KR20060092782A - Ceramic foam molding and its manufacturing method - Google Patents

Abstract

The present invention relates to a foamed molded article manufactured using ceramic foam particles and inorganic binder as main ingredients,

Interior and exterior materials for building, partition boards and interior and exterior materials for ships, cores for sandwich panels, fire doors, firewalls, and other ceramic materials suitable for various industrial fields requiring non-flammability, pollution-free, heat insulation, light weight, water resistance, etc. It is about.

More specifically, various foamed ceramic particles including pulverized vermiculite, pearlite, obsidian, and pine stone are used alone or in combination,

Thus, one or more kinds of inorganic adhesives including gypsum, cement, clay, sodium silicate, unfinished gel silicate, sodium silicate cement, etc. are mixed, and as other reinforcing materials, steel fiber, fiber debris, paper grinding (powder type) The present invention relates to a ceramic foam molding which is manufactured by mixing glass wool (glass wool), or strengthening durability by mounting a wire mesh or a synthetic resin network therein.

Sandwich panel, non-combustible interior material, interior partition, foam ceramic, pearl rock, vermiculite, soda silicate, non-flammable panel, fire door, fire wall

Description

Ceramic foam moldings and manufacturing method thereof

The present invention relates to a ceramic foam molding prepared using the ceramic foam particles and the inorganic binder,

It is a ceramic foam molding suitable for industrial materials in various industrial fields such as building interior and exterior materials, interior partition boards and interior and exterior materials for ships, cores for sandwich panels, fire doors, firewalls, and non-flammability, pollution-free, heat insulation, light weight, and water resistance. .

Known techniques related to the present invention include

There are styrofoam, foam urethane, foam rubber,

In addition, there is a known technique for foaming molded articles prepared by mixing synthetic resins, which are organic adhesives, with various kinds of foamed ceramic particles, and drying them.

However, in some cases, there is a known technique when using an inorganic adhesive sodium silicate.

Since the raw material is a natural ingredient, it does not cause environmental pollution afterwards, but since sodium silicate used as an adhesive contains a large amount of water, the time required for drying and curing during the manufacturing process of the foamed molding is prolonged. This is impossible,

Although the finished product has been manufactured through prolonged drying, sodium silicate, an adhesive, reacts with H2O in the air during storage and use, causing whitening, which breaks the bonding strength between the raw materials constituting the foamed molding and can be used in actual construction sites. Has no drawbacks.

In addition, in the molded foam manufactured using the synthetic resin as a raw material, the flammability is very strong due to the characteristics of the synthetic resin, which is a main raw material, which causes toxic gas generation, and post waste is a factor of environmental pollution.

Therefore, in the present invention to solve various problems caused by the existing foam molding,

In addition, in order to provide a more durable ceramic foam molding,

Thermally expandable ceramic foam particles are used as the main raw material,

Mixed with an inorganic adhesive,

In the ceramic foamed molding produced by inserting this into the mold of the upper end or various shapes of the conveyor (continuous) or fixed-made conveyor, and pressing, drying and curing the above,

In order to enhance the bonding force between the ceramic foam molding raw material,

It is manufactured by grooving or installing steel fiber, fiber crushed water, paper crushed product (including powder type), glass wool (glass wool), wire mesh, synthetic resin net,

It is to provide a ceramic foamed molded article and a method for producing the same, characterized in that produced by one or more drying methods of heating drying, hot air drying, microwave drying by the drying and curing method.

Hereinafter, the configuration of the present invention will be described in detail.

Crush various rocks including natural materials such as vermiculite, pearlite, obsidian, and pine stone to the desired size,

The pulverized particles are foamed at a high temperature of 800 to 1400 ° C. to form pores inside the particles, and by cooling the pulverized particles, foamed ceramic particles having a specific gravity of 0.1 or less are prepared.

Inorganic adhesives including gypsum, cement, clay, sodium silicate, unfinished gel silicate, sodium silicate cement, and the like, may be used alone or two or more of the above expanded ceramic particles may be mixed with each other. The above is mixed and mixed with the said foamed ceramic particle.

However, in the above mixing ratio of the expanded ceramic particles and the adhesive,

As the ratio of the adhesive increases, the weight of the ceramic foamed molding increases accordingly, and therefore, it may be desirable to reduce the mixing ratio of the adhesive in materials in the field where light weight is particularly required.

In addition, when the ratio of the foamed ceramic particles is increased, the bonding force between the foamed particles is reduced, thereby reducing the strength of the ceramic foamed molding.

Therefore, in actual production of the ceramic foam molding, the mixing ratio between the raw materials is appropriately increased or decreased to have suitable physical properties for the use of the ceramic foam molding to be produced.

The mixed raw material is administered to a mobile (continuous) or fixed conveyor or various types of molds (including bulk type) desired to be manufactured, and the amount of the mixed raw material is pre-measured and installed on the top of the conveyor to adjust the thickness and pressure. The administered mixed raw material passes through the lower part of the compression roller, and by compressing it, the particles are evenly distributed and the bonding strength between the particles is increased.

