KR101927195B1 - Method of manufacturing glass fiber reinforced concrete formwork using expanded polystyrene - Google Patents

Abstract

The present invention relates to a method for manufacturing a glass fiber reinforced concrete formwork using expanded polystyrene. More specifically, the present invention relates to a method for manufacturing a glass fiber reinforced concrete formwork using expanded polystyrene, to facilitate processes, reduce production cost, enable precise molding since the moldability is excellent to prevent the surface thereof from being uneven due to abrasion after molding regardless of the number of molding operations and a dimension and a shape thereof are not deformed, and facilitate a manufacturing process of inner and outer materials of buildings since a shape process is unrestricted.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention [0001] The present invention relates to a method for manufacturing a glass fiber reinforced concrete using a foamed polystyrene,

More particularly, the present invention relates to a method of manufacturing a glass fiber reinforced concrete molded article using expanded polystyrene, and more particularly, to a method for manufacturing a glass fiber reinforced concrete molded article using expanded polystyrene, The present invention also relates to a method for manufacturing a glass fiber reinforced concrete molded article using the expanded polystyrene so that the shape and the shape of the structure can be easily formed.

GFRC (Glass Fiber Reinforced Concrete), which is a glass fiber reinforced concrete, is an interior or exterior material for molding molding requiring an aesthetic approach because it can develop external aesthetics and its use is increasing in major developed countries including Europe.

Since GFRC has high durability according to high strength, it has been increasingly used as interior and exterior materials for molding molding in the field of construction in recent years in Korea. In some cases, the molding itself may be used as an interior or exterior material.

An example of such a GFRC is shown in Table 1 below.

division
Exterior material
Interior material
Molding example


Picture
Sample

However, in the conventional method for obtaining the GFRC molded body, since the mold has to have durability, FRP (Fiberglass Reinforced Plastics) is mainly used as a mold, and GFRC is sprayed thereon to form a molded body having the same shape as the mold.

Therefore, even if the re-molding is repeated after demoulding, the surface of the FRP mold is not worn or roughened, so that it is possible to maintain the accurate dimensions and shape.

However, the FRP mold has a limitation that the shape can not be freely formed because the strength is too strong and the degree of freedom of shape is decreased.

That is, CNC (Computerized Numerical Control) processing is performed by a computer program based on computer-aided design (CAD) information in accordance with a molded body selected to form a mold shape. Conventional FRP molds have too strong mechanical properties There is a disadvantage in that a lot of time and cost are wasted even if it is processed because CNC machining is not easy to process because a lot of work is done.

In order to solve this problem, attempts have been made to utilize expanded polystyrene (EPS), which is inexpensive and has excellent formability.

However, expandable polystyrene has poor mechanical properties and poor releasability of GFRC. Therefore, when it is used as a mold, the size and shape inaccuracy increase due to surface roughness due to abrasion, Despite its low price, its utilization is low.

Korean Patent Publication No. 1996-0011910 (1996.09.04), 'Fiberboard for interior materials and method for manufacturing the same' Korean Registered Patent No. 10-1187320 (2012.09.25.), 'Exposed Concrete Panel for Building Exterior Material Containing Carbon Additive and Its Manufacturing Method' Korean Registered Patent No. 10-1361713 (Mar. 23, 2014), 'Method for Manufacturing Synthetic Fiber for Fiber Reinforced Concrete'

The present invention has been made in view of the above-mentioned problems in the prior art, and it is an object of the present invention to provide a method for manufacturing a semiconductor device, which is easy to work and can reduce a manufacturing cost and is excellent in releasing property, And a method for manufacturing a glass fiber reinforced concrete molded body using the expanded polystyrene so that the shape and the shape of the structure are not deformed, .

