KR102626994B1 - Non-combustible ceramic molded body for lightweight building interior and exterior materials and its manufacturing method - Google Patents

Abstract

The present invention relates to a non-combustible ceramic molded body for interior and exterior lightweight building materials and a method of manufacturing the same. More specifically, the present invention relates to a lightweight and non-combustible ceramic molded body for use as a lightweight, non-combustible replacement for existing styrofoam, urethane foam, or glass fiber, the use of which is restricted according to environmental regulations for core materials for sandwich panels. A non-combustible ceramic for interior and exterior materials in lightweight construction that has been improved to improve the quality of construction as well as the convenience of use as it is excellent, blocks moisture absorption, has little deformation, and is highly resistant to external shocks. It can be cut with a regular saw and has a homogeneous cutting surface. It relates to molded bodies and their manufacturing methods.

Description

Non-combustible ceramic molded body for lightweight building interior and exterior materials and its manufacturing method}

The present invention relates to a non-combustible ceramic molded body for interior and exterior lightweight building materials and a method of manufacturing the same. More specifically, the present invention relates to a lightweight and non-combustible ceramic molded body for use as a lightweight, non-combustible replacement for existing styrofoam, urethane foam, or glass fiber, the use of which is restricted according to environmental regulations for core materials for sandwich panels. A non-combustible ceramic for interior and exterior materials in lightweight construction that has been improved to improve the quality of construction as well as the convenience of use as it is excellent, blocks moisture absorption, has little deformation, and is highly resistant to external shocks. It can be cut with a regular saw and has a homogeneous cutting surface. It relates to molded bodies and their manufacturing methods.

Sandwich panels are the most widely used lightweight construction material in prefabricated buildings.

A sandwich panel is like a sandwich, with steel plates on the outside on both sides and insulation materials such as Styrofoam, urethane, glass fiber, and various wools as the inner material. Thanks to the structure of steel plate-insulator-iron plate, construction costs can be greatly reduced, and it can be dismantled. It is widely used because of its reusable advantage.

However, despite these many advantages, it has limitations due to the following disadvantages.

For example, when a fire breaks out in a building, the flames climb up the walls and ceiling, attach to the Styrofoam or urethane inside the panel, and spread at a rapid rate. At this time, when the intermediate insulating materials such as Styrofoam or urethane, which are vulnerable to heat, ignite, they are trapped in the steel plate. Since the heat cannot escape, the temperature increases rapidly and reaches flashover, which spreads explosively, causing massive spread before the fire brigade arrives.

In addition, during a panel fire, toxic gases harmful to the human body are rapidly generated, such as carbon monoxide, hydrogen chloride, and hydrogen cyanide. These irritate the senses and respiratory organs of evacuees, preventing them from making normal judgments, causing many casualties. There are also disadvantages.

In addition, sandwich panels have the disadvantage of accelerating damage because they collapse faster than concrete buildings.

For this reason, the government plans to regulate core materials for sandwich panels by 2022 to minimize the use of organic materials such as Styrofoam and urethane foam, and to replace them with inorganic materials.

In this regard, glass fiber, an inorganic material, is also used, but glass fiber has the disadvantage of being relatively very heavy and expensive compared to Styrofoam or urethane foam of the same standard, so its utility is extremely limited.

In addition, because glass fiber has the ability to absorb moisture, its insulation properties drop sharply when it absorbs moisture, and when it comes into contact with the worker's body during construction work, allergic reactions such as tingling sensations are caused, so workers avoid it, so there is a need for improvement. It is a necessary situation.

Domestic registered patent No. 10-2032219 (2019.10.08.) Flame retardant board manufacturing device and sandwich panel manufacturing device Domestic registered patent No. 10-1354812 (2014.01.16.) Fire spread prevention type flame retardant and insulating composite board sandwich panel

The present invention was created to solve the problems of the prior art in consideration of the above-described problems in the prior art. It replaces existing styrofoam, urethane foam, or glass fiber, the use of which is restricted according to environmental regulations for the core material for sandwich panels, and is lightweight and non-combustible. A non-combustible ceramic for interior and exterior materials in lightweight construction that has been improved to improve the quality of construction as well as the convenience of use as it is excellent, blocks moisture absorption, has little deformation, and is highly resistant to external shocks. It can be cut with a regular saw and has a homogeneous cutting surface. The main purpose is to provide molded bodies and methods for manufacturing them.