In addition, pressure is applied to the mixed raw materials that are put into the mobile (continuous) or fixed mold by using a press to compress them at an even density, fix the shape, and increase the bonding strength between the particles.

In the next step of drying and curing,

Ceramic foam moldings are manufactured by drying and curing a heating device, a hot air device, and a microwave irradiation device, which are installed or connected to a conveyor and a mold fixing device, by a drying method using at least one drying device.

On the other hand, in determining the mixing ratio of the expanded ceramic particles and the adhesive,

As the ratio of the adhesive increases, the weight of the ceramic foamed molding increases accordingly, and therefore, it may be desirable to reduce the mixing ratio of the adhesive in materials in the field where light weight is particularly required.

In addition, when the ratio of the foamed ceramic particles is increased, the bonding force between the foamed particles is reduced, thereby reducing the strength of the ceramic foamable coating.

Therefore, in actual production of the ceramic foam molding, the mixing ratio between the raw materials is appropriately increased or decreased to have suitable physical properties for the use of the ceramic foam molding to be produced.

On the other hand, in order to enhance the strength of the ceramic foam molding prepared according to the above production method,

At least one kind of stir fiber, fiber crushed product, paper crushed product, glass wool (glass wool), etc. are added to the mixing process of the raw materials.

The additives increase the strength and durability of the overall ceramic foamed molding by helping the adhesive strength of the adhesive agent to increase the bonding strength between the foam particles.

However, to further enhance the strength of the foamed molding,

By subdividing the step of administering the foaming material to the top of the conveyor or the inside of the mold,

It is possible to further configure the process of mounting the wire mesh or synthetic resin net in the ceramic foam molding.

By the mounting method,

Dividing the raw material of the ceramic foam molding to be finished in an appropriate amount,

After the divided mixed raw material is administered to the upper end of the conveyor, and the administered mixed raw material passes through the compression roller, a wire mesh or synthetic resin network, which is prepared in advance for mounting in the foam molding, is placed on the upper end of the compressed mixed raw material. Laminated.

The remaining amount of the mixed raw material remaining on the upper end of the laminated wire mesh or synthetic resin network is administered, and by passing through the lower portion of the pressing roller to press the quantitative laminated portion by adhering, drying and curing to prepare a ceramic foam molding.

In order to attach despair to foam moldings of specific phenomena (including bulk molds), the mixed raw materials are divided as in the above case, a part of the divided raw materials are put into a mold, pressed by a press, and a mold is placed on the top of the compressed mixed raw materials. Laminated wire mesh or synthetic resin mesh made to be mounted inside,

The remaining mixed raw material is added to the upper end of the laminated wire mesh, pressed, dried, and hardened to manufacture.

In addition, in order to prevent whitening caused by foamed particles and adhesives, a waterproofing agent may be added to a raw material or a waterproof layer may be coated on the surface of the finished ceramic foamed molding to prepare a ceramic foamed molding having enhanced water resistance.

The foamed molded article manufactured through all the above processes can be further configured as a cutting and finishing process as necessary.

Example 1

The pulverized pearlescent particles were calcined at a high temperature of about 800 to l200 ° C. to produce expanded pearl cancer particles having a specific gravity of 0.1 or less, and a small amount of a waterproofing agent in a mixed raw material of the foamed pearl cancer particles and gypsum mixed at a weight ratio of 1: 1. Was added.

The mixed raw material is administered to the top of the movable conveyor in an amount such that a finished ceramic foam molding of a desired size can be produced,

After pressing by passing through the lower portion of the pressing roller installed on the top of the conveyor, using a hot air blower and a microwave irradiation machine installed on the top of the conveyor was dried and cured to a desired length to prepare a ceramic foam molding.

Example 2

The pulverized vermiculite particles and obsidian particles are calcined at a high temperature of about 1000 to 1400 degrees Celsius to prepare expanded vermiculite particles and expanded obsidian particles having a specific gravity of 0.05 or less, and mixed at a weight ratio of 1: 1.

The mixed foamed particles, gypsum and sodium silicate are mixed in a weight ratio of 2: 1: 1 to prepare a mixed raw material.

The amount of the mixed raw material was administered by the amount of 1/2 to the top of the mobile conveyor installed with a microwave and hot air device, and passed through the lower portion of the pressing roller installed in the conveyor, and then crimped, and then the wire mesh to the top of the compressed raw material Laminated to. The remaining 1/2 of the mixed raw material was administered to the upper end of the laminated wire mesh and recompressed with a compression roller.

Example 3

The pulverized pearlite particles are calcined at a high temperature of about 800 to 1200 ° C. to produce expanded pearlite particles having a specific gravity of 0.1 or less, and the expanded pearlite particles, clay, sodium silicate cement, and steel fiber are 4: 2: 1: 1. Mixing in a weight ratio of to prepare a mixed raw material.

The mixed raw material was administered to the top of the mobile conveyor, passed through the lower portion of the compression roller installed on the top of the roller, pressed, and then dried and cured by applying a microwave, the prepared rectangular ceramic foamed molding was cut to a desired length, Coating the sodium silicate cement on the surface of the cut foam molded article to impart a beauty to the surface, and by spray coating a photocatalyst on the top of the sodium silicate coating layer to prepare a ceramic foam molding.

