WO1999010150A1

WO1999010150A1 - Method for mobile production of substantially inorganic foams, and corresponding mobile installations

Info

Publication number: WO1999010150A1
Application number: PCT/AT1998/000195
Authority: WO
Inventors: Gerhard Melcher
Original assignee: Gerhard Melcher
Priority date: 1997-08-22
Filing date: 1998-08-19
Publication date: 1999-03-04
Also published as: EP0934234A2; AU8718598A; WO1999010296A3; ATA141297A; AT408344B; AU9343898A; WO1999010296A2

Abstract

The invention concerns a method for producing foam materials, based on inorganic substances, in particular based on phosphate, formed from at least two substantially inorganic aqueous constituents A and B. Said method enables the precise transporting and mixing, continuous to a great extent, of constituents which react by forming a solid material, in particular a light material. The two constituents A and B are conveyed each to separate containers (9) or produced therein, before being transported continuously through conduits, to a unit mixing the constituents (6) where they are mixed in a few seconds. The mixed material is produced in a few seconds, the reaction is then carried out between the two constituents A and B.

Description

Process for the mobile production of predominantly inorganic foams and corresponding mobile devices

State of the art

The production of predominantly inorganic foams based on phosphate is described in the Austrian patent AT-B-400 830. The accuracy of the dosage of the two predominantly inorganic, aqueous components is essential for the foam properties. The present invention addresses this task of a mobile manufacturing process and the description of mobile devices which can produce such foams in different quantities. Such foams are particularly suitable for insulation, fire protection and high-temperature resistant linings due to their excellent temperature resistance. By producing these foams with the help of mobile devices that can be easily brought from place of use to place of use, the area of use of the foams is considerably enlarged, in particular also because, in addition to a pouring job, a large-area spray application with the help of a spray nozzle is also possible. Stationary technical processes and systems are described in the simultaneously filed patent application "Process for the production of predominantly inorganic foams on stationary systems and the systems required for this". In German patent application DE-A-31 17 014, a device for producing a chemically reactive mixture from two plastic components is known, which are introduced in counterflow under high pressure into a mixing chamber. They are mixed in this and applied using a control piston. For the mixing, an agitator which can be moved in and out of the mixing chamber is provided, which, in addition to the mixing effect which is provided by the introduction of pressure by the components, is intended to cause thorough mixing and thus shorten the reaction time. Components that react very quickly cannot be processed with this device.

German patent application DE-A-31 43 298 discloses a process for producing an inorganic foam using a solution containing monoaluminum phosphate, a tertiary metal phosphate and a blowing agent, the components being mixed together in a reaction vessel and the foaming mixture subsequently is filled into a mold. Such a process is only possible with a slowly reacting one-component system. Rapidly reacting components react and foam so strongly already within the mixing device that a proper discharge of the mixture, for example into a mold, would not be possible.

Since an exact dosage, for example in a mixing ratio of A: B = 100: 15.8, of two highly viscous, solid-containing suspensions, which for example can contain coarse-grained abrasive substances with a particle size of up to 1.0 mm, is necessary Difficulties with conventional dosing pumps. When using gear pumps or positive displacement pumps, the solids require a relatively large gap between the delivery elements and the housing wall, so that incalculable delivery losses and an inaccurate metering of the components result. Furthermore, hose pumps are not suitable because of the high viscosities that are usually used, since the hoses contract due to the vacuum created when the component is sucked in, and there is no longer any delivery.

If it is necessary or inexpensive to deliver large quantities over long distances (for example in a high-rise building) for large-scale operations, as is necessary for many fire protection and insulation applications, it is even with theoretically exact pump delivery because of the pulsations caused by the long ones Hose lines not possible to achieve an exact and even dosage. In these cases, because of the high viscosities of the suspensions (2000 to 80,000 mPa.s, advantageously 5000 to 60,000 mPa.s, preferably 6500 to 30,000 mPa.s) and the resulting pressure losses with very high pressures (150, 250 bar and above) to work.

Devices of this type, as required here, will therefore be generally suitable for all systems in which two components must be mixed together in precisely metered amounts, irrespective of whether the two components are organic or inorganic in nature or whether they form foams or not. Such systems are generally recommended if two components are mixed homogeneously within a maximum of ls, 5s or a maximum of 10s and the mixed mass is applied to a base or into a cavity within seconds, after which it is reacted between the two components for setting is coming. The setting times of the component mixtures vary between 10 s and 10 min or a maximum of 60 min, preferably between 20 s and 5 min, so that rapid and continuous mixing of the two components is necessary and inexpensive. However, these devices, which are preferably designed to be mobile, can also be attached in a stationary manner. Their stationary use will be quite advantageous if, for example, comparatively small amounts of foam are required in short periods of time and the installation of an expensive continuous component production device is not justifiable.

