KR101284470B1 - Nonflammable light-weight pannel by advancing the water-proofing and wear resistance and producing method thereof - Google Patents

Abstract

PURPOSE: A manufacturing method of a non-flammable lightweight panel is provided to improve surface hardness or surface strength and wear resistance or scratch resistance by forming a surface reinforcement layer on a surface of hardened lightweight material. CONSTITUTION: A manufacturing method of a non-flammable lightweight panel comprises following steps. (a) A lightweight green compact is manufactured by mixing a powder binder, water, and expanded perlite. (b) The green compact on the step (b) is cured for 1-2 hours at high temperature of 60-120 degrees C. And (c) a surface reinforcement layer is formed by spraying magnesia phosphate based coating material on the surface of the dried and cured green compact. The lightweight green compact comprises 20-70 part by weight of the water and 30-150 part by weight of the expanded perlite about 100 part by weight of the powder binder. The powder binder comprises 40-99 weight percent of alpha-hemihydrate gypsum and 1-60 weight percent of white cement. The magnesia phosphate based coating material comprises 20-60 weight percent of fine grinded potassium phosphate monobasic (KH2PO4), 10-50 weight percent of magnesium hydroxide (Mg (OH)2), and 25-50 weight percent of the water. [Reference numerals] (AA) Start; (BB) End; (S10) Mold a lightweight product into a specific shape by mixing a power binder consisting of gypsum hemihydrate and white cement, mixed water, and expanded perlite; (S20) Cure the molded product at 60-120 degrees C for 1-2 hours; (S30) Form a surface-reinforcing layer by spreading a magnesia phosphate salt-based spreading agent onto the surface of the molded product

Description

Non-flammable lightweight panel with improved water resistance and abrasion resistance and its manufacturing method {NONFLAMMABLE LIGHT-WEIGHT PANNEL BY ADVANCING THE WATER-PROOFING AND WEAR RESISTANCE AND PRODUCING METHOD THEREOF}

The present invention relates to a non-flammable lightweight panel with improved water resistance and abrasion resistance, and to a method for manufacturing the same. The present invention relates to a non-flammable lightweight panel having improved water resistance and abrasion resistance, which can be used as an interior or exterior material of a building by improving insulation, sound insulation, workability, and the like, and a manufacturing method thereof.

Recently, the social demands for light weight of buildings and improvement of fire resistance have been increasing all over the world, and in particular, such performances are increasingly required in interior partition walls, interior panels, exterior walls and exterior panels of buildings. , Lightweight sandwich panels, ALC panels / blocks, lightweight hardeners using lightweight aggregates (such as expanded pearlite or expanded vermiculite) have been developed.

The lightweight sandwich panel is made of organic materials such as styropol and urethane as the core material, which is very lightweight, relatively inexpensive, and has excellent thermal insulation performance, and is mainly used as a building material for industrial buildings. As described above, various problems have been pointed out such as high flammability, which makes it difficult to extinguish the fire due to the rapid spread of flames when igniting, and moreover, a large amount of various harmful gases are generated during combustion.

The ALC panel / block is foam concrete manufactured by autoclave curing at high temperature and high pressure using silica sand, lime, and blowing agent, etc., but it has advantages such as excellent heat insulation and fire resistance, light weight, and convenient processing. Problems such as difficulty in application to a location affected by moisture due to large water absorption and poor water resistance have been pointed out.

The lightweight hardened body using the light aggregate (expanded pearlite, expanded vermiculite, etc.) is a product formed by combining the light aggregate with various binders (such as cement or gypsum or sodium silicate), and includes fire resistance, light weight, heat insulation, thermal insulation, and heat shielding. It has excellent voice and no risk of toxic gas emission in case of fire.But it is easy to be damaged due to poor abrasion resistance and scratch resistance due to its high absorption (wetness) and low hardness. It is pointed out that problems such as edge breakage occur easily during transportation and construction.

