KR101726589B1 - Expanded mortar and method for fabricating thereof - Google Patents

Abstract

The present invention has been developed for the purpose of adiabatic spraying used for finishing work to prevent moisture condensation and heat loss generated in the portion facing from the outside air. If necessary, A fireproof door core material, a freezing warehouse flooring material, a fireproof coating material, and the like, and a method of manufacturing the foamed mortar. Such foamed mortar according to the present invention is a modified silicate obtained by adding at least one of zinc chloride, aluminum monophosphate, aluminum phosphate, citric acid and boric acid to a silicate; 1 to 10% by weight, based on 100% by weight of the modified silicate, of a quick-setting admixture comprising at least one of sodium silicate, zinc carbonate and zinc oxide; 25 to 100% by weight of a filler comprising expanded perlite; 0.2 to 2% by weight of at least one blowing catalyst material of manganese dioxide and potassium iodide; And 4 to 20% by weight of a hydrogen peroxide solution.

Description

Expanded mortar and method for fabricating thereof [

The present invention relates to a mortar, and more particularly, to a mortar which has been developed for the purpose of adiabatic spraying used for finishing work to prevent moisture condensation and heat loss generated in a portion facing to the outside air, And to a fireproof mortar capable of coping with fire resistance and fire resistance performance including insulation properties such as a core material of a composite panel, a core material of a fire door, a freezing warehouse flooring, a fireproof coating material and the like.

Most of the conventional mortar for insulating spraying exhibits the heat insulating property by mixing the porosity of inorganic foamed light weight stones such as vermiculite or perlite and EPS grains with gypsum and cement.

However, such a porous lightweight stone does not participate in the reaction but merely serves as a simple aggregate, resulting in a remarkable increase in water-gypsum-cement ratio, which makes the mechanical properties very weak.

These insulation materials are easily broken even after curing due to their poor mechanical properties and scattered into the atmosphere, causing air pollution. And the problem of environmental pollution such as fungus living due to excessive moisture absorption characteristic of vermiculite and perlite used as an insulating material.

Examination of the prior art of refractory insulating mortar using porous lightweight stones, Patent No. 10-0326614 (name of the invention: refractory coating composition), due to excessive use of organic materials such as organic lightweight aggregate, latex and synthetic fiber, There is a problem that gas is expected to be generated, and there is no dust at the time of construction, but the strength of itself is too weak, and there is a problem that the coating composition after curing is contaminated with air due to generation of dust.

In addition, Japanese Patent Application No. 10-0693859 (entitled "Fireproof Coating Material for Concrete and Composition of Fireproof Coating for Concrete Using the Composition") and 10-0807244 entitled "High Refractory Inorganic Binder Composition and Refractory Board Using the Same" Silicate-based compositions are used as non-cementitious compositions because it is difficult to secure a sufficient pot life due to the occurrence of sharpness, and a large amount of silicate-based materials is required in order to secure sufficient slump for spraying.

In this conventional technique, silicate is denatured by adding strong acid such as hydrochloric acid, phosphoric acid, sulfuric acid or acetic acid to the silicate in most cases, which is complicated and dangerous in the domestic water stability and manufacturing process.

Japanese Patent Registration No. 10-1145871 discloses a sprayable material using an organic binder and a latent hydraulic material such as heavy oil and bottom ash, but it is difficult to apply the material because the insulation property is remarkably low. And the heavy metals in the bottom ash are volatilized and there is a risk of contamination.

In addition, Japanese Patent Laid-Open No. 10-2004-0082094 (entitled "Hydraulic composition using heavy oils") has a problem that it can not be applied as a heat insulator utilizing porosity of heavy oil.

On the other hand, since the patent registration No. 10-0760040 (name of the invention: a method of producing a foamed ceramic) requires a complicated rapid gelling process to expose it to carbon dioxide or immerse it in an acid solution after foaming, There is a problem in that it is not suitable for use.

Most of the thermal insulation mortar currently used is produced by mixing porous materials such as gypsum and cement with porous materials such as perlite, but it has a limit because it relies on simple fillers to lower the thermal conductivity.

SUMMARY OF THE INVENTION The present invention has been made to solve the problems of the prior art as described above, and it is an object of the present invention to provide a heat insulation spraying method for use in a finishing work for preventing moisture condensation and heat loss, Accordingly, it is an object of the present invention to provide a foamed mortar capable of coping with fire resistance and fire resistance performance including insulation properties such as a core material of a composite panel, a fire door core, a freezing warehouse flooring, There is a purpose.

To achieve the above object, the present invention provides a foamed mortar comprising: a modified silicate in which at least one of zinc chloride, aluminum monophosphate, aluminum phosphate, citric acid and boric acid is added to a silicate; 1 to 10% by weight, based on 100% by weight of the modified silicate, of a quick-setting admixture comprising at least one of sodium silicate, zinc carbonate and zinc oxide; 25 to 100% by weight of a filler comprising expanded perlite; 0.2 to 2% by weight of at least one blowing catalyst material of manganese dioxide and potassium iodide; And 4 to 20% by weight of a hydrogen peroxide solution.