Example 4

The pulverized vermiculite particles and pearlite particles are calcined at a high temperature of about 1000 to 1400 degrees Celsius to produce expanded vermiculite particles and expanded pearl cancer particles having a specific gravity of 0.05 or less, and the prepared foamed particles, expanded pearl cancer particles, and unfinished gel silicate 1 A mixed raw material was prepared by mixing at a mass ratio of 1: 1.

The mixed raw material was put into a fixed bulk mold and pressed by a press. The bulk ceramic foam molding separated from the mold was put into a fixed heating furnace equipped with a microwave irradiation apparatus, dried and cured, and the ceramic foam molding of the required size was prepared by cutting it into a desired thickness and size.

By manufacturing the ceramic foam molding according to the manufacturing method provided by the present invention, non-combustible, pollution-free in addition to industrial materials such as building interior materials, interior partitions, sandwich panel cores, marine interior materials, fireproof door cores, firewalls, thermal insulation materials and shock absorbers of various pipes It is possible to provide a ceramic foam molding that is suitable as an industrial material in a variety of industries that require properties such as properties, heat insulation, light weight, water resistance.

Bonding fabrics, papers, and synthetic resin films with various patterns on the surface of the ceramic foamed moldings produced by the various manufacturing methods, and various colors of silicate cement, fiber powder locking, ocher, elvan, jade, and illite. By coating a coating material of an organic or inorganic material, or by coating a photocatalyst and a matte catalyst, the ceramic foam molding having a variety of uses and complex functions can be manufactured by treating the surface thereof.

* Unfinished gel silicate *

Unfinished gel silicate

In order to prepare silica gel, an appropriate dose for inducing complete gelation (silica gel) of an acidic substance containing sulfuric acid, hydrochloric acid, boric acid, phosphoric acid, calcium chloride, quicklime, ammonium chloride, alcohol, and the like, administered to sodium silicate or sodium silicate By administering in a quantity less than

Sodium silicate or sodium silicate does not form a solid silica gel due to complete gelation reaction, and refers to a substance in a state of being changed into a gel-like substance with strong adhesion (see detailed description in the application 10-2004-009l653).

Ceramic foam molding prepared according to the present invention properties due to rapid ignition in the case of fire, which is a disadvantage of the raw materials of foam molding including conventional sandwich panel core, interior partition board, fire door core, etc. It solves the disadvantages that cause loss of phase and large casualties due to harmful gases during combustion,

The disadvantages of using ceramic foam particles and sodium silicate

Since sodium silicate used as an adhesive contains a large amount of water, the time required for drying and curing during the manufacturing process is greatly shortened to enable actual mass production.

It is possible to provide a more durable ceramic foam molding by using a mixture of materials and devices that enhance the durability.

In addition, by coating a variety of finishes and materials that emit far infrared rays beneficial to the human body, it is possible to express a variety of aesthetics and to provide a beneficial finish to the human body.

Claims (6)

Thermally expandable ceramic foam particles are used as the main raw material, Mixed with an inorganic adhesive, In the ceramic foamed molding produced by inserting this into the mold of the upper end or various shapes of the conveyor (continuous) or fixed-made conveyor, and pressing, drying and curing the above, In order to enhance the bonding force between the ceramic foam molding raw material, A method of manufacturing by mixing at least one kind of steel fiber, fiber crushed water, paper crushed product (including powder type), glass wool (glass wool) to the raw material, It is prepared by mounting one of the wire mesh or synthetic resin network inside the ceramic foam molding to prepare a formulation, using one of the above manufacturing method or by performing the two methods in parallel, Ceramic foam moldings and a method for producing the ceramic foam, characterized in that produced by one or more drying methods of heating drying, hot air drying, microwave drying by the drying and curing method. According to claim 1, On the surface of the ceramic foam molding To form a coating layer using one or more coating materials of various organic or inorganic materials, including colored sodium silicate cement, illite, loess, elvan, jade powder, photocatalyst, matt catalyst, or the like, Ceramic foam molding, characterized in that manufactured by adhering one or more of the fabric, paper, synthetic resin film, fiber powder locking to the various patterns. According to claim 1, The raw material of the ceramic foam particles is a variety of rocks having thermal expansion properties including vermiculite, pearlite, obsidian, pine stone, etc., ceramic foam, characterized in that produced by using the above alone or in combination of two or more Moldings. According to claim 1, The inorganic adhesive As gypsum, cement, clay, sodium silicate, unfinished gel silicate, sodium silicate cement, Ceramic foam molding, characterized in that prepared alone or in combination. According to claim 1, In order to enhance the water resistance of the ceramic foam molding, Ceramic foam molding, characterized in that prepared by adding a waterproofing agent to the raw material. In any one of 1,2,3,4,5, The ceramic foam molding is a ceramic foam molding, characterized in that one of a variety of architectural and industrial materials, including building interior, interior partition, sandwich panel core, marine interior, fire door core, firewall, heat insulating material and shock absorbing material of various pipes.