KR101513916B1 - Light weight insulation gypsum board containing hydrophobic silica aerogel and method for manufacturing thereof - Google Patents

Light weight insulation gypsum board containing hydrophobic silica aerogel and method for manufacturing thereof Download PDF

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KR101513916B1
KR101513916B1 KR1020130070941A KR20130070941A KR101513916B1 KR 101513916 B1 KR101513916 B1 KR 101513916B1 KR 1020130070941 A KR1020130070941 A KR 1020130070941A KR 20130070941 A KR20130070941 A KR 20130070941A KR 101513916 B1 KR101513916 B1 KR 101513916B1
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gypsum
powder
aerogel
slurry
mixture
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KR20140147521A (en
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정영철
노명제
박종철
김민우
이문형
한춘수
차인창
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주식회사 지오스에어로젤
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Priority to PCT/KR2014/005247 priority patent/WO2014204149A1/en
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    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
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Abstract

본 발명은 에어로겔 슬러리를 함유하는 경량 석고보드 및 그 제조방법에 관한 것으로, 물, 계면활성제, 바인더 및 에어로겔 분말을 혼합한 에어로겔 슬러리; 에어로겔 슬러리에 혼합된 석고 분말; 및 전분을 포함하고,
물, 계면활성제, 바인더 및 에어로겔 분말을 혼합하여 에어로겔 슬러리를 만드는 제1단계(S10); 에어로겔 슬러리에 석고 분말을 첨가하여 석고혼합물을 만드는 제2단계(S20); 석고혼합물을 몰드에 투입하는 제3단계(S30); 몰드에 수용된 석고혼합물을 응결 및 경화시키는 제4단계(S40); 및 경화된 석고혼합물을 몰드에서 탈형시켜 석고보드를 생산하는 제5단계(S50);를 포함하고, 제2단계(S20)에서 0.4∼0.6중량비의 전분을 더 첨가하는 제2-1단계(S21)을 포함하여 본 발명에 따른 경량 석고보드가 제조됨으로써,
단열성, 방음성, 내열성 및 내화성이 뛰어나고, 경량이면서 강도가 우수하며, 특히 종래보다 경화시간이 충분히 지연되어 대규모 생산설비에서 대량 생산이 가능하도록 된 것이다. The present invention relates to a lightweight gypsum board containing an aerogel slurry and a method for producing the same, which comprises an aerogel slurry in which water, a surfactant, a binder and an airgel powder are mixed; Gypsum powder mixed in aerogel slurry; And starch,
A first step (S10) of mixing the water, the surfactant, the binder and the airgel powder to form an aerogel slurry; A second step (S20) of adding a gypsum powder to the aerogel slurry to form a gypsum mixture; A third step (S30) of injecting the gypsum mixture into the mold; A fourth step (S40) of condensing and curing the gypsum mixture contained in the mold; And a fifth step (S50) of producing a gypsum board by demolding the cured gypsum mixture in a mold. In a second step (S21) of adding 0.4 to 0.6 weight of starch in a second step (S20) ) To produce a light gypsum board according to the present invention,
It is excellent in heat insulation, soundproofness, heat resistance and fire resistance, lightweight and excellent in strength. Especially, the curing time is sufficiently delayed than in the past, and mass production is possible in a large scale production facility.

Description

에어로겔 슬러리를 함유하는 경량 석고보드 및 그 제조방법{Light weight insulation gypsum board containing hydrophobic silica aerogel and method for manufacturing thereof}BACKGROUND OF THE INVENTION 1. Field of the Invention [0001] The present invention relates to a lightweight gypsum board containing an airgel slurry,

본 발명은 에어로겔 슬러리를 함유하는 석고보드에 관한 것으로, 보다 상세하게는 소수성 실리카 에어로겔을 슬러리화하고, 이 에어로겔 슬러리에 석고를 혼합하여 제조됨으로써, 경량이면서 단열성이 뛰어난 에어로겔 슬러리를 함유하는 경량 석고보드 및 그 제조방법에 관한 것이다.
The present invention relates to a gypsum board containing an aerogel slurry, and more particularly, to a gypsum board containing slurry of a hydrophobic silica aerogel and mixing gypsum with the aerogel slurry, whereby a lightweight gypsum board containing a lightweight, And a manufacturing method thereof.

건축물의 내벽이나 외벽 또는 천장용 마감재로 사용되거나 실내공간을 구획하여 공간을 효율적으로 활용하기 위해 내열성과 내화성이 우수한 석고보드가 널리 사용되고 있다. 하지만, 이 석고보드는 무거워 이동 및 시공이 어렵고, 시공후 건물에 큰 하중부담을 주는 것은 물론, 경질의 석고로 이루어지므로 단열성 및 방음성이 낮다는 문제가 제기되고 있다. A gypsum board having excellent heat resistance and fire resistance is widely used to be used as an interior wall, an outer wall or a ceiling finishing material of a building, or to efficiently utilize a space by dividing an interior space. However, since this gypsum board is heavy, it is difficult to move and construct, and a large load burden is imposed on the building after construction, and since it is made of hard gypsum, there is a problem that insulation and soundproofing are low.