In order to achieve the above-mentioned object, the present invention provides a method for producing a glass fiber reinforced resin (GFRC), comprising the steps of: mixing a first raw material, a second raw material, a third raw material, an EPS (Expandable Polystyrene) Concrete) powder molding step → drying and demolding of GFRC formed body, the method comprising the steps of: preparing a glass fiber reinforced concrete molded body using expanded polystyrene; Wherein the primary raw material mixing step comprises mixing 50 to 55 wt% of a copolymer of acrylic acid, styrene, and methacrylic acid, 0.50 to 1.00 wt% of triethanolamine, 0.10 to 0.15 wt% of hexamethylenetetramine, 0.15% by weight, 15-20% by weight of methanol and the balance sodium hydroxide; And indirectly heating the compounded mixture through the above process for 1 to 2 hours to form a first reactant; The second raw material blending step is carried out by mixing 30 to 35% by weight of a copolymer of acrylic acid, styrene and methacrylic acid, 0.50 to 1.00% by weight of triethanolamine, 0.10 to 0.15% by weight of hexamethylenetetramine, % By weight and the remainder in the first reactant; And cooling the mixed mixture through the process to form a second reactant; The third raw material blending step is a step of blending the starting material mixture of 3-chloropropylene oxide or 1-chloro-2,3-epoxypropane in an amount of 0.25 to 0.30% by weight, methyltrimethoxysilane in an amount of 0.3 to 0.5% by weight, polyvinyl alcohol in an amount of 10 to 15 By weight of a silicone resin, 1.5 to 2.0% by weight of a silicone resin and the remainder of the secondary reactant, and the final combination is completely mixed in the reactor to form a water soluble synthetic resin; The EPS mold making step is a step of making an EPS mold according to a dimension and a shape designed by CAD (Computer Aided Design) through a CNC (Computerized Numerical Control) shelf; The step of applying the water-soluble synthetic resin is a step of spraying the water-soluble synthetic resin on the surface of the EPS mold by mixing with water; Wherein the GFRC powder forming step is a step of powder-molding the GFRC molding raw material on the surface of the EPS mold to form a predetermined thickness; Wherein the drying and demolding of the GFRC formed body is a step of releasing the molded body from the EPS mold after the powder molding is completed.

At this time, in the step of applying the water-soluble synthetic resin, the mixing ratio of the water-soluble synthetic resin and water is 9: 1.

In addition, in the GFRC powder molding step, the GFRC molding raw material may contain 25-35 wt% of the portland cement, 20-40 wt% of the sand, 10-20 wt% of the glass fiber, 2-5 wt% of the epoxy resin, , 2-5 wt% of a water reducing agent, 2-5 wt% of pozzolan, and the remainder water.

According to the present invention, not only can the work be easy, the manufacturing cost can be lowered, but also the releasing property is excellent so that even when the molding is repeated several times, the surface is not roughened due to abrasion and the dimension and shape are not deformed, Thereby making it possible to easily make the inside and exterior of the building.

Hereinafter, preferred embodiments according to the present invention will be described in detail.

Before describing the present invention, the following specific structural or functional descriptions are merely illustrative for the purpose of describing an embodiment according to the concept of the present invention, and embodiments according to the concept of the present invention may be embodied in various forms, And should not be construed as limited to the embodiments described herein.

In addition, it should be understood that the embodiments according to the concept of the present invention include various modifications, equivalents, and alternatives included in the spirit and technical scope of the present invention, .

The method for manufacturing a glass fiber reinforced concrete molded article using expanded polystyrene according to the present invention comprises: a first raw material blending step; a second raw material blending step; a third raw material blending step; an EPS mold making step; a water soluble synthetic resin applying step; a GFRC powder forming step; And includes a molded body drying and demolding step.

In this case, the first, second, and third raw material mixing steps are to form a water-soluble synthetic resin to be applied to the surface of the EPS mold.

This water-soluble synthetic resin is a surface strengthening agent that performs a kind of binder function. It protects the surface and improves the durability of the EPS mold by increasing the bonding force during the fusion between the particles to prevent the surface of the EPS mold from being easily broken, .

For example, the primary raw material mixing step may be performed by mixing 50 to 55% by weight of a copolymer obtained by copolymerizing acrylic acid, styrene, and methacrylic acid, 0.50 to 1.00% by weight of triethanolamine, , 0.10 to 0.15% by weight of hexamethylenetetramine, 0.05 to 0.15% by weight of a silicone antifoaming agent, 15 to 20% by weight of methanol and sodium hydroxide (sodium hydroxide) and; And indirectly heating the compounded mixture through the above process for 1 to 2 hours to form a first reactant.

At this time, the copolymer is added in order to improve moldability by copolymerization of styrene and methacrylic acid, improve heat resistance, and increase the impact resistance remarkably when polyacrylic acid is added and copolymerized, among other things, to increase releasability of GFRC.

However, when it is added in an amount of more than 55% by weight, the emulsifying property is intensified and the viscosity is increased to deteriorate the coatability and formability. When the amount is less than 50% by weight, emulsification is inhibited and the mold release property sharply drops as well as heat resistance and impact resistance, Range.

And, triethanolamine is added to maintain pH control (weakly acidic retention) and surfactant and emulsification properly, and has a risk of EWG 5 grade.

In addition, hexamethylenetetramine is added in order to increase the preservative effect while decomposing the acidic salt while dissolving it to release the formaldehyde to sterilize and remove it, and to increase the binding effect upon curing. However, if it exceeds 0.15 wt% And it should not be exceeded. If it is added in an amount of less than 0.10% by weight, the anticorrosiveness and binding effect are reduced. Therefore, the range should be limited to the above range.

