KR20060126292A - Multi-layer ceramic panel and process of producing thereof - Google Patents

Abstract

A multi-layered ceramic panel and a manufacturing method thereof are provided to prevent the toxic gas from being generated in a fire, to secure good heat insulation and sound absorption characteristic of a low-specific gravity/high foam layer, and to improve the strength and sound insulation characteristic of a high-specific gravity/low foam layer. The multi-layered ceramic panel is produced by integrally molding and plasticizing the mixture for a high-specific gravity ceramic foam layer(1) and the mixture for a low-specific gravity ceramic foam layer(2). The high-specific gravity ceramic foam layer has the specific gravity of 0.8-1.2 and the void ratio of 5-10% after plasticizing. The low-specific gravity ceramic foam layer has the specific gravity of 0.1-0.4 and the void ratio of 60-80% after plasticizing.

Description

Multi-layer ceramic panel and process of producing thereof

1 and 2 is a perspective view showing an embodiment of a multi-layered ceramic panel of the present invention.

3 is a manufacturing process diagram of a multilayer ceramic panel of the present invention.

<Description of the symbols for the main parts of the drawings>

1: high specific gravity ceramic foam layer 2: low specific gravity ceramic foam layer

The present invention relates to a composite panel that can be used as a building interior and exterior materials, and more particularly, to form a multi-layer mixture for forming a low specific gravity foam layer as an inner layer and a mixture for forming a low specific gravity foam layer as an inner layer. The present invention relates to a ceramic panel having a multi-layer structure formed by injecting them into a mold sequentially, and molding and firing them.

Conventional building composite panels mainly consist of panels made by attaching steel plates on both sides of styrofoam or asbestos material with insulation performance. However, these panels were excellent in strength and insulation performance, so they were suitable for use in building. However, styrofoam used as insulation material was weak in fire due to its low heat resistance, and harmful gas was generated in case of fire. Asbestos emits carcinogens. The development of alternative materials has been sought.

In Korea Patent Application No. 2000-0065315, waste mineral fiber, glass wool, rock wool, ceramic fiber, etc. are collected and poured by other surface machine, and the binder is mixed and refined to a certain width by refining machine. After molding into a panel and cutting to a certain length according to the use to provide a method for producing a mineral composite panel having a different function by regenerating the mineral fiber waste, Korean Patent Application No. 2000-0036620 No. surface material of the metal sheet; Lower surface material of metal sheet; And a metal lattice core sandwiched between the upper and lower surface materials, and the upper and lower surface materials and the core material are bonded by an inorganic foam mainly composed of alkali silicates filled in the lattice space therebetween, and insulating at high temperatures. To provide a fire-resistant insulating composite panel that the effect is stable.

In addition, Korean Patent Application No. 1992-0017819 discloses a panel structure for building interior and exterior walls using Schiropole mixed lightweight concrete as a filler. It provides a lightweight composite panel structure for interior and exterior walls of the building interior and exterior walls, characterized in that the cellulose fiber cement board with the acrylic resin cement adhesive is mounted on the top, and then simultaneously compressed, demolded and joined together.

In the well-known technology, there is provided a mineral composite panel including glass wool, rock wool, and the like, which may contain carcinogens, and thus, there is a problem of harm to humans. The lightweight concrete is separately filled and bonded using an adhesive, or the metal surface material and the lattice are bonded. The process is complicated, such as using a panel to configure the use of the adhesive has the disadvantage of toxic emissions.

In addition, Korean Patent Application No. 1996-0012015 discloses a foamed glass manufacturing technology using calcium carbonate or dolomite as a new foamed glass manufacturing method, but since it has only a single layer of foamed glass structure, the surface strength of the product is low and can not be constructed. It is difficult to use as a building interior and exterior materials, such as the impossibility of the construction, such as impossible, and had a limitation that can be used as interior and exterior materials only when a composite structure is formed separately from other products.

Accordingly, the present invention solves all the problems of the prior art as described above, has excellent non-flammability, heat insulation, flawability and sound insulation, and when used as a building interior material to provide a composite panel excellent in construction and environmentally friendly Shall be.

