KR20230053772A - Inorganic core composition of sandwich panel with excellent non-flammability and light weight and its manufacturing method - Google Patents

Abstract

Disclosed contents relate to an inorganic core composition of a sandwich panel with excellent non-flammability and lightweightness and a manufacturing method, wherein the composition replaces part of Portland cement with calcium carbonate and fluidized bed boiler fly ash to have physical properties including non-flammability, lightweightness, insulation, and sound absorption as well as being eco-friendly. The manufacturing method of the inorganic core composition of a sandwich panel with excellent non-flammability and lightweightness comprises: a step (a) of mixing raw materials to make the same slurry; a step (b) of inserting the slurry into a mold and foaming and condensing the same; a step (c) of primarily curing the foamed and condensed slurry; a step (d) of detaching a semi-cured body having the primary curing completed from the mold, cutting the same, and secondary curing the same; and a step (e) of decreasing a temperature of a cured body having the secondary curing completed, and drying the same.

Description

INORGANIC CORE COMPOSITION OF SANDWICH PANEL WITH EXCELLENT NON-FLAMMABILITY AND LIGHT WEIGHT AND ITS MANUFACTURING METHOD}

Disclosed herein is a composition of an inorganic core material for a sandwich panel having excellent incombustibility and light weight and a manufacturing method thereof.

Unless otherwise indicated herein, material described in this section is not prior art to the claims in this application, and inclusion in this section is not an admission that it is prior art.

Sandwich panels are widely used as a major material for prefabricated buildings, and are manufactured by bonding or foaming a core material between steel plates. At this time, polyurethane foam and Styrofoam are mainly used as core materials, but organic core materials are sometimes used in consideration of aspects such as workability, insulation, and economic feasibility. However, in the case of using an organic core material, there is a problem in that a large amount of toxic gas is generated during combustion or fire, resulting in loss of life. In addition, since it is difficult to extinguish the fire in the early stages due to its high flammability, it is highly likely to develop into a large fire, and its use is restricted by policy.

Therefore, in order to solve the weakness of the core material for existing sandwich panels, manufacturers of the product are concentrating on research and development of ultra-lightweight inorganic core materials with excellent incombustibility.

Republic of Korea Patent No. 10-0577495 (2006.04.28) Republic of Korea Patent Publication No. 10-2017-0160949 (2017.11.28)

It is an object of the present invention to provide an inorganic core composition for sandwich panels having excellent incombustibility as well as heat insulation, light weight and sound absorption, and a manufacturing method thereof.

In addition, it is not limited to the technical problems as described above, and it is obvious that other technical problems may be derived from the following description.

According to one embodiment of the disclosed subject matter, the inorganic core composition for a sandwich panel having excellent incombustibility and light weight contains 100 parts by weight of a binder composed of 40 to 90% by weight of fluidized bed boiler fly ash and 10 to 60% by weight of Portland cement, and 55 to 55 to 50% of mixing water. 85 parts by weight, 0.05 to 8 parts by weight of silica fume as an outer halo, 0.05 to 2 parts by weight of a fluidizing agent as an outer halo, 0.05 to 1 part by weight of a fiber, and 0.05 to 0.9 parts by weight of a foaming agent as an outer halo.

According to another embodiment of the disclosed subject matter, the inorganic core composition for sandwich panels having excellent incombustibility and light weight is a binder composed of 0.1 to 40% by weight of calcium carbonate, 40 to 80% by weight of fluidized bed boiler fly ash, and 5 to 50% by weight of Portland cement. 100 parts by weight, 55 to 85 parts by weight of mixing water, 0.05 to 8 parts by weight of silica fume as an outer halo, 0.05 to 2 parts by weight of a fluidizing agent as an outer halo, 0.05 to 1 part by weight of a fiber, and 0.05 to 0.9 parts by weight of a foaming agent as an outer halo.

