RU2526449C2 - Heat-noise-moisture insulating, heat-resistant material and method for production thereof - Google Patents

Abstract

FIELD: chemistry.

SUBSTANCE: invention relates to production of high-strength, light-weight heat-noise-moisture insulating, heat-resistant structural materials. A crude mixture for producing heat-noise-moisture insulating, heat-resistant material, which contains filler - expanded pearlite or expanded vermiculite, quartz sand, schungite or liquid glass, contains said pearlite or vermiculite with particle size of 0.5-2.5 mm, quartz sand, containing not more than 3% silt and clay, with particle size of 0.01-0.03 mm, liquid glass with density of 1.45 g/cm³ and additionally basalt or glass fibre with particle size of 3-7 mm, magnesite powder, magnesium chloride solution with density of 1.2-1.25 g/cm³ and sodium silicofluoride, wherein the magnesite powder and schungite are in form of a magnesite-schungite mixture in ratio 1:3, with the following ratio of components, wt %: said sand - 21.5-26.88, said fibre - 0.54-0.65, said mixture - 8.06-9.14, said liquid glass - 10.75-12.37, sodium silicofluoride - 0.5-1.5, said solution - 2.0-2.2, said filler - the balance. The method of producing a structural article from said crude mixture is characterised by mixing quartz sand with a portion of liquid glass to a homogeneous mass, adding the expanded pearlite or vermiculite and basalt fibre or glass fibre, mixing to uniform distribution, adding the magnesite-schungite mixture in ratio 1:3, said magnesium chloride solution and then adding the remaining liquid glass, sodium silicofluoride and mixing all components to homogeneity, pouring the prepared mixture into a mould, the bottom of which is uniformly coated with a layer of quartz sand with thickness of 2.0-2.5 mm, leaving 2-3 mm from the top edges of the mould, filling the mould to the top edges with a mixture of the magnesite-schungite mixture in ratio of 1:3 with magnesium chloride solution with density of 1.2-1.25 g/cm³ in ratio of 2.86:1 which is mixed for 4-5 minutes, holding for 55-60 minutes and removing the article from the mould after vibrating the mould for 1.5-2.0 minutes.

EFFECT: reduced water absorption.

2 cl, 1 ex, 1 tbl

Description

The invention relates to the production of strong, light, heat, noise, moisture insulating, heat-resistant building materials that can be used both in the construction industry and in many other industries and the national economy, where it is necessary to provide reliable and durable thermal insulation of rooms, structures, units, etc.

Currently, one of the most popular facing materials for construction and cladding is gypsum board, which is a layered material with a gypsum inside, coated on 2 sides with wrapping paper.

The well-known "Method of manufacturing lightweight drywall" (call for the invention of the Russian Federation No. 2005116240, etc. October 15, 2003, conventional priority 10/29/2002 JP 2002-314847, published in the Russian Federation on January 20, 2006, IPC C04B 38/10 ), which includes the stages of blowing air into the foaming agent to produce foamed liquid, mixing this liquid with a mixed mixture containing calcined gypsum and water to obtain foamed liquid gypsum dough, pouring it into the space between the upper and lower sheets of drywall paper, forming the wrapping paper and foamed liquid gypsum a dough in the form of cardboard, approximate cutting and then drying the cardboard-like material and cutting the dried and formed material to the size of the product, where the method further includes the step of pre-adding an agent to control the size of the pores distributed in the foamed gypsum dough, to one of the following materials : mother liquor of a foaming agent or a mixture of a mother liquor of a foaming agent and water. As an agent for reducing pore size in a foamed gypsum test, surfactants can be used, such as sulfosuccinate, type sarcosinate, alkylbenzenesulfonate, alkanesulfonate, alkyl betaine.

The disadvantages of this method are the length of the manufacturing process of wall panels. In addition, the material consisting of one gypsum has such disadvantages as low strength and high moisture absorption, resulting in rapid destruction. And the use of organic surfactants as a stabilizer of pricing reduces the fire resistance of the product and leads to the release of chemicals during fires.

The material can only be used indoors, where there is no moisture. It takes a lot of time and money to bring the walls to final completion.

A known material is the core of a gypsum-based panel including a filler selected from the group of bulk polymer and mineral hollow elements (aluminosilicate microspheres, expanded perlite, vermiculite, glass and polymer balls, asbestos, polystyrene foam), fiber and an organic binder from the group of water-soluble polymers (patent for utility model of the Russian Federation No. 77574, IPC B32B 13/00, publ. October 27, 2008).