Here, the modified silicate preferably comprises 5 to 15% by weight of at least one additive of zinc chloride, aluminum monophosphate, aluminum phosphate, citric acid and boric acid in 100% by weight of the silicate.

The filler may be selected from the group consisting of Expandable Perlite, Microporous Silica, Fumed Silica, Fly Ash, Diatomite, Light Calcium Carbonate, , Expandable vermiculite, wollastonite, and aerogels (Aero Gel).

The filler may be selected from the group consisting of Expandable Perlite, Microporous Silica, Fumed Silica, Fly Ash, Diatomite, Light Calcium Carbonate, , Expandable Vermiculite, Wollastonite, Aerogel, and at least one of Illite, Bentonite, Zeolite, Silica Fume, Cericite, Aluminum Hydrate, Aluminum Oxide, Magnesium Oxide, Titanium Oxid, Loess, Kaolin Meta Kaolin, Acid Clay, , And EPS (Expandable Polystyrene) having a diameter of 1 to 5 mm.

On the other hand, the filler may be selected from the group consisting of hard calcium carbonate, calcium carbonate, microporous silica, fumed silica, soda lime borosilicate, fly ash, silica fume, expanded vermiculite, diatomaceous earth , Wollastonite, olivine, sericite, staurolite, talc, calcite, titanium dioxide, aluminum hydroxide, aluminum oxide and silica.

Here, the filler may be selected from the group consisting of shredded expanded polystyrene (EPS) having a diameter of 3 to 7 mm which is excellent in heat insulating property, nylon fiber, glass fiber, carbon fiber, aramid fiber, rock wool, pulp, It is preferable that at least one is added.

In order to control the initial adhesion and the viscosity of the slurry during the spraying, the filler is preferably selected from the group consisting of hydroxypropyl methylcellulose (HPMC), carboxymethylcellulose (CMC), gum arabic, methyl cellulose (MC) Or more.

Also, the foamed mortar may contain at least one reinforcing agent selected from the group consisting of nylon fiber, glass fiber, carbon fiber, aramid fiber, rock surface fiber, pulp and various kinds of cellulosic fibers, and at least one bubbling accelerator selected from nonionic surface active agents or vegetable and animal protein foams, It is preferable to further include an initial cohesive strength and viscosity adjusting agent of at least one of hydroxypropyl methylcellulose (HPMC), carboxymethylcellulose (CMC), gum arabic and methyl cellulose (MC).

Wherein the reinforcing agent has a thickness of 10 to 20 microns and a length of 2 to 5 mm and the amount of the reinforcing agent is 1 to 2% by weight based on 100% by weight of the modified silicate, 1% by weight of the modified silicate, and 1% to 6.0% by weight based on 100% by weight of the modified silicate.

And the concentration of hydrogen peroxide is preferably 30 to 40%.

According to an aspect of the present invention, there is provided a method for preparing a foamed mortar, comprising: preparing a modified silicate wherein at least one of zinc chloride, aluminum monophosphate, aluminum phosphate, citric acid and boric acid is added to a silicate; By weight of a sizing agent containing 1 to 10% by weight of at least one of sodium silicate, zinc carbonate and zinc oxide per 100% by weight of the modified silicate; Mixing 25 to 100% by weight of filler and diluent per 100% by weight of modified silicate with 25 to 100% by weight of additive; Mixing the pre-mixed filler and the additive with the modified silicate treated to prepare a slurry; And adding and mixing an additive including a foaming catalyst, a reinforcing agent, a foam activation agent and an initial adhesion promoter to the slurry, adding 4 to 20% by weight of a foaming agent, and then mixing the resultant with the slurry .

Wherein the modified silicate is prepared by preparing an additive prepared by dissolving at least one of zinc chloride, aluminum monophosphate, aluminum phosphate, citric acid and boric acid in an amount of 1 to 20 wt% in a general water of 100 wt% Adding 5 to 15% by weight of the additive; adding 5 to 30% by weight of general water to 100% by weight of the silicate additive added with the additive to the silicate; mixing the silicate additive and the normal water uniformly Thereby producing a modified silicate.

In the step of pre-mixing the filler and the additive in an amount of 25 to 100% by weight, the filler may be selected from the group consisting of Expandable Perlite, Microporous Silica, Fumed Silica, Fly Ash ), Diatomite, Light Calcium Carbonate, Expandable Vermiculite, Wollastonite and Aerogel can be used, and it is possible to use at least one of Illite, Bentonite (Bentonite), Zeolite, Silica Fume, Cericite, Aluminum Hydrate, Aluminum Oxide, Magnesium Oxide, Titanium Oxid, Or a mixture of at least one selected from the group consisting of Loess, Kaolin, Meta Kaolin and Acid Clay may be selected and mixed to achieve a further increase in thermal conductivity and an ultra-light weight of less than 0.1 g / only Layer, it is preferable to add 1 to the diameter of EPS (Expandable Polystyrene) crushing size of 5mm to realize functions to absorb the shock from the outside effectively.