As described above, the manufacturing technology of eco-friendly lightweight panel that satisfies the social demands of consumers by combining absorbency, water resistance, abrasion resistance, scratch resistance, etc. with excellent fire resistance (non-flammability) and light weight has not been completed until now. .

Accordingly, the present invention has been made to solve the above-mentioned problems, and an object of the present invention is to form a surface hardening layer on the surface of a light hardened body, thereby improving surface hardness, surface strength, abrasion resistance, and scratch resistance, thereby carrying and constructing and To provide a non-combustible lightweight panel and its manufacturing method that can suppress the damage and damage to the surface or edge of the lightweight panel when in use.

Another object of the present invention is to provide a non-combustible lightweight panel and a method for manufacturing the same, which can improve the absorption resistance or resistance to water resistance even when applied to water or moisture exposure by imparting the absorption resistance and water resistance to the surface reinforcement layer. To provide.

It is still another object of the present invention to use a magnesia phosphate-based coating material which cures within 1 hour after applying the surface reinforcement layer, and has excellent non-flammability, light weight, heat insulation, abrasion resistance, water resistance, and aesthetic appearance on a surface within a short time. It is to provide a non-combustible lightweight panel and a method of manufacturing the same.

According to a feature of the present invention for achieving the above object, the present invention, in the manufacturing method of a non-flammable lightweight panel improved water resistance and wear resistance by utilizing expanded pearlite, powder binder consisting of hemihydrate gypsum and back cement, blending Mixing molding step of mixing the water and expanded pearlite to form a lightweight molded product into a predetermined shape; Dry curing step of curing the molded product produced in the mixed molding step for 1 to 2 hours at a high temperature of 60 ~ 120 ℃; And a surface hardening step of forming a surface hardening layer by spraying the magnesia phosphate coating material on the surface of the dried and cured molded body by spraying.

And the lightweight molded body is composed of 20 to 70 parts by weight, 30 to 150 parts by weight of expanded pearlite with respect to 100 parts by weight of the powder binder, the powder binder is 40 to 99% by weight of the hemihydrate gypsum and 1 to 60% by weight It consists of a back cement.

In addition, the lightweight molded article may be added in the range of 1 to 10 parts by weight based on 100 parts by weight of the powder binder from the group consisting of fibers, water repellents, high fluidizing agent.

In addition, the magnesia phosphate coating material is 20 to 60% by weight of finely ground potassium phosphate (KH ₂ PO ₄ ), 10 to 50% by weight of magnesium hydroxide (Mg (OH) ₂ ), and 25 to 50% by weight of the blended water Is made of.

At this time, the magnesia phosphate-based coating material may be added in the range of 0.1 to 10 parts by weight based on 100 parts by weight of the coating agent from the group consisting of inorganic pigments, wollastonite powder, acrylic resin, boric acid, water repellent.

On the other hand, the composition of the non-combustible lightweight panel according to the present invention is manufactured by the manufacturing method according to the present invention described above.

According to the non-combustible lightweight panel and the manufacturing method thereof having improved water resistance and abrasion resistance according to the present invention, the hardness and wear resistance of the panel surface are greatly improved while maintaining the excellent incombustibility, lightness, and heat insulation properties of the lightweight panel using expanded pearlite. It is effective to prevent damage and damage to the panel body or the corners during transportation, construction and use.

In addition, according to the present invention is formed so that the absorption prevention and impermeable layer is integrally formed on the surface layer of the lightweight panel using expanded pearlite to greatly improve the absorption resistance and water resistance of the lightweight panel can be used in the place where moisture or moisture acts. have.

Furthermore, according to the present invention, by applying a light hardening body based on fast hard alpha-hydrated gypsum and a magnesia phosphate coating material cured within 1 hour, a non-flammable lightweight panel can be manufactured in a short time, thereby significantly improving productivity. It is composed of pure inorganic materials, which is eco-friendly and has the advantage of completely eliminating harmful gas in the event of fire.

