KR101691526B1 - Manufacturing method of non-firing lightweight board, and lightweight board manufactured thereby - Google Patents

Abstract

The present invention relates to a manufacturing method of a lightweight board and, more specifically, to a manufacturing method of a lightweight board using an inorganic solidification agent by a non-plastic method, and a lightweight board manufactured thereby, wherein the manufacturing method comprises the steps of: preparing and mixing functional materials including a lightweight composition, an inorganic solidification agent composition and an organic binder, and manufacturing a mixture by adding water, wherein the lightweight composition is configured by a first element containing at least one of pearlite and vermiculite, a second element containing at least one of pumice, volcanic stone, and a foam glass, bottom ash, and wooden flour; manufacturing a molding product by pressing and molding the mixture at the pressure of 100 to 150 kgf/cm^2; and steam-curing the manufactured molding product at 50 to 60C for 3 to 5 hours and manufacturing a board by natural drying. When manufacturing the mixture, the lightweight composition, the functional materials, the inorganic solidification agent composition and the water is contained in the ratio of 30 to 50:20 to 40:20 to 30:10 to 20. In addition, the organic binder is contained in the amount of 0.1 to 1.0 part by weight with respect to 100 parts by weight of the mixture.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention [0001] The present invention relates to a method of manufacturing a lightweight board of a non-burning type,

More particularly, the present invention relates to a non-sintered lightweight board manufacturing method using an environmentally friendly inorganic solidifying agent and a lightweight board manufactured by the method.

The loess used in our traditional houses has been proved to have many good effects in terms of human health. In particular, our country's loess is known to generate 6 ~ 15 ㎛ far infrared rays, which is similar to human body, and it has insecticidal resistance against insects and insects, good heat accumulation, good deodorizing effect, It has also been found to have a number of positive effects.

Hwangto used as the main material, absorbs the far infrared rays and heat energy from the loess to the deepest part of the body's skin, activates the blood circulation and the physiological action of the cells, thereby facilitating metabolism and promoting sweating, pain relief, deodorizing effect, By discharging waste products, it is a material contributing to health promotion such as hangover, sleeping, fatigue recovery as well as various adult diseases.

However, the loess has a relatively high strength in spite of its excellent function as described above, and after drying, it has a weak bonding force with other materials and breaks or cracks. Therefore, modern buildings have relatively high strength instead of clay soil or wood Cement and steel materials with excellent bonding strength have begun to be used. Furthermore, in order to impart durability and adhesiveness to the interior materials of modern buildings, volatile organic compound materials are mixed and toxic substances emitted from these chemicals are used for headache, It is reported that the cause of indoor syndrome such as nausea, vomiting, allergy (atheism, atopy) is found, and in the cement manufactured in Korea, a large amount of hexavalent chromium is detected, As reported through this media, But surprise people is the unfortunate situation that currently do not offer enough material to replace cement or existing built residence.

On the other hand, as the demand for high - quality housing space has increased due to the increase in living standards due to the increase of income, various kinds of boards with bio ceramics have been produced in order to meet the needs of various consumers. Among these, gypsum board which is widely used is a plate made by mixing the gypsum with the sawdust and mixing with water in thick paper. It is widely used for wall, partition, and ceiling because it has good heat resistance and durability. However, when the gypsum board comes into contact with water, moisture penetrates and molds grow on the gypsum board.

Accordingly, the inventor of the present invention has focused on the above-mentioned technical problems, and has found that, while having various functions as compared with the conventional gypsum board for architectural purposes, it is possible to maintain the properties of functional materials such as loess with light weight, The present invention also provides a method of manufacturing a lightweight board that can be manufactured by a firing method to improve the economical efficiency.

Another object of the present invention is to provide a lightweight board manufactured by the above method.