Also, in the step of pre-mixing the filler and the additive in an amount of 25 to 100% by weight, the additive may be a hard calcium carbonate, One type of inorganic filler which is comparatively excellent in thermal insulation properties such as silicate (Soda Lime Borosilicate), fly ash, silica fume, expanded vermiculite, diatomaceous earth, wollastonite, olivine, sericite, feldspar, talc, calcite, titanium dioxide, aluminum hydroxide, (EPS) having a diameter of 3 to 7 mm, which is excellent in heat insulation property, and a nylon fiber, a glass fiber, a carbon fiber, an aramid fiber, a cotton wool, a pulp, various kinds of cellulosic Fiber or the like, or to adjust the initial adhesion and the viscosity of the slurry when sprayed, It is preferable to add at least one of hydroxypropyl methylcellulose (HPMC), carboxymethylcellulose (CMC), gum arabic, methyl cellulose (MC) and xanthan gum.

Then, an additive including a foaming catalyst, a reinforcing agent, a bubble activator and an initial adhesion promoter is added to the slurry, and the foaming agent is added in an amount of 4 to 20% by weight of hydrogen peroxide,

As the foaming catalyst, at least one of manganese dioxide (MnO2) and potassium iodide is added in an amount of 0.2 to 2% by weight based on 100% by weight of the modified silicate in an amount of 0.1 to 1% by weight and mixed for 3 to 5 minutes using a paddle mixer To prepare a slurry,

The reinforcing agent may be at least one of a nylon fiber, a glass fiber, a carbon fiber, an aramid fiber, a rock surface fiber, a pulp and various kinds of cellulose fibers. The reinforcement has a fiber thickness of 10 to 20 microns and a length of 2 to 5 mm By weight based on 100% by weight of the modified silicate, and the bubble activator is added in an amount of 0.6 to 1% by weight based on the modified silicate based on the nonionic surfactant or the vegetable and animal protein foam stabilizer. And the initial viscosity and the viscosity adjusting agent are selected from the group consisting of HPMC (Hydroxypropyl methylcellulose), Carboxymethylcellulose (CMC), Arabic gum, methyl cellulose (MC) and xanthan gum And 1 to 6% by weight based on 100% by weight of the modified silicate.

The blowing agent is preferably a hydrogen peroxide solution having a concentration of 30 to 40%.

The present invention has the following effects.

First, since the specially developed modified silicate is used, it is possible to provide a foamed mortar capable of improving main water resistance and improving adhesion to a base surface when producing foamed mortar.

Secondly, the modified silicate of the present invention can solve the problem of re-shrinkage which may occur due to delay of hardening after bubbling.

Thirdly, it is a specially developed modified silicate and lightweight filler material, which has excellent thermal conductivity with various applications such as microporous silica, fumed silica, fly ash, diatomaceous earth, hard calcium carbonate, expanded vermiculite, There is an effect that the material can be selected.

Fourth, when applied to hydraulic mortar with hydraulic spraying, it is possible to solve the problems of initial strength and initial adhesive strength at the time of construction, in particular, the problem of strength reduction due to expansion due to bubble generation.

Fifth, it is possible to provide a foamed mortar capable of expanding at least about 2 to 4 times its original thickness by self-foaming by a catalyst after spraying, thereby improving the heat insulating performance.

Sixth, it is possible to reduce the initial curing time by the use of quick-setting and to work more than 100mm when spraying one time, so that the air can be shortened compared with the conventional work.

Seventh, according to the foamed mortar of the present invention, it is possible to realize a product whose thermal conductivity corresponds to 0.034 W / mK according to the selection of the filler and the amount of foaming.

Eighth, it is possible to replace the foamable combustible resin such as styrofoam or foam polyurethane excellent in heat insulation effect, thereby minimizing the damage caused by fire, and it is possible to manufacture spark insulation material having remarkably excellent workability as well as economy .

1 is a flow chart for explaining a method of producing modified silicate for use in the foamed mortar according to the present invention.
FIG. 2 is a view for schematically explaining a device configuration used in the manufacturing process of the foamed mortar according to the present invention.
3 is a flow chart for explaining a method of manufacturing foamed mortar according to the present invention.
4 to 6 are photographs showing the results of the first to third embodiments of the foamed mortar according to the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings.

In addition, although the term used in the present invention is selected as a general term that is widely used at present, there are some terms selected arbitrarily by the applicant in a specific case. In this case, since the meaning is described in detail in the description of the relevant invention, It is to be understood that the present invention should be grasped as a meaning of a term that is not a name of the present invention. Further, in describing the embodiments, descriptions of technical contents which are well known in the technical field to which the present invention belongs and which are not directly related to the present invention will be omitted. This is for the sake of clarity of the present invention without omitting the unnecessary explanation.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a flow chart for explaining a method for producing a modified silicate used in a foamed mortar according to the present invention. FIG.