이에 대한 개선책으로 에어로겔을 함유하는 석고보드에 대한 개발이 요구되고 있다. 여기서, 에어로겔은 기공율이 90% 이상, 비표면적이 1,500m2/g 정도이며, 나노 다공성 구조를 가진 투명 또는 반투명한 극저밀도의 첨단 소재이다. 이러한 에어로겔은 촉매 및 촉매 담체, 방음재 등의 분야에 응용이 가능하고, 특히 실리카 에어로겔은 매우 낮은 열전도도 특성을 가지기 때문에 냉장고, 자동차, 항공기, 의류, 극저온 저장탱크, 산업용 파이프 라인, 보온병 등에 사용될 수 있는 매우 효율적인 초단열 재료이다. 다만, 일반적으로 모노리스 형태로 제조되는 에어로겔은 높은 취성으로 인하여 작은 충격에도 쉽게 부서지는 등, 매우 취약한 강도를 보이며 다양한 두께 및 형태로의 가공이 어렵기 때문에 우수한 단열특성에도 불구하고 에어로겔 단독으로는 단열재로의 응용이 매우 어려운 실정이다. 따라서, 실리카 에어로겔을 다른 재료와 혼합하여 복합체 형성을 통한 단열재 제조가 다양하게 시도되고 있다. Development of a gypsum board containing aerogels is required as an improvement measure. Here, the airgel is a transparent or semitransparent ultra-low-density advanced material having a porosity of 90% or more and a specific surface area of 1,500 m 2 / g and having a nanoporous structure. Such aerogels can be applied to various fields such as catalysts, catalyst supports, soundproofing materials, etc. Especially, since silica airgel has very low thermal conductivity characteristics, it can be used for refrigerators, automobiles, aircraft, clothes, cryogenic storage tanks, industrial pipelines, It is a very efficient super insulation material. However, in general, airgel produced in monolith form is very fragile due to high brittleness and easily broken even by small impact. Therefore, it is difficult to process in various thicknesses and shapes. Therefore, in spite of excellent heat insulating property, Is very difficult to apply. Therefore, various attempts have been made to manufacture a thermal insulation material by mixing a silica airgel with other materials to form a composite.

이러한 단열재 중 실리카 에어로겔과 석고를 혼합하여 제조된 석고보드의 경우, 본 발명의 출원인이 출원한 대한민국 공개특허 제2013-0025116호에 개시되어 있다. 자세히 설명하자면, 물과 계면활성제를 혼합한 혼합용액에 실리카 에어로겔 분말 및 석고분말을 혼합하여 슬러리화하고, 이 슬러리를 몰드에서 응결 및 경화시켜 석고보드를 제조하였다. The gypsum board manufactured by mixing silica airgel and gypsum among these heat insulating materials is disclosed in Korean Patent Laid-Open Publication No. 2013-0025116 filed by the applicant of the present invention. Specifically, silica aerogel powder and gypsum powder were mixed into a mixed solution prepared by mixing water and a surfactant to form a slurry, and the slurry was solidified and cured in a mold to prepare a gypsum board.

하지만, 혼합용액에 실리카 에어로겔 분말과 석고분말을 함께 투입하여 슬러리를 만들게 되면 그 경화시간이 매우 빠르고, 이 때문에 대규모의 생산설비에 적용하기에는 한계가 있다는 문제점이 있었다.
However, when the silica aerogel powder and the gypsum powder are added to the mixed solution together to form a slurry, the curing time is very fast, and thus there is a problem in applying the silica aerogel powder and the gypsum powder to a large-scale production facility.

KR2013-0025116 10KR2013-0025116 10

상기된 문제점을 해소하기 위해 안출된 본 발명은, 물과, 계면활성제, 바인더와 실리카 에어로겔 분말을 혼합하여 슬러리로 만들고, 이 슬러리에 석고 분말을 혼합하여 석고보드를 제조함으로써, 유연성과 신축성이 뛰어나고, 경량이면서 단열성이 월등하며, 특히 대규모 생산설비에서 대량 생산이 가능하도록 된 에어로겔 슬러리를 함유하는 경량 석고보드 및 그 제조방법을 제공함에 그 목적이 있다.
The present invention, which has been devised to overcome the above-described problems, is to provide a gypsum board in which water, a surfactant, a binder and a silica airgel powder are mixed to form a slurry, and the gypsum powder is mixed with the slurry, A lightweight gypsum board containing a slurry of an airgel which is lightweight and excellent in heat insulation, and is capable of mass production in a large-scale production facility, and a method of manufacturing the same.

