RU2568199C1 - Mineral foamed-fibre heat insulation material - Google Patents

Abstract

FIELD: construction.

SUBSTANCE: invention relates to construction materials and describes a foamed-fibre material (with density of 0.100-0.500 g/cm³), used for production of construction and furniture structures, walls, ceilings, partitions, heat and sound insulation, heat insulation of domestic and industrial furnaces, electric heating instruments, assemblies having high temperature, pipelines. The mineral foamed-fibre heat insulation material produced by laying of laminating material into a form by means of a film, foil, sheet, soaking it with a composition containing liquid sodium glass with a silicate module 2.0-3.6 and finely ground mineral filler - clay, chalk or table salt, laying of mineral fibre in the form of mat with thickness from 3 to 100 mm, soaking from the top with the specified composition, coating by the laminating material with subsequent heating of the closed form to temperature of 200-400°C for 20-60 minutes with swelling to increase the volume 5-8 times at the following ratio of components, wt %: liquid sodium glass with a silicate module 2.0-3.6 20-79.8, mineral fibre 20-79.8, finely ground mineral filler 0.1-10, laminating material forming the surface 0.1-10. The invention is developed in the invention claim.

EFFECT: increased strength, durability and moisture resistance of heat insulation material.

2 cl, 7 ex

Description

The invention relates to building materials and describes a foam-fibrous material (density - 0.100-0.500 g / cm ³ ) used for the production of building and furniture structures, walls, ceilings, partitions, heat and sound insulation, thermal insulation of household and industrial furnaces, electric heaters , nodes with high temperature pipelines.

State of the art

Known technical solution according to patent RU 2128633 C1 С04В 28/26, С04В 28/26, С04В 18:24, С04В 18:30, С04В 111: 20, publ. 01/10/1998. The raw material mixture and the method of obtaining a heat-insulating material, in which the known mixture contains liquid glass, wt.%, 82-89.3, filler - silica fume - a waste product of crystalline silicon - 8.93-16.4, sodium bicarbonate - 1.6- 1.77, with granulation and heat treatment at 250 ° C. The disadvantage is the limited scope - in the form of granules, as a filler in the production of building materials.

Known material is basalt heat-insulating rigid cardboard (http://kamni.ws/?p=687), containing basalt staple fiber, as a concrete clay binder, soda ash, water-repellent liquid.

The disadvantages of this cardboard are: low moisture resistance and strength, due to the weakness of the intermolecular bonds of the binder - concrete clay, formed during drying at temperatures up to 200 ° C, and the technological complexity of manufacturing products of a given shape and density.

A technical solution is known according to patent RU 2173674 C2 С04В 28/26 С04В 111: 20 Composition and method for producing expanded silicate material, according to which the composition contains liquid glass, wt.%, 47-92, crushed foam silicate - 5-18, finely divided mineral filler 0 , 1-43, oleic acid 0.02-0.04, saturated aqueous sugar solution 0.4-1.0, water 0.6-2.0, in which the components are mixed mechanically in a screw granulator, or granulation in liquid media. To prevent mutual adhesion, the granular raw material mixture is dusted with finely ground foam silicate and dried at room temperature for 2 hours or in a dryer at a temperature of not more than 100 ° C for 30 minutes and after separation of the dusting material, the granules are poured with an even layer into a swelling mold at a temperature of 450-500 ° C for 30-80 minutes.

The disadvantages of the known composition are participation as the main components of the crushed foam silicate, which causes the need for additional long-term production processes of granulation, dusting and drying, the need for further technological steps to obtain the final product. Known material is a semi-finished product, the absence of a fibrous structure does not allow to use as a structural material. In addition, the disadvantages of foam silicate as a substance are reflected in the properties of a known material that is intended to be used as a heat-insulating material: more weight compared to other types of heat-insulating materials (due to the high density of the foam glass); instability to shock effects of products from it while the damaged material loses its properties of heat conductivity and moisture resistance; the manufacture of shells or blocks requires additional equipment, which leads to additional energy costs.