In order to solve the above problems, the present inventors mix waste glass powder, foaming agent, molding and firing aids, additives and the like to form a ceramic foam mixture having a different specific gravity into a multilayer structure, which is excellent in non-combustibility and thermal insulation, and is excellent in sound insulation and sound absorption. In addition, the present invention has been completed to know that it can economically provide an eco-friendly composite panel containing no carcinogens and harmful gases.

Therefore, according to the present invention, the mixture for the high specific gravity ceramic foam layer and the mixture for the low specific weight ceramic foam layer are formed and fired integrally, and after firing, the specific gravity of the high specific weight ceramic foam layer is 0.8 to 1.2 and the porosity of 5 to 10%. It has a multi-layered ceramic panel, characterized in that the specific gravity of the low specific gravity ceramic foam layer after firing has a porosity of 60 ~ 80%.

In addition, the fine porosity of one or two or more mixtures selected from the group consisting of 30 to 50% by weight of waste glass powder, 0.5 to 5% by weight of foaming agent, 10 to 30% by weight of molding and calcining aids, diatomaceous earth, clay and fly ash A mixture of a high specific gravity ceramic foam layer mixed with 30-40 wt% of inorganic powder and 8-15 wt% of water, 40-60 wt% of waste glass powder, 1-10 wt% of blowing agent, 10-30 wt% of molding and firing aid, A low specific gravity ceramic foaming layer mixture of 5 to 30% by weight of particulate porous inorganic powder and 8 to 15% by weight of water, which is one or more mixtures selected from the group consisting of diatomaceous earth, clay and fly ash, is sequentially added to the mold. After injection into a two-layer or three-layer structure, molded under a pressure of 1 ~ 1.2ton.f and demolded the molded material and then fired for 10-30 minutes at 650 ~ 850 ℃ of the multi-structure ceramic panel A manufacturing method is provided.

Hereinafter, the present invention will be described in more detail with reference to the accompanying drawings.

1 and 2 are perspective views showing an embodiment of a multilayer ceramic panel of the present invention, Figure 3 is a process chart showing a manufacturing process of the multilayer ceramic panel of the present invention.

Multi-layered ceramic panel of the present invention is an environmentally friendly composite panel that can be used as a composite panel for interior and exterior of the building, as shown in Figure 1 and 2 of the high specific gravity ceramic foam layer (1) and low specific gravity ceramic foam layer (2) ), Which is formed of two or more layers, wherein the high specific gravity ceramic foam layer comprises 30 to 50% by weight of waste glass powder, 0.5 to 5% by weight of blowing agent, 10 to 30% by weight of molding and baking aid, diatomaceous earth, clay and ply It is made of a high specific gravity ceramic foaming layer mixture of 30 to 40% by weight of the particulate porous inorganic powder and 8 to 15% by weight of water, one or more mixtures selected from the group consisting of ash, the low specific gravity ceramic foaming layer 40 to 60% by weight of waste glass powder, 1 to 10% by weight of foaming agent, 10 to 30% by weight of molding and firing aid, diatomaceous earth, clay and fly ash. 5 to 30% by weight and water to 8 to 15% by weight of the mixture is a mixture for the low specific gravity ceramic foam layer, the mixture for the high specific gravity ceramic foam layer and the mixture for low specific gravity ceramic foam layer is formed by integrally molding and firing.

The high specific gravity ceramic foam layer constituting the multilayered ceramic panel of the present invention as described above has a specific gravity after firing of 0.8 to 1.2 and a porosity of 5 to 10%, and the low specific gravity ceramic foam layer has a specific gravity after firing of 0.1 to 0.4. It has a porosity of 60 to 80%.

Referring to the manufacturing method of the multilayer structure ceramic panel of the present invention configured as described above are as follows.