상기 목적을 달성하기 위한 본 발명에 따른 에어로겔 슬러리를 함유하는 경량 석고보드는, 물, 계면활성제, 바인더 및 에어로겔 분말을 혼합한 에어로겔 슬러리; 및 에어로겔 슬러리에 혼합된 석고 분말;을 포함하여 이루어진 것을 특징으로 한다. To achieve the above object, the present invention provides a lightweight gypsum board containing an airgel slurry, comprising: an airgel slurry in which water, a surfactant, a binder and an airgel powder are mixed; And a gypsum powder mixed with the airgel slurry.

이때, 에어로겔 슬러리에서, 물은 석고 분말 대비 77∼138중량비, 계면활성제는 석고 분말 대비 0.08∼0.15중량비, 바인더는 석고 분말 대비 0.7∼1.4중량비이고, 에어로겔 분말은 2∼10중량비인 것을 특징으로 한다. At this time, in the airgel slurry, the water is 77 to 138 weight ratio of the gypsum powder, the surfactant is 0.08 to 0.15 weight ratio of the gypsum powder, the binder is 0.7 to 1.4 weight ratio of the gypsum powder, and the airgel powder is 2 to 10 weight ratio .

또한, 석고 분말은 90∼98중량비인 것을 특징으로 한다. Further, the gypsum powder is characterized by being 90 to 98 weight ratio.

여기서, 계면활성제는 알킬황산염, 알킬에테르황산염, 황산염알카놀 아마이드 및 글리세라이드 황산염 등을 포함한 음이온 계면활성제인 것을 특징으로 한다. Herein, the surfactant is an anionic surfactant including an alkylsulfate, an alkyl ether sulfate, an alkanolamide sulfate and a glyceride sulfate.

또한, 바인더는 우레탄계, 폴리비닐알콜, 에폭시계, 셀룰로오스계 및 녹말계 중 어느 하나인 것을 특징으로 한다. Further, the binder is characterized by being one of urethane type, polyvinyl alcohol, epoxy type, cellulose type and starch type.

또한, 에어로겔 분말은 1∼50㎛의 크기, 5∼30mW/mK의 열전도도, 0.05∼0.1g/cm3의 밀도를 갖는 소수성 실리카 에어로겔 분말인 것을 특징으로 한다. The airgel powder is characterized by being a hydrophobic silica airgel powder having a size of 1 to 50 탆, a thermal conductivity of 5 to 30 mW / mK, and a density of 0.05 to 0.1 g / cm 3 .

또한, 석고 분말은 반수석고 및 이수석고 중 어느 하나이거나 또는 둘을 혼합된 것을 특징으로 한다.Further, the gypsum powder is characterized in that either one or both of a semi-gypsum and a hydrous gypsum are mixed.

그리고, 에어로겔 슬러리에 석고 분말과 함께 석고 분말 대비 0.4∼0.6중량비의 전분이 더 추가되는 것을 특징으로 한다. The starch is further added to the aerogel slurry in an amount of 0.4 to 0.6 wt% based on the gypsum powder together with the gypsum powder.

한편, 본 발명에 따른 에어로겔 슬러리를 함유하는 경량 석고보드의 제조방법은, 물, 계면활성제, 바인더 및 에어로겔 분말을 700∼900rpm으로 50∼70분 정도 교반하여 에어로겔 슬러리를 만드는 제1단계(S10); 에어로겔 슬러리에 석고 분말을 첨가하고, 500∼700rpm으로 1분 30초∼2분 30초 정도 교반하여 석고혼합물을 만드는 제2단계(S20); 석고혼합물을 몰드에 투입하는 제3단계(S30); 몰드에 수용된 석고혼합물을 응결 및 경화시키는 제4단계(S40); 및 경화된 석고혼합물을 몰드에서 탈형시켜 석고보드를 생산하는 제5단계(S50);를 포함하고, 물은 석고 분말 대비 77∼138중량비, 계면활성제는 석고 분말 대비 0.08∼0.15중량비, 바인더는 석고 분말 대비 0.7∼1.4중량비이고, 에어로겔 분말은 2∼10중량비이며, 석고 분말은 90∼98중량비인 것을 특징으로 한다. Meanwhile, a method of manufacturing a light gypsum board containing an aerogel slurry according to the present invention includes a first step (S10) of producing an aerogel slurry by stirring water, a surfactant, a binder and an aerogel powder at 700-900 rpm for 50-70 minutes, ; A second step (S20) of adding a gypsum powder to the aerogel slurry, stirring the mixture at 500 to 700 rpm for about 1 minute, 30 seconds to 2 minutes and 30 seconds to make a gypsum mixture; A third step (S30) of injecting the gypsum mixture into the mold; A fourth step (S40) of condensing and curing the gypsum mixture contained in the mold; And a fifth step (S50) of producing a gypsum board by demolding the cured gypsum mixture in a mold, wherein the water is 77 to 138 weight ratio of the gypsum powder, the surfactant is 0.08 to 0.15 weight ratio of the gypsum powder, 0.7 to 1.4 weight ratio of the powder to the powder, 2 to 10 weight ratio of the airgel powder, and 90 to 98 weight ratio of the gypsum powder.