According to another embodiment of the disclosed subject matter, a method for manufacturing an inorganic core material for a sandwich panel having excellent incombustibility and light weight includes (a) mixing raw materials to form a slurry, (b) charging the slurry into a mold, followed by foaming and condensation (c) primary curing of the foamed and condensed slurry, (d) secondary curing after demolding and cutting the semi-cured body after the primary curing has been completed, and (e) secondary curing and drying the cured product after curing is completed.

According to one embodiment disclosed in the present specification, the inorganic core composition for a sandwich panel having excellent incombustibility and light weight and a method for manufacturing the same are not only environmentally friendly but also nonflammable and lightweight by replacing a part of Portland cement with calcium carbonate and fluidized bed boiler fly ash. It has very excellent effects on physical properties such as heat resistance, heat insulation and sound absorption.

In addition, there is an effect of creating high added value.

1 is a process chart for explaining a method for manufacturing an inorganic core material for a sandwich panel having excellent incombustibility and light weight according to another embodiment of the disclosure disclosed herein.
2 to 6 are photographs showing the inorganic core material according to Example 1 or Example 2.

Hereinafter, with reference to the accompanying drawings, look at the configuration and operation effects of preferred embodiments of the disclosure. For reference, in the drawings below, each component is omitted or schematically illustrated for convenience and clarity, and the size of each component does not reflect the actual size. In addition, like reference numerals refer to like components throughout the specification, and reference numerals for like components in individual drawings will be omitted.

The inorganic core composition for sandwich panels having excellent incombustibility and light weight disclosed herein replaces a portion of Portland cement with calcium carbonate and fluidized bed boiler fly ash, unlike the conventional method in which only Portland cement is used as a binder. Therefore, it is not only environmentally friendly, but also has very excellent physical properties such as incombustibility, light weight, heat insulation and sound absorption.

The inorganic core material composition for a sandwich panel having excellent incombustibility and light weight according to the present embodiment may include a binder, mixing water, silica fume as an outer shell, a fluidizing agent as an outer shell, fibers, and a foaming agent as an outer shell.

The binder may consist of 40 to 90% by weight of fluidized bed boiler fly ash and 10 to 60% by weight of Portland cement, or 0.1 to 40% by weight of calcium carbonate, 40 to 80% by weight of fluidized bed boiler fly ash and 5 to 50% by weight of Portland cement. there is.

Fluidized bed boiler fly ash is a by-product generated in the boiler and can be added as an admixture for Portland cement, and the specific surface area measured by the brain fineness tester may be 5,000 to 7,000 cm ² /g. For example, the fly ash of a fluidized bed boiler is composed of CaO and CaSO ₄ , unlike the fly ash generated in a thermal power plant containing a large amount of SiO ₂ , specifically CaSO ₄ 44.2%, CaO 36.5%, SiO2 7.6% and CaCO ₃ may consist of 11.6%.

The fluidized bed boiler fly ash may be included in 40 to 90% by weight based on the total weight of the binder, and when calcium carbonate is included, it may be included in 40 to 80% by weight. If the fluidized bed boiler fly ash is less than 40% by weight, the effect of increasing the compressive strength may be insignificant, and if it exceeds 90% by weight, there is a risk of rapid heating and cracking or volume expansion increase.

Portland cement is a typical hydraulic cement. In this embodiment, Portland type 1 cement can be used, and its main components include silica, aluminum, iron oxide, and lime.

Such Portland cement may be included in 10 to 60% by weight based on the total weight% of the binder, and when calcium carbonate is included, it may be included in 5 to 50% by weight. If the Portland cement is less than 5% by weight, strength or durability may be reduced, and if it exceeds 60% by weight, strength or durability is improved but drying shrinkage may occur, which is not preferable.