The disadvantages of this material are the relatively low strength of the products and high water absorption, low thermal performance. These shortcomings worsen the technological and operational characteristics of the material. The use of a polymer binder makes the material fire hazardous and leads to the release of harmful chemicals.

Closest to the proposed solution is a heat-insulating foamed carbon-containing material (RF patent No. 2263647, IPC C04B 38/02, published November 10, 2005) having an inorganic cellular structure obtained by foaming a slip composition prepared by mixing a ground mixture with a blowing agent - finely dispersed crystalline silicon mixed with liquid glass, with the following mass ratios of components in the slip composition: liquid glass: silicon = (3-6): 1 and a charge: liquid glass = (1.0-1.5: 1). The mixture contains a mineral filler - 22.5-47.0 wt.h .; calcined shungite - 12.5-17.5 parts by weight and aluminum powder - 5.0-7.5 parts by weight The mineral filler used is quartz sand, quartzite, perlite, vermiculite, chamotte, dinas, cement, fly ash, slag. The material withstands high temperatures, but has great moisture absorption.

The disadvantages of this material are low strength characteristics, especially tensile and bending strength.

The material withstands high temperatures, but has great moisture absorption. When using it, a large investment of time and material is required to ensure the design, which significantly increases the cost of work.

The present invention completely eliminates these disadvantages, and the introduction of additional components into the mixture makes it possible to give products from the developed material unique operational characteristics and solve a number of technical problems.

The technical result is achieved by the fact that the raw material mixture for obtaining heat, moisture, moisture insulating heat-resistant material contains a mineral filler - expanded perlite or expanded vermiculite, quartz sand, shungite and liquid glass, in contrast to the prototype contains the specified perlite or vermiculite, with a size of 0.5-2 , 5 mm, quartz sand containing silt and clay no more than 3%, with a size of 0.01-0.03, liquid glass with a density of 1.45 g / cm ³ and optionally basalt fiber or glass fiber with a size of 3-7 mm, magnesite powder, chloride solution m rotting density 1,2-1,25 g / cm ³ and sodium fluorosilicate, wherein the magnesia powder and shungite - a magnesian shungite mixture in a ratio of 1: 3, with the following ratio of components, wt%: said sand - 21.5 26.88; the specified fiber is 0.54-0.65; the specified mixture is 8.06-9.14; the specified liquid glass is 10.75-12.37; sodium silicofluoride - 0.5-1.5; the specified solution is 2.0-2.2; the specified filler is the rest.

Also, the technical result is achieved by the fact that to implement a method of manufacturing a building product, characterized in that quartz sand is mixed with part of the liquid glass to a homogeneous mass, expanded perlite or vermiculite and basalt fiber or glass fiber are introduced, mixed until uniform distribution, after magnesia is introduced shungite mixture, in a ratio of 1: 3, magnesium chloride, add the remaining liquid glass, sodium silicofluoride and mix all the components until uniform, pour the preparation the mixture into a mold, the bottom of which is uniformly covered with a layer of quartz sand with a layer of 2.0-2.5 mm, so that 2-3 mm remains to its upper edges, then the mold is filled to the upper edges with a magnesia-mixed mixture for 4-5 minutes shungite mixture in a ratio of 1: 3 with a solution of magnesium chloride with a density of 1.2-1.25 g / cm ³ in a ratio of 2.86: 1, withstand 55-60 minutes and after vibration exposure to the form for 1.5-2, 0 min remove it.

The differences of the proposed material from the known (prototype) are: the introduction into the mixture of shungite dispersion (0.02-0.05 mm), without calcination and in the form of magnesia-shungite mixture (in a ratio of 1: 3); the introduction of basalt fiber or fiberglass, the dispersion of the mineral filler, quartz sand (0.01-0.03 mm).

With the low bulk density of the new material 0.2-0.25 t / m ^3, high compressive strength, good thermal insulation for construction needs, low water absorption, high fire resistance, environmental friendliness, good noise insulation, adhesion and the original front side design.

The proposed material has high strength characteristics, which gives undeniable advantages in comparison with known materials, in practical use, as building boards, panels, as well as for various lubricants, plasters.