The modified silicate used in the foamed mortar according to the present invention is prepared by dissolving 1 to 20 wt% of at least one of zinc chloride, aluminum monophosphate, aluminum citrate and boric acid in 100 wt% of general water (S110) . At this time, the additive may further include at least one of potassium chloride, aluminum sulfate, and magnesium sulfate.

Then, the additive is added in an amount of 5 to 15% by weight based on 100% by weight of the silicate (S120).

Subsequently, 5 to 30% by weight of general water is added to 100% by weight of the silicate additive to which the additive is added to the silicate (S130).

Subsequently, a silicate addition and a general water are uniformly mixed in a high-speed rotary stirrer to prepare a modified silicate (S140).

The silicate includes at least one of the first to fourth species (the molar ratio of the first kind of sodium silicate (SiO2 / Na2O: 2.1 to 2.3), the second kind of sodium silicate (SiO2 / Na2O molar ratio: 2.4 to 2.6) (Molar ratio of SiO2 / Na2O: 3.10 to 3.30) and a fourth kind of sodium silicate (molar ratio of SiO2 / Na2O: 3.4 to 3.6)) of sodium silicate, powdery sodium silicate, potassium silicate and lithium silicate Can be manufactured.

For example, liquid sodium silicate and potassium silicate may be used, sodium silicate and potassium silicate may be used, sodium silicate may be used alone, lithium silicate may be used alone, or powdered sodium silicate may be used alone.

For reference, a foamed ceramic excellent in water resistance can be obtained when foamed ceramics are manufactured using the modified silicate prepared from the modified silicate of the present invention using lithium silicate.

In addition, powdered sodium silicate requires heating by using a heat source to dissolve in water, or it needs to dissolve for a long time.

For reference, the sodium silicate of the first type and the sodium silicate of the second type in the solution type sodium silicate have a high curing time because of the high content of the sodium component and have a high probability of whitening and relatively high viscosity.

In the case of the third type sodium silicate, the viscosity is relatively more appropriate than that of the first, second and fourth kinds of sodium silicate, and the cost is low. Since there are many domestic production sites, it is convenient to purchase. Therefore, considering economical efficiency and productivity, Is most preferably used.

In the case of the fourth type sodium silicate, the viscosity is relatively low as compared with the first and second types of sodium silicate, so that it is easy to control the desired slump and the SiO 2 content is high, so that it is easy to improve the treatment and water resistance.

As the additive to be added to the silicate for producing the modified silicate, at least one of zinc chloride, potassium chloride, aluminum monophosphate, aluminum phosphate, boric acid, citric acid, aluminum sulfate and magnesium sulfate may be selected and mixed.

Each of the additives is preferably dissolved in water and is advantageously added in an amount of 10% by weight based on 100% by weight of water, or 2% to 15% by weight based on 100% by weight of the silicate with respect to the at least one additive And preferably 5 to 12% by weight.

If the additive content is less than 2% by weight, sufficient denaturation can not be attained. Therefore, there is a problem that mechanical strength of the heat insulating layer may be lowered due to moisture or water. When the additive content is more than 15% by weight, And a large amount of water is used for viscosity control due to an increase in the viscosity, so that the bonding strength of the heat insulating layer is lowered and the mechanical strength is lowered.

It is effective to use a homomixer or the like which is a high-speed mixer when the additive is added, and it is preferable to add the additive in a state where the silicate is put into a high-speed mixer and rotated.

In addition, since the viscosity is increased after the complete mixing reaction by adding the additives, 5 to 15% by weight of water can be used as a diluent based on 100% by weight of the modified silicate.

For reference, when the amount of water to be added is at least 15% by weight, problems such as a decrease in strength and an increase in shrinkage after curing may occur. Water may be used in tap water, ground water or industrial water without any particular limitation, except for water containing a large amount of impurities that react with silicates to lower the binding force or change the properties of the modified silicate.

FIG. 2 is a schematic view for explaining the apparatus configuration used in the manufacturing process of the foamed mortar according to the present invention, and FIG. 3 is a flowchart for explaining the foamed mortar manufacturing method according to the present invention.

The method for producing a mortar according to the present invention produces the modified silicate shown in FIG. 1 (S100).

Subsequently, one or more of sodium silicate, zinc carbonate, and zinc oxide is added in an amount of 1 to 10% by weight based on 100% by weight of the modified silicate (S150) to enhance the solubility of the modified silicate.

On the other hand, the light-weight filler and other additives capable of improving the mechanical properties of the sprayed material with excellent heat insulation performance are premixed (S200).

The lightweight filler may be selected from the group consisting of Expandable Perlite, Microporous Silica, Fumed Silica, Fly Ash, Diatomite, Light Calcium Carbonate Expandable Vermiculite, Wollastonite, and Aerogel may be used. In addition, Illite, Bentonite, Zeolite, Silica Fume, Cericite, Aluminum Hydrate, Aluminum Oxide, Magnesium Oxide, Titanium Oxid, Loess, Kaolin, Meta Kaolin, , Acid clay (Acid Clay) may be selected and mixed. In order to further enhance the thermal conductivity and realize an ultra-light weight of less than 0.1 g / cm 2, and to effectively realize the role of the insulating layer to absorb impact from the outside, expanded EPS (Expandable Polystyrene) having a diameter of 1 to 5 mm is added The addition of EPS can also contribute to cost reduction by significantly reducing the weight of the slump per unit volume.

