity of the concrete. there was.

This is considered to be the result of natural fibers and ceramic balls as a porous material because they have superior heat insulating properties as compared to activated ocher which is one component of the binder.

<Test Example 7>

Semi-non-burning material  Performance test

Three composite insulating material test specimens of Examples 6 to 10 were prepared, and the size of the test specimens was used as the width (220 mm) × length (220 mm) × thickness (20 mm). The test specimens were dried for at least 30 days in a well-ventilated room after drying for at least 24 hours in a dryer at 35-45 ^o C, and cured for at least 24 hours in a desiccator. KS F 2271: 2006 (Gas Hazard Test) And the KS F ISO 5660-1: 2008 (heat release test) semi-combustible test method.

The results are shown in Table 3.

Table 3 below shows the results of the analysis conducted by the Korea Institute of Construction and Environmental Testing. According to the Ministry of Land, Transport and Maritime Affairs Publication No. 2009-866 (flame retardant performance criteria for building interior finishing materials) All release tests must be passed.

As can be seen in Table 3, it was found that the composite insulating material of the present invention prepared using a natural fiber and a porous ceramic ball as a core material and using activated ocher as a binder is suitable as a semi-combustible material.

Claims (7)

Activated ocher: calcined raw ocher: 40 to 50 parts by weight of water and 26 to 38 parts by weight of core material composed of porous ceramic balls and natural fibers, based on 100 parts by weight of the binder prepared by mixing the cement in a weight ratio of 1: 1 Composite insulation using a porous ceramic ball and natural fiber as a core material, characterized in that made.
The method of claim 1,
The core material is a composite insulating material using a porous ceramic ball and natural fiber as a core, characterized in that consisting of 20 to 30 parts by weight of porous ceramic ball and 6 to 8 parts by weight of natural fiber with respect to 100 parts by weight of the binder.
The method according to claim 1 or 2,
The porous ceramic ball is a 4.45mm diameter A type porous ceramic ball: B type porous ceramic ball with a diameter of 2.60mm is composed of a weight ratio of 1: 1,
The natural fiber is a composite heat insulating material using a porous ceramic ball and natural fiber as a core, characterized in that wood chips: sawdust is composed of a weight ratio of 1: 1.
a) mixing the fired activated ocher: cement in a weight ratio of 1: 1 to prepare a binder;
b) adding water to the binder of step a) to form a paste; And
c) a method of manufacturing a composite insulating material using a porous ceramic ball and a natural fiber as a core material comprising the step of mixing the core material consisting of a porous ceramic ball and a natural fiber in the binder of step b).
5. The method of claim 4,
The water is added 40 to 50 parts by weight based on 100 parts by weight of the binder,
The core material is a method for producing a composite insulating material using a porous ceramic ball and natural fiber as a core material, characterized in that 26 to 38 parts by weight based on 100 parts by weight of the binder.
The method of claim 5,
The core material is a composite ceramic material using a porous ceramic ball and natural fiber as a core, characterized in that consisting of 20 to 30 parts by weight of porous ceramic ball and 6 to 8 parts by weight of natural fiber with respect to 100 parts by weight of the binder.
7. The method according to any one of claims 4 to 6,
The porous ceramic ball is a 4.45mm diameter A type porous ceramic ball: B type porous ceramic ball with a diameter of 2.60mm is composed of a weight ratio of 1: 1,
The natural fiber is a method of manufacturing a composite thermal insulation material using a porous ceramic ball and natural fiber as a core, characterized in that wood chips: sawdust is composed of a weight ratio of 1: 1.

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