In carrying out the present invention, when the raw materials are mixed, molded and calcined by heating, carbon dioxide and crystal water components contained in the blowing agent are decomposed and bubbled while the waste glass is softened to a near liquid state by heat. It will be foamed while forming a. Therefore, the higher the weight ratio of the waste glass powder, the higher the weight ratio of the blowing agent, the more foaming occurs, the lower the specific gravity and the better the heat insulation and sound absorption. On the other hand, the strength is lowered, and also the product is vitrified, the workability is reduced, and if the surface is not applied to the surface cracks or fragile tends to show a disadvantage. Therefore, in the present invention, the inner layer maximizes the foaming, while being light and increasing the heat insulation and sound absorption, and the outer layer relatively reducing the foaming to compensate for the strength, and softening the surface layer to improve the processability and nail workability. The mixture is prepared by varying the mixing amount of the composition forming the middle ceramic foam layer and the low specific gravity ceramic foam layer, and the mixture is manufactured by molding and firing the mixture to complement properties such as specific gravity, strength, thermal conductivity, sound absorption, and sound insulation. To manufacture a multi-layered ceramic panel that can be used as interior and exterior materials for buildings.

As shown in Figure 3, the waste glass is ground to have a uniform particle size of 100 ~ 150㎛ to prepare a waste glass powder, the waste glass powder 30-50% by weight, foaming agent 0.5-5% by weight, 10 to 30% by weight of molding and firing aids, 30 to 40% by weight of fine porous inorganic powders and 8 to 15% by weight of water, which are one or two or more selected from the group consisting of diatomaceous earth, clay and fly ash One or two or more mixtures selected from the group consisting of a mixture for heavy ceramic foam layers and waste glass powder 40 to 60% by weight, foaming agent 1 to 10% by weight, molding and firing aids 10 to 30% by weight, diatomaceous earth, clay and fly ash To prepare a mixture for the low specific gravity ceramic foam layer mixed 5-30% by weight of the porous inorganic powder of phosphorus fine particles and 8-15% by weight of water (S100, S110, S120), the mixture for the high specific gravity ceramic foam layer and low specific gravity ceramic foam 2 or 3 layers of layer mixture sequentially into the mold After injection and lamination into a layered structure, and molded under a pressure of 1 ~ 1.2ton.f (S130), after demolding the molded material and calcined at 650 ~ 850 ℃ for 10-30 minutes, dried, cut and processed A multi-layered ceramic panel is manufactured (S140, S150, S160). Here, the mixture for the high specific gravity ceramic foam layer forms a high specific gravity ceramic foam layer, and the mixture for the low specific gravity ceramic foam layer forms the low specific weight ceramic foam layer integrally, and the high specific weight ceramic foam layer is used as an interior and exterior material for building. A layer is formed, and a low specific gravity ceramic foam layer forms an inner layer.

The blowing agent used in the present invention may be any one selected from calcium carbonate and calcium phosphate as a fine powder, or a mixture thereof, and may further use carbon, graphite, and the like.

The molding and firing aid used in the present invention serves as an inorganic binder for forming into a plate shape and a liquid sodium silicate, sodium hydroxide, sodium carbonate and sodium sulfate containing a low density fine particle Si0 ₂ in the sodium component to control the firing temperature. Powdered sodium compounds which are one or a mixture of two or more selected from the group consisting of can be used.

In forming the multi-structure ceramic panel of the present invention, the constituent material of the low specific gravity ceramic foam layer is the same material as the high specific gravity ceramic foam layer, and the mixed amount of the waste glass powder and the foaming agent of the mixture for the high specific gravity ceramic foam layer Mixed with less than the mixing amount of the mixture for the low specific gravity ceramic foaming layer, and increased the mixing amount of the fine porous inorganic powder relatively to soften the surface layer to improve the strength, processability and workability, the mixture for the low specific gravity ceramic foaming layer Silver increased the amount and size of the foam by increasing the mixing amount of the waste glass powder and the blowing agent than the mixture for the high specific gravity foam layer, low specific gravity, improved insulation and sound absorption.

In the case of the mixed composition applied to the present invention, the waste glass powder can be used as a main material constituting the mixture by pulverizing the cullet of the building glass or bottle glass for general construction and pulverizing it, and the mixing ratio is high specific gravity ceramic foam layer In the case of 30 to 50% by weight, in the case of a low specific gravity ceramic foam layer, 40 to 60% by weight is preferable. Below the lower limit, vitrification is difficult, so that an increase in heat treatment temperature and deterioration of foaming characteristics may occur, and in a state in which the upper limit is exceeded, an increase in specific gravity or a decrease in strength may occur.