Other additives include calcium carbonate, calcium carbonate, microporous silica, fumed silica, soda lime borosilicate, fly ash, silica fume, expanded vermiculite, and the like, having a size of 1 to 2 microns or less. And one kind or more of inorganic fillers having relatively excellent heat insulating properties such as diatomaceous earth, wollastonite, olivine, sericite, petroleum, talc, calcite, titanium dioxide, aluminum hydroxide, aluminum oxide, silica sand and the like.

(EPS) having a diameter of 3 to 7 mm, which is excellent in heat insulation property, one kind of nylon fiber, glass fiber, carbon fiber, aramid fiber, rock wool, pulp, various kinds of cellulose fibers or the like Add more than that.

In order to control the initial cohesion and viscosity of the slurry during spraying, a mixture of hydroxypropylmethylcellulose (HPMC), carboxymethylcellulose (CMC), gum arabic, methyl cellulose (MC), xanthan gum And the mixture is pre-mixed.

The premixed lightweight filler and other additives are then first premixed with the modified silicate treated at step S300. Here, when the filler and other additives are used as 100% by weight, the amount of the modified silicate is preferably 100 to 400% by weight, more preferably 250 to 300% by weight. Based on the modified silicate, the fillers and other additives are from 25 to 100% by weight. If the amount of the modified silicate is less than 100% by weight, the slump is very low, so that the spraying operation can not be performed, and even if the spraying is possible, it can be prevented that foaming occurs, and when the amount of the modified silicate is more than 400% There is a problem that the thermal conductivity may be lowered due to excessive amount of the modified silicate and the layer separation may occur due to the lightweight filler such as the EPS pole during mixing.

The state of the mixture in this primary mixing is advantageous to maintain the slump 13-20, most preferably 16-17. In this case, when the slump is 13 or less, the flowability is low, so it is difficult to transfer the slurry to the discharge port at the time of construction using the equipment to be sprayed, and there is a possibility that expansion due to sufficient foaming during the foaming process may not be performed. Is 20 or more, the fluidity is so high that the layer separation of the modified silicate may occur at the time of transferring to the light-weight filler and the discharge port, the uniform foaming by the foaming agent can not be provided, .

Then, additives such as a foaming catalyst, a reinforcing agent, a foam activation agent and an initial adhesion promoting agent are added and mixed.

Here, as a foaming catalyst, at least one of manganese dioxide (MnO2) and potassium iodide is added in an amount of 0.1 to 1 wt% based on the total weight%, and mixed using the paddle mixer 10 for 3 to 5 minutes to prepare a slurry. It is 0.2 to 2% by weight based on 100% by weight of the modified silicate.

Such a foaming catalyst promotes a decomposition reaction with hydrogen peroxide water used as a blowing agent to be described later and plays a role of generating a large amount of oxygen. Hydrogen peroxide used as a blowing agent is decomposed into water and oxygen by lowering the activation energy by a catalyst such as manganese dioxide and potassium iodide. At this time, the mass of the catalyst does not decrease, and the hydrogen peroxide water is decomposed into water and oxygen by the following reaction.

[Reaction Scheme]

In the present invention, the rate of the decomposition reaction by the direct contact between the hydrogen peroxide solution and the catalyst, manganese dioxide and potassium iodide is very rapid, and there is a great difficulty in bubble control. However, in the mixed slurry state with the modified silicate and light- (TEST) that the rate of decomposition reaction can be controlled sufficiently. The decomposition reaction is carried out in the final mixing step, and it is preferable that the decomposition reaction is controlled to proceed for about 20 to 30 minutes in consideration of the time of transporting the slurry and the spraying time.

On the other hand, it is preferable to use manganese dioxide as the foaming catalyst, because the cost is relatively lower than that of potassium iodide and the control of the decomposition reaction rate is relatively easy. The added amount of manganese dioxide may be 0.1 to 1.0 wt%, and most preferably 0.4 to 0.6 wt% based on 100 wt% of the whole slurry. When the addition amount is 0.1 wt% or less, the decomposition reaction rate is too slow to obtain the desired foam. When the addition amount is 1.0 wt% or more, the decomposition reaction rate becomes too fast, which makes it difficult to construct and abnormal bubble formation occurs, Lt; / RTI >

As the reinforcing agent of the present invention, one kind or more of nylon fiber, glass fiber, carbon fiber, aramid fiber, rock surface fiber, pulp, various kinds of cellulose fibers and the like may be added, and the reinforcing agent has a fiber thickness of 10 to 20 microns or less And the length is preferably 2 to 5 mm, and it is preferable to add 0.5 to 1% by weight based on 100% by weight of the slurry. It is 1 to 2% by weight based on 100% by weight of modified silicate.