According to an aspect of the present invention,

Functional ingredients comprising a lightweight composition comprising at least one of pearlite, vermiculite, a first component of at least one of pumice, volcanic stone, foamed glass, a second component of at least one of foamed glass, bottom ash, and wood flour and loess, Preparing a binder and mixing, and further mixing water to prepare a mixture;

Pressing the mixture at a pressure of 100 to 150 kgf / cm < 2 > to produce a molded product; And

And curing the molded product at 50 to 60 ° C for 3 to 5 hours, followed by natural drying to prepare a board,

In the preparation of the mixture, the lightweight composition, the functional material, the inorganic solidifying agent composition and the water are contained in a ratio of 30:50:20 to 40:20 to 30:10 to 20, and the organic binder is added in an amount of 100 parts by weight Wherein the inorganic solidifying agent is contained in an amount of 0.1 to 1.0 part by weight.

Preferably, the lightweight composition comprises at least one of a first component, a second component, a bottom ash and a wood flour at a ratio of 30 to 50:10 to 20:30 to 45: 1 to 5,

The functional material may further include at least one selected from the group consisting of ilite, sericite, zeolite, anionite, activated carbon, charcoal, and photocatalyst (TiO2).

Also preferably, in the present invention,

40 to 70 parts by weight of a blast furnace slag fine powder containing a pozzolan mineral material, 10 to 20 parts by weight of slaked lime, 20 to 30 parts by weight of anhydrous gypsum, 10 to 20 parts by weight of desulfurized gypsum, 5 to 10 parts by weight of fly ash, And 0.1 to 0.5 parts by weight of sodium sulfate (Na2SO4).

Preferably, in the present invention, the organic binder is one or more selected from the group consisting of starch, polyvinyl alcohol, vinyl acetate emulsion, acrylic emulsion, SBR emulsion, cellulose, carboxy methyl cellulose (CMC), and guar gum .

According to another aspect of the present invention, there is provided a lightweight board manufactured by the above method.

According to the present invention as described above, it is possible to provide an organic binder which is a functional material such as loess, ilite, sericite, zeolite and light aggregate pearlite, vermiculite, pumice, volcanic stone, foamed glass, bottom ash recycled, The present invention relates to the production of a functional lightweight board using an inorganic solidifying agent and can produce a building material excellent in a decorative effect as a finishing material on a wall surface and a ceiling of a building interior material.

The lightweight board according to the present invention is less expensive than conventional construction materials such as cement and thus has a low manufacturing cost and is manufactured in a non-fired curing manner. Thus, there is no change in physical properties, It is effective.

In addition, the lightweight board according to the present invention has the effect of adding far infrared rays emission and humidity control functions of yellow soil, sericite, and zeolite without damaging the original functions of deodorization, antibacterial, air purification, Friendly inorganic fire-retardant board that can create a pleasant indoor environment because it is not an emission of harmful environmental substances (VOCs) as well as fire prevention because it is an inorganic mineral material.

1 is a flowchart illustrating a manufacturing process of a lightweight board according to an embodiment of the present invention.
2 is a photograph of a lightweight board manufactured according to an embodiment of the present invention.

Hereinafter, the present invention will be described in detail.

Hereinafter, embodiments and examples of the present invention will be described in detail so that those skilled in the art can easily carry out the present invention.

It should be understood, however, that the present invention may be embodied in many different forms and is not limited to the embodiments and examples described herein.

Also, throughout this specification, when a component is referred to as "comprising ", it means that it can include other components as well, without departing from the other components unless specifically stated otherwise.

Also, throughout this specification, when a step is referred to as being "on" or "before" another step, it is intended to include not only the case where a step is in a direct time series relationship with another step, Includes the same rights as in the case of an indirect temporal relationship in which the temporal order of the two phases may change.

The present invention relates to a method for producing a lightweight board in a non-firing manner by using an inorganic solidifying agent. More specifically, the present invention relates to a method for producing a metal mold, comprising the steps of: applying a lightweight material such as pearlite, vermiculite, pumice, bottom ash, volcanic stone, foamed glass, wood powder, natural inorganic solidifying agent, The mixture is put into a mold, molded by a hydraulic press, demolded, and then a lightweight board is manufactured by low temperature steam curing and natural drying.