1 is a flow chart showing a manufacturing method of a non-flammable lightweight panel according to the present invention;
Figure 2 is a photograph showing the surface properties of the non-combustible lightweight panel according to an embodiment of the present invention,
Figure 3 is a photograph showing the corner details of the non-combustible lightweight panel according to an embodiment of the present invention,
Figure 4 is a photograph showing the surface absorption performance of the non-flammable lightweight panel according to an embodiment of the present invention,
Figure 5 is a photograph showing the details of the broken corner portion during transportation in the lightweight panel manufactured by the comparative example illustrated in the present invention,
Figure 6 is a photograph of the scratches generated by scratching the surface portion during transportation in the lightweight panel manufactured by the comparative example illustrated in the present invention.

Hereinafter, with reference to the accompanying drawings, a non-combustible lightweight panel having improved water resistance and abrasion resistance according to the present invention and a manufacturing method thereof will be described in more detail.

1 is a flowchart illustrating a method of manufacturing a non-flammable lightweight panel according to the present invention.

In the method for manufacturing a non-flammable lightweight panel having improved water resistance and abrasion resistance according to the present invention, a powder binder consisting of semi-hydrated gypsum and back cement, mixed water and expanded pearlite are mixed to produce a lightweight molded article and molded into a predetermined shape. It starts from the step.

In more detail, the lightweight molded body corresponds to the core material (core) of the non-flammable lightweight panel of the present invention, and is composed of alpha-type hemihydrate gypsum, back cement, compounded water and expanded pearlite, and alpha type hemihydrate gypsum and back cement. The powder binder is composed of 20 to 70 parts by weight, 30 to 150 parts by weight of expanded pearlite, and 40 to 99% by weight of alpha-type hemihydrate gypsum and 1 to 60% by weight of cement. It consists of.

Here, as the powder binder, the alpha-type hemihydrate gypsum can be used to express ultra-high hardness and non-shrinkage, which is inherent in the alpha-type hemihydrate gypsum, and the cured product is used by mixing 1 to 60% by weight of the cement cement. It can improve the whiteness and long-term strength of and improve the weak water resistance of hardened gypsum hardened body.

Further, the lightweight molded article may be added 1 to 10 parts by weight of one or more additives from the group consisting of fibers, water repellents, and high fluidizing agents based on 100 parts by weight of the powder binder. That is, as an additive, the fiber is used to increase the impact resistance, bending strength and peeling peel resistance of the lightweight molded article, and there is no limitation on the type, but short fibers such as polypropylene fiber, nylon fiber, PET fiber, etc. for the purpose of light weight. Preference is given to using.

In addition, the water repellent is used to improve the absorption resistance and water resistance of the lightweight molded article, there is no limitation on the type, but the use of silicone-based or silane-based water repellent.

On the other hand, the high fluidizing agent is used to improve the strength and water-tightness of the cured paste by reducing the number of units while ensuring the fluidity of the paste, there is no particular limitation.

In addition, in the mixing molding step, a powder binder or an additive and a blending water are added, the paste slurry is beamed, and then expanded pearlite is added and mixed to prepare a lightweight mixture, and the prepared lightweight mixture is filled into a mold having a predetermined shape. Molding is performed by vibrating pressure for a predetermined time (step S10).

Next, the drying curing step of curing the molded product produced in the mixing molding step for 1 to 2 hours at a high temperature of 60 ~ 120 ℃ is carried out.

In the dry curing step, it is preferable to perform dry curing with hot air at a high temperature of about 60 ~ 120 ℃ so that the lightweight molded product molded in the mixing molding step can be cured and dehydrated in a short time, the curing time is about 1 ~ Two hours is appropriate, and after curing is completed, it is maintained at room temperature (step S20).

Finally, a surface hardening step is performed to form a surface hardening layer by applying a magnesia phosphate coating material to the dry cured molded body by spraying.