In addition, silicone antifoaming agents are added in order to inhibit embryo formation, to inhibit the formation of bubbles which deteriorate the appearance quality and to deteriorate the appearance quality, and to maintain homogeneous orientation. In particular, silicone antifoam agents have very low surface tension It is added to enhance compatibility.

However, when it is added in an amount exceeding 0.15% by weight, the incompatibility is increased, and if it is added in an amount of less than 0.05% by weight, stabilization of bubble, that is, foaming becomes weak.

In addition, methanol contains less carbon and hydrogen than ethanol and boiling point is lower than that of ethanol, so it is an easy solvent for low temperature indirect heating. Such methanol is preferable as a solvent for hexamethylenetetramine, which is a crystalline solid.

However, since it is volatile, flammable and toxic, it should be added to the above range.

The sodium hydroxide added as the remainder contributes to the alkylation of the intramolecular polar group of the copolymer because of its excellent ability to decompose insoluble salts and its excellent reactivity at low temperatures.

In addition, the process of indirectly heating the blend for 1 to 2 hours to form the first reactant is to alkylate the polar groups present in the molecule in the copolymer by indirect heating to improve the reactivity.

Meanwhile, the second raw material mixing step may be performed by mixing 30 to 35% by weight of a copolymer of acrylic acid, styrene and methacrylic acid, 0.50 to 1.00% by weight of triethanolamine, 0.10 to 0.15% by weight of hexamethylenetetramine, 0.0 >% < / RTI > by weight of formic acid and the remainder of the primary reactant; And cooling the mixed mixture through the above process to form a second reactant.

Since formic acid is prepared by adding glycerin to aquatic acid, it has a high scale dissolving power and is used for acid washing. It is used for improving the adhesion property of GFRC on the surface of EPS by implementing the surface modification property do.

However, since the amount thereof is changed to formalin by reacting with methanol, it should be added within the above range.

The reason why the first reactant is added again is to promote emulsion film formation and improve the releasability of GFRC.

In addition, the third raw material mixing step may be carried out by mixing 0.25 to 0.30% by weight of 3-chloropropylene oxide or 1-chloro-2,3-epoxypropane, 0.3 to 0.5% by weight of methyltrimethoxysilane, 10 to 15% by weight of a polyvinyl alcohol, 1.5 to 2.0% by weight of a silicone resin and the remainder of the secondary reaction product, and the final product is completely mixed and reacted in the reactor to form a water- to be.

At this time, 3-chloropropylene oxide or 1-chloro-2,3-epoxypropane is added to stabilize the emulsion as epichlorohydrin, which is a chlorine-based material having high reactivity.

However, it is flammable and toxic.

In addition, methyltrimethoxysilane is added to increase durability by enhancing the bonding force between emulsified materials by absorbing only oil by hydrophobicity. However, it should be limited to the above range in consideration of hydration reactivity.

Polyvinyl alcohol is added to enhance acid resistance and chemical resistance. It is required to be limited to the above range in order to control the viscosity because it increases the bonding force between the components, promotes the film formation and strengthens the releasing property, and is used as an increasing agent.

In addition, the silicone resin is a polymer mainly composed of silicon and oxygen bonds, and is added in order to increase the adhesive force and to strengthen the binding force between the adhesive force and the constituent components.

However, if it exceeds 2.0% by weight, the viscosity becomes too high and the coating property becomes poor. When the content is less than 1.5% by weight, the adhesive strength and the fixing strength are lowered.

When the raw material mixing step for the primary, secondary, and tertiary materials is completed, a water soluble synthetic resin is completed.

In the EPS mold manufacturing step, the EPS is cut in numerical values and shapes designed by a CAD using a CNC lathe, and processed into a mold for molding.

Thus, when the EPS mold is completed, the water-soluble synthetic resin application step is performed.

The step of applying the water-soluble synthetic resin is a step of mixing the water-soluble synthetic resin prepared above with water to prepare a synthetic resin solution and spraying it on the surface of the EPS mold.

At this time, a polymetaphosphate may be further added to induce curing acceleration. The polymetaphosphate may be added in an amount of 1.5-2.5 parts by weight based on the entire water-soluble synthetic resin.

However, when the amount of the polymetaphosphate is excessively added, the ability to accelerate curing becomes stronger. However, when the amount exceeds 2.5 parts by weight, white precipitation can not occur. When the amount is less than 1.5 parts by weight, curing acceleration effect can not be expected.

