KR101473756B1 - Complex porous ceramic panel - Google Patents

Abstract

The present invention relates to a complex porous ceramic panel. Specifically, a complex porous ceramic panel for afforestation in a rooftop is composed of a supporting layer and a draining layer and is accordingly allowed to cultivate plants, more specifically, comprising 3-50 wt% of a lightweight aggregate and 50-97 wt% of a calcium sulphate based inorganic binding agent. To solve an existing problem like a long-term manufacturing panel, in the present invention provided is a complex porous ceramic panel which uses porous ceramic materials and thus is composed of at least two layers by using.

Description

COMPLEX POROUS CERAMIC PANEL [0002]

The present invention relates to a composite porous ceramic panel, and more particularly, to a composite porous ceramic panel for rooftop greening which is composed of a support layer and a drainage layer and is capable of plant growth.

In order to prevent global warming and to save energy, it is necessary to record the rooftop of the building by plant material and the technology related to it is urgent. A common technique for recording the rooftops of conventional buildings is the method of cultivating soil using artificial ceramic soil particles. However, this method requires a block layer to prevent plant rooting, a drainage layer to drain excess water, a growing layer to grow the roots of the plant, a soil layer to supply nutrients, And the construction period is long and troublesome.

On the other hand, it is a simple and useful rooftop greening method to grow and plant plants in a porous ceramic material and then move them to a place where they want to record, such as a building roof.

In order for plants to be planted on the roof, it is desirable that the porous ceramic material be made in the form of a porous ceramic panel having a certain strength and thermal stability and it needs to be lightweight. Furthermore, in order for the plant to grow normally, excess moisture must be discharged, so that the porous ceramic panel must have good drainage, but the degree of moisture required by the plant must also have water retention properties. Finally, the pH of the porous ceramic panel is capable of growing in a neutral growth environment.

As a technique for manufacturing porous ceramic materials, a high-temperature sintering method using a foaming agent and a room temperature curing method using a geopolymer using a reaction of an alkaline activator solution with a reactive oxide are known.

 According to the International Application Publication No. WO201200036218A1, a method of molding clay, sewage sludge and diatomaceous earth, drying and then sintering at 950 to 1200 is disclosed. Porous ceramics produced by this method are excellent in strength, drainage and moisture adsorption, but have a disadvantage in that energy consumption, manufacturing cost, and manufacturing time are required because the manufacturing process is performed by molding, drying, and sintering.

In order to overcome such disadvantages of high production cost, a technique which does not use diatomaceous earth having a limited production area and high production cost is disclosed in WO201300027792A1.

However, it is difficult to say that such an improvement technique is also improved due to the same manufacturing process. When sintering the molded body of clay and sewage sludge at high temperature, energy consumption is large and waste sludge is incinerated and a large amount of waste gas is generated. It can be said that the manufacturing method can not be done.

Examples of the ceramic material manufacturing technology using the geopolymer include Korean Patent Registration Nos. 10-0852215, 10-0846821 and 10-0852215, and Korean Patent Application Laid-Open No. 10-2012-0044011. These manufacturing techniques all relate to a geopolymer high-strength ceramic material which is aged and foamed at a temperature higher than room temperature together with a liquid silicate compound together with volcanic ash, fly ash, meta kaolin, aluminum powder and the like. The porous ceramic material thus produced is unsuitable for use as a plant food panel because it uses a liquid silicate compound having a high pH. This is because the plant can grow at a pH of 6-7 at a slightly acidic and neutral level. On the other hand, all of the cement materials and lightweight foamed concrete foamed using aluminum powder, quicklime and the like have high pH, which is inadequate for planting material panels.

Korean Patent Application Laid-Open No. 10-2010-0070501 related to a porous ceramic block also discloses a method of classifying bottom ash by particle size and mixing peatmoss with cement and calcium sulfate-based binder to provide a high strength drainable block .

However, since the pH is high due to the use of strong alkali cement as in the other conventional techniques described above, it is unsuitable as a panel for planting food and has a long period of production because it must be cured for 7 to 30 days after molding.

The present invention has been made to solve the problems of the prior art described above, and it is an object of the present invention to provide a method of manufacturing a porous ceramics material, which does not require a sintering process with a large energy consumption, The present invention provides a composite porous ceramic panel for rooftop greening comprising two or more layers.

