RU2197448C1 - Raw material mixture for manufacture of heat-insulating material and method of production of such mixture - Google Patents

Abstract

FIELD: manufacture of building materials; heat-insulating materials for industrial and civil buildings; heat power engineering. SUBSTANCE: proposed method includes preparation of complex additive on base of quicklime, stirring mixture components and forming this mixture; complex additive is prepared by mixing 90 parts by weight of quicklime, 10 parts by weight component selected from versene group, carbamide, chrome potassium alum and 300 parts by weight of water; after slaking of lime, mixture is cooled to temperature of 18 ?5 C; then, mixture is stirred to homogeneity, after which all components of mixture, mass- %: cement, 10.0 to 12.0; complex additive, 5.0 to 7.0; magnesium oxide, 10.0 to 12.0; salt of valence metal, 4.0 to 6.0; carbide formaldehyde resin, 6.0 to 8.0; filler, 10.0 to 12.0; water glass, 12.0 to 12.5; foam-generating agent, 0.6 to 0.8 and water being the remainder are mixed are rate of 150 to 200 r/min during 1 to 2 minutes; then, rate of mixing is increased to 720 to 1200 r/min and mixing is continued for 1 to 2 minutes; foam thus formed is poured in mold for hardening. Proposed method improves heat-insulating properties due to reduction of toxic and combustible components and enhances fire resistance and water tightness. EFFECT: enhanced efficiency; reduced power requirements. 3 cl, 1 tbl, 4 ex

Description

 The invention relates to the production of building materials and can be used as thermal insulation material in the construction of industrial and civil buildings, as well as in heat engineering as thermal insulation of structures and assemblies.

 Currently known compositions of raw mixes for heat-insulating materials and methods for their preparation using organic polymer thermoplastic (polyurethane, polystyrene, polyvinyl chloride, etc.) materials as binders, which are filled with gas upon receipt, and a light heat and sound insulation foam is formed, these materials are flexible, durable, waterproof, but easily combustible, and emit toxic gases when burned. Foams based on thermosetting polymer binders (phenoplasts, aminos, epox sidoplasts, etc.). These materials are lightweight, durable, but tougher than thermoplastics, and difficult to burn, produce and use toxic substances.

 Known heat-insulating materials, gas-filled based on inorganic binders (cement, water glass, etc.). These materials are difficult to burn and do not emit toxic substances during operation, but they are heavier than foams based on organic polymer binders, and they are obtained at high temperatures and with significant energy consumption (Chemical Encyclopedia. Scientific Publishing House. Moscow: 1992 , p. 455-460).

 Currently, a special class is made up of integral thermal insulation foams. There are one-component integrated foams containing polymers of the same type, and multicomponent, consisting of 2 or 3 different polymers (binders). The structure of integral foams combines the structural features and properties of foamed and non-foamed polymeric materials, and filled. From ordinary isotropic foams, they are distinguished by the uneven distribution of density over the cross section. Integrated foams have better physical and mechanical properties than isotropic ones (Chemical Encyclopedia. Scientific Publishing House, 1992, vol. 3, p. 455). This type of heat-insulating materials includes arbolite, etc.

Known raw mix for the manufacture of heat-insulating material, different from integral foams, including in terms of dry residue: liquid glass 16-18 wt.%, Ethyl silicate 0.04-0.16 wt.%, Expanded vermiculite 150-65 wt.% And water. The preparation of a heat-insulating material based on this composition is carried out by mixing water glass, expanded vermiculite ethyl silicate and water, followed by mixing them to a homogeneous mass and vibropressing under a pressure of 300-100 g / cm ² for 3-3.5 hours (SU 15271215, С 04 B 28/26, 12/07/1989).

A disadvantage of the known composition is the high moisture absorption (4.5 -5.1%) due to the content of metal oxides (CaO, MgO, NaO) in the expanded vermiculite, which are capable of absorbing moisture by nature. In addition, there is some complication of the manufacturing technology of the material with the use of expensive equipment (vibrating press) and prolonged heating of 3.0-3.5 hours with high temperature, which leads to increased energy consumption
Known raw mix to obtain a thermal insulation material (arbolite), containing, by weight. %: cement 24-25, cement dust 24-25, gypsum 2.9-3.5, blowing agent 0.25-0.4, urea resin 5-6, polyacetal glycol 0.05-0.06, sawdust 10- 12, water - the rest (SU 1502522, С 04 B 28/24, from 1989).