Since the reinforcing agent enhances the strength of the foam, the reinforcing agent may be added at a ratio exceeding the above-mentioned ratio depending on the application place of the product, so that the reinforcing agent is not specially formed. However, when the addition amount is 0.5% by weight or less, it is preferable to add more than 0.5% by weight because it has little role as a reinforcing agent. Also, the reinforcing agent not only helps to increase the strength after curing because foam is formed at room temperature in the case of the foamed mortar of the present invention, but also helps to minimize the rebounding rate by improving the initial strength against expansion after curing.

The bubble activator provides lubricity to the slurry to smooth the generation of bubbles due to the catalyst, thereby uniformizing the particle size of the bubbles.

The cell activator may generally be a nonionic surfactant or, if desired, vegetable and animal protein foam. The preferable amount of addition is from 0.3 to 0.5% by weight, and other ratios may be added depending on the situation. And 0.6 to 1% by weight based on the modified silicate.

The initial cohesion and viscosity control agent may be one or more of HPMC, CMC, gum arabic, MC, xanthan gum and the like, and since there may be an additive that is gelled when contacted with modified silicate such as MC, And it is preferable to select an additive having good solubility to the modified silicate to be applied to the present invention because the mixing time in the working process is relatively short as 3 to 5 minutes. The initial cohesion and the viscosity controlling agent are preferably 0.5 to 3.0 wt% (preferably 1 to 6 wt% based on 100 wt% of the modified silicate) based on 100 wt% of the slurry, and when the added amount is 0.5 wt% or less, When it is added in an amount of 3.0% by weight or more, the fire-retardant performance is lowered and the viscosity becomes higher and it becomes difficult to spray.

Then, a foaming agent is added to the slurry (S400). At this time, a hydrogen peroxide solution having a concentration of 30 to 40% is added as the foaming agent. Here, the amount of the hydrogen peroxide solution may be 2 to 10% by weight based on 100% by weight of the slurry. At this time, it is 4 to 20% by weight based on modified silicate. Most preferably 4 to 6% by weight. If the addition amount is less than 2% by weight, the amount of bubbles to be generated is small and the desired expansion can not be obtained. As a result, the thermal conductivity may decrease. When the addition amount is 10% by weight or more, There is a problem that it can not function as a thermal insulating material to be lowered and sprayed.

Then, the mixture is mixed for 20 to 40 seconds (S500).

Next, the foamed mortar mixed with the pump & compressor 30 is supplied through the hopper 20 to perform spraying (S600), and the expansion due to the catalytic reaction is gradually performed for about 20 minutes. It is possible to control the amount of hydrogen peroxide by spraying.

Finally, natural drying and curing are performed (S700).

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

50 g of expanded perlite having a particle size of 0.1 to 1.0 mm, 30 g of hard calcium carbonate having a size of 2 to 1 micron or less, 5 g of fused silica of OCI, 20 g of 5 mm EPS poles, 15 g of sodium silicate, 15 g of zinc carbonate, , 3 g of nonionic surfactant, 3 g of manganese dioxide, 3 g of gum arabic and 450 g of modified silicate were added and mixed for about 3 to 4 minutes using a paddle mixer. 35 g of hydrogen peroxide was added and the mixture was mixed for 0.5 to 1.0 minutes to prepare a slurry Were prepared.

After that, it was poured into a transparent acrylic jig having a size of 300 × 300 × 40 mm and then left for 30 minutes. After confirming that the expansion occurred due to the rapidity and sufficient foaming, it was demolded and completely dried in the dryer for measuring the thermal conductivity. The sample was dried at a temperature of about 70 to 80 ° C. until there was no further weight loss.

Fig. 4 shows a foamed mortar sample shape according to Example 1. Fig.

60 g of diluted perlite having a particle size of 0.1 to 1.0 mm, 50 g of hard calcium carbonate of 2 microns or less, 12 g of sodium silicate, 12 g of zinc carbonate, 7 g of pulp, 3 g of nonionic surfactant, 4 g of manganese dioxide, 450 g of silicate and 50 g of water were charged and mixed for about 3 to 4 minutes using a paddle mixer. The slurry was prepared by adding 40 g of hydrogen peroxide solution and 0.5 to 1.0 minute of final mixing. The subsequent steps are the same as those in the first embodiment.

Fig. 5 shows a foamed mortar sample shape according to Example 2. Fig.

40 g of Glass Bubble (Soda Lime Borosilicate) of 3M Company having a particle size of 20 microns or less and a volume density of 0.15 g / cm2, 20 g of fused silica of OCI, 7 g of sodium silicate, 7 g of zinc carbonate, 2 g of nylon fiber, 4 g of manganese dioxide, 3 g of HPMC, 450 g of modified silicate and 50 g of water were added and mixed for about 3 to 4 minutes by using a paddle mixer for primary mixing, followed by addition of 35 g of hydrogen peroxide and final mixing for 0.5 to 1.0 minute to prepare a slurry. Thereafter, the same procedure as in Example 1 was carried out to prepare a sample.

Fig. 6 shows a sample shape of the foamed mortar according to Example 3. Fig.

