KR102131064B1 - Manufacturing Method of Interior Materials and Interior Materials Thereby - Google Patents
Manufacturing Method of Interior Materials and Interior Materials Thereby Download PDFInfo
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- KR102131064B1 KR102131064B1 KR1020200045159A KR20200045159A KR102131064B1 KR 102131064 B1 KR102131064 B1 KR 102131064B1 KR 1020200045159 A KR1020200045159 A KR 1020200045159A KR 20200045159 A KR20200045159 A KR 20200045159A KR 102131064 B1 KR102131064 B1 KR 102131064B1
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- South Korea
- Prior art keywords
- weight
- parts
- binder
- dust
- expanded pearlite
- Prior art date
Links
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 30
- 239000000463 material Substances 0.000 title abstract description 28
- 239000011230 binding agent Substances 0.000 claims abstract description 73
- 239000000428 dust Substances 0.000 claims abstract description 63
- 238000002156 mixing Methods 0.000 claims abstract description 30
- 238000000034 method Methods 0.000 claims abstract description 29
- 239000002245 particle Substances 0.000 claims abstract description 27
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical compound O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims abstract description 17
- 239000004034 viscosity adjusting agent Substances 0.000 claims abstract description 14
- 239000001488 sodium phosphate Substances 0.000 claims abstract description 13
- 229910000162 sodium phosphate Inorganic materials 0.000 claims abstract description 13
- RYFMWSXOAZQYPI-UHFFFAOYSA-K trisodium phosphate Chemical compound [Na+].[Na+].[Na+].[O-]P([O-])([O-])=O RYFMWSXOAZQYPI-UHFFFAOYSA-K 0.000 claims abstract description 13
- 239000012153 distilled water Substances 0.000 claims abstract description 12
- 238000001035 drying Methods 0.000 claims abstract description 11
- 239000004115 Sodium Silicate Substances 0.000 claims abstract description 8
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 claims abstract description 8
- 229910052911 sodium silicate Inorganic materials 0.000 claims abstract description 8
- 229920003171 Poly (ethylene oxide) Polymers 0.000 claims abstract description 6
- 238000005507 spraying Methods 0.000 claims abstract description 5
- 229910001562 pearlite Inorganic materials 0.000 claims description 69
- 238000010438 heat treatment Methods 0.000 claims description 7
- 239000002994 raw material Substances 0.000 claims description 6
- 238000000465 moulding Methods 0.000 claims description 4
- 239000004035 construction material Substances 0.000 claims 1
- 238000010521 absorption reaction Methods 0.000 abstract description 15
- 238000010276 construction Methods 0.000 abstract description 9
- 239000010451 perlite Substances 0.000 abstract description 9
- 235000019362 perlite Nutrition 0.000 abstract description 9
- 238000009413 insulation Methods 0.000 abstract description 8
- 239000011148 porous material Substances 0.000 description 10
- 238000005452 bending Methods 0.000 description 6
- 239000008188 pellet Substances 0.000 description 6
- 230000000694 effects Effects 0.000 description 5
- 239000011435 rock Substances 0.000 description 5
- 230000000052 comparative effect Effects 0.000 description 4
- 238000001879 gelation Methods 0.000 description 4
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 description 3
- CDBYLPFSWZWCQE-UHFFFAOYSA-L Sodium Carbonate Chemical compound [Na+].[Na+].[O-]C([O-])=O CDBYLPFSWZWCQE-UHFFFAOYSA-L 0.000 description 3
- KGBXLFKZBHKPEV-UHFFFAOYSA-N boric acid Chemical compound OB(O)O KGBXLFKZBHKPEV-UHFFFAOYSA-N 0.000 description 3
- 239000004327 boric acid Substances 0.000 description 3
- 239000000203 mixture Substances 0.000 description 3
- 238000004806 packaging method and process Methods 0.000 description 3
- 229910021538 borax Inorganic materials 0.000 description 2
- -1 boric acid and borax Chemical class 0.000 description 2
- 150000001642 boronic acid derivatives Chemical class 0.000 description 2
- 238000001816 cooling Methods 0.000 description 2
- 239000005332 obsidian Substances 0.000 description 2
- 239000004328 sodium tetraborate Substances 0.000 description 2
- 235000010339 sodium tetraborate Nutrition 0.000 description 2
- 239000003381 stabilizer Substances 0.000 description 2
- 239000004575 stone Substances 0.000 description 2
- 239000003039 volatile agent Substances 0.000 description 2
- 229910018072 Al 2 O 3 Inorganic materials 0.000 description 1
- 229910004298 SiO 2 Inorganic materials 0.000 description 1
- 230000006378 damage Effects 0.000 description 1
- 238000005034 decoration Methods 0.000 description 1
- 230000007547 defect Effects 0.000 description 1
- 230000002542 deteriorative effect Effects 0.000 description 1
- 230000001747 exhibiting effect Effects 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 239000010437 gem Substances 0.000 description 1
- 229910001751 gemstone Inorganic materials 0.000 description 1
- 239000003779 heat-resistant material Substances 0.000 description 1
- 239000011810 insulating material Substances 0.000 description 1
- 231100000956 nontoxicity Toxicity 0.000 description 1
- 238000003756 stirring Methods 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 230000002195 synergetic effect Effects 0.000 description 1
Classifications
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
- C04B14/02—Granular materials, e.g. microballoons
- C04B14/04—Silica-rich materials; Silicates
- C04B14/14—Minerals of vulcanic origin
- C04B14/18—Perlite
- C04B14/185—Perlite expanded
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D46/00—Filters or filtering processes specially modified for separating dispersed particles from gases or vapours