The surface reinforcing step is to form a surface reinforcement layer on the surface of the light-weight panel by coating the magnesia phosphate-based coating material to the thickness of about 0.1 ~ 2㎜ on the surface of the cured lightweight molded body, basically magnesia phosphate-based ceramic coating material It is applied directly to the surface of the lightweight molded body by spraying equipment to integrate the surface reinforcement layer and the lightweight molded body, and curing for about 1 hour at room temperature after coating to complete the non-combustible lightweight panel improved water resistance and wear resistance of the present invention.

Here, the magnesia phosphate coating material is a product designed to be touch-dried within about 5 minutes after application, and to be cured within 1 hour to allow service return, and the magnesia phosphate coating material is finely ground potassium phosphate (KH). ₂ PO ₄ ) 20 to 60% by weight, magnesium hydroxide (Mg (OH) ₂ ) 10 to 50% by weight, characterized in that the composition consists of 25 to 50% by weight, is an environmentally friendly inorganic coating material composed of pure inorganic systems.

Furthermore, in the present invention, in order to improve the performance of the coating material, 0.0-10 parts by weight may be used by adding at least one of inorganic pigments, wollastonite powder, acrylic resin and boric acid to 100 parts by weight of the coating material ( Step S30).

Hereinafter, an embodiment according to the present invention will be described.

Figure 2 is a photograph showing the surface properties of the non-flammable lightweight panel according to an embodiment of the present invention, Figure 3 is a photograph showing the details of the corner of the non-flammable lightweight panel according to an embodiment of the present invention, Figure 4 is an embodiment of the present invention Figure 5 is a photograph showing the surface absorption performance of the non-combustible lightweight panel according to the example, Figure 5 is a photograph showing the details of the damaged corner portion during transportation in the lightweight panel manufactured by the comparative example illustrated in the present invention, Figure 6 In the light weight panel manufactured by the comparative example exemplified in the present invention, a scratch is generated on the surface of the panel during transportation.

[Example]

Step 1: In the mixing molding step, 900 g of alpha-type half-water gypsum (Yoosung Tech), 100 g of back cement (Union Cement) and 350 g of mixed water (tap water) are added to the bibim mixer, and then mixed for 1 minute, followed by expansion. 550 g of pearlite (Gyeongdong Ceratech Co., Ltd.) was added thereto, and the mixture was prepared for 2 minutes, and the resultant mixture was filled in a molding mold, and then subjected to pressurization and vibration molding using a table vibrator. .

Step 2: In the dry curing step, the molded lightweight molded body was cured for 60 minutes in a high temperature curing chamber having a temperature of 85 ± 5 ° C. and a humidity of 30 ± 10%.

Step 3: In the surface reinforcing step, the two-component cartridge spraying equipment is applied to magnesia phosphate coating material (AMS) consisting of 405 g of finely ground potassium phosphate (Youngjin Chemical Co., Ltd.), 375 g of magnesium hydroxide, and 220 g of water. The non-flammable lightweight panel of the present invention was completed by applying a thickness of about 0.3 to 0.5 mm on the surface of the lightweight molded article.

[Comparative Example]

Step 1: In the mixing molding step, 1,000 g of alpha-type half-water gypsum (Yoosung Tech) and 350 g of mixed water (tap water) are added to a bibim mixer, and then beamed for 1 minute, followed by 450 g of expanded pearlite (Kyungdong Ceratech Co., Ltd.). The mixture was prepared by injecting the mixture for 2 minutes, and the mixture was filled in a molding mold, and then subjected to pressure vibration molding using a table vibrator, and maintained for about 1 hour indoors.

Step 2: In the dry curing step, the lightweight molded product was prepared by curing the molded lightweight molded product in a high temperature curing chamber having a temperature of 85 ± 5 ° C. and a humidity of 30 ± 10% for 90 minutes.