Calcium carbonate (CaCO ₃ ) is a well-known type of natural calcium carbonate, ground calcium carbonate (GCC) obtained by simple crushing of limestone, calcite, marble, etc., and precipitated carbonic acid produced according to a well-known precipitation/production process At least one selected from calcium (Precipitated Calcium Carbonate, PCC) and mineral materials may be used.

In addition, in addition to the above-mentioned calcium carbonate, ground calcium carbonate and precipitated calcium carbonate, the direct reaction between carbon dioxide (CO ₂ ) and calcium oxide (CaO) or industrial by-products discharged from power plants, waste incineration facilities, and sewage slurry treatment facilities, specifically Carbon dioxide (CO ₂ ) captured through the mineral carbonation reaction can be further used. The industrial by-products may be steelmaking slag, waste concrete powder, or domestic waste incineration ash containing a large amount of calcium oxide (CaO), and may be used by adding acids and ammonium salts as solvents for the purpose of pH control, but are not limited thereto.

Mixing water (w / b) usually uses water, and this mixing water may be included in 55 to 85 parts by weight based on 100 parts by weight of the binder, which is preferable because it may adversely affect workability when it is out of the above-mentioned range. can't

Silica fume is a micro-silica particle obtained by collecting and filtering amorphous SiO ₂ contained in waste gas generated when manufacturing silicon (Si), ferrosilicon (FeSi), silicon alloy, etc. with a dust collector, and has high strength and durability. It is known as an essential component for manufacturing products that require this product, and serves as a high-strength mixture for fillers, grout materials, and fast-setting cement systems. On the other hand, the concrete structure is densified according to the micro filler effect in which calcium silicate (CSH) hydrate (gel) is generated by causing a pozzolanic reaction between silica fume and Ca(OH) ₂ as an external halogen, increasing long-term strength and improving durability. Although it is quite effective in increasing the resistance to concrete material separation, it is expensive, so it is preferable to limit it to the content mentioned below in consideration of economic feasibility.

Silica fume may be included in an amount of 0.05 to 8 parts by weight based on 100 parts by weight of the binder. If the amount of silica fume is less than 0.05 parts by weight, it may be difficult to develop high compressive strength, and if it exceeds 8 parts by weight, curing is fast. It may occur and the physical properties and durability may deteriorate.

The outer halo fluidizing agent is a material added for the distribution of materials in the slurry and the ease of mixing, and polycarboxylate may be used.

The outer half fluidizing agent may be included in an amount of 0.05 to 2 parts by weight based on 100 parts by weight of the binder. If the outer half fluidizing agent is less than 0.05 parts by weight, a problem of lack of fluidity due to the polymer component of calcium carbonate may occur, as well as agitation workability. The securing of and strength compensation function may be insignificant, and if it exceeds 2 parts by weight, the effect of using more than necessary may not be so great. Therefore, it is preferable to satisfy the above-mentioned range so as to prevent the problem of lack of fluidity due to the polymer component of calcium carbonate, to secure stirring workability and to double the function of strength compensation.

The fiber is a material added to improve durability, and one or more selected from glass fiber, carbon fiber, aramid fiber, and polyester fiber may be used.

These fibers may be included in 0.05 to 1 part by weight based on 100 parts by weight of the binder. If the fiber is less than 0.05 part by weight, the durability improvement effect may be insignificant, and if it exceeds 1 part by weight, formability may be poor.

The outer halo foaming agent is a material added to improve the lightness and heat insulation of the cured product, and aluminum powder, which is generally used in terms of foam stability and foaming performance, can be used.

Such an externally divided foaming agent may be included in 0.05 to 0.9 parts by weight based on 100 parts by weight of the binder. If the externally divided foaming agent is less than 0.05 parts by weight, the effect of reducing surface tension may be insignificant, and if it exceeds 0.9 parts by weight, use more than necessary. The effect of this may not be very large.

Hereinafter, a method for manufacturing an inorganic core material for a sandwich panel having excellent incombustibility and light weight disclosed in the present specification will be described in detail with reference to the drawings.