According to preliminary studies of microbial contamination and mold resistance carried out by the Chemical and Pharmaceutical Academy of St. Petersburg, magnesia-shungite materials are resistant to most cultures of fungi and bacteria, which allows us to draw conclusions about the bactericidal nature of this building material and the possibility of its use even in critical health care facilities, pre-school and school premises.

An analysis of the known mixtures used in the manufacture of fireproof building materials shows that the use of components such as water glass, expanded perlite, vermiculite, silica sand, shungite is known. However, we applied various time regimes and a certain sequence of mixing the components, the dispersed composition of the component was changed, and the use of materials in combination with other additives allows us to obtain positive qualities in almost all basic parameters. For example, a combination of shungite with a magnesian binder gives an increase in the tensile and bending strength of not only the front part, but also the plate as a whole.

The new material has the best sound and heat insulating properties and has a low bulk density. To exclude the ability of perlite to absorb moisture, the dry mineral filler is crushed to sizes 50-70 times smaller than perlite particles, pre-mixed with liquid glass, which leads to enveloping the filler particles with a cementitious solution to close the moisture access to the absorbent material.

Thus, the application of these techniques in the implementation of the proposed raw mix and method allows to obtain a qualitatively new positive characteristics and properties of heat, noise, moisture insulating, heat-resistant material. This composition with new additions of components gives the mixture new properties that are not the sum of the properties of the starting components, but significantly exceed them, indicating additional processes occurring in the material being prepared.

The proposed raw material mixture to obtain a heat, moisture, moisture insulating heat-resistant material is prepared as follows.

Initially, quartz sand (fineness of 0.01-0.03 mm) with a sludge content of not> 3% and half liquid glass with a density of 1.45 g / cm ^{3 are} mixed until a homogeneous composition. Then, expanded perlite or vermiculite, with a grain size of 0.5–2.5 mm, is added, and inorganic fiber — basalt fiber or 3–7 mm fiber — is mixed with the resulting mixture in a mixer until the components are evenly distributed throughout the volume. Then, a magnesia-shungite mixture (in a 1: 3 ratio) with a solution of magnesium chloride (density 1.2-1.25 g / cm ³ ) in a ratio of 2.86: 1 is added to the mixed composition; the rest is liquid glass, sodium silicofluoride as a solvent and all components are mixed for 4-5 minutes.

Simultaneously, a mixture of magnesia-shungite mixture is prepared separately in a ratio of 1: 3 with a solution of magnesium chloride with a density of 1.2-1.25 g / cm ³ in a ratio of 2.86: 1.

Next, in the pre-prepared mold installed on the work table, the bottom of which is evenly covered with a layer (2.0-2.5 mm) of quartz sand, pour the initially prepared mixture so that 2-3 mm remain on the upper plane of the mold, onto this mixture immediately poured magnesia-schungite mixture with a solution of magnesium chloride to fill the form to the upper edge.

In this form, the form was aged 55-60 minutes, at a temperature of 28-35 ° C. After that, the mold was vibrated for 1.5-2.0 minutes with a frequency of 50-150 Hz and an amplitude of 0.2-0.6 mm, and then the mold was removed.

Thus, a building product is made in the form of a plate, block or wall panel based on heat, noise, moisture insulating, heat-resistant material. The front side of the product, which is formed from a magnesia-shungite mixture with a hardener (magnesium chloride), has an original design, has special hardness and strength, and is comparable to natural materials such as granite, marble, etc. The poured mixture has a self-leveling effect. Using various profiles for the front side of the product during solidification, it is possible to achieve perfectly smooth or with a pattern of various designs of the front surface of the building product. The remaining surfaces of the building product are rough to increase the adhesion of the blocks or panels to each other and better adhesion of the rear sides.

Description of the components of the mixture:

- quartz sand fineness (0.01-0.03 mm), crushed, with a sludge and clay content not> 3%, according to GOST 8736-93;

- schungite dispersion (0.02-0.05 mm) of the following composition: carbon 28.6%, SiO2 - 57.2%, the rest are oxides of Al, Mg, Ni, F, K. The ratio of the mineral and carbon phases is 3.6;

- sodium liquid glass, GOST 13079-81, with a density of 1.45 g / cm3 and a silicate module of 2.3-2.6, (according to GOST) as a binder;

- sodium silicofluoride (Na2SiF6) - a substitute for water glass, GOST 19433-88;

- magnesia binder - magnesite powders, GOST 1216-87;

- magnesium chloride, GOST 7759-73 as a substitute for a magnesian binder;

- expanded perlite, GOST 10832-91, filler;

- expanded vermiculite, GOST 12865-67, filler;

- basalt fiber GOST 21880-94 or fiberglass.