In addition, when the water-soluble synthetic resin is mixed with water at a weight ratio of 9: 1, when water is added in excess of this ratio, hardening delay occurs and adhesion of water-soluble synthetic resin at the surface of the EPS mold is decreased. Care must be taken that peeling may occur.

In addition, the curing time after application of the water-soluble synthetic resin according to the present invention is preferably 1-2 hours.

Thus, when the water-soluble synthetic resin is applied and dried and cured, a surface strengthening layer is formed on the surface of the EPS mold, and when the GFRC molded body is demolded, the EPS mold is easily demolded and the EPS mold surface is not torn. Lt; / RTI >

Above all, EPS mold is excellent in shape freedom, and CNC machining is free, so that it is easy to design in a desired shape and shape.

Thereafter, a GFRC powder forming step is performed.

The GFRC powder forming step is a step of powder-molding the GFRC raw material in the form of a powder coating with a shotcrete facility, which is regarded as a kind of spraying.

When the GFRC material is adhered and fixed with the designed thickness through such powder molding, a molded article having the same shape as the EPS mold is formed.

Wherein the GFRC material comprises 25-35 wt% of a cementitious reactive material, 20-40 wt% of sand, 10-20 wt% of glass fibers, 2-5 wt% of an epoxy resin, 5 wt%, pozzolan 2-5 wt%, and balance water.

The epoxy resin is a resin added to prevent deterioration of concrete, and the water reducing agent is a kind of admixture added to improve the workability of concrete by decreasing the unit water by the dispersing action of cement or air entraining action.

And pozzolan is a silica mixture that binds with lime in the presence of water to produce an insoluble siliceous compound and cure the cement through such hydration (condensation solidification).

Thus, after the powder molding is completed, the GFRC molded body drying and demolding steps are performed.

The GFRC molded body is dried and demolded by separating the cured molded body from the EPS mold for about 2 days by releasing the molded body, and the GFRC molded body after demoulding is finally dried for about 7 days by natural drying method and then commercialized .

Hereinafter, examples will be described.

[Example 1]

In order to confirm the characteristics of the EPS mold when the GFRC molded body was manufactured by the manufacturing method according to the present invention, the following experiment was conducted.

First, in the primary raw material mixing step, 50 wt% of a copolymer of acrylic acid, styrene and methacrylic acid, 0.50 wt% of triethanolamine, 0.10 wt% of hexamethylenetetramine, 0.05 wt% of silicone defoamer, % By weight and the balance sodium hydroxide; Through the above process, the compounded compound was indirectly heated for 1 hour to form a first reaction product.

The second raw material compounding step is a step of mixing 30 wt% of a copolymer of acrylic acid, styrene and methacrylic acid, 0.50 wt% of triethanolamine, 0.10 wt% of hexamethylenetetramine, 0.01 wt% of formic acid, Mixing with the reactant; Through the above process, the mixed mixture was cooled to form a second reaction product.

In addition, the third raw material compounding step is carried out by mixing 0.25% by weight of 3-chloropropylene oxide, 0.3% by weight of methyltrimethoxysilane, 10% by weight of polyvinyl alcohol, 1.5% by weight of silicone resin, , And the resulting blend was completely mixed and reacted in a reactor to form a water-soluble synthetic resin.

The water-soluble synthetic resin thus prepared was applied to the prepared EPS mold sample to a thickness of 2 mm and cured for 2 hours.

Thereafter, a raw material for molding GFRC consisting of 25 wt% of portland cement, 20 wt% of sand, 10 wt% of glass fiber, 2 wt% of epoxy resin, 2 wt% of water reducing agent, 2 wt% of pozzolan, Powder molding was performed on the surface of the sample, followed by demolding after curing for 2 days.

[Example 2]

The primary raw material mixing step was conducted by mixing 55 wt% of a copolymer of acrylic acid, styrene and methacrylic acid, 1.0 wt% of triethanolamine, 0.15 wt% of hexamethylenetetramine, 0.15 wt% of silicone defoamer, 20 wt% And the balance of sodium hydroxide; Through the above process, the compounded compound was indirectly heated for 1 hour to form a first reaction product.

In the second raw material mixing step, 35 wt% of a copolymer of acrylic acid, styrene and methacrylic acid, 1.0 wt% of triethanolamine, 0.15 wt% of hexamethylenetetramine, 0.02 wt% of formic acid, Mixing with the reactant; Through the above process, the mixed mixture was cooled to form a second reaction product.

In addition, the third raw material compounding step is a step of mixing 0.3 wt% of 3-chloropropylene oxide, 0.5 wt% of methyltrimethoxysilane, 15 wt% of polyvinyl alcohol, 2.0 wt% of silicone resin, , And the resulting blend was completely mixed and reacted in a reactor to form a water-soluble synthetic resin.