1 is a process chart for explaining a method for manufacturing an inorganic core material for a sandwich panel having excellent incombustibility and light weight disclosed herein. Hereinafter, a method for manufacturing a biodegradable sheet according to this embodiment will be described with reference to this.

Referring to FIG. 1, first, raw materials are mixed to form a slurry (S10).

As raw materials, 100 parts by weight of a binder composed of 40 to 90% by weight of fluidized bed boiler fly ash and 10 to 60% by weight of Portland cement, 55 to 85 parts by weight of mixing water, 0.05 to 8 parts by weight of silica fume as an outer halo, 0.05 to 2 parts by weight of a fluidizing agent as an outer halo By weight, 0.05 to 1 part by weight of fiber and 0.05 to 0.9 parts by weight of a foaming agent are mixed to form a slurry, or 0.1 to 40% by weight of calcium carbonate, 40 to 80% by weight of fluidized bed boiler fly ash, and 5 to 50% by weight of Portland cement. 100 parts by weight of binder, 55 to 85 parts by weight of mixing water, 0.05 to 8 parts by weight of silica fume, 0.05 to 2 parts by weight of fluidizer as outer half, 0.05 to 1 part by weight of fiber, and 0.05 to 0.9 parts by weight of foaming agent as outer half Mixed slurry get angry Since the reasons for limiting the specific components and component ratios of the raw materials have been described in detail above, they will be omitted.

Then, the slurry is loaded into a mold and then foamed and solidified (S20).

After loading the slurry prepared in step S10 into a mold, the volume is increased by a foaming reaction, and condensation is allowed to proceed by a hydration reaction for 1 to 3 hours, preferably 2 hours at room temperature of 20 to 25 ° C. .

If the temperature is out of the above-mentioned range, it is not preferable because temperature cracking may occur.

If the time is less than 1 hour, it is difficult to complete the hydration action of the binder and water, and if it exceeds 3 hours, work efficiency may be reduced due to an increase in time more than necessary.

After that, the foamed and condensed slurry is cured first (S30).

The slurry, which is foamed and condensed in step S20, may be cured first for 5 to 7 hours at a temperature of 60 to 70 ° C.

Then, after the semi-hardened body for which the primary curing is completed is demolded and cut from the mold, the secondary curing is performed (S40).

After demolding and cutting the semi-hardened body for which the primary curing is completed in step S30, the secondary curing may be performed at a temperature of 60 to 70 ° C. for 5 to 7 hours.

If the above-mentioned primary and secondary curing temperature and time are not satisfied, it is easily damaged by external impact, and it may be difficult to secure a specific gravity of 0.2 to 0.3 and a compressive strength of 40 MPa or more.

Finally, after the secondary curing is completed, the cured body is cooled and dried (S50).

In step S40, the cured body, after which the secondary curing has been completed, is cooled to room temperature of 20 to 25° C., and then dried using a dryer until the cured body is completely dried.

<Example 1>

Fluidized bed boiler fly ash 70kg, Portland type 1 cement 30kg, silica fume 0.6kg, fiber 0.07kg, plasticizer 0.24kg, aluminum powder 0.08kg mixed with 63kg water to form a slurry, put in a mold, and then foam 23 It was condensed for about 2 hours at room temperature of ℃. Then, after primary curing for 6 hours in a constant temperature curing room at about 65 ° C, the mold was removed, and as shown in FIGS. Secondary curing in a room for 6 hours, reducing the temperature and drying to prepare an inorganic core material.

<Example 2>

20kg of calcium carbonate, 55kg of fluidized bed boiler fly ash, 25kg of Portland type 1 cement, 0.4kg of silica fume as an outer halo, 0.06kg of fiber, 0.5kg of a fluidizer as an outer halo, and 0.08kg of aluminum powder were mixed with 63kg of water to form a slurry, and then put it into a mold. After foaming, it was condensed for about 2 hours at room temperature of 23°C. Then, after primary curing for 6 hours in a constant temperature curing room at about 65 ° C, the mold was removed, and as shown in FIGS. Secondary curing in a room for 6 hours, reducing the temperature and drying to prepare an inorganic core material.

