KR20220139482A - 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 lightweight building interior and exterior materials, and a manufacturing method thereof. More specifically, the present invention relates to a non-combustible ceramic molded body for lightweight building interior and exterior materials, and a manufacturing method thereof, wherein the non-combustible ceramic molded body is lightweight, has excellent incombustibility, and replaces existing Styrofoam, urethane foam, or glass fibers, whose use is restricted according to environmental regulations for core materials for sandwich panels. In addition, deformation of the non-combustible ceramic molded body hardly occurs by blocking moisture absorption, and the non-combustible ceramic molded body has high resistance to external impact, can be cut with a general saw, and has a homogeneous cut surface, and thus is improved to improve the quality of construction as well as convenience in use.

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 materials for lightweight construction and a method for manufacturing the same, and more particularly, it is lightweight and non-combustible by replacing the existing Styrofoam, urethane foam, or glass fiber whose use is restricted according to environmental regulations of the core material for sandwich panels. Non-combustible ceramic for interior and exterior materials for lightweight construction improved to improve convenience in use as well as improve construction quality because it is excellent, has little deformation by blocking moisture absorption, has high resistance to external impact, can be cut with a general saw, and has a homogeneous cutting surface It relates to a molded article and a method for manufacturing the same.

In prefabricated buildings, sandwich panels are the most used lightweight building materials.

Sandwich panels, like sandwiches, are made with iron plates on both sides of the insulation and insulation materials such as styrofoam, urethane or glass fiber, and various types of wool. It is widely used because of its reusability.

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

For example, when a fire occurs in a building, the flame rises up the walls and ceiling and transfers to the styrofoam or urethane inside the panel and spreads rapidly. Because the heat cannot escape, the temperature rises rapidly, reaching an explosive flashover, which spreads tremendously before the fire brigade arrives.

In addition, when a panel fire occurs, toxic gases harmful to the human body are rapidly generated, such as carbon monoxide, hydrogen chloride, and hydrogen cyanide. There are also disadvantages.

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

For this reason, the government is planning to regulate the core material for sandwich panels by minimizing the use of organic components such as Styrofoam and urethane foam by 2022, and making it mandatory to replace them with inorganic components.

In this regard, although glass fiber, which is an inorganic material, is also used, glass fiber is relatively heavy and expensive compared to styrofoam or urethane foam of the same standard, so its utility is extremely limited.

In addition, in the case of glass fiber, since it has moisture absorbing power, the thermal insulation property drops sharply when moisture is absorbed. situation is necessary.

Domestic Registered Patent No. 10-2032219 (2019.10.08.) Device for manufacturing flame retardant board and device for manufacturing sandwich panel Domestic Patent Registration No. 10-1354812 (2014.01.16.) Fire-proof type flame retardant, insulation composite board sandwich panel

The present invention was created to solve the problems in the prior art as described above, and is lightweight and non-combustible by replacing the existing styrofoam, urethane foam, or glass fiber whose use is restricted according to environmental regulations of the core material for sandwich panels. Non-combustible ceramic for interior and exterior materials for lightweight construction improved to improve convenience in use as well as improve construction quality because it is excellent, has little deformation by blocking moisture absorption, has high resistance to external impact, can be cut with a general saw, and has a homogeneous cutting surface Its main object is to provide a molded article and a method for manufacturing the same.

The present invention provides a means for achieving the above object, in a non-combustible ceramic molded body for interior and exterior materials for lightweight construction used as a core material of a sandwich panel; The core material is a light weight, characterized in that 2-6% by weight of water, 1-15% by weight of an organic binder, 10-20% by weight of an inorganic binder and a molded article formed by high pressure by putting a composition consisting of the remaining perlite powder in a mold Provided is a non-combustible ceramic molded body for interior and exterior materials of buildings.

In this case, the organic binder is characterized in that it is a mixture of dextrin or polyvinyl alcohol (PVA) alone, or a mixture of dextrin and PVA in a weight ratio of 1:1.

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

In addition, the present invention is a raw material preparation step; After the prepared raw material 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 perlite powder, this composition is put in a drum-type mixer and mixed and stirred at a speed of 100-150rpm for 30 minutes. step; When the stirring is completed, putting the stirred composition into a mold and press-molding at high pressure; When the molding is completed, drying in a dryer maintained at 100-180 ℃; It also provides a method of manufacturing a non-combustible ceramic molded body for interior and exterior materials for lightweight construction, comprising; putting the dried dried body in a kiln for heat treatment and heat treatment at 700-900° C. for 2-3 hours.

In this case, 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 based on the weight to be mixed; In the inorganic binder preparation process, a mixture of feldspar, silica, limestone, borax, soda ash, zinc oxide, lithium carbonate, and alumina in equal proportions is mixed in a melting furnace for glass, melted at a temperature of 1500° C. It is also characterized in that it is a process of vitrification by dropping it into a water tank and cooling it rapidly.

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

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

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

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

Second, it is lightweight and has excellent incombustibility.