- B01D46/02—Particle separators, e.g. dust precipitators, having hollow filters made of flexible material
- B01D46/023—Pockets filters, i.e. multiple bag filters mounted on a common frame
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
- B28B11/24—Apparatus or processes for treating or working the shaped or preshaped articles for curing, setting or hardening
- B28B11/248—Supports for drying
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B20/00—Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups C04B14/00 - C04B18/00 and characterised by shape or grain distribution; Treatment of materials according to more than one of the groups C04B14/00 - C04B18/00 specially adapted to enhance their filling properties in mortars, concrete or artificial stone; Expanding or defibrillating materials
- C04B20/0076—Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups C04B14/00 - C04B18/00 and characterised by shape or grain distribution; Treatment of materials according to more than one of the groups C04B14/00 - C04B18/00 specially adapted to enhance their filling properties in mortars, concrete or artificial stone; Expanding or defibrillating materials characterised by the grain distribution
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B20/00—Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups C04B14/00 - C04B18/00 and characterised by shape or grain distribution; Treatment of materials according to more than one of the groups C04B14/00 - C04B18/00 specially adapted to enhance their filling properties in mortars, concrete or artificial stone; Expanding or defibrillating materials
- C04B20/02—Treatment
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B20/00—Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups C04B14/00 - C04B18/00 and characterised by shape or grain distribution; Treatment of materials according to more than one of the groups C04B14/00 - C04B18/00 specially adapted to enhance their filling properties in mortars, concrete or artificial stone; Expanding or defibrillating materials
- C04B20/02—Treatment
- C04B20/04—Heat treatment
- C04B20/06—Expanding clay, perlite, vermiculite or like granular materials
- C04B20/068—Selection of ingredients added before or during the thermal treatment, e.g. expansion promoting agents or particle-coating materials
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/24—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing alkyl, ammonium or metal silicates; containing silica sols
- C04B28/26—Silicates of the alkali metals
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/34—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing cold phosphate binders
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2103/00—Function or property of ingredients for mortars, concrete or artificial stone
- C04B2103/44—Thickening, gelling or viscosity increasing agents
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Structural Engineering (AREA)
- Materials Engineering (AREA)
- Organic Chemistry (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Physics & Mathematics (AREA)
- Architecture (AREA)
- Inorganic Chemistry (AREA)
- Civil Engineering (AREA)
- Mechanical Engineering (AREA)
- Acoustics & Sound (AREA)
- Thermal Sciences (AREA)
- Electromagnetism (AREA)
- Building Environments (AREA)
Abstract
Description
본 발명은 건축용 내장재 제조방법 및 이에 의해 제조된 건축용 내장재에 관한 것으로, 팽창 펄라이트 분진을 활용하여 단열성, 기계적 강도, 흡음성이 우수한 건축용 내장재의 제조방법 및 이에 의해 제조된 건축용 내장재에 관한 것이다.The present invention relates to a method for manufacturing a building interior material for a building and a building interior material manufactured by the same, and to a method for manufacturing a building interior material having excellent heat insulation, mechanical strength, and sound absorption by using expanded pearlite dust, and a building interior material manufactured thereby.
흑요석(Obsidian), 진주암(Perlite), 송지석(Pitch-Stone) 등은 점성의 용암이나 마그마가 지표의 호수로 흘러들어 급격히 냉각되면서 형성된 휘발분이 농집된 비정질의 암석으로서, 보통 회색, 갈색, 청색의 색깔을 가지며, 주성분은 SiO2, Al2O3 등으로 이루어져 있다. 이러한 암석들은 외관 및 함유 휘발성분의 양에 의해 구분되며, 화학적 성분은 원석의 종류와 관계없이 유사하다.Obsidian, Perlite, and Pitch-Stone are amorphous rocks with concentrated volatiles formed as viscous lava or magma flows into the lake of the surface and rapidly cools, usually gray, brown, and blue. It has the color of, and the main component is composed of SiO 2 , Al 2 O 3, etc. These rocks are distinguished by their appearance and the amount of volatiles they contain, and their chemical composition is similar regardless of the type of gemstone.
상기 암석들을 분쇄하여 입도 별로 선별한 후 고온에서 가열하면, 함유 휘발성분이 휘발하며 암석 입자 내부가 팽창하여 내부 기공이 형성되는 바, 이후 냉각, 이송 및 포장 단계를 거쳐 팽창된 펄라이트(perlite)를 형성한다. 팽창된 펄라이트는 펄라이트 원료인 암석의 부피 대비 10 내지 20배 정도의 크기로 저밀도에 다공질이고, 흡수능력이 좋으며, 경량성, 단열성, 보온성, 흡음성, 무독성 및 불연성 등의 성질이 있어 내열재료, 방음재료, 경량골재 및 단열재료 등 건축용 내장재로 널리 이용되고 있다.When the rocks are crushed and sorted by particle size, and heated at a high temperature, the contained volatile matter volatilizes and the inside of the rock particles expands to form internal pores. Afterwards, the expanded perlite is formed through cooling, transport, and packaging steps. do. The expanded pearlite is 10 to 20 times larger than the volume of the rock, which is the raw material of pearlite, and is porous at low density, has good absorption capacity, and has properties such as light weight, heat insulation, heat retention, sound absorption, non-toxicity and non-combustibility, heat-resistant material, sound insulation It is widely used as interior materials for construction such as materials, lightweight aggregates, and insulating materials.