As a means for solving the problems of the present invention, a composite porous ceramic panel

A calcium sulfate-based inorganic binder, or a lightweight aggregate, which is a pearlite or a bottom ash, and a calcium sulfate-based inorganic binder, for weight reduction, and a support layer composed of a bottom support comprising at least one of coco peat, peat moss, pulp or cellulose , A lightweight aggregate, the inorganic binder, a thickener and a surfactant, and a drainage layer disposed on the support layer.

In the composite porous ceramic panel according to the present invention, when the lightweight aggregate is used for lightening the support layer, the lightweight aggregate and the inorganic binder are compounded in a ratio of 3 to 50 wt%: 50 to 97 wt%, and the lightweight aggregate, The inorganic binder, the organic fiber, the thickener, and the surfactant in an amount of 20 to 65 wt%: 30 to 75 wt%: 1 to 4 wt%: 0.1 to 3 wt%: 0.1 to 1 wt%.

In the composite porous ceramic panel according to the present invention,

And a moss-up layer comprising the lightweight aggregate, the inorganic binder, the organic fiber, the thickener, and the surfactant and being laid on the drainage layer,

35 to 45% by weight: 40 to 50% by weight: 5 to 12% by weight: 1 to 5% by weight: 0.1 to 2% by weight of the lightweight aggregate of the moss-up layer, inorganic binder, organic fiber, thickener and surfactant .

The composite porous ceramic panel according to the present invention comprises

Firstly, it can be manufactured in a short time in a wet-cured manner,

Second, since it is manufactured by wet curing without sintering at a high temperature, it is environmentally friendly since energy consumption is low and waste gas is not generated,

Third, because it is lightweight and has strength, it is excellent in mobility and workability, so that it is possible to easily install a recording facility even on the roof of any type of building,

Fourth, by planting a plant such as moss in advance in the composite porous ceramic panel and moving and setting it, the plant can be stably grown,

Fifth, recycling can be recycled as landscaping material because the main ingredient is calcium sulfate, organic matter, and porous ceramics, which are useful for plant growth.

1 is a schematic view showing a layer structure of a composite porous ceramic panel according to the present invention,
FIGS. 2A to 2C are photographs of a composite porous ceramic panel according to the present invention made of a supporting layer of Example 1, a drainage layer of Example 6, and a mushrooming layer of Example 10. FIG.
FIG. 3 (a) is a photograph of a moss growing layer of a composite porous ceramic panel for frost moss cultivation (Example 15), FIG. 3 (b) is a picture of the growth state of a frosty moss after 3 months of planting,
4 is an inspection report on the pH and EC of the drainage layer according to the present invention.

The embodiments of the present invention can be modified into various other forms, and the scope of the present invention is not limited to the embodiments described below.

The embodiments of the present invention are provided to more fully describe the present invention to those skilled in the art. Accordingly, the shapes and sizes of the elements in the drawings may be exaggerated for clarity of description, and the elements denoted by the same reference numerals in the drawings are the same elements. In the drawings, like reference numerals are used throughout the drawings.

In addition, to include an element throughout the specification does not exclude other elements unless specifically stated otherwise, but may include other elements.

Hereinafter, preferred embodiments of the present invention will be described with reference to the accompanying drawings.

The composite porous ceramic panel for rooftop greening according to the present invention comprises

And a drainage layer (second layer) formed on the support layer and including the inorganic binder, the lightweight aggregate, the organic fiber, the thickener, and the surfactant, and a bottom support layer (first layer) comprising an inorganic binder.

The support layer (first layer) is formed of an inorganic binder to form a frame of the entire panel and exhibits sufficient strength to prevent the panel from being damaged during transportation or installation as a bottom layer of the panel.

As the inorganic binder used in the support layer, calcium sulfate-based binders such as anisostearate, anhydrous gypsum, hemihydrate gypsum and natural gypsum may be used singly or in combination.

In the case where the total thickness of the ceramic panel is as thin as 5 cm or less, it is possible to constitute the support layer by using only the inorganic binder alone. However, when the thickness of the ceramic panel is thicker than 5 cm, Aggregates and inorganic binders can be used together.

The lightweight aggregate used in the support layer may be pearlite made by expanding the high temperature of the perlite as an aggregate having a small specific gravity and innumerable pores, or bottom ash discharged as a byproduct from a thermal power plant. The use of the bottom ash having a diameter of 1 to 15 mm desirable.

