KR20060006701A - Lightweight building material and its manufacturing method - Google Patents

Abstract

Ceramic raw material and soda silicate, glass, glass wool, rock wool, waste glass wool, waste rock wool, feldspar, gypsum, which are single or mixed with unfoamed pearl rock or unfoamed vermiculite particles as main raw materials. The present invention relates to a ceramic foam composition and a method for producing the same, which are prepared by being interchanged with one or more kinds of raw materials such as raw materials such as an independent plate, sheet or bulk, and cut into a shape suitable for a use.

Building interior materials, building exterior materials, lightweight building materials, lightweight panels, sandwich panels, cores for sandwich panels, panel filling materials, lightweight building materials, ceiling materials, ceramic foams

Description

Ceramic foam composition and its manufacturing method

1 is an embodiment of the present invention

(A; Independent plate foam, B; Bulk foam C; Sheet foam)

The present invention relates to a ceramic foam composition which is a lightweight building material used as a partition of a building, a ceiling interior material, a core of a sandwich panel, and other building materials, and a manufacturing method thereof.

In general, building materials used for building walls, partitions, ceilings, etc., provide heat dissipation that blocks external heat from entering through walls and prevents heat from being emitted from inside and outside the building. It is required to function as a sound barrier by sound insulating and sound absorption.

And in the core of the sandwich panel can be seen that the same function is basically required.

In addition, in the recent development trend of various building materials, non-combustible and environmentally friendly conditions are additionally required for building materials. Therefore, various developments of non-combustible lightweight building materials are being made.

Looking at the prior art with respect to lightweight building materials as follows.

Korean Patent No. 191355 discloses a lightweight concrete prepared by mixing air-containing agent, methyl cellulose, zinc stearate salt and styrofoam to concrete, and has 85-95 kg of ferrite, 10-15 kg of cement, 500 g-800 g of light, Light-weight building composition composed of 500 g to 800 g of tourmaline, 1 to 2 kg of fly ash, 100 to 300 g of mica, 50 to 100 g of surfactant, 50 to 100 g of thickener, 50 to 100 g of reinforcing agent and a small amount of pigment and a method for producing the same -2002-0090192 has been published, the step of preparing a mixture consisting of the selected pearlite particles, liquid sodium silicate and a curing agent and water by mixing and kneading in a stirrer (S1); Filtering the compounding material added excessively to the kneaded pearlite while using a mesh conveyor (S2); And when the step (S2) is completed, the step of forming, curing, drying and cooling in the state of inserting the mineral wool nonwoven fabric in the center of the molding according to the shape and form of the product to be produced (S3) 10-2004-0050827, which is a method of manufacturing a building material having a multifunctional, porous ceramic shape using perlite, has been disclosed in the publication. In the prior art, the complexity of raw materials to be introduced into the manufacturing process, the complexity of the process, the resulting increase in manufacturing cost, complete safety against fire, environmental pollution after disposal, and the use of liquid silicate as an adhesive It has a problem due to the whitening phenomenon.

In order to provide a ceramic foam composition, which is a lightweight building material that compensates for the above problems, the present invention is harmless to the human body and is stable to fire, does not cause environmental pollution, and enables the recycling of raw materials. In order to reduce the input cost to reduce the raw material cost, and to provide a lightweight building material with super light weight, soundproofing, and heat dissipation, the particles of unfoamed pearlite or unfoamed vermiculite alone or two particles of the unfoamed state Mixed at a constant ratio and mixed with the two particles to serve as a binder, a liquid adhesive or a raw material of pulverized powder, ceramic adhesive and sodium silicate, glass, glass wool, rock wool, waste glass wool, waste rock wool, feldspar Provided is a ceramic foam composition manufactured by replacing and mixing with one or more types of raw materials such as, gypsum, and a method of manufacturing the same.

Ceramic foam composition and its manufacturing method according to the present invention are as follows.