한편, 팽창 펄라이트를 제조하는 공정, 즉, 펄라이트 원료 암석의 이송, 예열, 팽창, 냉각, 이송 및 포장 단계의 각 단계에서 펄라이트 분진을 포함하는 다량의 비산 먼지가 발생하는 바 백필터 집진기를 활용하여 포집한다. On the other hand, the process of manufacturing expanded pearlite, that is, the transfer, preheating, expansion, cooling, transportation of the raw material of the pearlite, and a large amount of scattering dust including pearlite dust are generated at each stage of the packaging step to utilize the bag filter dust collector Capture.
이렇게 포집된 펄라이트 분진을 활용하여 건축용 내장재를 제조하려는 시도가 있었다. 그러나 상기 펄라이트 분진은 약 0.043mm 이하 크기로 오픈셀 기공을 다량 포함하고 있는 바, 무수한 기공의 영향으로 결합제와 혼합하는 과정에서 분진이 수분을 급격히 흡수하여 바인더의 혼합 불균형이 발생하고 제품의 강도 편차가 발생할 뿐만 아니라, 균일한 혼합을 위한 혼합시간 증가로 밀도가 증가하고 분진의 기공이 파괴되어 열전도율이 높아지게 되어 내장재의 단열효과가 저하되는 문제점이 있었다.There have been attempts to manufacture interior materials for construction using the collected pearlite dust. However, the pearlite dust contains a large amount of open cell pores with a size of about 0.043 mm or less, and in the process of mixing with a binder under the influence of countless pores, the dust absorbs moisture rapidly, resulting in unbalance of the binder and variation in product strength Not only does this occur, but the density increases and the pores of the dust are destroyed due to the increase in the mixing time for uniform mixing, thereby increasing the thermal conductivity, thereby deteriorating the insulation effect of the interior material.
<선행기술문헌><Prior Art Document>
한국특허등록공보 제10-1543958호Korean Patent Registration Publication No. 10-1543958
본 발명의 목적은 팽창 펄라이트 분진을 활용하여 우수한 단열성, 기계적 강도, 흡음성을 나타내는 건축용 내장재의 제조방법 및 이를 의해 제조되는 건축용 내장재를 제공하는 것이다. An object of the present invention is to provide a method for manufacturing a building interior material exhibiting excellent thermal insulation, mechanical strength, and sound absorption by utilizing expanded pearlite dust, and a building interior material manufactured by the method.
본 발명은,The present invention,
(가) 팽창 펄라이트 분진을 준비하는 단계;(A) preparing an expanded pearlite dust;
(나) 상기 팽창 펄라이트 분진에 제1 바인더를 분무하여 입자를 성장시키는 단계;(B) spraying a first binder to the expanded pearlite dust to grow particles;
(다) 상기 입자를 성장시킨 팽창 펄라이트를 열처리하는 단계;(C) heat treating the expanded pearlite from which the particles are grown;
(라) 상기 열처리된 팽창 펄라이트에 대해 제2 바인더를 혼합하는 단계;(D) mixing a second binder with respect to the heat-treated expanded pearlite;
(마) 상기 혼합 후 팽창 펄라이트를 상온에서 성형하는 단계; 및(E) molding the expanded pearlite after mixing at room temperature; And
(바) 상기 성형된 팽창 펄라이트를 건조하는 단계;를 포함하며,(F) drying the molded expanded pearlite; includes,
상기 제1 바인더는 규산소다 100 중량부에 대하여 인산나트륨 1 내지 5 중량부, 폴리에틸렌옥사이드 0.01 내지 0.5 중량부, 점도 조절제 0.5 내지 3 중량부 및 증류수 200 내지 400 중량부를 포함하고, The first binder includes 1 to 5 parts by weight of sodium phosphate, 0.01 to 0.5 parts by weight of polyethylene oxide, 0.5 to 3 parts by weight of a viscosity modifier, and 200 to 400 parts by weight of distilled water with respect to 100 parts by weight of sodium silicate,
상기 제2 바인더는 규산소다 100 중량부에 대하여 인산나트륨 1 내지 5 중량부, 점도 조절제 0.5 내지 3 중량부 및 증류수 50 내지 200 중량부를 포함하는 건축용 내장재 제조방법을 제공한다.The second binder provides a method for manufacturing a building interior material including 1 to 5 parts by weight of sodium phosphate, 0.5 to 3 parts by weight of a viscosity modifier, and 50 to 200 parts by weight of distilled water based on 100 parts by weight of soda silicate.
상기 단계(가)에서, 팽창 펄라이트 분진은 펄라이트 원료를 이용한 팽창 펄라이트 제조 과정에서 발생하는 비산 먼지를 집진기를 이용하여 포집하여 얻을 수 있다.In the above step (a), the expanded pearlite dust can be obtained by collecting scattering dust generated in the process of manufacturing expanded pearlite using pearlite raw materials using a dust collector.
상기 단계(나)에서, 성장된 입자의 크기는 0.01 내지 3 mm일 수 있다.In the step (B), the size of the grown particles may be 0.01 to 3 mm.
상기 단계(나)에서 팽창 펄라이트 분진 100 중량부에 대해 제1 바인더 50 내지 200 중량부를 분무할 수 있다.In step (b), 50 to 200 parts by weight of the first binder may be sprayed with respect to 100 parts by weight of expanded pearlite dust.
상기 단계(다)에서, 상기 열처리는 600 내지 800℃에서 1 내지 15분간 수행될 수 있다.In the step (c), the heat treatment may be performed at 600 to 800°C for 1 to 15 minutes.