In addition to calcium carbonate and calcium phosphate, the blowing agent may additionally use carbon, graphite, and the like. A mixing ratio of 0.5 to 5% by weight for the high specific gravity layer and 1 to 10% by weight for the low specific gravity layer is appropriate. Below the lower limit, the thermal insulation property decreases due to the increase in specific gravity, and when the upper limit is exceeded, the strength decreases due to excessive foaming and deformation of the product may occur.

Molding and firing aids assist in molding or lower the temperature of the heat treatment during firing and promote foaming. The mixing ratio is preferably 10 to 30% by weight for both the high specific gravity layer and the low specific gravity layer. If it is less than the lower limit, it may be difficult to form a certain shape or an increase in the heat treatment temperature may occur. If the upper limit is exceeded, durability or strength may decrease.

Fine porous inorganic powder serves to improve the physical properties and processability of the product, the mixing ratio of 30 to 40% by weight in the high specific gravity layer, 5 to 30% by weight in the low specific gravity layer is appropriate. If the value is less than the lower limit and the upper limit is exceeded, cracking, construction and workability may be deteriorated due to the difference in thermal expansion coefficient.

In the present invention, the mixture for the high specific gravity ceramic foam layer and the mixture for the low specific weight ceramic foam layer are sequentially injected into a mold in a two-layer or three-layer structure, and then molded under a pressure of 1 to 1.2 ton.f. The low specific gravity ceramic foaming layer may be formed to be disposed between the two-layer structure of the high specific gravity ceramic foaming layer and the low specific gravity ceramic foaming layer or the high specific gravity ceramic foaming layer. In case of two-layer structure, it is suitable for exterior having strength and insulation by building on the exterior wall of the building, and in case of three-layer structure, it is used for exterior of building as well as integral partition walls such as partitions inside the building. It can be suitably used also for the use which has a characteristic.

    In the present invention, after demolding the molded material can be produced for 10-30 minutes at 650 ~ 850 ℃ to manufacture a ceramic panel that can be used as interior and exterior building materials. When the firing temperature and the firing time is less than the lower limit, sufficient foaming is not achieved, so that the desired low specific gravity foam is not obtained, and the strength is also weakened. When the firing temperature is higher than the upper limit, the foamed structure is again vitrified by excessive heat. As it softens, shrinkage of the foam layer occurs again, and thus there is a problem in that a structure having a specific specific gravity and shape cannot be obtained.

    The specific gravity of the high specific gravity ceramic foam layer of the multilayer structure ceramic panel of the present invention prepared as described above is 0.8 ~ 1.2, the specific gravity of the low specific weight ceramic foam layer can be obtained a multi-layer ceramic panel, specific gravity 0.1 ~ The low specific gravity ceramic foam layer of 0.4 is excellent in physical properties such as specific gravity, thermal conductivity, porosity, etc. and can be usefully used as a building insulation. However, the low specific gravity ceramic foam layer is difficult to use alone as a building panel due to its weak compressive strength and nail construction properties.

Therefore, in the present invention, a high specific gravity ceramic foam layer having a specific gravity of 0.8 to 1.2 may be integrally formed to contact one or both surfaces of the low specific gravity ceramic foam layer, thereby reinforcing compressive strength and bending strength, and at the same time improving the impact resistance of the surface. It can be supplemented to make nail construction possible. If the specific gravity of the high specific gravity ceramic foam layer is less than 0.8, the strength is weak. If the specific gravity exceeds 1.2, problems of specific gravity and thermal conductivity may occur.

In the present invention, it is preferable that the porosity of the high specific gravity ceramic foam layer is 5 to 10%, and the porosity of the low specific gravity ceramic foam layer is preferably 60 to 80%. In addition, the size distribution of the foamed hole of the high specific gravity ceramic foam layer is preferably 10 ~ 30㎛, the size distribution of the foamed hole of the low specific gravity ceramic foam layer is preferably 200 ~ 400㎛. Here, when the porosity of the high specific gravity ceramic foam layer and the size distribution of the foamed hole are less than the lower limit or exceed the upper limit, the strength required for use as interior and exterior materials of buildings may not be obtained, and the porosity and foaming of the low specific gravity ceramic foam layer If the size distribution of the ball is less than the lower limit or exceeds the upper limit, the insulation is inferior, and there is a disadvantage in that the thermal conductivity and specific gravity are high.