Accordingly, in accordance with one aspect of the present invention, the present invention provides a lightweight composition comprising a pearlite, a first component comprising at least one of vermiculite, a second component comprising at least one of pumice, volcanic stone, foamed glass, bottom ash, Preparing an inorganic solidifying agent composition and an organic binder, mixing and mixing water to prepare a mixture; Pressing the mixture at a pressure of 100 to 150 kgf / cm < 2 > to produce a molded product; And a step of curing the molded product by steam curing at 50 to 60 ° C. for 3 to 5 hours and then naturally drying to prepare a board. In the preparation of the mixture, the lightweight composition, the functional material, the inorganic solidifying agent composition And water in a ratio of 30 to 50:20 to 40:20 to 30:10 to 20, and the organic binder is contained in an amount of 0.1 to 1.0 part by weight based on 100 parts by weight of the mixture.

Specifically, the steps will be described separately.

First, the step of preparing a mixture for lightweight board molding is a step of mixing a light weight material composition and a functional material including loess, an inorganic solidifying agent composition and an organic binder, and further mixing water to prepare a mixture.

Wherein the lightweight composition comprises at least one of pearlite, at least one of vermiculite, at least one of pumice, volcanic stone, foamed glass, bottom ash, and wood flour, : 30 to 45: 1 to 5. In addition, wood flour wood, which can produce phytoncide effect, can be used as the wood flour.

In this case, it is important that the functional material, yellow loess, is used in good quality. It is known that yellow loess soil in a region famous for ceramics or rice is generally good in composition and far-infrared rays are emitted in a large amount, and red soil is unconditionally yellow loess It is important to understand the constituents and structural characteristics of the loess which are beneficial to the human body. The loess must be at least viscous and it should be uncontaminated soil.

In addition, the clay is loose when the loess is dried, and clay is a lot.

Therefore, in the present invention, it is important that the inner surface of the loess has a moisture content and a viscosity of about 5 to 10% so that stirring and mixing can be performed with a minimum amount of water or the like when the composition is mixed with the raw material composition.

The functional material may further include at least one selected from the group consisting of ilite, sericite, zeolite, anionite, activated carbon, charcoal, TiO2, and natural fibers.

Also, since the lightweight composition, the functional material, and the inorganic binder and the organic binder are mixed with the mixture according to the present invention, the lightweight board can be manufactured by only the press molding and the steam curing process without the firing process. Therefore, it is important to have a proper compounding ratio in the preparation of the mixture. The light weight composition, the functional material, the inorganic solidifying agent composition and the water are contained in a ratio of 30:50:20 to 40:20 to 30:10 to 20 , And the organic binder is contained in an amount of 0.1 to 1.0 part by weight based on 100 parts by weight of the mixture.

At this time, when the inorganic solid material containing the pozzolan is appropriately mixed and designed, the inorganic solidifying agent is subjected to ion agglomeration reaction and pozzolan reaction of the functional material of the loess, and potential hydraulic reaction of the blast furnace slag, A predetermined strength can be ensured even without a process.

In one embodiment of the present invention, the solidifying agent comprises 40 to 70 parts by weight of a blast furnace slag fine powder containing a pozzolanic mineral material, 10 to 20 parts by weight of slaked lime, 20 to 30 parts by weight of anhydrous gypsum, 10 to 20 parts by weight of desulfurized gypsum , 5 to 10 parts by weight of fly ash, 1 to 5 parts by weight of silica fume, and 0.1 to 0.5 parts by weight of sodium sulfate (Na2SO4). The solidifying agent produced by each numerical range of the above solidifying agent produces a large amount of Ettringite among its components, the chemical component of which is 3CaOAl2O3 3CaSO4 32H2O, and this component takes a large amount of water as the binding water It accelerates the reaction and also acts to control the movement of soil particles, which facilitates solidification. The hydrate is formed by the calcium hydroxide, which further increases the solidification of the soil particles. The SiO2, Al2O3, etc. contained in the soil particles Is effective only in the numerical range within which the components of calcium hydroxide and hydrate are activated to promote curing by activating pozzolan.

In the present invention, the fine blast furnace slag powder is obtained by rapidly quenching the molten slag produced together with the pig iron in the furnace, and drying and crushing the granulated slag to obtain a fine powder, which is potentially hydraulic. The reactivity of the blast furnace slag is generally higher as the basicity and vitrification ratio are higher, the specific gravity is in the range of 2.92 to 2.95, and the specific gravity of the blast furnace slag is 4000 to 6000 cm 2 / g. As the blast furnace slag powder is used, the surface activity is increased and the elution rate of Al 2 O 3 is accelerated, so that the production of ettringite is accelerated. In addition, the gelation of the C-S-H hydrate is accelerated and the unreacted portion is reduced.