When the lightweight aggregate and the inorganic binder are used together, they may be used in a blend ratio of 3 to 50 wt%: 50 to 97 wt% of the total dry weight of the support layer. When the weight of the lightweight aggregate is less than 3 wt%, it does not contribute to the weight reduction of the support layer. When the weight of the lightweight aggregate exceeds 50 wt%, the strength of the lightweight aggregate decreases. And most preferably 10 to 40% by weight, depending on the conditions of the construction site. When the inorganic binder is less than 50% by weight, the strength of the inorganic binder is lowered and the support layer can not be performed. When the inorganic binder is more than 97% by weight, the final panel is heavy,

The support layer (first layer) is poured in the form of a slurry mixed with water. The thickness of the support layer can be determined according to the characteristics and use of the panel, the weight of the panel, , There is a fear that the strength is lowered and that it may be damaged during transportation and installation. If it is more than 3 cm, the panel is heavy and workability is deteriorated.

Next, the drainage layer (second layer) is composed of a lightweight aggregate, a calcium sulfate-based inorganic binder, an organic fiber, a thickener and a surfactant and is deposited on the support layer (first layer) And discharges excess amount mainly.

As the lightweight aggregate, pearlite and bottom ash can be used as in the support layer.

As the inorganic binder, as in the support layer, a calcium sulfate-based binder may be used.

In the case of the composite porous ceramic panel according to the present invention, as shown in FIG. 4, since the cement material or silicate compound foamed by using high-pH aluminum powder and quicklime is not used, pH 7.27 is exhibited, It is possible to provide optimum conditions.

Unlike the support layer, the drainage layer is made up of organic fibers, which are intended to provide the water with minimum water holding capacity and to provide a minimum amount of organic matter for the roots of the plant to survive. Coco peat, peat moss, pulp, and cellulosic fibers may be used singly or in combination, and preferably have a length of 1 to 7 mm.

In the present invention, a thickener is added so that a lightweight aggregate, a calcium sulfate inorganic binder, and a blend of organic fibers are mixed with water to prevent cracks from being generated when the drainage layer is dried. Specifically, polyvinyl alcohol, polyvinyl acetate, vinyl acetate resin, acrylic resin, carboxymethylcellulose, methylcellulose, polyethylene oxide, ethylene vinyl acetate, clay, and the like may be used alone or in combination as a thickening agent.

In the present invention, a surfactant is added to impart dispersibility, lubrication, bubble generation, and air entrainment performance so that a lightweight aggregate, a calcium sulfate inorganic binder, and a combination of organic fibers are mixed with water and slurried. Specifically, alkyl type, olefin type, sodium type, benzene type, lignin type, melamine type, naphthalene type, aminosulfonic type, polycarbonate type and polyether type surfactant are used.

20 to 65 wt%: 30 to 75 wt%: 1 to 4 wt%: 0.1 to 3 wt%: 0.1 to 1 wt% of the total dry weight of the drainage layer, % ≪ / RTI > by weight.

When the lightweight aggregate is less than 20 wt%, the drainage function can not be performed properly, and when it exceeds 65 wt%, the lightweight aggregate is not sufficiently combined. Preferably 30 to 45% by weight may be used in combination.

If the calcium sulfate inorganic binder is less than 30 wt%, the lightweight aggregate is not bonded. If the calcium sulfate inorganic binder is more than 75 wt%, the panel is heavy and the mobility is poor, and the drainage function may not be smooth.

When the organic fiber is blended at less than 1% by weight, the water-holding capacity required for the viability of the plant is hardly exhibited. If blended at more than 4% by weight, the binding strength of the panel is lowered.

When the thickener is used in an amount less than 0.1% by weight, it is difficult to expect a dry crack preventing effect. If the thickener is used in an amount exceeding 3% by weight,

If the surfactant is used in an amount of less than 0.1 wt%, it is difficult to expect a well-dispersed slurry, and even if the surfactant is used in excess of 1 wt%, an increase in dispersion effect due to excessive use can not be expected.

The drainage layer (second layer) is placed in a slurry state mixed with water, and the support layer and the drainage layer are hydrated and bonded by the reaction of the inorganic binder of the support layer and the inorganic binder and the thickener of the drainage layer.

The thickness of the drainage layer can be determined according to the characteristics and use of the panel, the weight of the panel, the type and amount of the calcium sulfate binder, and is generally 1 to 5 cm.

The composite porous ceramic panel according to the present invention comprises

(A third layer) composed of the lightweight aggregate, the calcium sulfate-based inorganic binder, the organic fiber, the thickener and the surfactant and being laid on the drainage layer, wherein the lightweight aggregate of the moss-raised layer, the calcium sulfate- , The organic fiber, the thickener and the surfactant may be used in a proportion of 35 to 45 wt%: 40 to 50 wt%: 5 to 12 wt%: 1 to 5 wt%: 0.1 to 2 wt%.