The present invention is a means to achieve the above-mentioned object, in the non-combustible ceramic molded body for lightweight construction interior and exterior materials used as the core material of sandwich panels; The core material is a lightweight material characterized in that it is a molded body formed under high pressure by placing a composition consisting of 2-6% by weight of water, 1-15% by weight of organic binder, 10-20% by weight of inorganic binder, and the remaining pearlite powder in a mold. Provides non-flammable ceramic molded bodies for interior and exterior building materials.

At this time, the organic binder has the characteristic of being a mixture of dextrin or PVA (polyvinyl alcohol) alone, or dextrin and PVA mixed at a weight ratio of 1:1.

In addition, the inorganic binder is characterized by vitrifying any one selected from feldspar, silica, limestone, borax, soda ash, zinc, lithium carbonate, and alumina, or a mixture of two or more mixed in the same ratio.

In addition, the present invention includes a raw material preparation step; The prepared raw materials are composed of 2-6% by weight of water, 1-15% by weight of organic binder, 10-20% by weight of inorganic binder, and the remaining perlite powder, and then the composition is placed in a drum mixer and mixed and stirred at a speed of 100-150 rpm for 30 minutes. step; When stirring is completed, putting the stirred composition into a mold and press molding it at high pressure; When molding is completed, drying in a dryer maintained at 100-180°C; A method of manufacturing a non-combustible ceramic molded body for lightweight construction interior and exterior materials is also provided, comprising placing the dried body in a heat treatment kiln and heat treating it at 700-900° C. for 2-3 hours.

At this time, the raw material preparation step includes an organic binder preparation process, an inorganic binder preparation process, and a perlite powder preparation process; The organic binder preparation process is a process of preparing dextrin or PVA to match the weight to be mixed; The inorganic binder preparation process involves placing a mixture of feldspar, silica, limestone, borax, soda ash, zinc, lithium carbonate, and alumina in equal proportions in a glass melting kiln and melting it at a temperature of 1500°C. Then, the melt is placed in water at room temperature. Another characteristic is that it is a process of vitrifying by dropping it into a water bath and rapidly cooling it.

In addition, the perlite powder preparation process is characterized in that it is a process of calcining pearlite at 1200°C and then pulverizing it to obtain a powder with an average particle diameter of 5 mm or less.

Additionally, the heat treatment kiln is characterized by using a continuous kiln (Roller Hearth Kiln) (RHK).

According to the present invention, the following effects can be obtained.

First, it can replace existing styrofoam, urethane foam, or glass fiber, whose use is restricted according to environmental regulations for core materials for sandwich panels.

Second, it is lightweight and has excellent non-flammability.

Third, it blocks moisture absorption and causes almost no deformation.

Fourth, it has high resistance to external shocks.

Fifth, it can be cut with a regular saw and the cutting surface is homogeneous, which not only improves convenience in use but also improves construction quality.

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

The non-combustible ceramic molded body for interior and exterior lightweight construction according to the present invention is used as the core material of a sandwich panel, and consists of 2-6% by weight of water, 1-15% by weight of organic binder, 10-20% by weight of inorganic binder, and the remaining pearlite powder. A composition consisting of is placed in a mold and molded at high pressure is used.

At this time, the organic binder may be dextrin or polyvinyl alcohol (PVA).

In particular, dextrin refers to a low molecular weight carbohydrate obtained by hydrolyzing starch, and is added to increase the bonding viscosity for molding perlite powder and ensure fluidity against external force.

In addition, PVA is a water-soluble polymer and is added to secure bonding and buffering power when molding perlite powder and to ensure molding stability by maintaining shock absorption against external forces.

Of course, the organic binder may be added as a mixture of dextrin and PVA in a weight ratio of 1:1.

In addition, the inorganic binder is one selected from feldspar, silica, limestone, borax, soda ash, zinc oxide, lithium carbonate, and alumina, or a vitrified mixture of two or more mixed in the same ratio.

This inorganic binder is added to maintain shape retention while increasing the binding function through the reaction between the inorganic perlite and water, and above all, to increase incombustibility.

In addition, the perlite powder refers to a powder made by calcining pearlite at 1200°C and then pulverizing it so that the average particle diameter is 5 mm or less.