The chemical composition of the blast furnace slag powder used in the present invention is shown in Table 1 below.

Ingredients unit Chemical composition ratio SiO2 % 33.7 Al2O3 % 13.3 Fe2O3 % 1.1 CaO % 41.3 MgO % 6.53

The above-mentioned slaked lime of the present invention is a white powder state sold in the general market, and has a CaO content of 70% or more for industrial use and has a particle size of more than 200 meshhigh 90%. As a stimulant for enhancing strength through binding of loess material, The aggregation reaction and the pozzolan reaction can be performed sufficiently.

The slaked lime is an irritant for imparting the alkalinity necessary for the hydration reaction of the blast furnace slag, and can rapidly break down the inner particle film formed by contact with moisture within the range of the present invention, so that the initial compression strength due to the acceleration of the hydration reaction can be increased have. The chemical composition of the slaked lime of the present invention is shown in Table 2 below.

Ingredients unit Chemical composition ratio CaO % 70.15 SiO2 % 1,38 MgO % 1.34 Fe2O3 % 0.12 Al2O3 % 0.58

The anhydrous gypsum of this application is generally used gypsum, and when it is mixed with slag and slaked lime and reacted with water, the hydration reaction of ettringite (3CaO, Al2O3, 3CaSO4, 32H2O) And the initial strength is increased and the hydration is promoted.

As described above, according to the present invention, blast furnace slag for improving long-term strength, anhydrous gypsum for improving initial strength, and slaked lime are mixed at appropriate ratios to provide a significant improvement in strength. The chemical composition of anhydrous gypsum Respectively.

Ingredients unit Chemical composition ratio SiO2 % 0.5 Al2O3 % 0.7 Fe2O3 % 0.3 CaO % 41.2 MgO % 0.2 SO3 % 58.9

The desulfurization gypsum of the present invention is produced in a desulfurization process of a petroleum refining process and is used to promote early strength and increase durability so that the pozzolanic reaction can be sufficiently performed. The desulfurized gypsum of the present invention was dried and pulverized at high temperature, and the chemical composition thereof is shown in Table 4 below.

Ingredients unit Chemical composition ratio CaO % 60.65 SiO ₂ % 0.59 MgO % 3.38 Fe ₂ O ₃ % 0.32 Al ₂ O ₃ % 0.56 SO ₃ % 22.5 Ig. loss % 12-13

The fly ash of the present invention is a fine powder by-product obtained by rapidly injecting pulverized coal into a hot air stream in a furnace at a high temperature power plant or the like and then instantaneously burning it at a high temperature of 150 ° C to 200 ° C, It refers to ashes that are scattered and collected by dust collector. The generation rate of fly ash is about 15 to 45% of the raw coal, the specific gravity is 2.34, and the powder degree (㎠ / g) is about 5000 to 8000.

The silica fume is a spherical superfine particle produced as a byproduct when a silicon alloy such as metal silicon or ferrosilicon is produced in an electric furnace or the like. The powder is also 0.1 m or more in diameter and the main component is amorphous SiO2.

The organic binder may be selected from starch, polyvinyl alcohol, vinyl acetate emulsion, acrylic emulsion, SBR emulsion, cellulose, carboxy methyl cellulose (CMC) and guar gum, or a combination of two or more thereof . If the amount of the organic binder used is excessive, the moldability and the strength may be lowered, and as the amount of the organic component increases, the mixture tends to stick to the upper and lower portions of the mold. 0.1 to 1.0 part by weight based on the total weight of the composition.

In the present invention, it is also possible to use? -Type sepiolite for the additive in the mixture. When used, it is included to exhibit the cohesive action of the organic binder and to stabilize the fixation of the organic binder to improve the strength of the board. This can suppress the increase of oil content as an inorganic matter. The fiber length of the? -Type sepiolite is preferably 20 μm to 2 mm. When the fiber length is longer than 2 mm, the dispersion of the? -Type sepiolite tends to deteriorate. When the fiber length is shorter than 20 m, the aggregation action of the organic binder tends to decrease.