The above-mentioned moss-up layer (third layer) is an organic moss (thickener and surfactant) coated on the surface when water is sprayed on the moss-up layer when a plant having a very small root of 1 to 2 mm like moss is planted, Melts and melts and attaches the melon to the panel easily.

In the moss-uplift layer, calcium sulfate-based inorganic binders can be used in a lesser amount than the drainage layer, and organic fibers for supplying organic matter can be further used.

At this time, the organic fiber functions to retain moisture so that moss can grow. If it is less than 5% by weight, the water holding effect is small. If it exceeds 12% by weight, mold may be formed due to excessive water retention.

As the thickening agent used in the moss-up layer, a water-soluble polymer such as polyvinyl acetate or methylcellulose is used. If the thickener is used in an amount of less than 1% by weight, the effect of adhering moss is small. If the thickener is used in an amount exceeding 5% by weight, the adhesive strength is excessively high,

Examples of the surfactant used in the moss-uplift layer include alkyl-, olefin-, sodium-, benzene-, lignin-, melamine-, naphthalene-, aminosulfonic-, polycarboxylic-, and polyether-based surfactants used in the drainage layer If it is less than 0.1 wt% as in the case of a drainage layer, it is difficult to expect a well-dispersed slurry, and even if it is used in an amount exceeding 2 wt%, an increase in surfactant effect due to excessive use can not be expected.

The moss-up layer (third layer) is poured in a slurry state mixed with water, and the support layer and the drainage layer are hydrated and bonded while the drainage layer and the calcium sulfate-based inorganic binder and thickener of the moss-up layer are reacted.

The thickness of the moss growth layer can be determined according to the characteristics and usage of the panel, the weight of the panel, the type and amount of the calcium sulfate binding agent, and the thickness is generally 1 to 3 cm.

The calcium sulfate inorganic binder, organic fiber, and light aggregate used in the composite porous ceramic panel according to the present invention are useful materials for plant growth, and therefore waste materials can be recycled as landscaping materials when the buildings are disposed of due to reconstruction or the like.

Example : Composite Porous Ceramic Panel  making

For better understanding of the present invention, the first layer (support layer) having a width of 60 cm, a width of 60 cm and a thickness of 5 cm was produced, and the compounding ratio and the characteristics are shown in Table 1.

Mixing ratio and characteristics of supporting layer Yes Example
One Example
2 Example
3 Example
4 Example
5 Comparative Example 1 Bottom ash
(weight%) - 3 15 30 50 55 Half plaster
(weight%) 100 97 85 70 50 45 Bending strength
(kgf / cm ² ) 17.5 16.1 8.3 6.5 4.3 Measure
Impossible importance 1.9 1.3 0.9 0.8 0.7 0.5

* Bending Strength: The 3 point strength is measured based on KS L1591.

A lightweight aggregate is a by-product discharged from the thermal power plant average particle diameter of 6mm, an apparent specific gravity of 0.45g / cm ³ Bottom ash is used. When pearlite expanded perlite is used, the same strength characteristics are exhibited.

Bottom ash was dry mixed with semi-gypsum as an inorganic binder, and 50 wt% of water was added to the total weight. The slurry was wet-mixed slurry using a mixing machine to form a square frame with a thickness of 1.5 cm and cured within 1 hour Strength is expressed.

In case of Comparative Example 1 in Table 1, the strength is too weak to be measured.

Next, the blending ratios and characteristics of the second layer (drainage layer) and the third layer (moss-up layer) are shown in Table 2.

The mixing ratio and the characteristics of the second layer (drainage layer) and the third layer (mossy layer) Second layer Third Floor Yes Example
6 Example
7 Example
8 Example
9 Example
10 Example
11 Pearlite
(weight%) 20 24.5 30 44 40 36 Anhydrous plaster
(weight%) 74 70 65 48 44.5 45 Organic pulp
(weight%) 3.0 3.0 3.0 5.5 9 12 Thickener
(weight%) 2.9 2.0 1.0 2.0 6 5 Surfactants
(weight%) 0.1 0.5 1.0 0.5 2.5 3 Water absorption rate
(%) 30.8 35.9 38.5 50.1 55.5 60.3 importance 0.8 0.7 0.6 0.5 0.5 0.5

* Moisture Absorption Rate: The manufactured panel was dried at 100 ° C until reaching the constant weight

 After immersing in water for 1 hour, the weight is increased.