Description of the invention

The object of the invention is to describe a dosing method which is also suitable for aqueous suspensions which may contain abrasive substances and which can also be used on the spot and which allows an exact, widely continuous conveying and mixing of two or more components, which react to form a solid, especially a light material. This requirement must be met even if the corresponding component storage tanks are at a greater distance from the mixing unit.

This object is achieved for the method according to the features specified in claim 1 and for the device according to the features specified in claim 7.

It has been found that the problem of the exact metering of inorganic suspensions according to the invention is advantageously achieved by working with metering devices in which pistons are located, which advantageously by means of an intermediate circuit medium which is well meterable or by a corresponding device which an exact movement of the piston, for example a spindle, can be released. In small systems, it is advantageous for the mixing process of the components to take place in the metering device at the same time. In this case, corresponding movable mixing units must be provided that do not hinder the subsequent squeezing process by the pistons. In large systems, such a device will not be expedient, but the homogeneously mixed components will be pumped into the metering device via high-pressure lines and, since no further homogenization of the components is necessary, squeezed out. The quantities of the components have to be matched to the respective application.

With the method according to the invention, an at least predominantly inorganic foamed mass can be produced by rapidly mixing a first component (A) and a second component (B). The first component (A) contains an acidic aqueous solution of predominantly polyvalent, preferably bivalent or trivalent cations and phosphoric acid to form a phosphate, with an average of 0.8 to 1.75 protons of the three-base phosphoric acid molecules being neutralized by the cations, in which solution one or more types of a granular, platelet or powdery filler are finely divided, a room temperature viscosity in the range from 2000 mPa.s to 80,000 mPa.s, but preferably in the range from 6,500 mPa.s to 60,000 mPa.s, is advantageously adjusted by choosing the type, consistency and / or amount of the filler and / or its water content . The second component (B) contains an oxide, hydroxide or a polyvalent salt of a weak acid as a hardener and has a blowing agent which may also partially act as a hardener, such as a carbonate, which develops a gas, preferably CO ₂ , under curing conditions, the component (B) preferably pasted or in the form of an aqueous suspension and, advantageously by choosing the type, consistency and / or amount of blowing agent, the duration of the gas development process (rise time) in the range from 3 s to 10 min, but preferably in the range from 5 s to 5 min, and the longer setting process (setting time), advantageously by selecting the type, consistency and / or amount of the hardening substances in the range from 10 s to 60 min, but preferably in the range from 20 s to 10 min becomes. After the mixture of components (A) and (B) has been introduced into a room or onto a base, the mixed mass is foamed and set.

The invention is explained in more detail with reference to the figures.

Figure 1 shows a large system in which larger distances between the storage containers of the components (2), which can include volumes of 1.5 or 10 and more cubic meters, and the component mixing device (6) are to be bridged. According to the invention, the system is divided into two sub-assemblies, the two sub-assemblies from the large storage tanks (2), which are led to the construction site by a truck (1), for example, by high-pressure pumps (3) through separate hose lines (through the first sub-assembly). 4) to a second sub-assembly, which carries out the metering of the components (5). This sub-assembly consists, for example, of two or more smaller storage, pressure or dosing containers and is mobile or easily movable at the point where the foam is used.

Figure 2 shows, for example, a mobile metering device (5) on wheels with two containers (9), in which in addition to the metering process, the mixing process of one component can be carried out. As shown in FIG. 2 for an embodiment, the small mobile device consists of the components specified below.

The basic device is a mobile device which is preferably located on wheels and which is easy to bring to construction sites, for example by motor vehicles, and must be easy to maneuver in appropriate premises. There is a scaffold (7) on this device which is used to fasten various parts, for example the control panel (8), the metering pumps (15), etc. The two containers (9) for the two components, which can be pressurized with 5 bar, 10 bar or more, can have a volume of 20.30, 40.50 and more liters. The lids (10), which are set up for opening or removal, have sealing devices for the dispersing disk shaft (11) or the dispersing disk (12) in order to allow pressure to build up in the container (9), and closable filling openings for the addition of solid and liquid raw materials (13), ventilation openings (14), wash water openings (15) and press-out openings for the ready-mixed components (16). These openings can either be separated from one another or, for example, in the form of two openings, which can take on several functions. All openings can be closed. According to a preferred embodiment, the containers contain a dispersing disc (12) which is driven directly by a motor (17) or by appropriate devices from a central drive unit and which can preferably be pulled upwards (removable from the piston zone) with the drive. In the pressure vessel (9) there is also a floating piston (18) on the bottom, which can be moved by a pressure fluid. The hydraulic fluid is conveyed from a hydraulic fluid container (19) by a metering pump (20), the metering pump (20) being controlled by a drive motor and a gear (21) or being driven at a fixed speed. The two components are conveyed through the pressure fluids with the aid of the floating pistons (18) through hose lines (22) to a component mixing device (6) and processed there by spraying or pouring. The movement of the piston (18) can also be achieved by means of suitable mechanical devices, for example spindles. If necessary, a wash water tank (23) is to be provided, from which wash water can be drawn into the tank (9) after the squeezing process has ended by moving the piston (18) downwards via lines.