그리고, 제2단계(S20)에서 석고 분말 대비 0.4∼0.6중량비의 전분을 더 첨가하는 것을 특징으로 한다.
In the second step S20, the starch is added in an amount of 0.4 to 0.6 weight ratio to the gypsum powder.

상술된 바와 같이 본 발명에 따르면, 물, 계면활성제, 바인더 및 소수성 실리카 에어로겔 분말을 혼합하여 만든 슬러리에 석고분말 및 전분을 추가 혼합하여 석고보드를 제조함으로써, 단열성, 방음성, 내열성 및 내화성이 뛰어나고, 경량이면서 강도가 우수하며, 특히 종래보다 경화시간이 충분히 지연되어 대규모 생산설비에서 대량 생산이 가능하다는 효과가 있다. As described above, according to the present invention, gypsum powder and starch are mixed with a slurry prepared by mixing water, a surfactant, a binder and a hydrophobic silica airgel powder to produce a gypsum board. Thus, the gypsum board is excellent in heat insulation, soundproofness, heat resistance, Light weight and excellent strength. Especially, since the curing time is sufficiently delayed than the conventional one, mass production is possible in a large scale production facility.

또한, 석고보드를 에어로겔 슬러리에 석고 분말을 혼합하여 제조하게 되면 경화시간을 종래보다 오랫동안 지연시킬 수 있어 대형 설비에서 대량 생산할 수 있다는 효과가 있다. Further, when the gypsum board is manufactured by mixing the gypsum powder with the airgel slurry, the curing time can be delayed for a longer time than the conventional method, and mass production can be achieved in a large facility.

또한, 경화시간이 충분히 지연됨은 물론 최적의 혼합속도 및 시간이 제공되기 때문에 경화하는 동안 에어로겔 분말과 석고분말이 고루게 분포할 수 있는 효과가 있다. In addition, since the curing time is sufficiently delayed and the optimum mixing speed and time are provided, the airgel powder and the gypsum powder can be uniformly distributed during curing.

그리고, 산업부산물인 폐석고의 활용이 가능함으로써, 자원 재활용이 가능하여 원료 확보가 용이하고, 또한 실리카 에어로겔이 친환경 소재이므로 환경 보호에 일조할 수 있는 효과가 있다.
In addition, since the waste by-product, which is an industrial by-product, can be utilized, the raw material can be easily recycled because the resource can be recycled, and the silica airgel is an eco-friendly material, thereby contributing to environmental protection.

본 명세서에서 첨부되는 다음의 도면들은 본 발명의 바람직한 실시예를 예시하는 것이며, 발명의 상세한 설명과 함께 본 발명의 기술사상을 더욱 이해시키는 역할을 하는 것이므로, 본 발명은 그러한 도면에 기재된 사항에만 한정되어 해석되어서는 안된다.
도 1은 본 발명에 따라 에어로겔 슬러리에 석고분말을 혼합하여 제조된 석고보드의 제조방법이 도시된 순서도이다.
도 2는 본 발명에 따라 물, 계면활성제, 바인더 및 소수성 실리카 에어로겔 분말이 혼합된 상태의 에어로겔 슬러리가 도시된 사진이다.
도 3은 도 2의 에어로겔 슬러리에 석고분말 및 전분이 혼합된 상태의 혼합물이 도시된 사진이다.
도 4는 본 발명에 따라 제조된 석고보드가 도시된 사진이다.
도 5a 및 도 5b는 종래의 에어로겔 슬러리가 포함되지 않은 석고보드와, 본 발명의 석고보드를 주사전자 현미경으로 가시화된 구조가 도시된 사진이다. BRIEF DESCRIPTION OF THE DRAWINGS The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate preferred embodiments of the invention and, together with the description, serve to further the understanding of the technical idea of the invention, It should not be interpreted.
1 is a flowchart showing a method of manufacturing a gypsum board manufactured by mixing gypsum powder with an aerogel slurry according to the present invention.
2 is a photograph showing an aerogel slurry in which water, a surfactant, a binder and a hydrophobic silica airgel powder are mixed according to the present invention.
FIG. 3 is a photograph showing a mixture of gypsum powder and starch mixed in the aerogel slurry of FIG. 2; FIG.
4 is a photograph showing a gypsum board manufactured according to the present invention.
5A and 5B are photographs showing a gypsum board not containing a conventional aerogel slurry and a structure in which a gypsum board of the present invention is visualized by a scanning electron microscope.

이하에서는 첨부된 도면을 참조하여 본 발명이 속하는 기술분야에서 통상의 지식을 가진 자가 본 발명을 쉽게 실시할 수 있도록 바람직한 실시예를 상세하게 설명한다. 다만, 본 발명의 바람직한 실시예에 대한 동작 원리를 상세하게 설명함에 있어 관련된 공지 기능 또는 구성에 대한 구체적인 설명이 본 발명의 요지를 불필요하게 흐릴 수 있다고 판단되는 경우에는 그 상세한 설명을 생략한다.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. However, the detailed description of known functions and configurations incorporated herein will be omitted when it may unnecessarily obscure the subject matter of the present invention.