상기 단계(라)에서, 열처리된 팽창 펄라이트 100 중량부에 대해 제2 바인더 10 내지 50 중량부를 혼합할 수 있다.In the step (d), 10 to 50 parts by weight of the second binder may be mixed with respect to 100 parts by weight of the heat-treated expanded pearlite.
상기 단계(바)에서, 상기 건조는 100 내지 300℃에서 수행될 수 있다.In the step (bar), the drying may be performed at 100 to 300 ℃.
한편, 본 발명은, 상기 제조방법을 이용하여 제조되는 건축용 내장재를 제공한다.On the other hand, the present invention provides a building interior material manufactured using the above manufacturing method.
본 발명에 따른 건축용 내장재는 팽창 펄라이트 분진에 제1 바인더를 이용하여 입자를 성장시킨 후 열처리하여 제조 과정에서 발생하는 바인더의 혼합 불균형을 방지할 수 있는 바 팽창 펄라이트 입자 및 내부 기공 파괴와 이로 인한 열전도율 상승을 방지할 수 있어 우수한 단열성을 나타낸다. The interior material for construction according to the present invention is a bar capable of preventing the mixing imbalance of the binder generated in the manufacturing process by growing the particles by using the first binder in the expanded pearlite dust, and then expanding the expanded pearlite particles and internal pores and causing thermal conductivity. Since it can prevent the rise, it exhibits excellent thermal insulation properties.
또한, 본 발명에 따른 건축용 내장재는 팽창 펄라이트 분진에 제1 바인더를 적용 후 제2 바인더를 혼합 후 건조하는 과정을 추가로 포함하여 제조되는 바, 제조 과정에서 급격한 수분 흡수 현상을 방지하여, 저밀도이면서도 우수한 굽힘 강도, 흡음성을 나타낸다.In addition, the building interior material according to the present invention is manufactured by further comprising a process of mixing the second binder after applying the first binder to the expanded pearlite dust, thereby preventing rapid water absorption in the manufacturing process, while being low density. It shows excellent bending strength and sound absorption.
더욱이, 본 발명은 종래 팽창 펄라이트 제조 과정에서 발생하는 비산 먼지를 포집하여 얻은 팽창 펄라이트 분진을 활용하는 바 매우 경제적이고 친환경적이다. Moreover, the present invention is very economical and eco-friendly as it utilizes expanded pearlite dust obtained by collecting scattered dust generated during the conventional expanded pearlite production process.
본 발명은, The present invention,
(가) 팽창 펄라이트 분진을 준비하는 단계;(A) preparing an expanded pearlite dust;
(나) 상기 팽창 펄라이트 분진에 제1 바인더를 분무하여 입자를 성장시키는 단계;(B) spraying a first binder to the expanded pearlite dust to grow particles;
(다) 상기 입자를 성장시킨 팽창 펄라이트를 열처리하는 단계;(C) heat treating the expanded pearlite from which the particles are grown;
(라) 상기 열처리된 팽창 펄라이트에 대해 제2 바인더를 혼합하는 단계;(D) mixing a second binder with respect to the heat-treated expanded pearlite;
(마) 상기 혼합 후 팽창 펄라이트를 상온에서 성형하는 단계; 및(E) molding the expanded pearlite after mixing at room temperature; And
(바) 상기 성형된 팽창 펄라이트를 건조하는 단계;를 포함하며,(F) drying the molded expanded pearlite; includes,
상기 제1 바인더는 규산소다 100 중량부에 대하여 인산나트륨 1 내지 5 중량부, 폴리에틸렌옥사이드 0.01 내지 0.5 중량부, 점도 조절제 0.5 내지 3 중량부 및 증류수 200 내지 400 중량부를 포함하고, The first binder includes 1 to 5 parts by weight of sodium phosphate, 0.01 to 0.5 parts by weight of polyethylene oxide, 0.5 to 3 parts by weight of a viscosity modifier, and 200 to 400 parts by weight of distilled water with respect to 100 parts by weight of sodium silicate,
상기 제2 바인더는 규산소다 100 중량부에 대하여 인산나트륨 1 내지 5 중량부, 점도 조절제 0.5 내지 3 중량부 및 증류수 50 내지 200 중량부를 포함하는 건축용 내장재 제조방법을 제공한다.The second binder provides a method for manufacturing a building interior material including 1 to 5 parts by weight of sodium phosphate, 0.5 to 3 parts by weight of a viscosity modifier, and 50 to 200 parts by weight of distilled water based on 100 parts by weight of soda silicate.
단계(가)에서 상기 팽창 펄라이트 분진은 펄라이트 원료를 고열로 충분히 팽창시킨 후 분쇄하는 종래 팽창 펄라이트 제조 과정에서 수득할 수 있으나, 상세하게는, 상기 팽창 펄라이트 제조 과정에서 발생하는 비산 먼지를 집진기를 이용하여 포집하여 얻을 수 있다. 상기 집진기는 당업계에서 사용하는 것이라면 제한이 없으나, 예를 들어 백필터 집진기일 수 있다.In the step (a), the expanded pearlite dust can be obtained in a conventional expanded pearlite production process in which the pearlite raw material is sufficiently expanded with high heat and then pulverized, but in detail, scattering dust generated during the expanded pearlite production process is used as a dust collector. It can be obtained by collecting. The dust collector is not limited as long as it is used in the art, but may be, for example, a bag filter dust collector.