EXAMPLE 1. First, silica sand, crushed (0.01-0.03 mm), with silt and clay content not> 3%, -19 kg (19.0 wt%, relative to the total weight of the raw mix, see table) was mixed in a mixer with liquid glass 4.5 kg (4.5 wt.%) to a homogeneous composition, then expanded perlite or vermiculite was introduced - 57 kg (57 wt.%), basalt fiber or glass fiber - 0.4 kg (0.4 wt.%), mixing until uniform, after this was introduced magnesia-shungite mixture in a mass ratio of 1: 3, in the amount of 7.15 kg (7.15 wt%), a solution of magnesium chloride (density 1.2-1.25 / cm ³⁾ in an amount of 2.5 kg (2.5%), then the stirred mixture was added sequentially the remaining water glass, in an amount of 4 kg (4 wt%), stirred for 4-5 minutes, then added chloride solution magnesium, (with a density of 1.2-1.25 g / m3), in an amount of 2.5 kg (2.5%) and sodium silicofluoride (NaSiF ₆ ) in an amount of 0.4 kg (0.4 wt%), were mixed for 4-5 minutes. Then, the mixture was poured onto the bottom of the pre-prepared mold, covered with a uniform layer of 2.0-2.5 mm quartz sand, so that 2-3 mm remained to the upper plane of the mold.

Simultaneously with the preparation of the first mixture in another mixer, a composition of magnesia-schungite mixture (in a mass ratio of 1: 3) in the amount of 7.15 kg was prepared, with a solution of magnesium chloride in the amount of 2.5 kg. After uniform mixing for 4-5 minutes, this mixture was filled into the mold to the upper edges. The mixture in the mold was left for 25-30 minutes and then subjected to vibration for 1.5-2.0 minutes, after which the mold was removed.

The resulting products were kept under a canopy for a month, at a temperature of 20-28 ° C, then tested for strength according to GOST 10180, determined density according to GOST 17623, thermal conductivity according to GOST 7076, acoustic characteristics according to GOST 23499-79, water absorption according to GOST 5802-86 . The test results are shown in the table “Composition and properties of heat-moisture-noise-insulating heat-resistant material”, (mixture No. 1).

Mixtures 2-5 are prepared in a similar manner, with different components. Mixture No. 6 is a prototype.

The analysis of the test results of the properties of samples of heat, noise, moisture insulating heat-resistant building material, based on the data given in the table shows the following.

1. Introduction to the composition of the raw material mixture of expanded perlite (vermiculite), in the claimed amounts, with a grain size of 0.5-2.5 mm, allows to obtain lightweight building products with high heat and noise moisture insulating fire-resistant characteristics (mixture 2-4). A further increase in the amount of expanded filler in the mixture is impractical, since there is a decrease in the strength of the resulting heat, noise, moisture insulating building material.

2. The introduction of inorganic fiber, in the claimed quantities, leads to an increase in the strength of the building product, especially bending strength.

3. The introduction of liquid glass together with crushed quartz sand, in the claimed quantity and form, provides an optimal ratio of such characteristics of heat-noise-moisture-insulating heat-resistant material, such as “strength: density”, low bulk weight, and water absorption is especially sharply reduced.

4. The introduction of magnesia-shungite mixture (in a ratio of 1: 3), shuttered with magnesium chloride, in the claimed quantities, can significantly increase the strength and heat resistance of finished products, especially the front part, and provides an original design. Compounds 2-4 are accepted as optimal.

The inventive heat, noise, moisture insulating material, in comparison with the prototype, has the following advantages:

- the density of the material is reduced by 1.5-3.0 times;

- thermal conductivity 2.0-2.5 times;

- strength characteristics of the material increase on average by 3 times;

- soundproofing characteristics increase by 1.6-2.0 times;

- water absorption is reduced by 3.5 times.

The physicochemical nature of the technical solution to achieve the problem is as follows.