In this case, the perlite is a powder used in the field of materials different from pearlite (a metal structure in which ferrite and cementite are arranged in layers), which is a metal structure related to the transformation of metals used in the metal field. Therefore, there should be no confusion due to the similarity of the terms, and for the purpose of distinction, it is described as 'perlite' rather than pearlite.

Perlite according to the present invention is a powder with an average particle diameter of 5 mm or less, with a specific gravity of 0.2, a porosity of 90%, and a thermal conductivity of 0.04-0.07 kcal/mhr·c.

This type of perlite not only has very high non-flammable properties that do not burn or melt even at 900℃, but also has no thermal deformation and almost no moisture absorption, so it does not deform at all due to external shock, so it can be used semi-permanently, and above all, it is light. It is very suitable for making lightweight construction materials.

In particular, when making a molded body, when cutting by sawing, the cutting surface is cut cleanly and forms a uniform cutting surface, and there is almost no dust during cutting, so processing and construction are convenient and excellent.

The molded body according to the present invention is manufactured as follows.

That is, the method of manufacturing a non-combustible ceramic molded body for lightweight building interior and exterior materials according to the present invention includes a raw material preparation step.

The raw material preparation step includes an organic binder preparation process, an inorganic binder preparation process, and a perlite powder preparation process.

At this time, the organic binder preparation process is a process of preparing dextrin or PVA to suit the weight to be mixed; The inorganic binder preparation process involves placing a mixture of feldspar, silica, limestone, borax, soda ash, zinc, lithium carbonate, and alumina in equal proportions in a glass melting kiln and melting it at a temperature of 1500°C. The melt is then placed in a water bath containing room temperature water. It is a process of vitrifying by dropping into and rapid cooling; The perlite powder preparation process is a process of calcining pearlite at 1200°C and then pulverizing it to obtain a powder with an average particle diameter of 5mm or less.

When the raw materials are prepared in this way, the prepared raw materials are placed in a drum-type mixer and mixed and stirred at a speed of 100-150 rpm for 30 minutes.

At this time, the mixture of prepared raw materials is composed of 2-6% by weight of water, 1-15% by weight of organic binder, 10-20% by weight of inorganic binder, and the remaining pearlite powder.

Then, when mixing is completed, the mixed composition is placed in a mold and press molded at high pressure.

Once molding is completed, a drying step is performed in a dryer maintained at 100-180°C.

This is to ensure that the voids are maintained uniformly while relieving the high-pressure molding stress after molding.

Afterwards, the dried body is placed in a heat treatment kiln and heat treated at 700-900°C for 2-3 hours.

At this time, the heat treatment kiln uses RHK (Roller Hearth Kiln), a continuous kiln, so that continuous processing is possible and high temperature stability can be maintained, which is efficient in improving productivity.

In addition, in the present invention, 10 parts by weight of desulfurized gypsum, 5 parts by weight of dimethylpolysiloxane, and magnesium sulfate are added to 100 parts by weight of polystyrene resin to increase self-extinguishing properties of the molded body, which is a heat-treated final product, and thereby contribute to suppressing the spread of fire in the event of a fire. A coating solution consisting of 15 parts by weight, 5 parts by weight of dihydroxybutanedioic acid, and 10 parts by weight of strontium carbonate can be spray-coated on the surface of the molded body that will form the core material.

At this time, desulfurized gypsum is added to increase fast hardening properties, suppress cracking by preventing shrinkage, absorb and decompose smoke, and increase self-extinguishing properties.

Additionally, dimethylpolysiloxane is added to increase anti-foaming properties and water repellency to prevent the spread of smoke and extinguish flames.

Additionally, magnesium sulfate is added to accelerate hardening and enhance self-extinguishing properties against flame.

In addition, dihydroxybutanedioic acid is added to strengthen anchoring properties by preventing the reduction of voids due to inter-particle adsorption during mixing and to increase incombustibility by strengthening heat resistance.

In addition, strontium carbonate is added to increase smoothness and strengthen flame retardancy due to heat insulation and heat resistance.