A method of obtaining a heat-insulating material from it includes mixing a cement binder, urea resin, gypsum, organic aggregate, foaming agent, water and curing it in a mold. First, a complex supplement is prepared. Obtaining a complex additive is that the organic filler (sawdust) is impregnated with an organic binder, so that the filler becomes waterproof and not combustible. And to prevent sticking of wood sawdust into an ingot, they need to be mixed for a long time when heated.In this case, the urea resin is mixed with polyacetal glycol, 2 parts of water are added for 1 hour, mixed with sawdust in a ratio of 1: 1 by weight. It is dried at a temperature of 60-65 ^{° C.} for 3.5-4 hours. A complex additive is obtained in the form of fine granules. Then it is mixed with cement, cement dust, gypsum, a foaming agent and water until a homogeneous mixture is obtained, which is then solidified in the form (SU 1502522, С 044 В 28/24, from 1989).

 A disadvantage of the known mixture is the use of components that do not have standardization (cement dust, sawdust) and prolonged heating of the complex additive, which leads to increased energy consumption.

 The closest in technical essence to this invention is the known raw material mixture for the manufacture of heat-insulating material and the method for its preparation. The raw mixture contains, wt.%: Surfactant 2.0-3.0, liquid glass 16.0-18.0, urea-formaldehyde resin 4.0-6.0, zinc oxide 6.0-7.0, boric acid 17.0-19.0, aluminum sulfate 5.0-6.0, aluminum powder 0.5-1.0, water - the rest. The mixture is mixed, foamed, molded, and then the material is processed in the field of currents of ultrahigh frequency of 15-20 MHz for 20-30 minutes A material is obtained with high physico-mechanical, heat-insulating properties (SU 2148045, С 04 4 В 28/26, 40/00, dated April 27, 2000).

 A disadvantage of the known mixture for the manufacture of heat-insulating material and the method for its preparation is the use of acids that are dangerous when used, stored and transported, and boric acid is scarce, the modifier zinc oxide is expensive and deficient, and the use of drying the material in the field of an ultrahigh current frequency leads to high energy costs.

 The problem to which the invention is directed, is to increase the thermal insulation properties, reduce the toxic and combustible components that make up the raw material mixture, reduce energy consumption when receiving the raw material mixture and thermal insulation material, increase the water resistance of the thermal insulation material.

This goal is achieved in that the raw mixture for the manufacture of heat-insulating material, including water glass, urea-formaldehyde resin, contains a complex additive based on quicklime, foaming agent and water, characterized in that it additionally contains cement, magnesium oxide, divalent, trivalent salt a metal selected from the group: gypsum, calcium chloride, calcium carbonate, magnesium chloride, aluminum sulfate, and a filler selected from the group: talc, kaolin, mica, and as a complex additive, use quicklime mixture with a component selected from the group: Trilon B, urea, chromium potassium alum, aluminum-ammonium alum, in a 9: 1 ratio with the addition of water in an amount three times the amount of the initial dry components of the complex additive, in the following ratio of mixture components, wt.%:
Liquid glass - 12.0-12.5
Urea-formaldehyde resin - 6.0-8.0
Complex additive - 5.0-7.0
Foaming agent - 0.6-0.8
Cement - 10.0 -12.0
Magnesium Oxide - 10.0-12.0
The specified salt of divalent, trivalent metal is 4.0-6.0
Specified Filler - 10.0-12.0
Water - Else
The claimed ratio of components in the raw material mixture is necessary and sufficient to achieve the goal. In this thermal insulation material two binders are used - inorganic - cement (mainly Portland cement), liquid glass (sodium) and organic - urea-formaldehyde resin. A method of obtaining a heat-insulating material from a raw mixture, including the manufacture of a complex additive, mixing the components of the mixture and molding the mixture according to the invention, characterized in that the complex additive is prepared by mixing 90 weight. chyu quicklime, 10 weight. including a component selected from the group: Trilon B, urea, chromium potassium alum, aluminum ammonium alum and 300 weight. h water. After extinguishing the lime, the mixture is cooled to a temperature of 18 ± 5 ^o C and then stirred until smooth. Further, all the components included in the raw mix are mixed at a speed of 150-200 rpm for 1-2 minutes, followed by an increase in the mixing speed to 720-1200 rpm, at which stirring is continued for another 1-2 minutes, then the resulting foam is poured into the mold for curing. The following materials manufactured by the domestic industry are used for the manufacture of the raw material mixture and for the production of thermal insulation material:
Cement GOST 1581-85, GOST 10178-76
Gypsum GOST 125-79
Calcium chloride GOST 450-77
Magnesium Chloride GOST 7759-73
Calcium carbonate (chalk) GOST 120085-88
Foaming agent PO-1 GOST 6948-81
Urea-formaldehyde resin GOST 14231-78
Magnesium oxide GOST 4224-75
Mica GOST 855-65
Talc GOST 19729-76
Kaolin GOST 19608-84
Trilon B GOST 10652-73
Urea GOST 2081-92, GOST 6691-77
Alum chromium-potassium GOST 4162-79
Alum aluminum-ammonium GOST 4238-77
Liquid sodium glass GOST 13078-81
Quicklime GOST 9179-77.