In the present invention, Examples 1 to 3 are compared with Comparative Examples 1 to 3.

[Comparative Example 1]

Comparative Example 1 was carried out in the same manner as in Example 1 except that a sample was prepared with the exception of manganese dioxide, aqueous hydrogen peroxide, and nonionic surfactant.

[Comparative Example 2]

Comparative Example 2 was carried out in the same manner as in Example 2 except for the use of manganese dioxide, hydrogen peroxide solution, and nonionic surfactant.

[Comparative Example 3]

Comparative Example 3 was carried out in the same manner as in Example 3 except that manganese dioxide, hydrogen peroxide solution and nonionic surfactant were excluded.

Three samples of each of Examples 1 to 3 and Comparative Examples 1 to 3 were produced, measured for the following experimental items, and their average values were determined and shown in Table 1

Examples 1 to 3, which are advantageous to practical application in terms of product price competitiveness, have been described in detail in Examples 4 to 7 below, by controlling the amount of hydrogen peroxide water input.

In Example 4, a raw material was added in the same amount as in Example 1, and 20 g of hydrogen peroxide as a foaming agent was prepared in the same manner.

In Example 5, the same amount of raw material as in Example 1 was added, and 25 g of hydrogen peroxide as a foaming agent was prepared in the same manner.

In Example 6, a raw material was added in the same amount as in Example 1, and 30 g of hydrogen peroxide as a foaming agent was prepared in the same manner.

In Example 7, a raw material was added in the same amount as in Example 1, and 40 g of hydrogen peroxide as a foaming agent was prepared in the same manner.

One sample of each of Examples 4 to 7 was prepared and measured for the following experimental items and shown in Table 2

As shown in Table 2, it can be seen that as the amount of hydrogen peroxide is increased, the foaming progresses actively to increase the degree of expansion and decrease the density. However, as in Example 7, when the amount of the hydrogen peroxide solution is excessively large, the expansion degree becomes worse, but the thermal conductivity is not improved as expected. This suggests that formation of abnormal bubbles by excessive foaming hinders improvement of the desired thermal conductivity. Also, it was found that the excessive foaming significantly reduced the mechanical strength of the insulating layer to be sprayed and thus it was difficult to apply.

As another example of the embodiment, Example 1 was tested by controlling the addition amount of manganese dioxide, which is a catalyst, in Example 1. Examples 8 to 10 were described in detail.

In Example 8, a raw material was added in the same amount as in Example 1, and 5 g of manganese dioxide as a catalyst was sampled in the same manner.

In Example 9, a raw material was added in the same amount as in Example 1, and 7.5 g of manganese dioxide as a catalyst was prepared in the same manner.

In Example 10, a raw material was added in the same amount as in Example 1, and 10 g of manganese dioxide as a catalyst was sampled in the same manner.

One sample of each of Examples 8 to 10 was prepared and measured for the following experimental items and shown in Table 3

As a result of the above Table 3, it can be seen that as the addition amount of manganese dioxide increases, the foaming progresses rapidly and the occurrence of abnormal bubbles increases and the mechanical strength of the sparked insulating layer is remarkably lowered. In addition, even when the amount of manganese dioxide added is increased, the overall density is not changed, and the complete foaming time is shortened, which makes it difficult to secure the desired spraying time. This is because the contact rate between the hydrogen peroxide solution and the manganese dioxide acting as the catalyst increases and the reaction rate becomes faster.

As another example of the embodiment, Example 1 was tested in Examples 1 to 13 in which the amount of sodium diisobutylphosphate and zinc carbonate added was controlled.

In Example 11, a raw material was added in the same amount as in Example 1, and a sample was prepared in the same manner without adding sodium disilicate and zinc carbonate as quick-setting agents.

In Example 12, the same amount of raw material as in Example 1 was added, and 7.5 g of sodium persulfate and zinc carbonate were added in amounts of 7.5 g each, and the sample was produced in the same manner.

In Example 13, the same amount of raw material as in Example 1 was added, and 25 g of each of sodium persulfate and zinc carbonate were added to the sample in the same manner.

One sample of each of Examples 11 to 13 was prepared and measured for the following experimental items and shown in Table 4

As a result of the above Table 4, when the rapid setting agent was not added, the resin shrinks after expansion, and the central portion is recessed to obtain a desired heat insulating layer. As in Example 13, the hardening time is shortened The curing progressed before complete expansion by the foaming agent, resulting in a reduction of the effect of the foaming agent. Therefore, it is important to determine the appropriate amount of quick-setting payment considering the construction time for one workload. These decisions can be controlled by various field tests (FIELD TEST).

While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it should be understood that various changes and modifications will be apparent to those skilled in the art. It is to be understood that the present invention is not limited to the above-described embodiments. Accordingly, the scope of protection of the present invention should be construed according to the following claims, and all technical ideas which fall within the scope of equivalence by alteration, substitution, substitution and the like within the scope of the present invention, Range. In addition, it should be clarified that some configurations of the drawings are intended to explain the configuration more clearly and are provided in an exaggerated or reduced size than the actual configuration.