In particular, in the present invention, 10 parts by weight of a phosphorescent luminous material having a nano particle size is added to 100 parts by weight of the polystyrene resin, so that when the steel plates on both sides fall apart in the event of a fire, a display function appears in a dark place by the phosphorescence phenomenon, allowing for evacuation. By allowing people to visually check this, evacuation efficiency can be increased and casualties can be reduced.

This phosphorescent luminous body is a powder made by heating strontium minerals (e.g., celestite or strontianite), removing impurities, and pulverizing them into nano-sized particles to increase the content of strontium aluminate (SrAl ₂ O ₄ ).

The physical properties of the sandwich panel core material (invention material) manufactured according to the present invention were confirmed and compared with the conventional glass fiber core material and are shown in Table 1.

item Conventional materials invention thermal conductivity 0.09-0.10 kcal/mhr·c 0.04-0.07kcal/mhrㆍc Non-flammable non-combustible non-combustible fire resistance temperature 600℃ 900℃ durability When used for a long time, it absorbs moisture in the air, causing freezing, lowering insulation, and sagging due to the fibrous properties. Even when used for a long time, there is no moisture absorption at all, and the resistance to external shock is strong, so no deformation occurs. Workability Scattering of glass residue during work, hazardous when in contact with the human body No problem Processability Causes fiber wrapping phenomenon when cutting Forming a uniform cutting surface with a general saw

As shown in the example in Table 1 above, when the molded body according to the present invention is used as a core material for a sandwich panel, it is very efficient in terms of durability, workability, and processability as well as fire resistance and incombustibility, and is very advantageous and low cost compared to existing materials. And it was confirmed that weight reduction can be achieved.

Meanwhile, an anti-corrosion coating layer may be applied to the surface of the dryer to prevent corrosion.

The coating materials for this anti-corrosion coating layer include 10% by weight of methacrylamide, 20% by weight of hydrobenzotriazole, 25% by weight of hafnium, 15% by weight of molybdenum emulsifier (MoS ² ), 15% by weight of titanium oxide (TiO ² ), It consists of 15% by weight of ethylenediamine, and the coating thickness can be 9㎛.

Methacrylamide, hydrobenzotriazole, and ethylenediamine play a role in preventing corrosion and discoloration.

Hafnium is a corrosion-resistant transition metal element that has excellent water resistance and corrosion resistance.

Molybdenum emulsification plays a role in providing slideability and lubricity to the surface of the coating film.

Titanium oxide is added for purposes such as fire resistance and chemical stability.

The reason why the ratio of the components and the coating thickness were limited as above is because the present inventor analyzed the test results after repeated failures and found that the ratio showed the optimal anti-corrosion effect.

In addition, an anti-pollution layer made of an anti-pollution coating composition may be applied to the mold and drum-type mixer to effectively prevent adhesion and remove contaminants.

The anti-fouling coating composition contains citrate and diethylene glycol monobutyl ether in a molar ratio of 1:0.01 to 1:2, and the total content of citrate and diethylene glycol monobutyl ether is 1 to 10 based on the total aqueous solution. It is weight %.

The molar ratio of citrate and diethylene glycol monobutyl ether is preferably 1:0.01 to 1:2. If the molar ratio is outside the above range, the applicability of molds and drum mixers may decrease or moisture adsorption on the surface will increase after application. Therefore, there is a problem in that the coating film is removed.

The citrate and diethylene glycol monobutyl ether are preferably used in an amount of 1 to 10% by weight in the total composition aqueous solution. If the amount is less than 1% by weight, there is a problem that the applicability to molds and drum mixers is reduced, and if it exceeds 10% by weight, the application is difficult. Crystal precipitation is likely to occur due to an increase in film thickness.

Meanwhile, as a method of applying this anti-pollution composition to a mold and a drum type mixer, it is preferable to apply it by spraying. Additionally, the final coating film thickness of the mold and drum type mixer is preferably 700 to 2500 Å, more preferably 900 to 2000 Å. If the thickness of the coating film is less than 700 Å, there is a problem of deterioration in the case of high temperature heat treatment, and if it exceeds 2500 Å, there is a disadvantage in that crystal precipitation on the coating surface is likely to occur.

Additionally, this anti-pollution coating composition can be prepared by adding 0.1 mole of citrate and 0.05 mole of diethylene glycol monobutyl ether to 1000 ml of distilled water and then stirring.