 Each component of the invention performs a specific function: cement - Portland cement, mixtures of salts of divalent and trivalent metals with magnesium oxide - magnesia binders - (see the Building Industry and Building Materials Industry. Encyclopedia. M: Stroyizdat, 1996, p. 278), and liquid sodium glass - inorganic binders.

 Urea-formaldehyde resin - an organic binder - forms a durable heat-insulating cellular material. Lime makes it possible to obtain a stable foam using liquid glass, urea binds free formaldehyde in the resin, while at the same time it prevents the destruction of the resin by lime. Urea can be replaced by Trilon B or alum.

 Fillers: talc, kaolin or mica improve the structure of the heat-insulating material, increase fire resistance.

 Foaming agent PO-1 promotes the formation of dispersed foam in the mixture and the formation of gas cells in the material, which increases the thermal insulation properties in the material.

 When the content of the mixture of salt is less than 4.0 wt.%, Magnesium oxide less than 10.0 wt. %, foaming agent less than 0.6 wt.%, urea-formaldehyde resin less than 6.0 wt.% deteriorating in strength and thermal insulation properties, incomplete foaming is observed - the material is heavier.

 Without a complex additive, the raw mix instantly coagulates with the formation of delamination and separation of water from the components, as well as inhomogeneities.

 When mixing the feed mixture at a speed of less than 150 rpm, uniformity is achieved more slowly. If the mixing time in the first mixing step is less than 1 min, then the mixture is not homogeneous. Stirring for more than 2 minutes is not economical; productivity decreases. With a stirring speed of less than 720 rpm in the second step, foaming is reduced. A mixing time of less than 1 min reduces foaming in the volume of the raw material mixture, with a mixing time of more than 2 minutes, coagulation begins, fluidity is lost, and a thick rubbery mass is formed.

 Water is introduced into the feed mixture to improve mixing and fluidity of the components.

 To obtain comparative data and substantiate the essence of the invention, the raw mixes of the present invention were prepared, a complex additive was introduced into the raw mix and the mixture was mixed at a speed of 150-200 rpm for 1-2 minutes to obtain a homogeneous dispersed mixture, and then stirred at a speed of 720-1200 rpm for 1-2 minutes and poured the resulting foam into the mold for curing.

 The table shows the results of experimental studies of samples of thermal insulation material made from the compositions of the inventive raw mix and the production method in comparison with the known prototype RU 2148045 C 04 V 28 / 26,40 / 00.

In the experiments and the formula, the amount of resin and liquid glass was calculated in terms of dry matter:
Composition 1, wt.%:
Cement - 10.0
Complex additive (quicklime + trilon B) - 5.0
Magnesium Oxide - 10.0
Magnesium chloride (salt) - 4.0
Urea formaldehyde resin - 6.0
Filler (talc) - 10.0
Sodium Liquid Glass - 12.0
Foaming agent, e.g. PO-1 - 0.6
Water - Else
Composition 2, wt.%:
Cement - 12.0
Complex additive (quicklime + aluminum ammonium alum) - 7.0
Magnesium Oxide - 12.0
Salt (magnesium sulfate) - 8.0
Urea-formaldehyde resin - 8.0
Filler (mica) - 6.0
Liquid glass - 12.5
Foaming agent, e.g. PO-1 - 0.8
Water - Else
Preparation of a complex additive to 90 g of quicklime was added 300 g of water and 10 g of urea, Trilon B or alum. Quenching occurred for 20-30 minutes with slow stirring. After cooling to 18 ± 5 ^° C, the mixture was stirred until uniform. The complex additive is obtained in the form of a condensed solution. The resulting additive was used in all formulations (see table).