Next, a molded article for manufacturing a lightweight board is produced from the mixture thus prepared. Specifically, the mixture is introduced into a mold mold, molded by a hydraulic press, and then deformed to produce a molded article. At this time, molding can be performed by pressurizing at a pressure of 100 to 150 kgf / cm 2 for 5 to 8 seconds.

Finally, the molded article is finally cured by low-temperature steam curing and naturally dried to produce a lightweight board. At this time, the steam curing is performed at a low temperature of 50 to 60 DEG C for 3 to 5 hours. In addition, the natural drying can be naturally dried at a temperature ranging from 20 to 30 ° C for about 1 to 7 days.

Thus, the present invention can provide a lightweight board manufactured by the above method.

Hereinafter, the present invention will be described in detail with reference to examples, but the present invention is not limited to the following examples.

≪ Example 1 >

1. Preparation of raw material composition

First, 20 parts by weight of pearlite, 15 parts by weight of vermiculite, 5 parts by weight of pumice, 5 parts by weight of volcanic stone, 5 parts by weight of foamed glass, 45 parts by weight of bottom ash, At a constant rate.

As a functional material, yellow loess is prepared by natural drying and screening process and having a grain size of 5 mm or less.

The solidifying composition comprises 40 to 70 parts by weight of a blast furnace slag fine powder containing pozzolanic mineral material, 10 to 20 parts by weight of slaked lime, 20 to 30 parts by weight of anhydrous gypsum, 10 to 20 parts by weight of desulfurized gypsum, 5 to 10 parts by weight of fly ash, 1 to 5 parts by weight of silica fume and 0.1 to 0.5 parts by weight of sodium sulfate (Na2SO4) were added thereto and mixed at a constant rate so as to be precisely mixed to prepare a solidifying agent.

2. Manufacture of lightweight board

50 kg of lightweight material, 20 kg of loess, 30 kg of solidifying agent, and 0.9 kg of organic binder were mixed at a constant speed so as to be precisely mixed, and then about 15 L of water was injected into a round stirrer to spray the mixture in a spray- .

The mixture with appropriately adjusted water content ratio was pressurized at a pressure of 100 to 150 kgf / cm 2 for 5 to 8 seconds in a pressurized press (a pore size of 200 ton hydraulic press).

The light yellow board formed by the above molding frame was cured at 50 ~ 60 ℃ for 3 ~ 5 hours in a steam curing room equipped with steam, and then cured in a yard.

≪ Example 2 >

A light yellowish board product was produced in the same manner as in Example 1 except that 45 kg of lightweight material, 29 kg of loess, 26 kg of solidifying agent and 0.6 kg of organic binder were used.

≪ Example 3 >

A light yellowish board product was produced in the same manner as in Example 1, except that 40 kg of lightweight material, 38 kg of loess, 22 kg of solidifying agent and 0.3 kg of organic binder were used.

≪ Comparative Example 1 &

A light yellowish board product was produced in the same manner as in Example 1 except that 30 kg of lightweight material, 55 kg of loess, 15 kg of solidifying agent and 2.0 kg of organic binder were used.

≪ Comparative Example 2 &

A light yellowish board product was produced in the same manner as in Example 1, except that 60 kg of lightweight material, 30 kg of loess, 10 kg of solidifying agent and 3.0 kg of organic binder were used.

≪ Test Example 1 >

The bending strengths of the light yellowish board manufactured according to the above Examples and Comparative Examples were measured. The results are shown in Table 5 below.

exam
Item division Lightweight material
kg (parts by weight) ocher
kg (parts by weight) Solidifying agent
kg (parts by weight) Binder (starch)
kg (parts by weight) Flexural strength
(N / cm) Remarks Measuring age
(14 days) Flexural strength Example 1 50 (50) 20 (20) 30 (30) 0.9 (0.9) 16 Flexural strength \
(Based on KS built-in tiles)
12 (N / cm) Example 2 45 (45) 29 (29) 26 (26) 0.6 (0.6) 14 Example 3 40 (40) 38 (38) 22 (22) 0.3 (0.3) 12 Comparative Example 1 30 (30) 55 (55) 15 (15) 2.0 (2.0) 8 Comparative Example 2 60 (60) 30 (30) 10 (10) 3.0 (3.0) 5