<구성><Configuration>

본 발명에 따라 에어로겔 슬러리를 함유하는 경량 석고보드는, 에어로겔 슬러리에 석고 분말 및 전분이 혼합되어 제조된다. A light gypsum board containing an aerogel slurry according to the present invention is produced by mixing gypsum powder and starch with an aerogel slurry.

에어로겔 슬러리는 석고 분말 대비 77∼138중량비의 물과, 석고 분말 대비 0.08∼0.15중량비의 계면활성제 및, 석고 분말 대비 0.7∼1.4중량비의 바인더, 그리고 석고 분말 대비 2∼10중량비의 에어로겔 분말이 혼합되어 이루어진다. The aerogel slurry is mixed with water of 77 to 138 weight ratio with respect to gypsum powder, a surfactant of 0.08 to 0.15 weight ratio with respect to gypsum powder, a binder of 0.7 to 1.4 weight ratio with respect to gypsum powder, and airgel powder of 2 to 10 weight ratio with respect to gypsum powder .

여기서, 계면활성제는 알킬황산염(alkyl sulfate), 알킬에테르황산염(alkyl ether sulfate), 황산염알카놀 아마이드(sulfate alkanol amide) 및 글리세라이드 황산염(glyceride sulfate) 등을 포함한 음이온 계면활성제이다. Here, the surfactant is an anionic surfactant including alkyl sulfate, alkyl ether sulfate, sulfate alkanol amide, and glyceride sulfate.

또한, 바인더는 우레탄계, 폴리비닐알콜, 에폭시계, 셀룰로오스계 및 녹말계 중 어느 하나를 이용한다. The binder may be one of urethane type, polyvinyl alcohol, epoxy type, cellulose type and starch type.

그리고, 에어로겔 분말은 소수성 실리카 에어로겔 분말이고(이하 에어로겔 분말이라 함), 입자크기는 1∼50㎛이고, 열전도도는 5∼30mW/mK이며, 밀도는 0.05∼0.1g/cm3으로 비중이 낮다. 이 에어로겔 분말을 소량으로 혼합하여 완제품인 석고보드의 중량을 현저히 낮추면서 탁월한 단열 효과를 얻을 수 있다. The airgel powder is a hydrophobic silica airgel powder (hereinafter referred to as an airgel powder), the particle size is 1 to 50 μm, the thermal conductivity is 5 to 30 mW / mK, the density is 0.05 to 0.1 g / cm 3 and the specific gravity is low . By mixing this airgel powder in a small amount, the weight of the gypsum board as an end product can be remarkably reduced, and an excellent heat insulating effect can be obtained.

한편, 석고 분말은 석고보드를 제조하기 위한 기본 물질로서, 상술된 에어로겔 슬러리에 에어로겔 슬러리 대비 90∼98중량비로 혼합한다. 이 석고 분말은 반수석고 및 이수석고 중 어느 하나이거나 또는 둘을 혼합한 것이다. On the other hand, the gypsum powder is a base material for producing gypsum board and is mixed with the above-mentioned aerogel slurry at a ratio of 90 to 98 by weight relative to the aerogel slurry. This gypsum powder is a mixture of one or both of semi-gypsum and austenitic gypsum.

또한, 전분은 에어로겔 슬러리와 석고 분말이 혼합된 석고혼합물에 석고보드용 종이인 합지를 함침시켰을 때, 석고혼합물과 합지가 쉽게 점착할 수 있도록 하는 물질이다. 이 전분은 석고 분말 대비 0.4∼0.6%중량비, 보다 바람직하게는 0.5중량비로 혼합한다. 전분이 0.4중량비보다 미만이거나 0.6중량비를 초과할 경우 석고혼합물과 합지의 점착이 용이하지 않다.
In addition, starch is a substance that allows easy adhesion of gypsum mixture and lumber when a gypsum mixture containing a mixture of aerogel slurry and gypsum is impregnated with a gypsum board paper. The starch is mixed at a weight ratio of 0.4 to 0.6% by weight, more preferably 0.5 at a weight ratio to the gypsum powder. When the starch is less than 0.4 weight ratio or exceeds 0.6 weight ratio, adhesion of the gypsum mixture and the laminate is not easy.

<제조방법><Manufacturing Method>

이하에서는 본 발명에 따른 에어로겔 슬러리를 함유한 석고보드의 제조방법을 도 2 내지 도 4b를 참조하여 자세히 설명한다. Hereinafter, a method of manufacturing a gypsum board containing an aerogel slurry according to the present invention will be described in detail with reference to FIGS. 2 to 4B.