Third, there is almost no deformation by blocking moisture absorption.

Fourth, resistance to external impact is high.

Fifth, it can be cut with a general saw, and the cut surface is homogeneous, so it is possible to increase the convenience of use as well as the 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 materials for lightweight construction according to the present invention is used as a core material of a sandwich panel, and contains 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. Put the composition consisting of in a mold and use the one molded under high pressure.

In this case, as the organic binder, dextrin or polyvinyl alcohol (PVA) may be used.

In particular, dextrin refers to a low-molecular-weight carbohydrate obtained by hydrolyzing starch (starch), and is added to secure fluidity against external force while increasing binding viscosity for molding perlite powder.

In addition, as a water-soluble polymer, PVA is added to secure bonding strength and buffering power during molding of perlite powder, and to maintain shock absorption against external forces to secure molding stability.

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

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

Such an 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, it is added to increase incombustibility.

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

In this case, the perlite is a powder used in a material field different from perlite (a metal structure in which ferrite and cementite are arranged in layers), which is a metal structure related to the transformation of a metal used in the metal field. Therefore, it should not be confused due to the similarity of the terms, and for the sake of differentiation, it was written as 'perlite' rather than perlite.

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

Such perlite not only has very high non-combustible properties that it does not burn or melt even at 900℃, but also has no thermal deformation and almost no moisture absorption, so it can be used semi-permanently because it is not deformed against external impact at all. It is very suitable for making lightweight building materials.

In particular, when cutting by sawing when a molded body is made, the cutting surface is cleanly cut to form a uniform cutting surface, and there is little dust during cutting, so processing and constructability are convenient and excellent.

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

That is, the method for manufacturing a non-combustible ceramic molded body for interior and exterior materials for lightweight construction 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.

In this case, the organic binder preparation process is a process of preparing dextrin or PVA based on the weight to be mixed; In the inorganic binder preparation process, a mixture of feldspar, silica, limestone, borax, soda ash, zinc oxide, lithium carbonate, and alumina in equal proportions is mixed in a glass melting kiln, melted at 1500℃, and then melted in a water tank at room temperature. It is a process of vitrification by dropping it on the surface and quenching it; The perlite powder preparation process is a process to obtain a powder made to have an average particle diameter of 5 mm or less by calcining pearlite at 1200°C and pulverizing it.

When the raw material is prepared in this way, a step of mixing and stirring the prepared raw material into a drum-type mixer at a speed of 100-150 rpm for 30 minutes is performed.

At this time, the mixture of the prepared raw materials is composed 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.

Then, when mixing is completed, a step of putting the mixed composition into a mold and press-molding at high pressure is performed.

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

This is to release the high-pressure molding stress after molding and to keep the voids uniform.

Thereafter, the dried dried body is put in a kiln for heat treatment and heat treatment is performed at 700-900° C. for 2-3 hours.

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

In addition, in the present invention, with respect to 100 parts by weight of polystyrene resin, 10 parts by weight of desulfurized gypsum, 5 parts by weight of metal polysiloxane, 15 parts by weight of magnesium sulfate to increase the self-extinguishing property of the heat-treated molded article, which is the final product, to contribute to suppressing the spread in case of fire. , 5 parts by weight of dihydroxybutanedioic acid, and 10 parts by weight of strontium carbonate may be spray-coated on the surface of the molded body constituting the core material.

At this time, the desulfurized gypsum is added to increase the quick-setting properties and, in particular, suppress cracks through shrinkage prevention, absorb and decompose smoke, and increase self-extinguishing properties.

In addition, metal polysiloxane is added to increase antifoaming properties and water repellency to suppress the spread of smoke and flames.

Magnesium sulfate is also added to accelerate curing and enhance self-extinguishing properties against flames.

In addition, dihydroxybutanedioic acid is added to enhance anchoring properties by preventing void reduction due to adsorption between particles during mixing, and to increase incombustibility according to heat resistance enhancement.

In addition, strontium carbonate is added to increase smoothness and to enhance flame retardancy according to heat shielding and heat resistance.

In particular, in the present invention, when 10 parts by weight of a photoluminescent light emitting material having a nano particle size is further mixed with respect to 100 parts by weight of the polystyrene resin, when the iron plates on both sides fall off during a fire, the display function appears in the dark due to the photoluminescence phenomenon to evacuate. Evacuation efficiency can be improved and human casualties can be reduced by allowing the person to visually confirm this.

Such a photoluminescent emitter is a powder pulverized to a nano particle size in a state in which the content of strontium aluminate (SrAl ₂ O ₄ ) is increased by heating a strontium mineral (eg, celestite or strontianite) and removing impurities.

The physical properties of the core material for sandwich panels (inventive material) manufactured according to the present invention were confirmed and compared with the glass fiber core material, which is a conventional material, as shown in Table 1.