Experimental Results and Analysis

The test specimens of Examples and Comparative Examples prepared as described above were observed and measured for density, incombustibility (combustibility), water absorption, moisture permeability, surface hardness, dust generation, and surface properties. Table 1].

division Example Comparative example Test Methods density
(ton / ㎥) 0.54 0.51 Weight ÷ volume, test body 10 × 10 × 10㎝, measured after drying (40 ± 3 ℃, RH 10%) for 24 hours after manufacture combustibility Not burning Not burning Evaluated by the diffusion of flames when the surface of the test specimen was directly heated by gas stove Absorption rate (%) 12.3 57.9 Percentage of the measured weight divided by the weight before immersion after immersion of the test body (10 × 10 × 10 cm) for 24 hours Moisture permeability Almost infiltrate Instantaneous penetration / absorption Judging whether the water penetrates into the test body when water is injected using the eyedropper on the test surface. Surface Hardness (H) 4.3 0.5 or less Measured by pencil hardness tester Dust
Occurrence Does not occur at all Large amount of dust Evaluate the degree of bleeding from the surface of the specimen by hand Surface properties lubricity coarseness Evaluation by observing the surface of the test body manufactured by the naked eye Overall assessment Very good Bad

As shown in [Table 1], the Examples and Comparative Examples showed substantially the same level in density and combustibility, but the Examples showed significantly improved performance compared to the Comparative Examples in water absorption and surface hardness, and water permeability and dust generation and In terms of surface properties it can be seen that the Example is superior to the Comparative Example.

This enhances the water resistance while increasing the surface hardness by the surface hardening layer formed through the surface hardening step according to the present invention (see FIG. 4), and strengthens the binding of the lightweight molded body to prevent dust generation and smooth the surface properties. It seems to be.

Accordingly, as shown in FIG. 6, the lightweight panel according to the comparative example is often broken in the corner portion during transportation, but as shown in FIG. 3, in the embodiment according to the present invention, the lightweight panel is transported. Even when an impact is applied, the incidence of breakage of the edge portion is significantly reduced. That is, in the embodiment according to the present invention can withstand an external impact of about 8 times or more than the comparative example.

In addition, as shown in FIG. 7, in the light weight panel according to the comparative example, scratches are more likely to occur on the surface during transportation, but in the embodiment according to the present invention, the scratch hardness is remarkably large because the surface hardness is significantly larger than that of the comparative example. Degrades.

It is to be understood that the invention is not limited to the disclosed embodiment, but is capable of many modifications and variations within the scope of the appended claims. It is self-evident.

Claims (6)

In the manufacturing method of a non-flammable lightweight panel improved water resistance and wear resistance by utilizing expanded pearlite,
A powder molding step consisting of a half water gypsum and a back cement, and a mixing molding step of mixing the mixing water and the expanded pearlite to form a lightweight molded product into a predetermined shape;
Dry curing step of curing the molded product produced in the mixed molding step for 1 to 2 hours at a high temperature of 60 ~ 120 ℃; And
And a surface hardening step of forming a surface hardening layer by spraying the magnesia phosphate-based coating material on the surface of the dried and cured molded body by spraying.
The lightweight molded body is composed of 20 to 70 parts by weight of the blended water and 30 to 150 parts by weight of expanded pearlite, based on 100 parts by weight of the powder binder,
The powder binder is composed of 40 to 99% by weight of alpha-type hemihydrate gypsum and 1 to 60% by weight of back cement,
The lightweight molded article is added with one or more additives in the range of 1 to 10 parts by weight based on 100 parts by weight of the powder binder from the group consisting of fibers, water repellents, high fluidizing agents,
The magnesia phosphate coating material is composed of 20 to 60% by weight of finely ground potassium monophosphate (KH ₂ PO ₄ ), 10 to 50% by weight of magnesium hydroxide (Mg (OH) ₂ ), and 25 to 50% by weight of the blended water. under,
The magnesia phosphate coating material is water resistant and abrasion resistance, characterized in that at least one additive is added in the range of 0.1 to 10 parts by weight based on 100 parts by weight of the coating agent from the group consisting of inorganic pigments, wollastonite powder, acrylic resin, boric acid, water repellent agent. This improved non-combustible lightweight panel manufacturing method. delete delete delete delete Non-combustible lightweight panel, characterized in that produced by the manufacturing method of claim 1.

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