도 1은 본 발명에 따라 에어로겔 슬러리에 석고분말을 혼합하여 제조된 석고보드의 제조방법이 도시된 순서도이고, 도 2는 본 발명에 따라 물, 계면활성제, 바인더 및 소수성 실리카 에어로겔 분말이 혼합된 상태의 에어로겔 슬러리가 도시된 사진이며, 도 3은 도 2의 에어로겔 슬러리에 석고분말 및 전분이 혼합된 상태의 혼합물이 도시된 사진이고, 도 5는 본 발명에 따라 제조된 석고보드가 도시된 사진이며, 도 5a 및 도 5b는 종래의 에어로겔 슬러리가 포함되지 않은 석고보드와, 본 발명의 석고보드를 주사전자 현미경으로 가시화된 구조가 도시된 사진이다. FIG. 1 is a flowchart showing a method of manufacturing a gypsum board produced by mixing gypsum powder with an aerogel slurry according to the present invention. FIG. 2 is a view showing a state in which water, a surfactant, a binder and a hydrophobic silica airgel powder are mixed FIG. 3 is a photograph showing a mixture of gypsum powder and starch mixed in the aerogel slurry of FIG. 2, FIG. 5 is a photograph showing a gypsum board manufactured according to the present invention, and FIG. 5A and 5B are photographs showing a gypsum board not containing a conventional airgel slurry and a structure obtained by visualizing the gypsum board of the present invention with a scanning electron microscope.

본 발명에 따른 에어로겔 슬러리를 함유한 석고보드의 제조방법은, 도 1에 도시된 바와 같이, 먼저 물, 계면활성제, 바인더 및 에어로겔 분말을 일정 비율로 혼합하여 에어로겔 슬러리를 만든다(S10). 이때, 물, 계면활성제 및 바인더는 석고 분말 대비 각각 77∼138중량비, 0.08∼0.15중량비 및 0.7∼1.4중량비로 혼합한다. 또한, 에어로겔 분말은 석고 분말 대비 2∼10중량비로 혼합한다. 여기서, 에어로겔 슬러리는 물, 계면활성제 및 바인더를 먼저 혼합한 후, 에어로겔 분말을 추가하여 혼합하는 공정이 물, 계면활성제 및 바인더의 혼합용액에 에어로겔 분말이 고루 분포되도록 혼합하는데 용이하다. 물론 물, 계면활성제, 바인더 및 에어로겔 분말을 한꺼번에 넣고 혼합할 수도 있다. 또한, 에어로겔 슬러리를 만들기 위한 교반속도는700∼900rpm으로 50∼70분, 보다 정확하게는 대략 60분 정도로 교반한다. 이때, 교반속도가 700rpm 미만일 때는 에어로겔 슬러리의 제조시간이 매우 오래 걸리거나 에어로겔 슬러리를 제조할 수 없고, 900rpm 이상일 때는 제조하고자 하는 에어로겔 슬러리가 용액형태의 슬러리가 아닌 젖은 분말 형태의 슬러리로 제작되어 추후 석고보드를 제조할 수 없게 된다. 이렇게 제조된 에어로겔 슬러리는 도 2에서의 사진과 같다. As shown in FIG. 1, a method for producing a gypsum board containing an aerogel slurry according to the present invention comprises mixing water, a surfactant, a binder and an airgel powder at a predetermined ratio to produce an aerogel slurry (S10). At this time, the water, the surfactant and the binder are mixed at a weight ratio of 77 to 138 weight ratio, 0.08 to 0.15 weight ratio and 0.7 to 1.4 weight ratio, respectively, to the gypsum powder. Also, the aerogel powder is mixed at a weight ratio of 2 to 10 based on the gypsum powder. Here, the aerogel slurry is easy to mix so that the aerogel powder is uniformly distributed in a mixed solution of water, a surfactant, and a binder by mixing water, a surfactant, and a binder, and then adding and mixing an aerogel powder. Of course, water, a surfactant, a binder and an airgel powder may be mixed together at once. Further, the agitation speed for making the aerogel slurry is from 700 to 900 rpm for 50 to 70 minutes, more precisely about 60 minutes. At this time, when the stirring speed is less than 700 rpm, the production time of the aerogel slurry is very long or the aerogel slurry can not be produced. When the stirring speed is 900 rpm or more, the aerogel slurry to be produced is made into a wet powder slurry The gypsum board can not be manufactured. The aerogel slurry thus produced is shown in the photograph of FIG.