Hereinafter, the following examples are given as non-limiting examples of manufacturing the multi-structure ceramic panel of the present invention.

Example 1

The high specific gravity foam layer is 38% by weight of crushed waste glass powder with a particle size of 100 ~ 150㎛, 38% by weight of diatomaceous earth, 1% by weight of calcium carbonate and calcium phosphate, and dry uniformly for 2 hours in a ball-mill. After mixing, 5% by weight of sodium silicate, 8% by weight of sodium hydroxide, and 9% by weight of water are completely dissolved and thoroughly mixed with the powder, which is finished with a ball mill, and wet mixed. Low specific gravity foam layer was put into 47% by weight of waste glass powder pulverized to a particle size of 150 ~ 100㎛, 25% by weight of diatomaceous earth, 5% by weight of calcium carbonate and calcium phosphate, respectively, and uniformly dry for 2 hours in a ball-mill. After mixing, 5% by weight of sodium silicate, 8% by weight of sodium hydroxide, and 8% by weight of water are completely dissolved and thoroughly mixed with the powder finished with the ball mill and wet mixed. After laminating the high specific foam layer and the low specific foam layer into a high specific foam layer and a low specific foam layer in a mold, press processing at about 1 to 1.2 ton.f, and then put in a dryer at about 100 ° C. for about 2 hours. After drying for a while, it is removed from the mold and put into an electric furnace to raise it to 800 ℃ for about 2 hours, hold it at 800 ℃ for about 20 minutes, then slowly cool down to 400 ℃ for about 2 hours, and further cool down to 200 ℃ and then cut and The double structure panel was manufactured by processing.

Example 2

High specific gravity foam layer is 38% by weight of crushed waste glass powder with a particle size of 100 ~ 150㎛ 38% by weight of diatomaceous earth, 1% by weight of calcium carbonate and calcium phosphate uniformly dry mixing for 2 hours in a ball-mill (ball-mill) Then, 5% by weight of sodium silicate, 8% by weight of sodium hydroxide, and 9% by weight of water are sufficiently mixed and wet-mixed with the powder finished ball mill. 39% by weight of the diatomaceous earth, 1% by weight of calcium carbonate and calcium phosphate to 39% by weight of the waste glass powder in the same manner as the high specific gravity foam layer, and dry mixed for about 2 hours in a ball-mill (ball-mill), and then silicic acid 8% by weight of soda, 4% by weight of sodium hydroxide, and 9% by weight of water are sufficiently mixed and wet mixed with the ball mill-finished powder to prepare a high specific gravity foam layer. The low specific gravity foam layer was mixed with 47% by weight of waste glass powder pulverized to a particle size of 150 ~ 100㎛ and 25% by weight of diatomaceous earth calcium carbonate and 5% by weight of calcium phosphate and dry mixed uniformly for 2 hours in a ball-mill. Next, 5% by weight of sodium silicate, 8% by weight of sodium hydroxide, and 8% by weight of water are sufficiently mixed and wet mixed with the powder which has finished the ball mill. The high specific gravity foam layer, the low specific gravity foam layer, and the high specific gravity foam layer were sequentially laminated in a mold, press-processed at about 1 ton, and then dried in a dryer at about 100 ° C. for about 2 hours, and then removed from the mold. Into an electric furnace was raised to 800 ℃ for about 2 hours, and maintained at 800 ℃ for about 20 minutes, then slowly cooled to 400 ℃ over about 2 hours, further cooled to 200 ℃ and cut and processed to prepare a tri-structure panel. .

Comparative Example 1

Lightweight concrete products made of silica and gypsum as the main raw materials and mixed with raw materials of quicklime, cement, crust, aluminum powder with water to form a slurry, put into a mold, molded into a certain shape, and foamed and cured in an autoclave. Was prepared.

Comparative Example 2

Resin-coated steel sheets were used on both sides of the outer layer, and glass wool, an inorganic fiber insulation material, was pressed into the inner layer to prepare a composite sandwich panel, which is a composite panel for construction.

The properties of the products manufactured through the above Examples and Comparative Examples were measured and compared as shown in Table 1 below.