즉, 본 발명은 종래 일반적으로 수행되던, 흑요석(Obsidian), 진주암(Perlite), 송지석(Pitch-Stone)에 선택되는 하나 이상의 펄라이트 원료를 이용한 팽창 펄라이트 제조 과정에서 발생하는 비산 먼지를 포집하여 상기 비산 먼지에 포함된 팽창 펄라이트 분진을 활용하는 바 매우 경제적이며 친환경적이다. That is, the present invention collects the scattering dust generated in the process of manufacturing expanded pearlite using one or more pearlite raw materials selected from obsidian, perlite, and pitch-stone, which have been conventionally performed. It is very economical and environmentally friendly because it utilizes expanded pearlite dust contained in scattering dust.
상기 포집된 펄라이트 분진은 약 0.043 mm 이하의 입도 크기를 가지며 오픈셀 기공을 다량 포함하고 있는 바, 무수한 기공의 영향으로 결합제와 혼합하는 과정에서 분진이 수분을 급격히 흡수하여 바인더의 혼합 불균형이 발생할 수 있다. 이에 단계(나)에서, 상기 펄라이트 분진에 제1 바인더를 분무하여 입자를 성장시켜 팽창 펄라이트 입자 및 내부 기공 파괴와 이로 인한 열전도율 상승을 방지할 수 있는 바 이러한 문제를 해결할 수 있다. 단계(나)는 경우에 따라 펠릿기에서 진행할 수 있다.The collected pearlite dust has a particle size of about 0.043 mm or less and contains a large amount of open cell pores, and the mixing imbalance of the binder may occur due to the rapid absorption of dust during the process of mixing with the binder under the influence of countless pores. have. Accordingly, in step (B), by spraying the first binder to the pearlite dust to grow the particles, it is possible to prevent the expansion of the pearlite particles and the internal pores and thereby increase the thermal conductivity. Step (B) may be carried out in a pelleting machine as the case may be.
이때, 성장된 분진 입자의 크기는 0.01 내지 3 mm로, 상세하게는 펠릿 형태일 수 있다. 성장된 입자의 크기가 상기 범위를 벗어나 지나치게 작거나 클 경우 오히려 바인더와 혼합 불균형 현상이 심해지거나 제조 공정성이 저하될 우려가 있어 바람직하지 않다.At this time, the size of the grown dust particles is 0.01 to 3 mm, and may be in the form of pellets. If the size of the grown particles is too small or too large outside the above range, it is not preferable because there is a fear that the mixing imbalance with the binder may become serious or the manufacturing process may deteriorate.
상기 팽창 펄라이트 분진 100 중량부에 대해 제1 바인더 50 내지 200 중량부를 분무할 수 있다. 제1 바인더의 함량이 50 중량부 미만일 경우 본 발명이 의도한 효과를 얻을 수 없으며, 200 중량부를 초과할 경우 오히려 분진과 혼합 불균형 현상이 심해지거나 제조 공정성이 저하될 우려가 있어 바람직하지 않다. 상세하게는 상기 팽창 펄라이트 분진 100 중량부에 대해 제1 바인더 70 내지 150 중량부를 분무할 수 있다.50 to 200 parts by weight of the first binder may be sprayed with respect to 100 parts by weight of the expanded pearlite dust. If the content of the first binder is less than 50 parts by weight, the intended effect of the present invention cannot be obtained, and if it exceeds 200 parts by weight, it is not preferable because there is a possibility that the imbalance of dust and mixing becomes severe or the manufacturing processability may deteriorate. Specifically, 70 to 150 parts by weight of the first binder may be sprayed with respect to 100 parts by weight of the expanded pearlite dust.
상기 제1 바인더에서, 인산나트륨은 pH 안정화제 및 경화촉진제로, 1 중량부 미만일 경우 바인더의 겔화가 급격히 이루어지고 점도가 매우 높아져 분진과 혼합이 어려울 수 있고, 5 중량부를 초과할 경우 분진과 혼합하는 과정에서 경화가 진행되어 강도가 낮아질 수 있어 바람직하지 않다In the first binder, sodium phosphate is a pH stabilizer and a curing accelerator, and if less than 1 part by weight, gelation of the binder is rapidly achieved and viscosity is very high, so mixing with dust may be difficult, and when it exceeds 5 parts by weight, mixing with dust During the process, curing progresses and the strength may be lowered, which is undesirable.
상기 폴리에틸렌옥사이드는 분진과 바인더를 균일하게 혼합할 수 있도록 도와주며, 0.01 중량부 미만일 경우 혼합의 불균형이 발생하고 0.5 중량부를 초과할 경우 경제성이 저하되어 바람직하지 않다.The polyethylene oxide helps to uniformly mix the dust and the binder, and if it is less than 0.01 part by weight, an imbalance of mixing occurs, and when it exceeds 0.5 part by weight, the economic efficiency is lowered, which is not preferable.
상기 점도 조절제는 바인더의 점도를 조절하며, 붕산 및 붕사(borax) 등의 붕산염 중 적어도 하나 이상을 사용하는 경우 바인더의 점도가 향상될 수 있다. 상기 점도 조절제의 함량이 0.5 중량부 미만일 경우 적정 점도가 낮아지고, 3 중량부를 초과할 경우 겔화가 급격히 이루어져 바인더로써 사용이 어려워질 수 있어 바람직하지 않다.The viscosity modifier controls the viscosity of the binder, and when using at least one of borates such as boric acid and borax, the viscosity of the binder may be improved. When the content of the viscosity modifier is less than 0.5 part by weight, the appropriate viscosity is lowered, and if it exceeds 3 parts by weight, gelation is rapidly performed, which may be difficult to use as a binder, which is not preferable.