The disclosed content is only an example, and can be variously modified and implemented by those skilled in the art without departing from the subject matter of the claim claimed in the claims, so the protection scope of the disclosed content is limited to the specific It is not limited to the examples.

Claims (9)

100 parts by weight of a binder consisting of 40 to 90% by weight of fluidized bed boiler fly ash and 10 to 60% by weight of Portland cement;
55 to 85 parts by weight of mixed water;
0.05 to 8 parts by weight of silica fume as an external halo;
0.05 to 2 parts by weight of a fluidizing agent in an outer halo;
0.05 to 1 part by weight of fiber; and
0.05 to 0.9 parts by weight of an external halo foaming agent; Inorganic core composition for sandwich panels with excellent incombustibility and light weight.
100 parts by weight of a binder composed of 0.1 to 40% by weight of calcium carbonate, 40 to 80% by weight of fluidized bed boiler fly ash, and 5 to 50% by weight of Portland cement;
55 to 85 parts by weight of mixed water;
0.05 to 8 parts by weight of silica fume as an external halo;
0.05 to 2 parts by weight of a fluidizing agent in an outer halo;
0.05 to 1 part by weight of fiber; and
0.05 to 0.9 parts by weight of an external halo foaming agent; Inorganic core composition for sandwich panels with excellent incombustibility and light weight.
According to claim 1 or 2,
The specific surface area of the fluidized bed boiler fly ash is 5,000 to 7,000 cm ² / g, an inorganic core composition for sandwich panels with excellent incombustibility and light weight.
According to claim 1 or 2,
The outer halo fluidizing agent is a polycarboxylic acid-based inorganic core composition for sandwich panels with excellent incombustibility and light weight.
(a) mixing raw materials to form a slurry;
(b) foaming and coagulating the slurry after loading it into a mold;
(c) first curing the foamed and condensed slurry;
(d) performing secondary curing after demolding and cutting the semi-cured body after the primary curing is completed from the mold; and
Method for manufacturing an inorganic core material for a sandwich panel having excellent incombustibility and light weight, including the step of (e) sensing the temperature of the cured body after the secondary curing and then drying it.
According to claim 5,
In the step (a), the raw materials are 100 parts by weight of a binder composed of 40 to 90% by weight of fluidized bed boiler fly ash and 10 to 60% by weight of Portland cement, 55 to 85 parts by weight of mixing water, 0.05 to 8 parts by weight of silica fume as an outer halo, A method of manufacturing an inorganic core material for sandwich panels with excellent incombustibility and light weight, comprising 0.05 to 2 parts by weight of a furnace fluidizer, 0.05 to 1 part by weight of fiber, and 0.05 to 0.9 parts by weight of an outer halo foaming agent.
According to claim 5,
In the step (a), the raw material is 100 parts by weight of a binder composed of 0.1 to 40% by weight of calcium carbonate, 40 to 80% by weight of fluidized bed boiler fly ash, and 5 to 50% by weight of Portland cement, 55 to 85 parts by weight of mixed water, and 0.05 to 8 parts by weight of silica fume, 0.05 to 2 parts by weight of a fluidizing agent as an outer halo, 0.05 to 1 part by weight of fiber, and 0.05 to 0.9 parts by weight of a foaming agent as an outer halo.
According to claim 5,
In the step (b), the condensation is performed for 1 to 3 hours at room temperature of 20 to 25 ° C. Method for producing an inorganic core material for sandwich panels with excellent non-combustibility and light weight.
According to claim 5,
The first curing in step (c) and the second curing in step (d) are performed at a temperature of 60 to 70 ° C for 5 to 7 hours.

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