Item conventional material invention thermal conductivity 0.09-0.10 kcal/mhr·c 0.04-0.07 kcal/mhr·c Non-combustible non-combustible non-combustible refractory temperature 600℃ 900℃ durability When used for a long time, it absorbs moisture in the air and causes freezing, deterioration of insulation, and sagging due to fibrous properties. There is no moisture absorption even when used for a long time, and there is no deformation at all due to strong resistance to external impact. Workability The scattering of glass residues during work, harmful when in contact with the human body No problem machinability Inducing fibrous winding phenomenon during cutting Forming a uniform cutting surface with a general saw

As shown 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 fire resistance, non-combustibility, durability, workability, and workability, and is very advantageous compared to conventional materials and has low cost. And it was confirmed that weight reduction can also be achieved.

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

The coating material of this anti-corrosion coating layer is methacrylamide 10% by weight, hydroxybenzotriazole 20% by weight, hafnium 25% by weight, molybdenum emulsification (MoS ² ) 15% by weight, titanium oxide (TiO ² ) 15% by weight, It is composed of ethylenediamine 15% by weight, and the coating thickness can be formed to 9㎛.

Methacrylamide, hydroxybenzotriazole, and ethylenediamine serve to prevent corrosion and discoloration.

Hafnium is a transition metal element with corrosion resistance, and plays a role to have excellent waterproofness and corrosion resistance.

Molybdenum emulsified serves to impart lubricity and lubricity to the surface of the coating film.

Titanium oxide is added for the purpose of fire resistance and chemical stability.

The reason why the ratio of the constituents and the coating thickness are numerically limited as described above is that the present inventors repeatedly failed several times and analyzed through test results. As a result, the optimal anti-corrosion effect was exhibited at the ratio.

In addition, an antifouling coating layer made of an antifouling coating composition may be applied to the mold and drum mixer to effectively achieve adhesion prevention and removal of contaminants.

The antifouling 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. % by weight.

The molar ratio of citrate and diethylene glycol monobutyl ether is preferably 1:0.01 to 1:2. When the molar ratio is out of the above range, the applicability of the mold and drum mixer is lowered or moisture adsorption on the surface after application is increased. Therefore, there is a problem that the coating film is removed.

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

On the other hand, as a method of applying the present antifouling coating composition to a mold and a drum-type mixer, it is preferable to apply by a spray method. In addition, the final coating film thickness of the mold and drum 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 in that it is deteriorated in the case of high-temperature heat treatment, and if it exceeds 2500 Å, there is a disadvantage that crystal precipitation on the coated surface is easy to occur.

In addition, the present antifouling coating composition may be prepared by adding 0.1 mol of citrate and 0.05 mol of diethylene glycol monobutyl ether to 1000 ml of distilled water and then stirring.

The reason why the ratio of the constituents and the thickness of the coating film were numerically limited as described above was that the present inventors repeated several failures and analyzed the test results.

Claims (7)

A non-combustible ceramic molded body for interior and exterior materials for lightweight construction used as a core material of a sandwich panel; The core material is composed 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 perlite powder. A non-combustible ceramic molded body for interior and exterior materials for lightweight construction, characterized in that the composition is put into a mold and molded under high pressure. According to claim 1, The organic binder is dextrin or PVA (polyvinyl alcohol) alone, or a mixture of dextrin and PVA in a weight ratio of 1:1, the non-combustible ceramic molded body for interior and exterior materials for lightweight construction. According to claim 1, The inorganic binder is feldspar, silica, limestone, borax, soda ash, zinc oxide (亞鉛華), lithium carbonate, characterized in that any one selected from, or a mixture of two or more mixed in the same ratio is vitrified A non-combustible ceramic molded body for interior and exterior materials of lightweight construction. Raw material preparation step; After the prepared raw material 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 perlite powder, this composition is put in a drum mixer at a speed of 100-150rpm for 30 minutes Mixing and stirring with a furnace; When stirring is completed, putting the stirred composition into a mold and press-molding at high pressure; When the molding is completed, drying in a dryer maintained at 100-180 ° C; Drying the dried body in a kiln for heat treatment and heat-treating at 700-900° C. for 2-3 hours. According to claim 4, The raw material preparation step comprises an organic binder preparation process, inorganic binder preparation process, perlite powder preparation process; The organic binder preparation process is a process prepared according to the weight to be mixed by basis weight of dextrin or PVA, ; In the inorganic binder preparation process, a mixture of feldspar, silica, limestone, borax, soda ash, zinc oxide, lithium carbonate, and alumina in equal proportions is mixed in a melting furnace for glass, melted at a temperature of 1500° C. A method of manufacturing a non-combustible ceramic molded body for interior and exterior materials for lightweight construction, characterized in that it is a process of vitrification by dropping it into a water tank and cooling it rapidly. The method of claim 5 , wherein the perlite powder preparation process is a process of obtaining a powder made to have an average particle diameter of 5 mm or less by calcining pearlite at 1200° C. and pulverizing it. The method of claim 4, wherein the heat treatment kiln uses a roller hearth kiln (RHK), which is a continuous kiln.