The closest in properties to the present invention is the technical solution according to patent RU 2101255 C1 С04В 28/26, С04В 28/26, С04В 18:24, С04В 18:30, С04В 111: 20, publ. 01/10/1998, according to which the Raw mix for the manufacture of heat-insulating material contains liquid glass, wt.%, 30-35, fibrous filler - spikelet straw - 25-40, wool - 15-20, chopped fur flap - 10-25, with hot pressing at a temperature of 100-110 ° C. The disadvantage of this raw material mixture is the use of organic fillers that are subject to burnout under prolonged exposure to high temperatures and hygroscopic when exposed to moisture, which reduces the indicators of fire resistance, moisture resistance and strength.

To eliminate these shortcomings, a material with improved performance characteristics is proposed: increasing fire resistance, hardness and density, increasing moisture resistance, reducing hygroscopicity, chemical resistance to alkaline and acidic environments, eliminating weathering of mineral fibers, environmental cleanliness, obtaining foam material of high strength of a given shape with laminated surfaces .

Thermal insulation materials for industrial use are often made porous, since the thermal conductivity of air or gases forming the pores is small. The use of inorganic, silicon-organic, basalt, mineral-fibrous materials as a structural filler results in the formation of closed pores from the intumescent binder silicate reinforced with mineral fiber. When a sodium silicate binder is introduced into a porous inorganic mineral fiber, molecular cohesion forces appear on the surface of the fibers, the water of the sodium silicate solution is adsorbed on the surfaces to be bonded, which increases the density and viscosity of the adhesive. The equilibrium of the particles of silicic acid H ₂ SiO ₃ (SiO ₃ ) is disturbed, the polymer chains of silicic acid lengthen, intertwine, condense, and the polycondensation process occurs with the formation of an adhesive compound of the fibers. Heating to a temperature of 200-400 ° C causes the solution to swell with the formation of closed voids. The swelling of the material during heating is due to the fact that water cannot freely escape from the solution due to its high viscosity and the formation of a dense crust on the surface. At the same time, as a result of heating, polymerization of sodium silicate occurs and its crystallization on the surface of mineral fibers. The ongoing polymerization process allows you to laminate surfaces and create combined materials. The properties of the claimed material are the result of thermodynamic processes that occur when heating sodium silicate in a limited space of mineral-fibrous materials and the use of the basic physicochemical properties of silicates - expansion during heat treatment and good adhesion to almost any surface. The main physicochemical properties of silicates are used - good adhesion to almost any surface - the adhesive ability and the property of viscous solutions of sodium silicate swell when heated to 200-400 ° C, increasing in volume by 5-8 times, with the formation of closed voids, which allows you to get durable fire-resistant thermal insulation materials, with low hygroscopicity, withstanding mechanical stress.

The essence of the invention lies in the fact that the use of mineral fiber, glass fiber or basalt fiber materials as a base, followed by wetting with a binder - liquid glass with finely ground mineral filler, and laminating materials with subsequent heating allows the production of heat-insulating materials in the form of plates, shells or any complex configuration, with the simultaneous receipt of the laminated surfaces of the product.

To obtain this material, a mixture is proposed, with the ability to change the initial percentage of components:

An aqueous solution of sodium silicate, i.e. liquid sodium glass, with a silicate module of 2.0-3.6, wt.% from 20 to 79.8;

Mineral fiber, with a density of from 50 to 350 g / cm ³ - wt.% From 79.8 to 20;

Finely ground mineral filler: for example clay, or chalk, or common salt, wt.% From 0.1 to 10;

Laminating material, wt.% From 0.1 to 10.

The components are mechanically interconnected, followed by heating at 200-400 ° C for 20-60 minutes. Heating takes place in furnaces or, as a special case, microwave radiation. The power of microwave radiation is 20-50 mW / cm ³ at a frequency of 2450-3000 MHz.

Mineral fiber from inorganic basaltic rocks, silicon-organic fiber, is a structural filler - non-combustible, is sintered by heating, while the fibers form a structure that increases the strength and hardness of the final product; makes it possible to obtain the final product with a certain stable form. Sodium silicate is used in the form of an aqueous solution: liquid sodium glass with a silicate module of 2.3-3.6. This component is a binder and when heated forms bubbles that increase the thermal insulation properties of the material. The finely ground mineral filler increases the hardness, moisture resistance of the material, is added in the form of an aqueous solution or suspension. Clay, chalk or sodium chloride is added as a finely divided mineral filler, which increases the hardness of the material.