As shown in Table 5, in the case of Examples 1 to 3 falling within the mixed weight range according to the present invention, the flexural strength was improved by the ion flocculation reaction between the loess and the solidifying agent, the pozzolan reaction and the latent hydraulic reaction of the blast furnace slag 12 >, it can be confirmed that it exhibits excellent bending strength. Also, in the case of the lightweight board manufactured in the embodiment, it was confirmed that the texture of the board surface is natural.

On the other hand, in Comparative Example 1 in which the content of the inorganic solidifying agent was small, the content of the organic binder was relatively large, and the content of the loess was high, the bending strength was insufficient and the surface texture was somewhat deteriorated. In Comparative Example 2, in which the content of the inorganic solidifying agent is small, the content of the organic binder is relatively large, and the content of the lightweight material is high, the bending strength is the least, and the surface texture is poor.

In addition, in Comparative Examples 1 and 2 in which the organic binder was added in an excess amount over a certain amount, molding holding and strength deterioration occurred, and it was confirmed that the raw material sticks to the mold surface and the lower mold frame.

From the results of these Examples, it can be seen that the lightweight board manufactured according to the present invention can secure a predetermined strength even when it is manufactured by the inorganic solidifying agent and the organic binder in a non-sintering manner without firing, and when the natural mineral inorganic solidifying agent is added It is also possible to prevent loosening due to water.

Accordingly, it is an object of the present invention to provide an environmentally-friendly lightweight board which is capable of producing a lightweight board economically in a non-fired curing manner and having no property change, being resistant to moisture absorption and desorption, and emitting no harmful environmental substances (VOCs) .

The present invention is not limited to the above-described embodiments, and various changes and modifications may be made without departing from the spirit and scope of the present invention. It can be understood that It is therefore to be understood that the above-described embodiments are illustrative in all aspects and not restrictive.

Claims (5)

Functional ingredients comprising a lightweight composition comprising at least one of pearlite, vermiculite, a first component of at least one of pumice, volcanic stone, foamed glass, a second component of at least one of foamed glass, bottom ash, and wood flour and loess, Preparing a binder and mixing, and further mixing water to prepare a mixture;
Pressing the mixture at a pressure of 100 to 150 kgf / cm < 2 > to produce a molded product; And
Curing the formed product at 50 to 60 ° C. for 3 to 5 hours and then naturally drying at 20 to 30 ° C. for 1 to 7 days to prepare a board,
In the preparation of the mixture, the lightweight composition of the functional material, the inorganic solidifying agent composition and the water are contained in a ratio of 30:50:20 to 40:20 to 30:10 to 20, and the organic binder is 0.1 To 1.0 part by weight,
The lightweight composition comprises the first component, the second component, the bottom ash, and the wood powder in a ratio of 30 to 50:10 to 20:30 to 45: 1 to 5,
Wherein the functional material further comprises at least one selected from the group consisting of ilite, sericite, zeolite, anionite, activated carbon, charcoal, TiO2,
Wherein the inorganic solidifying agent composition comprises 40 to 70 parts by weight of a blast furnace slag fine powder containing pozzolanic mineral material, 10 to 20 parts by weight of slaked lime, 20 to 30 parts by weight of anhydrous gypsum, 10 to 20 parts by weight of desulfurized gypsum, 1 to 5 parts by weight of silica fume and 0.1 to 0.5 parts by weight of sodium sulfate (Na ₂ SO ₄ ).
A method of manufacturing a non - burning lightweight board using an inorganic solidifying agent. delete delete The method according to claim 1,
Wherein the organic binder is at least one selected from the group consisting of starch, polyvinyl alcohol, vinyl acetate emulsion, acrylic emulsion, SBR emulsion, cellulose, CMC (carboxy methyl cellulose) and guar gum. A method of manufacturing a non-burning lightweight board. A lightweight board produced by the method of any one of claims 1 to 4.

Images