 ※ Compressive strength test was carried out according to the method specified in KS F4914 (Lightweight Foam Concrete Panel (ALC Panel)) standard, and thermal conductivity was measured according to KS F2277 (Insulation performance test method of house insulation).

Example 1 Example 2 Comparative Example 1 Comparative Example 2 rescue High specific gravity surface layer + low specific gravity foam layer (2-layer structure) \ High specific gravity surface layer + low specific gravity foam layer + (3-layer structure) Foam layer monostructure Surface metal sheet + inner glass surface (three-layer structure) importance 0.2-0.5 0.4-0.6 0.5-0.7 0.2-0.5 Compressive strength (kgf / cm ² ) 40-55 50-60 30-70 10-50 Thermal conductivity (kcal / mh ℃) 0.09-0.11 0.10 ~ 0.12 0.09-0.12 0.05 ~ 0.15 Surface nail workability possible possible Impossible Not possible (some) Other nonflammable nonflammable nonflammable Flame retardant

As described above, the present invention not only achieves the same level of compressive strength and thermal conductivity as compared to the existing lightweight foam concrete or composite sandwich panel, but also can easily nail the surface, and has excellent non-flammability and insulation. It is excellent in voice and sound absorption, and can provide eco-friendly composite panel that does not contain carcinogens and harmful gases economically.

Claims (6)

The mixture for the high specific gravity ceramic foam layer and the mixture for the low specific weight ceramic foam layer is formed and fired integrally, and after firing, the specific gravity of the high specific weight ceramic foam layer is 0.8 to 1.2 and has a porosity of 5 to 10%. Multi-layer ceramic panel, characterized in that the specific gravity of the ceramic foam layer has a porosity of 60 ~ 80%. The method of claim 1, wherein the high specific gravity ceramic foam layer mixture is 30-50% by weight of waste glass powder, 0.5-5% by weight of blowing agent, 10-30% by weight of forming and calcining aid and diatomaceous earth, clay and fly ash 30 to 40% by weight of fine porous inorganic powder, which is a selected one or two or more mixtures, wherein the low specific gravity ceramic foam layer mixture is 40 to 60% by weight of waste glass powder, 1 to 10% by weight of blowing agent, forming and calcining A multi-layered ceramic panel, comprising 10 to 30% by weight of the preparation and 5 to 30% by weight of particulate porous inorganic powder, which is one or a mixture of two or more selected from the group consisting of diatomaceous earth, clay and fly ash. 3. The multilayer ceramic panel of claim 2, wherein the blowing agent uses any one or a mixture of calcium carbonate and calcium phosphate. 3. The molding and calcining aid according to claim 2, wherein the shaping and calcining aid is a powdered sodium compound which is any one or a mixture of liquid sodium silicate, sodium hydroxide, sodium carbonate and sodium sulfate containing low density particulate Si0 ₂ in the sodium component. Multi-layered ceramic panels. The low weight ceramic foam layer according to any one of claims 1 to 4, wherein the multi-structure ceramic panel is disposed between a two-layer structure of a high specific gravity ceramic foam layer and a low specific weight ceramic foam layer or a high specific weight ceramic foam layer. Multi-layer ceramic panel, characterized in that the three-layer structure. Fine granular porous inorganic powder which is one or two or more mixtures selected from the group consisting of 30 to 50% by weight of waste glass powder, 0.5 to 5% by weight of blowing agent, 10 to 30% by weight of forming and calcining aids, diatomaceous earth, clay and fly ash. A mixture of a high specific gravity ceramic foam layer containing 30 to 40% by weight and 8 to 15% by weight of water, 40 to 60% by weight of waste glass powder, 1 to 10% by weight of blowing agent, 10 to 30% by weight of forming and firing aid, diatomaceous earth, Two layers of low-density ceramic foaming layers mixed with 5-30% by weight of particulate porous inorganic powder and 8-15% by weight of water, one or two or more mixtures selected from the group consisting of clay and fly ash, were sequentially Or after the injection into a three-layer structure, forming under a pressure of 1 ~ 1.2ton.f and demolding the molded material and then firing for 10-30 minutes at 650 ~ 850 ℃ manufacturing method of a multi-layered ceramic panel .

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