The inventive material contains a laminating material that increases the strength, durability and durability of the final product - for example, in the form of a plate. In this case, the laminating material is mechanically connected to other components in the state of the raw material before heating. After heating, the process of foaming (swelling) of sodium silicate with a mineral filler occurs, moisture evaporates, the laminating material is firmly connected to the filler bonded with foamed sodium silicate. Thus, the product acquires a rigid form of building material suitable for further use (for example, finishing work, insulation during construction) without additional processing. At the same time, the claimed material has improved operational characteristics: less weight, increased strength, moisture resistance, durability, laminated surfaces.

As a special case, instead of heat treatment in furnaces, the material can be heated using microwave radiation with a power of 20-50 mW / cm ³ at a frequency of 2450-3000 MHz.

The technical result is an increase in strength, durability and moisture resistance of the insulating material.

The technical result is achieved by the fact that the mineral foam-fibrous heat-insulating material is obtained by laying in the form of a laminating material in the form of a film, foil, sheet, wetting it with a composition containing liquid sodium glass with a silicate module of 2.0-3.6 and finely divided mineral filler - clay, chalk or salt, laying mineral fiber in the form of mats with a thickness of 3 to 100 mm, wetting it from above with the specified composition, coating with a laminating material, followed by heating the closed form to tempera rounds of 200-400 ° C for 20-60 minutes with expansion to a volume increase of 5-8 times in the following ratio of components, wt.%:

liquid sodium glass with silicate module 2.0-3.6 20-79.80 mineral fiber 20-79.8 finely divided mineral filler 0,1-10 surface forming laminating material 0,1-10

As a special case, this heating was carried out by microwave radiation with a power of 20-50 mW / cm ³ at a frequency of 2450-3000 MHz.

An example implementation.

At stage 1, a liquid is prepared containing an aqueous solution of sodium silicate and a solution or suspension of finely ground mineral filler by mechanical mixing of the components in the tank. To prepare an aqueous solution of sodium silicate use liquid sodium glass GOST 13078-81 with a silicate module of 2.3-3.6, in which add a solution or suspension of finely divided mineral filler.

At the 2nd stage, laminating material - film, foil or other sheet material - is laid on metal forms.

At stage 3, the prepared liquid is applied to the inner surface of the laminating material for wetting: an aqueous solution of sodium silicate containing a solution or suspension of finely divided mineral filler, and mineral fiber or fiberglass or basalt-fibrous materials used in the form of mats (plates) with a thickness of 3 or more up to 100 mm.

In step 4, for uniform distribution, the surface of the mineral fibrous material is wetted from above with the indicated liquid.

At the 5th stage, the wetted surface of the mineral-fibrous material is covered with a laminating material and the mold is closed, forming a closed volume.

At the 6th stage, the mold is heated in furnaces to a foaming temperature of liquid glass of 200-400 ° C for 20-60 minutes. The temperature regime and the heating time of the substance depend on the thickness of the material and the desired density of the product, resulting in the expansion of the specified binder, with an increase in volume of 5-8 times, with simultaneous adhesion to mineral fibers and the formation of closed voids, which allows to obtain fireproof heat-insulating materials with low hygroscopicity, withstanding mechanical loads.

The resulting material is ready for use in construction in the form of non-combustible, fire-resistant, heat-insulating products of a rigid form, high strength, with laminated surfaces, inorganic porous filler, capable of bearing mechanical stress and not exposed to moisture. The temperature of use of the claimed material during operation is from -100 to + 300 ° C.

Characteristics of the components used.

The diameter of the primary mineral fiber, microns: thin, 9-15 microns; thickened, 15-25 microns; thick, 25-150 microns, and coarse - with a diameter of 50-500 microns.

Thin fibers from rocks are a layer of randomly arranged fibers with a diameter of 9-15 microns and a length of 3-1500 mm;

thickened fibers with a diameter of 15-25 microns and a length of 5-1500 mm;

thick fibers are randomly spaced fibers 5-3000 mm long, 25-150 microns in diameter;

coarse fibers are a relatively loose dispersed fibrous mass with a fiber length of 3-15 mm, a diameter of 150-500 microns.