The water-soluble synthetic resin thus prepared was applied to the prepared EPS mold sample to a thickness of 2 mm and cured for 2 hours.

Thereafter, the raw material for molding GFRC consisting of 35 wt% of portland cement, 40 wt% of sand, 20 wt% of glass fiber, 5 wt% of epoxy resin, 5 wt% of water reducing agent, 5 wt% of pozzolan, Powder molding was performed on the surface of the sample, followed by demolding after curing for 2 days.

[Example 3]

In the same manner as in Example 1, before addition of the water-soluble synthetic resin, 2.0 parts by weight of metaphosphate was added to the total amount of the water-soluble synthetic resin.

[Comparative Example]

For comparison, the raw material for molding GFRC of Example 2 was directly powder-formed on the surface of the EPS mold, and after 2 days of curing, the mold was demolded.

As a result of the test, it was confirmed that the mold releasing property in the mold releasing was smoothly occurred in Examples 1, 2, and 3. However, in the case of the comparative example, the release was very poor.

In addition, the state of the surface of the EPS mold was confirmed by a magnifying glass when demoulding.

As a result, in Examples 1, 2 and 3, surface scratches and surface damage did not occur. However, in Comparative Examples, the surface was torn and dents were found in many places, and surface cracks were also generated.

In addition, after curing the water-soluble synthetic resin, 11 rows of 1 mm spacers were cross-cut with an Adhesion Tester (Cross Cutter, ASTM) to make 100 squares, and taping was performed to confirm adhesion, 1, and Example 3 was 0.

At this time, the box that was dropped out was limited mainly to the corner, so that it was virtually impossible to say that there was virtually no dropout.

As a result, it was confirmed that the adhesive strength was excellent.

Claims (3)

First raw material blending step → Secondary raw material blending step → Third raw material blending step → EPS (Expandable Polystyrene) mold making step → Water soluble synthetic resin applying step → GFRC (Glass Fiber Reinforced Concrete) powder molding step → GFRC molded article drying and demolding step A method for manufacturing a glass fiber reinforced concrete molded article using expanded polystyrene comprising:
Wherein the primary raw material mixing step comprises mixing 50 to 55 wt% of a copolymer of acrylic acid, styrene, and methacrylic acid, 0.50 to 1.00 wt% of triethanolamine, 0.10 to 0.15 wt% of hexamethylenetetramine, 0.15% by weight, 15-20% by weight of methanol and the balance sodium hydroxide; And indirectly heating the compounded mixture through the above process for 1 to 2 hours to form a first reactant;
The second raw material blending step is carried out by mixing 30 to 35% by weight of a copolymer of acrylic acid, styrene and methacrylic acid, 0.50 to 1.00% by weight of triethanolamine, 0.10 to 0.15% by weight of hexamethylenetetramine, % By weight and the remainder in the first reactant; And cooling the mixed mixture through the process to form a second reactant;
The third raw material blending step is a step of blending the starting material mixture of 3-chloropropylene oxide or 1-chloro-2,3-epoxypropane in an amount of 0.25 to 0.30% by weight, methyltrimethoxysilane in an amount of 0.3 to 0.5% by weight, polyvinyl alcohol in an amount of 10 to 15 By weight of a silicone resin, 1.5 to 2.0% by weight of a silicone resin and the remainder of the secondary reactant, and the final combination is completely mixed in the reactor to form a water soluble synthetic resin;
The EPS mold making step is a step of making an EPS mold according to a dimension and a shape designed by CAD (Computer Aided Design) through a CNC (Computerized Numerical Control) shelf;
The step of applying the water-soluble synthetic resin is a step of spraying the water-soluble synthetic resin on the surface of the EPS mold by mixing with water;
Wherein the GFRC powder forming step is a step of powder-molding the GFRC molding raw material on the surface of the EPS mold to form a predetermined thickness;
Wherein the drying and demolding of the GFRC formed body is a step of releasing the molded body from the EPS mold after the powder molding is completed.
The method according to claim 1,
Wherein the mixing ratio of the water-soluble synthetic resin and water is 9: 1 in the water-soluble synthetic resin application step.
The method according to claim 1,
In the GFRC powder forming step, the GFRC molding raw material is prepared by mixing 25-35 wt% of the portland cement, 20-40 wt% of the sand, 10-20 wt% of the glass fiber, 2-5 wt% of the epoxy resin, 2-5% by weight of pozzolan, 2-5% by weight of pozzolan and the balance of water.