10: paddle mixer 20: hopper
30: Pumps & compressors

Claims (16)

delete delete delete delete delete delete delete delete delete delete Preparing a modified silicate in which at least one of zinc chloride, aluminum monophosphate, citric acid, and boric acid is added to the silicate (S100);
The modified silicate,
(S110) preparing an additive prepared by dissolving 1 to 20% by weight of at least one of zinc chloride, aluminum monophosphate, citric acid and boric acid in 100% by weight of general water;
Adding the additive in an amount of 5 to 15% by weight based on 100% by weight of the silicate (S120);
A step (S130) of adding 5 to 30% by weight of a general water to 100% by weight of the silicate additive to which the additive is added to the silicate; And
Mixing the silicate additive and the general water uniformly (S140)
Since the viscosity of the additive is increased by the addition of the additive, after the complete mixing reaction, 5 to 15% by weight of water based on 100% by weight of the modified silicate is diluted with a diluent;
(S150) of 1 to 10% by weight of the accelerating agent containing at least one of sodium silicate, zinc carbonate and zinc oxide per 100% by weight of the modified silicate diluted with the diluent;
(S200) premixing the filler and the additive in an amount of 25 to 100% by weight with respect to 100% by weight of the modified silicate treated in the step (S200);
The additive in the pre-mixing step may be selected from the group consisting of light calcium carbonate having a size of 1 to 2 microns or less, microporous silica, fumed silica, soda lime borosilicate, fly ash, silica fume, Containing one or more inorganic fillers having relatively excellent heat insulating properties such as diatomaceous earth, wollastonite, olivine, sericite, petroleum, talc, calcite, titanium dioxide, aluminum hydroxide, aluminum oxide,
(EPS) having a diameter of 3 to 7 mm, which is excellent in heat insulation property, and one type or a kind of nylon fiber, glass fiber, carbon fiber, aramid fiber, rock wool, pulp and various kinds of cellulose fibers Or more,
In order to adjust the initial cohesion and viscosity of the slurry during spraying, one or more of hydroxypropyl methylcellulose (HPMC), carboxymethylcellulose (CMC), gum arabic, methyl cellulose (MC) Lt; / RTI >
Mixing the premixed filler and the additive with the modified silicate to prepare a slurry (S300); And
Adding to the slurry an additive including a foaming catalyst, a reinforcing agent, a bubble activating agent and an initial cohesive strength enhancer, and mixing and mixing 4 to 20% by weight of a foaming agent based on 100% by weight of the modified silicate (S400) (S500). ≪ / RTI > delete 12. The method of claim 11,
In step S200 of pre-mixing 25 to 100% by weight of the filler and the additive,
Examples of the filler include Expandable Perlite, Microporous Silica, Fumed Silica, Fly Ash, Diatomite, Light Calcium Carbonate, It is possible to use at least one of Expandable Vermiculite, Wollastonite and Aero Gel and it is possible to use at least one of Illite, Bentonite, Zeolite, Silica Fume, Cericite, Aluminum Hydrate, Aluminum Oxide, Magnesium Oxide, Titanium Oxid, Loess, Meta Kaolin, Acid Clay, Or more, to further increase the thermal conductivity, to achieve an ultra-light weight of less than 0.1 g / cm 3, and to effectively realize the role of the insulating layer to absorb the impact from the outside, Wherein the expandable polystyrene (EPS) is added in an amount of 5 to 5 mm. delete 12. The method of claim 11,
Adding and mixing an additive including a foaming catalyst, a reinforcing agent, a foam activator and an initial adhesion promoter to the slurry, adding 4 to 20% by weight of a foaming agent based on 100% by weight of the modified silicate treated in the step (S400) (S500)
As the foaming catalyst, at least one of manganese dioxide (MnO 2) and potassium iodide is added in an amount of 0.1 to 1 wt% based on 100 wt% of the modified silicate, and the mixture is mixed for 3 to 5 minutes using a paddle mixer 10 to prepare a slurry ,
The reinforcing agent may be at least one of a nylon fiber, a glass fiber, a carbon fiber, an aramid fiber, a rock surface fiber, a pulp and various kinds of cellulose fibers. The reinforcing agent has a fiber thickness of 10 to 20 microns and a length of 2 to 5 mm By weight based on 100% by weight of the modified silicate,
The bubbling activator comprises 0.6 to 1% by weight of a nonionic surfactant or vegetable and animal protein foam based on the modified silicate,
The initial adhesive force and the viscosity controlling agent may be one or more selected from the group consisting of hydroxypropyl methylcellulose (HPMC), carboxymethylcellulose (CMC), gum arabic, methyl cellulose (MC) and xanthan gum, And 1 to 6% by weight based on 100% by weight of the treated modified silicate. 12. The method of claim 11,
Wherein the foaming agent is a hydrogen peroxide solution having a concentration of 30 to 40%, and the hydrogen peroxide solution is added, followed by secondary mixing for 20 to 40 seconds.

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