The reason for limiting the ratio of the components and the thickness of the coating film to the above values is that the present inventor analyzed the test results after repeated failures and found that the ratio showed the optimal anti-contamination application effect.

Claims (7)

In the non-combustible ceramic molded body for lightweight construction interior and exterior materials used as the core material of sandwich panels;
The core material is a molded body formed by placing a composition consisting of 2-6% by weight of water, 1-15% by weight of an organic binder, 10-20% by weight of an inorganic binder, and the remaining pearlite powder into a mold and molded under high pressure;
The outer surface of the molded body is coated with a coating solution, and the coating solution includes 10 parts by weight of desulfurized gypsum, 5 parts by weight of dimethylpolysiloxane, 15 parts by weight of magnesium sulfate, 5 parts by weight of dihydroxybutanediic acid, and carbonic acid, based on 100 parts by weight of polystyrene resin. A non-combustible ceramic molded body for lightweight construction interior and exterior materials, characterized by consisting of 10 parts by weight of strontium. According to paragraph 1,
The organic binder is a non-flammable ceramic molded body for lightweight construction interior and exterior materials, characterized in that it is dextrin or PVA (polyvinyl alcohol) alone, or a mixture of dextrin and PVA in a weight ratio of 1:1. According to paragraph 1,
The inorganic binder is a non-combustible material for interior and exterior lightweight construction, characterized in that it is made by vitrifying any one selected from feldspar, silica, limestone, borax, soda ash, zinc, lithium carbonate, and alumina, or a mixture of two or more mixed in equal proportions. Ceramic molded body. Raw material preparation stage; Mixing the prepared raw materials into a drum-type mixer and mixing and stirring at a speed of 100-150 rpm for 30 minutes; When stirring is completed, putting the stirred composition into a mold and press molding it at high pressure; When molding is completed, drying in a dryer maintained at 100-180°C; In the method of manufacturing a non-combustible ceramic molded body for lightweight construction interior and exterior materials, comprising: placing the dried body in a heat treatment kiln and heat treating it at 700-900° C. for 2-3 hours;
The mixing and stirring step is a step of mixing and stirring the composition after forming a composition with 2-6% by weight of water, 1-15% by weight of an organic binder, 10-20% by weight of an inorganic binder, and the remaining perlite powder;
In the drying step, a corrosion prevention coating layer is formed on the surface of the dryer, and the coating material for the corrosion prevention coating layer is 10% by weight of methacrylamide, 20% by weight of hydrocybenzotriazole, 25% by weight of hafnium, and molybdenum emulsified (MoS). ₂ ) 15% by weight of titanium oxide (TiO ₂ ), 15% by weight, and 15% by weight of ethylenediamine;
After the heat treatment step, the outer surface of the molded body is coated with a coating solution, and the coating solution contains 10 parts by weight of desulfurized gypsum, 5 parts by weight of dimethylpolysiloxane, 15 parts by weight of magnesium sulfate, and 5 parts by weight of dihydroxybutanedioic acid, based on 100 parts by weight of polystyrene resin. A method of manufacturing a non-combustible ceramic molded body for lightweight construction interior and exterior materials, characterized in that it consists of 10 parts by weight of strontium carbonate. According to clause 4,
The raw material preparation step includes an organic binder preparation process, an inorganic binder preparation process, and a perlite powder preparation process;
The organic binder preparation process is a process of preparing dextrin or PVA to match the weight to be mixed;
The inorganic binder preparation process involves placing a mixture of feldspar, silica, limestone, borax, soda ash, zinc, lithium carbonate, and alumina in equal proportions in a glass melting kiln and melting it at a temperature of 1500°C. Then, the melt is placed in water at room temperature. A method of manufacturing a non-flammable ceramic molded body for lightweight construction interior and exterior materials, characterized in that it is a process of vitrifying by dropping it into a water bath and rapidly cooling it. According to clause 5,
The perlite powder preparation process is a process for producing a non-combustible ceramic molded body for lightweight construction interior and exterior materials, characterized in that the perlite powder is fired at 1200°C and then pulverized to obtain a powder with an average particle diameter of 5 mm or less. According to clause 4,
A method of manufacturing a non-combustible ceramic molded body for lightweight building interior and exterior materials, characterized in that the heat treatment kiln uses a continuous kiln, RHK (Roller Hearth Kiln).