Foil - a thin metal sheet with a thickness of 0.001 to 0.5 mm.

Metal sheet - from 0.5 to 2 mm.

Laminating film - polyvinyl chloride, polypropylene, acrylonitrile-butadiene-styrene from 0.1 to 2 mm.

Laminating film of melamine or acrylic resin with a thickness of 0.1 to 2 mm.

Clay with a particle size of less than 0.01 mm or

Chalk with a particle size of less than 0.02 mm.

The combined components are heated during production to temperatures of 200-400 ° C; or microwave radiation with a power of 20-50 mW / cm ³ at a frequency of 2450-3000 MHz.

The effect of the ratio of components on the properties of the claimed material: with an increase in the percentage of mineral fiber, the density of the resulting material increases from 50 kg / m ³ to 500 kg / m ³ , and an increase in physical and mechanical properties, for example, the thermal conductivity of the obtained material, is achieved.

The thermal conductivity of the materials obtained is from 0.04 to 0.12 W / (m * K).

Example 1

Liquid sodium glass with silicate module 2.0 - wt.% 20;

Mineral fiber, with a density of 50 to 350 g / cm ³ , - wt.% 79.8;

Finely ground mineral filler: for example clay, or chalk, or table salt - wt.% 0,1;

Laminating material - wt.% 0.1.

Heating temperature 200 ° C; heating time> 320 s.

Characteristics: density 70-500 kg / m ³ , thermal conductivity 0.06 W / (m * K).

Usage: as a slab structural or decorative panels.

Example 2

Liquid sodium glass with silicate module 2.0 - wt.% 79.8;

Mineral fiber, with a density of 50 to 350 g / cm ³ - wt.% 20;

Finely ground mineral filler: for example clay, or chalk, or table salt - wt.% 0,1;

Laminating material - wt.% 0.1.

Heating temperature 200 ° C; heating time> 320 s.

Characteristics: density 70-500 kg / m ³ , thermal conductivity 0.07 W / (m * K).

Usage: heat and sound insulating or decorative panels of a given shape, use as non-combustible fillers of hidden cavities.

Example 3

Liquid sodium glass with silicate module 2.6 - wt.% 69.9;

Mineral fiber, with a density of 50 to 350 g / cm ³ - wt.% 20;

Finely ground mineral filler: for example clay, or chalk, or table salt - wt.% 10;

Laminating material - wt.% 0.1.

Heating temperature 200 ° C; heating time> 320 s.

Characteristics: density 70-500 kg / m ³ , thermal conductivity 0.07 W / (m * K).

Usage: heat and sound insulating or decorative panels of a given shape, use as non-combustible fillers of hidden cavities.

Example 4

Liquid sodium glass with silicate module 2.8 - wt.% 45;

Mineral fiber, with a density of 50 to 350 g / cm ³ , - wt.% 40;

Finely ground mineral filler: for example clay, or chalk, or table salt - wt.% 5.0.

Laminating material - wt.% 10.

Heating temperature 200 ° C; heating time> 320 s.

Characteristics: density 70-460 kg / m ³ , thermal conductivity 0.07 W / (m * K).

Usage: as a slab structural or decorative panels.

Example 5

Liquid sodium glass with silicate module 2.8 - wt.% 49.9;

Mineral fiber, with a density of 350 g / cm ³ - wt.% 47;

The thickness of the mineral web is 6 mm;

Finely ground mineral filler - clay, wt.% 0,1;

Laminating material - polyamide film with a thickness of 0.4 mm, wt.% 3;

Heating temperature 200 ° C; heating time> 320 s.

Characteristics: density 460 kg / m ³ , thermal conductivity 0.07 W / (m * K).

Usage: as thin-walled, plate decorative panels.

Example 6

Liquid sodium glass with silicate module 3.6 - wt.% 57;

Mineral fiber, with a density of 150 g / cm ³ wt.% 30;

The thickness of the mineral web is 20 mm;

Finely ground mineral filler - chalk - wt.% 10;

Laminating material - Thermolin fabric - 1.2 mm thick - wt.% 3;

Heating temperature 250 ° C; heating time> 780 s.