다음으로, 에어로겔 슬러리에 석고 분말을 넣고 교반하여 석고혼합물을 만든다(S20). 이때, 석고 분말은 에어로겔 슬러리 대비 90∼98중량비로 혼합한다. 또한, 에어로겔 슬러리에 석고 분말을 첨가한 상태에서 500∼700rpm의 교반속도로 1분 30초 내지 2분 30초, 보다 정확하게는 대략 2분 정도 교반한다. 이때의 교반속도는 반복된 작업을 통해 도 4b에서와 같이 에어로겔 슬러리에 석고 분말이 고루 분포된 상태를 얻을 수 있었다. 여기서, 석고 분말은 반수석고 및 이수석고 중 어느 하나이거나 또는 둘을 혼합된 것이다. 이렇게 제조된 에어로겔 슬러리와 석고 분말이 혼합된 상태는 도 3의 사진과 같다. 한편, 에어로겔 슬러리에 석고 분말과 함께 전분을 더 추가한다. 이 전분은 석고혼합물과 합지의 점착을 용이하게 하기 위한 것으로 석고 분말 대비 0.4∼0.6%중량비, 보다 바람직하게는 0.5중량비로 혼합한다. 이때의 중량비는 석고혼합물과 합지의 점착을 위한 반복된 작업을 통해 가장 안정된 점착상태를 얻었을 때의 비율이다. 물론, 전분을 추가하였을 때의 교반속도는 500∼700rpm으로 동일한다. Next, the gypsum powder is added to the aerogel slurry and stirred to produce a gypsum mixture (S20). At this time, the gypsum powder is mixed at 90 to 98 weight ratio with respect to the aerogel slurry. Further, in the state where the gypsum powder is added to the aerogel slurry, the mixture is stirred at a stirring speed of 500 to 700 rpm for 1 minute 30 seconds to 2 minutes 30 seconds, more precisely about 2 minutes. As a result, the gypsum powder was uniformly dispersed in the aerogel slurry as shown in FIG. 4B. Here, the gypsum powder is a mixture of one or both of semi-gypsum and austenitic gypsum. The mixed state of the airgel slurry and the gypsum powder thus prepared is shown in the photograph of FIG. On the other hand, starch is added to the airgel slurry together with the gypsum powder. The starch is mixed with the gypsum mixture at a weight ratio of 0.4 to 0.6 wt%, more preferably 0.5 wt. The ratio by weight is the ratio when the most stable adhesive state is obtained by repeated operation for adhesion of the gypsum mixture and the laminate. Of course, when the starch is added, the stirring speed is the same at 500 to 700 rpm.

이와 같이 제조된 석고혼합물은 경화시간이 종래보다 느려지게 되고, 이를 통해 대규모 생산설비로 대량 생산할 수 있다. The gypsum mixture thus produced is slower in curing time than in the prior art and can be mass-produced in large scale production facilities.

다음으로, 몰드에 석고혼합물을 투입한다(S30). 만들고자 하는 석고보드의 크기 및 형태에 따라 미리 제작된 몰드에 본 발명에 따라 제조된 석고혼합물을 투입한다. Next, the gypsum mixture is injected into the mold (S30). The gypsum mixture prepared according to the present invention is put into a preformed mold according to the size and shape of the gypsum board to be made.

다음으로, 석고혼합물을 응결 및 경화시킨다(S40). 이때, 본 발명에 따라 제조된 석고혼합물은 종래의 그것보다 더 훨씬 경화속도가 느리고, 이로 인해 에어로겔 분말과 석고 분말이 전체 면적에 대해 고루 분포할 수 있다. Next, the gypsum mixture is solidified and cured (S40). At this time, the gypsum mixture produced according to the present invention has a much slower curing rate than that of the conventional gypsum mixture, so that the aerogel powder and the gypsum powder can be evenly distributed over the entire area.

끝으로, 경화된 석고혼합물을 몰드로부터 탈형시켜 석고보드를 생산한다(S50). 이로써, 도 4에서와 같이 경량이면서 내열성이 월등한 석고보드가 제조된다. 이때, 석고보드 내의 에어로겔 분말과 석고 분말의 분포 및 구조 등은 도 4b에서와 같고, 이는 종래의 석고보드의 구조가 도시된 도 4a와는 확연히 다른 구조임을 알 수 있다.
Finally, the cured gypsum mixture is demolded from the mold to produce a gypsum board (S50). As a result, a gypsum board which is light in weight and superior in heat resistance as shown in Fig. 4 is produced. The distribution and structure of the aerogel powder and the gypsum powder in the gypsum board are the same as those in FIG. 4B, which shows that the structure of the conventional gypsum board is distinctly different from that shown in FIG. 4A.

이상에서 설명한 바와 같이, 본 발명이 속하는 기술분야의 통상의 기술자는 본 발명이 그 기술적 사상이나 필수적 특징을 변경하지 않고서 다른 구체적인 형태로 실시될 수 있다는 것을 이해할 수 있을 것이다. 그러므로 상술한 실시예들은 모든 면에 예시적인 것이며 한정적인 것이 아닌 것으로서 이해해야만 한다. 본 발명의 범위는 상세한 설명보다는 후술하는 특허청구범위에 의하여 나타내어지며, 특허청구범위의 의미 및 범위 그리고 등가 개념으로부터 도출되는 모든 변경 또는 변형된 형태가 본 발명의 범위에 포함되는 것으로 해석되어야 한다.
As described above, those skilled in the art will appreciate that the present invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. It is therefore to be understood that the above-described embodiments are to be considered in all respects as illustrative and not restrictive. The scope of the present invention is defined by the appended claims rather than the detailed description and all changes or modifications derived from the meaning and scope of the claims and their equivalents should be construed as being included within the scope of the present invention.