상기 제1 바인더의 증류수의 함량이 200 중량부 미만일 경우 분진과 바인더의 균일할 혼합이 어렵고, 400 중량부를 초과하는 경우 지나치게 묽어질 수 있어 바람직하지 않다.When the content of distilled water in the first binder is less than 200 parts by weight, uniform mixing of the dust and the binder is difficult, and when it exceeds 400 parts by weight, it may be too thin, which is not preferable.
상세하게는, 상기 제1 바인더는 규산소다 100 중량부에 대하여 인산나트륨 2 내지 4 중량부, 폴리에틸렌옥사이드 0.1 내지 0.3 중량부, 점도 조절제 1 내지 3 중량부 및 증류수 200 내지 400 중량부를 포함할 수 있다.In detail, the first binder may include 2 to 4 parts by weight of sodium phosphate, 0.1 to 0.3 parts by weight of polyethylene oxide, 1 to 3 parts by weight of a viscosity modifier, and 200 to 400 parts by weight of distilled water with respect to 100 parts by weight of sodium silicate. .
상기 단계(다)에서, 열처리는 600 내지 800℃에서 1 내지 15분간 수행될 수 있다. 열처리 방법은 제한이 없으나, 예를 들어, 고온의 열풍 하에서 팽창 펄라이트를 교반하여 수행할 수 있다.In the step (c), heat treatment may be performed at 600 to 800°C for 1 to 15 minutes. The heat treatment method is not limited, for example, it may be performed by stirring the expanded pearlite under a hot hot air.
상기 열처리를 통해 제조 과정에서 급격한 수분 흡수 현상을 방지할 수 있는 바, 상기 열처리 조건을 벗어날 경우 이러한 효과를 얻을 수 없다. 상세하게는 650 내지 750℃에서 1 내지 10분간 수행될 수 있다. 이러한 열처리를 통해서 0.1 내지 3 mm, 상세하게는 0.5 내지 1.0 mm의 펠릿 형태로 제조할 수 있다.It is possible to prevent a rapid water absorption phenomenon in the manufacturing process through the heat treatment, and it is impossible to obtain such an effect when it is outside the heat treatment conditions. Specifically, it may be performed at 650 to 750°C for 1 to 10 minutes. Through this heat treatment, it can be produced in the form of pellets of 0.1 to 3 mm, specifically 0.5 to 1.0 mm.
상기 단계(라)에서 상기 열처리된 팽창 펄라이트에 제2 바인더를 혼합하여 이에 따라 제조되는 건축용 내장재의 강도, 흡음성 등 제반 성능이 더욱 향상될 수 있다.In the step (D), the second heat-treated expanded pearlite may be mixed with a second binder, thereby improving performance, such as strength and sound absorption, of the interior material for construction.
상기 단계(라)에서, 열처리된 팽창 펄라이트 100 중량부에 대해 제2 바인더 10 내지 50 중량부를 혼합할 수 있다. 제2 바인더의 함량이 10 중량부 미만일 경우 본 발명이 의도한 효과를 얻을 수 없으며, 50 중량부를 초과할 경우 오히려 분진과 혼합 불균형 현상이 심해지거나 제조 공정성이 저하될 우려가 있어 바람직하지 않다. 상세하게는, 열처리된 팽창 펄라이트 100 중량부에 대해 제2 바인더 20 내지 40 중량부를 혼합할 수 있다. In the step (d), 10 to 50 parts by weight of the second binder may be mixed with respect to 100 parts by weight of the heat-treated expanded pearlite. If the content of the second binder is less than 10 parts by weight, the intended effect of the present invention cannot be obtained, and if it exceeds 50 parts by weight, it is not preferable because there is a possibility that the imbalance of dust and mixing becomes severe or the manufacturing processability may deteriorate. In detail, 20 to 40 parts by weight of the second binder may be mixed with respect to 100 parts by weight of the heat-treated expanded pearlite.
제2 바인더에서, 인산나트륨은 pH 안정화제 및 경화촉진제로, 1 중량부 미만일 경우 바인더의 겔화가 급격히 이루어지고 점도가 매우 높아져 분진과 혼합이 어려울 수 있고, 5 중량부를 초과할 경우 분진과 혼합하는 과정에서 경화가 진행되어 강도가 낮아질 수 있어 바람직하지 않다In the second binder, sodium phosphate is a pH stabilizer and a curing accelerator, and if less than 1 part by weight, gelation of the binder is rapidly achieved and viscosity is very high, so mixing with dust may be difficult, and when it exceeds 5 parts by weight, mixing with dust In the process, curing progresses and the strength may be lowered, which is not preferable.
점도 조절제는 바인더의 점도를 조절하며, 붕산 및 붕사(borax) 등의 붕산염 중 적어도 하나 이상을 사용하는 경우 바인더의 점도가 향상될 수 있다. 상기 점도 조절제의 함량이 0.5 중량부 미만일 경우 적정 점도가 낮아지고, 3 중량부를 초과할 경우 많으면 겔화가 급격히 이루어져 바인더로써 사용이 어려워질 수 있어 바람직하지 않다.The viscosity modifier adjusts the viscosity of the binder, and when using at least one of borates such as boric acid and borax, the viscosity of the binder may be improved. When the content of the viscosity modifier is less than 0.5 part by weight, the appropriate viscosity is lowered, and when it exceeds 3 parts by weight, gelation is rapidly performed, which may be difficult to use as a binder, which is not preferable.