Expanded perlite (vermiculite), with a grain size of 0.5-2.5 mm, reduces the density of the material due to its bulk porous structure, which allows to increase such characteristics of the material as thermal conductivity, sound insulation and heat resistance.

Expanded perlite, which has a number of advantages (low density, heat resistance, heat-insulating qualities), has such a disadvantage as high hygroscopicity. To neutralize this disadvantage, crushed silica sand is mixed with liquid glass, which envelops perlite particles, protecting it, on the one hand, from contact with moisture, and on the other, increases the strength of the material as a whole.

The use of inorganic fibers with a size of 3-7 mm serves as a reinforcing additive, which gives the finished material additional strength (especially bending), which is important when using the material as a wall.

The introduction of shungite in the composition of the material provides anti-electrostatic intrinsic safety, which is important for the fire resistance of the material, and also protects the human body from the adverse effects of electromagnetic radiation of anthropogenic nature and static electricity. In addition, shungite rocks are characterized by high strength.

The magnesian binder was chosen based on the fact that the materials on it have high strength characteristics close to such natural materials as granite, marble. Magnesia binder - a combination of magnesium oxide powder with an aqueous solution of magnesium chloride. As a result of phase interactions in the MgO-MgCl2-H2O system, a structure is formed, with the formation of crystals of Mg hydroxychloride, having a fiber-tangled microstructure that acts as an additional reinforcing material. The choice of a magnesian binder for heat, moisture, moisture insulating, heat-resistant material is explained by the fact that it allows one to obtain higher tensile and bending strengths (up to 20 MPa), and is also characterized by a high adhesion to various substances. This explains the choice of magnesia-shungite mixture, sealed with magnesium chloride, for the coating that forms the front side of the heat, noise, moisture insulating product.

Thus, the use of these components of the mixture can increase strength, heat, noise and moisture insulating indicators, heat resistance (fire resistance), eliminate the harmful effects on the human body of various types of electromagnetic radiation and static electricity. The material does not contain and does not emit substances harmful to human health, meets modern requirements for hygiene and comfort in residential, industrial, medical and educational institutions.

The material is intended for the manufacture of environmentally friendly, durable, durable heat-resistant, fireproof building materials.

Obtained by the present method, heat, noise and moisture insulating heat-resistant material and products from it do not form cracks, are durable and have good decorative characteristics and the ability to form the front surface of a wide spectrum material and the required design.

Table Composition and properties of heat, moisture and noise insulating heat-resistant material

Claims (2)

1. The raw material mixture to obtain a heat, noise, moisture insulating, heat-resistant material containing a mineral filler - expanded perlite or expanded vermiculite, quartz sand, shungite and liquid glass, characterized in that it contains the specified perlite or vermiculite with a size of 0.5-2.5 mm, silica sand containing sludge and clay no more than 3%, with a size of 0.01-0.03 mm, water glass with a density of 1.45 g / cm ³ and optionally basalt or glass fiber with a size of 3-7 mm, magnesite powder, chloride solution magnesium density 1,2-1,25 g / cm ³ and silicofluoride atrium, the magnesia powder and shungite - a magnesian shungite mixture in a ratio of 1: 3, with the following component ratio, wt. %:
specified sand 21.5-26.88 specified fiber 0.54-0.65 specified mixture 8.06-9.14 specified liquid glass 10.75-12.37 sodium silicofluoride 0.5-1.5 specified solution 2.0-2.2 specified filler rest 2. A method of manufacturing a building product from a raw mix according to claim 1, characterized in that quartz sand is mixed with a part of the liquid glass to a homogeneous mass, expanded perlite or vermiculite and basalt fiber or glass fiber are introduced, mixed until uniform distribution, then magnesia-shungite is introduced the mixture in a ratio of 1: 3, the specified solution of magnesium chloride, add the remaining liquid glass, sodium silicofluoride and mix all the components until homogeneous, pour the prepared mixture into a mold, bottom which is evenly coated with a layer of quartz sand with a layer of 2.0-2.5 mm, so that 2-3 mm remains to its upper edges, then to the upper edges the mold is filled with a mixture of magnesia-schungite mixture mixed for 4-5 minutes in a ratio of 1: 3 with a solution of magnesium chloride with a density of 1.2-1.25 g / cm ³ in a ratio of 2.86: 1, withstand 55-60 minutes and after vibration exposure to the form for 1.5-2.0 minutes it is removed.