Claims (14)

삭제delete 삭제delete 삭제delete 삭제delete 삭제delete 삭제delete 삭제delete 삭제delete 물, 계면활성제, 바인더 및 에어로겔 분말을 700∼900rpm으로 50분∼70분 정도 교반하여 에어로겔 슬러리를 만드는 제1단계(S10);
상기 에어로겔 슬러리에 석고 분말을 첨가하고, 500∼700rpm으로 1분 30초∼2분 30초 정도 교반하여 석고혼합물을 만드는 제2단계(S20);
상기 석고혼합물을 몰드에 투입하는 제3단계(S30);
상기 몰드에 수용된 상기 석고혼합물을 응결 및 경화시키는 제4단계(S40); 및
경화된 상기 석고혼합물을 상기 몰드에서 탈형시켜 석고보드를 생산하는 제5단계(S50);를 포함하고,
상기 물은 상기 석고 분말 대비 77∼138중량비, 상기 계면활성제는 상기 석고 분말 대비 0.08∼0.15중량비, 상기 바인더는 상기 석고 분말 대비 0.7∼1.4중량비이고, 상기 에어로겔 분말은 석고 분말 대비 2∼10중량비이며, 상기 석고 분말은 에어로겔 슬러리 대비 90∼98중량비인 것을 특징으로 하는 에어로겔 슬러리를 함유하는 경량 석고보드의 제조방법.
A first step (SlO) of making an aerogel slurry by stirring water, a surfactant, a binder and an airgel powder at 700 to 900 rpm for about 50 to 70 minutes;
A second step (S20) of adding a gypsum powder to the aerogel slurry and stirring the mixture at 500 to 700 rpm for about 1 minute, 30 seconds to 2 minutes and 30 seconds to form a gypsum mixture;
A third step (S30) of injecting the gypsum mixture into a mold;
A fourth step (S40) of condensing and hardening the gypsum mixture contained in the mold; And
And a fifth step (S50) of demolding the cured gypsum mixture in the mold to produce a gypsum board,
The water is 77 to 138 weight ratio of the gypsum powder, 0.08 to 0.15 weight ratio of the surfactant to the gypsum powder, 0.7 to 1.4 weight ratio of the binder to the gypsum powder, 2 to 10 weight ratio of the aerogel powder to the gypsum powder , And the gypsum powder is in a ratio of 90 to 98 by weight relative to the aerogel slurry.
제9항에 있어서,
상기 제2단계(S20)에서 상기 석고 분말 대비 0.4∼0.6중량비의 전분을 더 첨가하는 것을 포함하는 것을 특징으로 하는 에어로겔 슬러리를 함유하는 경량 석고보드의 제조방법. 10. The method of claim 9,
Wherein the step (S20) further comprises adding 0.4 to 0.6 weight percent of starch to the gypsum powder. 제 9항에 있어서,
상기 에어로겔 분말은 1∼50㎛의 크기, 5∼30mW/mK의 열전도도, 0.05∼0.1g/cm3의 밀도를 갖는 소수성 실리카 에어로겔 분말인 것을 특징으로 하는 에어로겔 슬러리를 함유하는 경량 석고보드의 제조방법.
10. The method of claim 9,
Wherein the aerogel powder is a hydrophobic silica aerogel powder having a size of 1 to 50 m, a thermal conductivity of 5 to 30 mW / mK and a density of 0.05 to 0.1 g / cm &lt; 3 &gt; Way.
제 9항에 있어서,
상기 석고 분말은 반수석고 및 이수석고 중 어느 하나이거나 또는 둘이 혼합된 것을 특징으로 하는 에어로겔 슬러리를 함유하는 경량 석고보드의 제조방법.
10. The method of claim 9,
Wherein the gypsum powder is one or both of semi-gypsum and anthracite gypsum.
제 9항에 있어서,
상기 바인더는 우레탄계, 폴리비닐알콜, 에폭시계, 셀룰로오스계 및 녹말계 중 어느 하나인 것을 특징으로 하는 에어로겔 슬러리를 함유하는 경량 석고보드의 제조방법.
10. The method of claim 9,
Wherein the binder is one of urethane, polyvinyl alcohol, epoxy, cellulose, and starch. The method of manufacturing a lightweight gypsum board according to claim 1, wherein the binder is one of urethane, polyvinyl alcohol, epoxy, cellulose and starch.
제 9항 내지 제 13항 중 어느 한 항을 통해 제조된 에어로겔 슬러리를 함유하는 경량 석고보드.A light gypsum board containing the aerogel slurry produced through any one of claims 9 to 13.
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