Characteristics: density 250 kg / m ³ , thermal conductivity 0.055 W / (m * K).

Usage: as a slab structural or decorative panels.

Example 7

Liquid sodium glass with silicate module 3.6 - wt.% 57;

Mineral fiber, with a density of 50 g / cm ³ - wt.% 20;

The thickness of the mineral web is 100 mm;

Finely ground mineral filler - table salt, wt.% 0,1;

Laminating material - aluminum foil 0.06 mm thick - 0.3%;

Heating temperature - 400 ° C; heating time> 600 s.

Characteristics: density 80 kg / m ³ , thermal conductivity 0.05 W / (m * K).

Usage: heat and sound insulating or decorative panels of a given shape, use as non-combustible fillers of hidden cavities.

The choice of finely ground mineral filler is determined by its availability and its replacement with any of these does not significantly affect the characteristics of the resulting material.

The choice of the percentage of the main components depends on the purpose of the further use of the material, since with a high percentage of sodium silicate and a low content of mineral fiber, a non-combustible foam material is formed that fills the specified form, with the introduction of the mineral filler at the initial stage of production, they increase the strength of the obtained material.

At maximum values of the mineral fiber content, we obtain a solid-porous material, with tightly bound fibers, which allows to bear a higher mechanical load, with a slight increase in the total mass from the initial mineral-fiber filler.

As a special case: heating using the microwave microwave method allows to produce material of greater thickness, but low density, with the uniform formation of a new, expanded structure, to reduce the time and energy costs of production and to produce the final product with simultaneously applied protective outer coating of cellulose, fabric or synthetic polymeric materials. Heating is performed using microwave microwave in ovens to a temperature of 200-300 ° C.

To obtain material in the form of panels and / or blocks, ready-made mineral fiber mats of low density and a small amount of binder are used in its composition. You can get products of a given shape, for example, shells - for finishing sections of complex shape or finishing pipes.

The resulting mineral-fibrous material with fully bonded mineral fibers has high heat and sound insulation properties, has low hygroscopicity, is non-combustible, flame retardant, is well processed (cut to the desired size), has good adhesion with adhesive materials, has a low weight, is capable of bearing insignificant mechanical load, can be used in the production of all types of heat-resistant panels.

The material can be used in construction and architecture for the production of lightweight non-combustible and waterproof decorative elements, heat and sound insulating products in the automotive and aviation industries, shipbuilding. In conjunction with laminated surfaces - in the manufacture of furniture, building partitions. When warming building structures, walls, ceilings and roofs, as a substitute for basalt and mineral-fiber mats, requiring wind and moisture insulation.

When the content of finely ground clay mineral filler in the sodium silicate solution is up to 10%, an increase in the strength of the obtained materials is achieved, with a simultaneous increase in thermal conductivity due to the formation of calcium silicate cement. The content of chalk or sodium chloride sodium chloride increases the hardness and strength of the material. If refractory slags of ferroalloy production are introduced into this binder as a filler, then high-temperature insulating materials for industrial apparatuses can be obtained.

Claims (2)

1. Mineral foam-fibrous heat-insulating material obtained by laying in the form of a laminating material in the form of a film, foil, sheet, wetting it with a composition containing liquid sodium glass with a silicate module of 2.0-3.6 and finely ground mineral filler - clay, chalk or table salt, laying mineral fiber in the form of mats with a thickness of 3 to 100 mm, wetting it from above with the specified composition, coating with a laminating material, followed by heating the closed form to a temperature of 200-400 ° C for 20-60 minutes with expanded by pressing to increase the volume by 5-8 times in the following ratio of components, wt.%:
liquid sodium glass with silicate module 2.0-3.6 20-79.8 mineral fiber 20-79.8 finely divided mineral filler 0,1-10 surface forming laminating material 0,1-10 2. Mineral foam-fiber insulation material according to claim 1, characterized in that said heating is carried out by microwave radiation with a power of 20-50 mW / cm ³ at a frequency of 2450-3000 MHz.