Ceramic adhesives and silicon silicate, which will be used alone in the unfoamed pearlite or unfoamed vermiculite particles, or the two unfoamed particles are mixed at a predetermined ratio and mixed with the two particles to serve as an adhesive. It is mixed with at least one of liquid or ground powder such as glass, glass wool, rock wool, peg glass wool, waste rock wool, feldspar, gypsum and the like.

When the raw materials are properly mixed, each object is molded independently using a fixed furnace using a plate- or bulk-type mold, or a sheet-shaped mold having a plurality of independent plate-shaped molds having a thickness or width and a length suitable for the upper part of a movable conveyor or a top of the conveyor. It is configured to fill the raw material, and heated to about 700 ~ 1200 ℃ using a continuous furnace installed in the conveyor. At this time, among the mixed raw materials of the pulverized powder type such as glass, glass wool, rock wool, waste glass wool, perac wool, feldspar, gypsum are melted at about 700 ~ 800 ℃ silver, the pulverized powder is not It is fused to the surface of the foamed pearlite and unfoamed vermiculite particles to maintain the bonding force in the state that the particles are bonded to each other, the unfoamed particles are foamed at about 800 ~ 1200 ℃ to form pores. (In the present invention, the raw materials of the liquid or pulverized powder having adhesiveness are also foamed together with melting at a high temperature, thereby making it possible to manufacture more lightweight building materials.)

The mixture filled in an independent plate shape (FIG. 1-A) or bulk type (FIG. 1-B), or a sheet form (FIG. 1-C), which is administered at an appropriate length, thickness and width on the upper end of a movable conveyor. The mixture of or a plurality of stand-alone mixtures listed in series on the top of a mobile conveyor are heat-foamed using a continuous furnace on the top of the conveyor and cooled and cured using a cooler.

Ceramic foam compositions of various shapes (independent plate shape (Fig. 1-A), bulk type (Fig. 1-B), sheet type (Fig. 1-C)) manufactured by the above process are cut and processed to desired size and thickness of the building. It will be used as core material for partitions, ceiling interior materials, sandwich panels, and other building materials that require sound insulation, heat dissipation and light weight.

Notable features of the ceramic foam composition according to the present invention,

Particles of pearlite and vermiculite, which are raw materials of the ceramic foaming composition, are differentiated from conventional manufacturing methods and foamed by mixing with adhesive raw materials in a non-foamed state, thereby eliminating the foaming process of pearlite and vermiculite which is a pre-processing step. In addition to the pores formed in the interior of the unfoamed pearl rock and unfoamed vermiculite, other mixed raw materials that serve as an adhesive (Fig. 1-a), a ceramic adhesive on the liquid or pulverized powder, sodium silicate, glass , Glass wool, rock wool, waste glass wool, waste rock wool, feldspar, gypsum, etc. are melted to perform the function of the adhesive, and at the same time by forming a pore by foaming at a specific temperature, the whole constituting the ceramic foam composition according to the present invention As the pores are formed in the raw material, the weight per unit volume is reduced, and the volume increase rate is significantly increased compared to other products. It is possible to provide a ceramic foam composition, which is a lightweight building material having an effect of lowering the production cost.

Example

Unfoamed pearl rock or unfoamed vermiculite with a diameter of about 1 mm is mixed in a weight ratio of 60% alone, 10% of liquid ceramic adhesive, and 30% of sodium silicate, and the mixture is administered at a thickness of 10 mm to the top of the moving conveyor, evenly distributed in a sheet form, This is to be heated for about 5 to 10 minutes through a continuous furnace of about 700 ~ 1200 ℃ installed on the conveyor. In the above process, sodium silicate is melted at about 800 ° C., and pearlite or vermiculite is foamed at about 1000 to 1200 ° C. to form pores.

In the present embodiment, the liquid ceramic adhesive increases the adhesion between the foamed raw materials and forms a film on the surface of the particles to serve as a waterproof layer, thereby preventing whitening of sodium silicate.

The time required for heating in the process will vary depending on the type of each component of the mixture, the mixing ratio or the thickness at which the mixture to be formed is administered. For example, when using a liquid adhesive raw material can reduce the heating time required for liquefaction, the heating time is shortened to take about 5 to 10 minutes of heating time, when using a powdery raw material heating time This increases to about 15-30 minutes.