Water absorption rate (%) = (increased weight / constant of drying panel) x 100

Pearlite having an average particle diameter of 5 mm and a specific gravity of 0.4 is used as the lightweight aggregate and an anhydrous gypsum is used as the calcium sulfate inorganic binder and the recycled waste paper pulverized with the length of 2 to 3 mm is used as the organic fiber Pulp is used.

As a thickener in the organic admixture, Samsung Chemie methylcellulose is used for the drainage layer, and polyvinyl alcohol is used for the moss growth layer. As the surfactant, alpha olefin sulfate surfactants such as olefins are used.

As an inorganic binder for calcium sulfate, anhydrous gypsum is used, and pearlite, recycled pulp, thickener and surfactant are dry-mixed and then 50 wt% of water is added to the total weight, and the mixture is made into a wet mixed slurry state , The slurry for drainage layer was poured into a rectangular frame having a base layer hardened on the bottom to a thickness of 3 cm and cured within 1 hour, and then the slurry for the moss-up layer was poured to a thickness of 3 cm by the same process to cure within 1 hour. A composite porous ceramic panel is fabricated.

As shown in Table 2, the water absorption rate of the drainage layer is significantly lower than that of the moss-up growth layer, and the drainage performance is excellent.

Figs. 2A to 2C are photographs of a composite porous ceramic panel according to the present invention made of a support layer of Example 2, a drainage layer of Example 7, and a moss growth layer of Example 11. Fig.

Table 3 shows the results of cultivating moss on the composite porous ceramic panel according to the present invention.

Frost moss adhesion test result Comparative Example
2 Example
12 Example
13 Example
14 Example
15 Example
16 Comparative Example
3 Bottom ash
(weight%) 15 25 42 41 41 38 38 Lee Soo Seok
(weight%) 85 70 50 48 45 43 40 Organic pulp (% by weight) - 3.9 5.7 7.5 9 12 13 Thickener
(weight%) - One 2 3 4 5 6 Surfactant (wt%) - 0.1 0.3 0.5 1.0 2.0 3.0 Moss
Adhesion Bad usually Great Great Great Great usually

* Adhesion: When water is poured into the panel and the moss is planted, it is dried for one day, then water is poured again, and the panel is turned over.

Excellent: moss does not fall off

Normal: moss falls below 1/4

Poor: Moss falling more than 1/4

As shown in Table 2, the composite porous ceramic panel manufactured according to the embodiment of the present invention has excellent moss adhesion, whereas the composite porous ceramic panel manufactured according to Comparative Example 2 has poor moss adhesion, It can be seen that the moss adhesion is usually lowered in the case of the composite porous ceramics panel manufactured according to the present invention.

FIG. 3 (a) is a photograph of a moss growing layer of a composite porous ceramic panel for frost moss cultivation (Example 15), and FIG. 3 (b) is a photograph of the growth state of frost moss after 3 months of planting.

The present invention is not limited to the above-described embodiment and the accompanying drawings, but is intended to be limited by the appended claims.

It will be apparent to those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims. something to do.

1: Composite Porous Ceramic Panel
10: First layer (support layer)
20: Second layer (drainage layer)
30: Third layer (moss growth layer)

Claims (7)

A bottom support layer composed of a calcium sulfate based inorganic binder which is blended in a proportion of 3 to 50% by weight: 50 to 97% by weight or a half gypsum, a lightweight aggregate which is pearlite or bottom ash and a calcium sulfate based inorganic binder which is a semi-gypsum,
3% by weight: 20 to 30% by weight: 65 to 74% by weight: 1.0% by weight of organic fiber as the organic pulp, lightweight aggregate as pearlite or bottom ash, calcium sulfate based inorganic binder as anhydrous gypsum, methyl cellulose as thickener and olefin type surfactant To 2.9% by weight: 0.1 to 1% by weight based on the total weight of the porous ceramic panel.
delete The method according to claim 1,
36 to 44% by weight: 43 to 50% by weight: 5.5 to 40% by weight of lightweight aggregate of pearlite or bottom ash, calcium sulfate-based inorganic binder of non-agglomerated kaolinite, organic fiber as organic pulp, polyvinyl alcohol as thickener and olefin- And a moss-up layer which is blended at a ratio of 12 to 12 wt%: 1 to 5 wt%: 0.1 to 2 wt% and is laid on the drainage layer.
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