제2 바인더의 증류수의 함량이 50 중량부 미만일 경우 분진과 바인더의 균일할 혼합이 어렵고, 200 중량부를 초과하는 경우 건조 과정에서 수분이 충분히 제거되지 않을 우려가 있어 바람직하지 않다.When the content of distilled water in the second binder is less than 50 parts by weight, it is difficult to uniformly mix the dust and the binder, and when it exceeds 200 parts by weight, there is a concern that moisture may not be sufficiently removed in the drying process, which is not preferable.
상세하게는, 상기 제2 바인더는 규산소다 100 중량부에 대하여 인산나트륨 1 내지 3 중량부, 점도 조절제 1 내지 3 중량부 및 증류수 50 내지 150 중량부를 포함할 수 있다.Specifically, the second binder may include 1 to 3 parts by weight of sodium phosphate, 1 to 3 parts by weight of a viscosity modifier, and 50 to 150 parts by weight of distilled water with respect to 100 parts by weight of sodium silicate.
상기 단계(마)에서, 혼합된 팽창 펄라이트를 일정한 크기와 형태로 성형할 수 있다. 본 발명에서는 이러한 성형 과정이 상온에서 진행될 수 있어 경제성 및 제조 공정성이 우수하다. In the above step (e), the mixed expanded pearlite can be molded into a certain size and shape. In the present invention, such a molding process can be performed at room temperature, and thus economic efficiency and manufacturing processability are excellent.
상기 단계(바)에서, 성형된 팽창 펄라이트의 건조는 100 내지 300℃에서 수행하여, 잔류하는 분진을 제거할 수 있다. 상기 건조 조건을 벗어날 경우 이러한 효과를 얻을 수 없어 바람직하지 않다. In the above step (bar), drying of the molded expanded pearlite can be performed at 100 to 300° C. to remove residual dust. If it is out of the above drying conditions, such an effect cannot be obtained, which is undesirable.
이러한 건조 과정 후, 선택적으로 가공을 진행하고 포장 및 출하를 통해 건축용 내장재를 제조할 수 있다.After this drying process, it is possible to selectively process and manufacture interior materials for construction through packaging and shipping.
한편, 본 발명은 상기 제조방법을 이용하여 제조되는 건축용 내장재를 제공한다.On the other hand, the present invention provides a building interior material manufactured using the above manufacturing method.
본 발명에 따른 건축용 내장재는 팽창 펄라이트 분진에 제1 바인더를 이용하여 입자를 성장시킨 후 열처리하여 제조 과정에서 발생하는 혼합 불균형을 방지할 수 있는 바 팽창 펄라이트 입자 및 내부 기공 파괴와 이로 인한 열전도율 상승을 방지할 수 있어 우수한 단열성을 나타낸다. The interior decoration material for construction according to the present invention can grow the particles using the first binder in the expanded pearlite dust and heat-treat them to prevent the mixing imbalance occurring during the manufacturing process, thereby expanding the expanded pearlite particles and the destruction of internal pores and the increase in the thermal conductivity. It can be prevented and shows excellent heat insulation.
또한, 본 발명에 따른 건축용 내장재는 팽창 펄라이트 분진에 제1 바인더를 적용 후 제2 바인더를 혼합 후 건조하는 과정을 추가로 포함하여 제조되는 바, 제조 과정에서 급격한 수분 흡수 현상을 방지하여, 저밀도이면서도 우수한 굽힘 강도, 흡음성을 나타낸다.In addition, the building interior material according to the present invention is manufactured by further comprising a process of mixing the second binder after applying the first binder to the expanded pearlite dust, thereby preventing rapid water absorption in the manufacturing process, while being low density. It shows excellent bending strength and sound absorption.
더욱이, 본 발명은 종래 팽창 펄라이트 제조 과정에서 발생하는 비산 먼지를 포집하여 얻은 팽창 펄라이트 분진을 활용하는 바 매우 경제적이고 친환경적이다. Moreover, the present invention is very economical and eco-friendly as it utilizes expanded pearlite dust obtained by collecting scattered dust generated during the conventional expanded pearlite production process.
이하, 본 발명에 따른 일부 실시예들을 참조하여 더욱 상세히 설명하지만, 본 발명의 범주가 그것에 의해 한정되는 것은 아니다. Hereinafter, with reference to some embodiments according to the present invention will be described in more detail, but the scope of the present invention is not limited thereto.
<실시예><Example>
백필터 집진기를 이용하여 포집한 팽창 펄라이트 분진 100 중량부를 펠릿기에 넣고 제1 바인더 100 중량부를 스프레이 분사하며 입자를 성장시켰다. 0.1 ~ 1.0 mm로 성장시킨 입자를 로타리킬른을 이용하여 700℃에서 5분간 열처리하였다. 이후 열처리된 분진 펠릿 100 중량부를 제2 바인더 30 중량부와 혼합하고 상온에서 성형 후 200℃에서 건조하여 건축용 내장재를 제조하였다. 이때, 제1 바인더 및 제2 바인더의 배합비는 하기 표 1과 같다. 100 parts by weight of the expanded pearlite dust collected by using a bag filter dust collector was put in a pellet, and 100 parts by weight of a first binder was spray-sprayed to grow particles. The particles grown to 0.1 to 1.0 mm were heat treated at 700°C for 5 minutes using a rotary kiln. Thereafter, 100 parts by weight of the heat-treated dust pellets were mixed with 30 parts by weight of the second binder, molded at room temperature, and then dried at 200° C. to prepare a building interior material. At this time, the mixing ratio of the first binder and the second binder is shown in Table 1 below.