2.Example

Unfoamed pearlite and unfoamed vermiculite with a diameter of about 1 mm are mixed at an appropriate ratio (in consideration of the unit cost of the raw material and the specific gravity of the foam), and mixed with a glass and glass wool mixed powder in a weight ratio of 6: 4. It is evenly distributed in the form of a sheet having a suitable length, width and uniform 10mm thickness on the top of the moving conveyor, and it is heated for about 15-30 minutes through a continuous furnace of about 700 ~ 1200 ℃ installed in the conveyor. In the above process, the glass and glass wool mixed powders exhibiting adhesion upon melting at temperatures of about 700 to 800 ° C. are bonded to each other at about 800 ° C., and are fused to the surface. In the mixture, unfoamed pearlite and unfoamed vermiculite are foamed to form pores. When the foaming is completed, the product is finished after the finishing process of cooling and curing the foam to an appropriate size.

As shown in the above embodiment, in the ceramic foam composition manufactured according to the present invention, a ceramic adhesive, a sodium silicate, glass, glass wool, which is a mixed raw material in a liquid or ground powder serving as an adhesive (Fig. 1-a) The mixture of rock wool, waste glass wool, waste rock wool, feldspar, gypsum and the like adheres to each other to perform the function of an adhesive, and at the same time, when heated to a higher temperature in the fused state, foam is formed to form pores. Unlike adhesives (binders) used as raw materials for building materials, pores are formed by foaming themselves while maintaining the adhesive state between mixtures, so that the pores are formed in the entire raw material constituting the foam, and the weight per unit volume is significantly reduced. The volume increase rate of raw material input is significantly higher than that of other products, which reduces raw materials and lowers production costs. It is possible to provide an effective ceramic foam composition.

The above embodiments are merely examples for better understanding of the present invention, and it is possible to perform various modifications such as mixing the input raw materials with each other, particle size of the pulverized product, dosage, foam length, thickness, shape, and the like. Reveal (Foam = ceramic foam = ceramic foam composition)

The ceramic foam composition prepared by the present invention simplifies the process by pre-foaming the raw material and adding it to the process by directly injecting the raw material in the unfoamed state into the process, and the pores are formed in the entire raw material constituting the foam per unit volume The weight is reduced, the sound absorption and insulation are excellent due to the abundant pores, and the volume increase rate compared to the input of raw materials is significantly increased than other products, so that it is possible to provide a ceramic foam composition having the effect of reducing the production cost by reducing raw materials. It is possible to use recycled raw materials and use only non-combustible raw materials. Therefore, it has various advantages to protect human life from the danger of fire.

Claims (3)

Unfoamed pearlite or unfoamed vermiculite is mixed with an adhesive alone or in combination, and the mixture is calcined at a high temperature to melt the adhesive mixed in the mixture, fused to the surfaces of the unfoamed pearlite and unfoamed vermiculite, and the particles are mutually bonded. And a ceramic foam composition prepared by expanding and foaming the non-foamed pearl rock and the unfoamed vermiculite, forming a foam having pores in the particles, and cooling the foam to cut to an appropriate size. In claim 1, The adhesive is a ceramic foam composition prepared by mixing one or more of a liquid or pulverized powder, a ceramic adhesive, sodium silicate, glass, glass wool, rock wool, waste glass wool, waste rock wool, feldspar, gypsum and a manufacturing method thereof. In claim 1, The foam is filled in an independent plate-shaped or bulk-type molding mold and fired using a fixed furnace to form and cool the foam as an independent individual, thereby forming a foam by cutting to a predetermined size, or suitable length and thickness at the top of the movable conveyor, One of the methods of forming a foam by heating foam-forming a sheet-like mixture administered in the width or a plurality of independent plate-like mixtures continuously arranged on the top of a mobile conveyor using a continuous furnace at the top of the conveyor, and cooling and curing using a cooler. Ceramic foam composition prepared by the method and a manufacturing method thereof.

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