 Example 1. All components of cement - 10.0 wt.%, A complex additive (lime with Trilon B) - 5.0 wt.%, Magnesium oxide - 10.0 wt.%, Magnesium chloride -4.0 wt.%, urea-formaldehyde resin - 6.0 wt.%, talc - 10.0 wt.%, sodium liquid glass - 12.0 wt.%, foaming agent PO-1 - 0.6 wt.% and water up to 100 wt.% was loaded into electric mixer (mixer). The raw material mixture was mixed at a speed of 150 rpm for 1 min until a homogeneous mixture was obtained, then the speed was increased to 720 rpm and stirred for 1 min.

The resulting foamy raw material mixture was poured into a plastic mold and cured for 24 hours at a temperature of 18 ± 5 ^o C. The sample was unloaded from the mold and for 2 days, kept at a temperature until stabilization. 3 days after manufacture, the sample was subjected to tests for physical and mechanical properties.

 Under conditions similar to example 1, a heat-insulating material was prepared in other examples with varying components, the mixing speed of the raw material mixture.

 So, in examples 2,3,4, a complex additive was used (a mixture of lime with chromium potassium alum, aluminum ammonium alum, carbamide, respectively) salts of divalent and trivalent metals, respectively magnesium carbonate, calcium chloride, gypsum, were added, an inorganic light filler of mica, kaolin was introduced , talc, and all other components were introduced into the raw mix by wt.% indicated in the table of comparative studies.

 As can be seen from the above examples, in the table of the results of experimental studies of samples of heat-insulating material made from the proposed compositions, and the method for their preparation in comparison with the known composition of the prototype (example 5) and its production method, the material made from the inventive raw material mixture, and the method of obtaining a heat-insulating material has better performance compared to the known material, namely, moisture absorption, heat conductivity coefficient, average density, ul chshilas fire raw materials and heat insulating material.

 The proposed raw material mixture for obtaining a heat-insulating material containing a complex additive that allows you to combine different - inorganic and organic - binders and get heat-insulating materials with a uniform structure using inexpensive natural fire-resistant fillers.

A method of obtaining a heat-insulating material from the proposed raw material mixture makes it possible to obtain a light strong (without shrinkage), fire-resistant heat-insulating material, hardening at room temperature 18 ± 5 ^o C, at atmospheric pressure. Thermal insulation material can be obtained directly at enterprises, construction sites, during the thermal insulation of aggregates, structures, pipes, by mixing the raw material mixture with the use of mixers, pouring the foamed raw material mixture into the capacity of the unit, applying the panels, pipes to the insulated surface. The applied foam mixture has good adhesion to various materials and cures at a temperature of 18 ± 5 ^o C. Even the foam does not lose its foamed shape and does not shrink
Thus, the use of the claimed invention allows to obtain a heat-insulating material with enhanced heat-insulating properties, using non-combustible, non-toxic, inexpensive components while reducing energy costs.

Claims (1)

1. The raw material mixture for the manufacture of heat-insulating material, including water glass, urea-formaldehyde resin, a complex additive based on quicklime, foaming agent and water, characterized in that it additionally contains cement, magnesium oxide, a salt of divalent or trivalent metal selected from the group: gypsum, calcium chloride, calcium carbonate, magnesium chloride, magnesium carbonate, aluminum sulfate, and a filler selected from the group: talc, kaolin, mica, and a mixture of quicklime with a component selected from the group: Trilon B, urea, chromium-hot alum, aluminum-ammonium alum in a ratio of 9: 1 with the addition of water in an amount three times the amount of the initial dry components of the complex additive, in the following ratio, wt. %:
Liquid glass - 12.0-12.5
Urea-formaldehyde resin - 6.0-8.0
Complex additive - 5.0-7.0
Foaming agent - 0.6-0.8
Cement - 10.0-12.0
Magnesium oxide - 10, -12.0
The specified salt of the divalent metal is 4.0-6.0
Specified Filler - 10.0-12.0
Water - Else
2. A method of obtaining a heat-insulating material, including the preparation of a complex additive based on quicklime, mixing the components of the mixture and molding it, characterized in that the complex additive is prepared by mixing 90 weight. including quicklime, 10 weight. including a component selected from the group: Trilon B, urea, chromium-hot alum, aluminum ammonium alum, and 300 weight. including water, after the lime is quenched, the mixture is cooled to a temperature of 18 ± 5 ^o C, then mixed until homogeneous, then all the components included in the raw material mixture according to claim 1, are mixed at a speed of 150-200 rpm for 1-2 minutes and then the mixing speed is increased to 720-1200 rpm and stirring is continued for another 1-2 minutes, the resulting foam is poured into the curing mold.

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