<비교예><Comparative Example>
백필터 집진기를 이용하여 포집한 팽창 펄라이트 분진 100 중량부를 펠릿기에 넣고 제2 바인더 100 중량부를 스프레이 분사하며 입자를 성장시켰다. 0.1 ~ 1.0 mm로 성장시킨 입자를 로타리킬른을 이용하여 700℃에서 5분간 열처리하였다. 이후 열처리된 분진 펠릿을 상온에서 성형 후 200℃에서 건조하여 건축용 내장재를 제조하였다. 제2 바인더의 배합비는 상기 표 1과 같다.100 parts by weight of the expanded pearlite dust collected by the bag filter dust collector was put in a pellet, and 100 parts by weight of a second binder was spray-sprayed to grow particles. The particles grown to 0.1 to 1.0 mm were heat treated at 700°C for 5 minutes using a rotary kiln. Thereafter, the heat-treated dust pellets were molded at room temperature, and then dried at 200° C. to prepare a building interior material. The mixing ratio of the second binder is shown in Table 1 above.
<실험예><Experimental Example>
실시예 및 비교예에서 각각 제조된 건축용 내장재의 밀도, 굽힘강도 및 흠음률을 측정하여 하기 표 2에 나타내었다. 여기서 밀도는 KS F 2200 : 2000, 굽힘강도는 KS F 2263 : 2005, 흡음률은 KS F 9016 : 2010 (평판열류계법)에 따라 측정하였다.In the examples and comparative examples, the density, bending strength, and defect rate of the building interior materials manufactured respectively are measured and are shown in Table 2 below. Here, the density was measured according to KS F 2200: 2000, the bending strength was KS F 2263: 2005, and the sound absorption was measured according to KS F 9016: 2010 (Plate Heat Flow Method).
(100 중량부)
제2 바인더
(30중량부)First binder
(100 parts by weight)
Second binder
(30 parts by weight)
(100)Second binder
(100)
상기 표 2에 따르면 실시예에 의해 제조된 건축용 내장재는 비교예와 비교하여 저밀도를 나타내면서도 우수한 굽힘강도 및 흡음률을 나타내는 것을 확인할 수 있다. 이는 제1 바인더와 제2 바인더의 유기적 조합에 의한 상승 효과로, 제1 바인더를 이용하여 팽창 펄라이트 분진과 혼합 불균형을 방지하여 팽창 펄라이트 입자 및 내부 기공 파괴와 이로 인한 열전도율 상승을 방지할 수 있으면서도, 제2 바인더를 혼합 후 건조하는 과정을 추가로 포함하여 제조 과정에서 급격한 수분 흡수 현상을 방지할 수 있기 때문이다. According to Table 2, it can be seen that the interior materials for construction manufactured by the Examples show excellent bending strength and sound absorption while showing low density compared to Comparative Examples. This is a synergistic effect due to the organic combination of the first binder and the second binder, while preventing the expansion of pearlite particles and mixing imbalance by using the first binder to prevent the expansion of the expanded pearlite particles and internal pores and thereby the increase in thermal conductivity, This is because it is possible to prevent a rapid water absorption phenomenon in the manufacturing process by further including a process of drying after mixing the second binder.
Claims (8)
(나) 상기 팽창 펄라이트 분진에 제1 바인더를 분무하여 입자를 성장시키는 단계;
(다) 상기 입자를 성장시킨 팽창 펄라이트를 열처리하는 단계;
(라) 상기 열처리된 팽창 펄라이트에 대해 제2 바인더를 혼합하는 단계;
(마) 상기 혼합 후 팽창 펄라이트를 상온에서 성형하는 단계; 및
(바) 상기 성형된 팽창 펄라이트를 건조하는 단계;를 포함하며,
상기 제1 바인더는 규산소다 100 중량부에 대하여 인산나트륨 1 내지 5 중량부, 폴리에틸렌옥사이드 0.01 내지 0.5 중량부, 점도 조절제 0.5 내지 3 중량부 및 증류수 200 내지 400 중량부를 포함하고,
상기 제2 바인더는 규산소다 100 중량부에 대하여 인산나트륨 1 내지 5 중량부, 점도 조절제 0.5 내지 3 중량부 및 증류수 50 내지 200 중량부를 포함하는 것을 특징으로 하는 건축용 내장재 제조방법.(A) preparing an expanded pearlite dust;
(B) spraying a first binder to the expanded pearlite dust to grow particles;
(C) heat treating the expanded pearlite from which the particles are grown;
(D) mixing a second binder with respect to the heat-treated expanded pearlite;
(E) molding the expanded pearlite after mixing at room temperature; And
(F) drying the molded expanded pearlite; includes,
The first binder contains 1 to 5 parts by weight of sodium phosphate, 0.01 to 0.5 parts by weight of polyethylene oxide, 0.5 to 3 parts by weight of a viscosity modifier, and 200 to 400 parts by weight of distilled water with respect to 100 parts by weight of sodium silicate,
The second binder is 1 to 5 parts by weight of sodium phosphate with respect to 100 parts by weight of sodium silicate, 0.5 to 3 parts by weight of a viscosity modifier, and 50 to 200 parts by weight of distilled water.
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| KR102427316B1 (en) * | 2021-11-04 | 2022-08-01 | 한국도시재생기술(주) | Composite plate manufacturing method with excellent thermal conductivity and weight reduction by recycling waste perlite and waste synthetic resin |
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