If you use these small devices in connection with the large system (Figure 1), it is recommended to provide two containers (9) for each component, one of which is used during the work process. filled and one is emptied. One has the advantage of alternately switching the two containers used for one component to ensure continuous delivery to the mixing gun (6), which is also guaranteed over longer periods of time.

In an advantageous manner, when components which have already been mixed and which are supplied under pressure to the second sub-assembly are delivered, containers are used which have a piston which can be acted upon on both sides by a switching process with components supplied under pressure. Here the component pressed under pressure into the container presses the component mass on the other side of the piston out of the container to the mixing gun. If the entire component mass is expressed on one side, this process now takes place from the other piston side after a switchover process. There is thus a simultaneous filling and squeezing process in the metering device in question. The control and coordination of the piston speeds in the two component containers, for example, required for the regulated mass flow of the components can be achieved by a control device, such as a metering valve, or by a mechanical device that controls the coordinated piston speed in the containers, for example a spindle or a rod that connects the pistons together. This gives a dosing device that is lighter than the device originally described. It is also recommended to use static mixers instead of a mixing gun (6), which enables further weight savings.

Furthermore, it is recommended to provide safety and control devices which, for example, apply pressure to the piston (18) or suck the pressure medium through the metering pumps in the individual positions of the piston (18) in the container (9), for example at the top or bottom dead center of the Container, regulate or allow or prevent the switching on of the metering disc (12) in the individual stages of the use of the device and the manufacturing process.

The manufacturing process of the inorganic foam from the two components takes place with the aid of a mixing and metering device according to FIG. 2 in the following manner.

1. Introducing the liquid and solid raw materials into the containers (9), if necessary in a specific sequence with the dispersing disc (12) running

2. Homogenization of the raw materials into the components in the containers (9), for example with the aid of a dispersing disc (12)

3. Prepare the container for the extrusion process, for example by removing the disper yaw washers (12) from the containers (9) and application of a new lid with a squeezing opening or by fixing the dispersing disks (12) below the lid so that they do not interfere with the piston movement in the squeezing process and at the same time through sealing surfaces to the lid Seal the shaft of the dispersing disc.

4. Vent the two containers (9) through the ventilation openings (14) or the press-out opening (16) by moving the pistons (18) up until the components fill the containers (9) completely.

5. Squeezing the two components in defined mixing ratios through the squeeze lines (22) by moving the pistons (18) upwards, preferably squeezing amounts of 10 g to 50 g of individual component per second.

6. Mixing the components in the component mixing chamber (6) or in the static mixer and pouring or spraying the resulting foam in cavities or on surfaces by hand or with the aid of automatic devices.

7. After the squeezing process has ended, washing water can be drawn in from a container (23) to be provided by moving the pistons (18) downwards or by washing water being filled into the container (9) in another way. The squeeze lines (22) or dedicated lines are preferably used for this purpose. This is followed by a subsequent washing process for the containers (9), preferably using the dispersing disks (12).

8. Squeezing the washing water through the hose lines (22) and cleaning them and, if necessary, subsequently blowing out the water residues with the aid of compressed air.

9. After pressing out the washing water, the pistons (18) are pulled down using the suction-controlled metering pumps (20) and the containers (9) can be filled again with the raw materials for the next mixing process.

It is also essential that, for example, when using the small devices on construction sites, the liquid and solid component components delivered in containers can only be filled into the component container (9) intended for them. This can be achieved, for example, by the fact that the individual lid openings of the containers (9) have different threads and thread dimensions, onto which only appropriately dimensioned funnels can be screwed, and into which only very specific forms of solid containers (square or rectangular packages) are inserted and opened can. Delivered liquid containers are also to be provided with threads that can only be inserted into the containers with the help of intermediate hoses equipped with corresponding counter threads (9) can be filled. It will also be beneficial to add additional differentiations, such as different lettering and colors.

The foams produced in this way by mobile or stationary systems based on phosphate are suitable as inorganic foamed insulation materials, for example as they can be used for facades or for interior insulation, or as fire protection compounds for fire protection bulkheads, fire protection door frame backfills, etc. or also for inorganic, high-temperature resistant light material linings that can be applied on site. The small device can, among other things, be made mobile in such a way that it is transported, for example, by a motor vehicle or even has wheels, or can be moved horizontally and vertically with the aid of a platform or a crane.

The use as a fire protection material requires, because of the necessary densities of the foamed material of (0.3 to 0.7 g / cm ^), an application of large quantities. In many cases it is also advisable to work with large quantities for use as insulation material, so that in addition to any small applications for which container volumes of 5, 10 and 20 liters will be advantageous, for larger technical applications component containers with a capacity of 30, 50, 70 or more liters will work or is to work with large plants.

h Analogously to the use of two components with two mixing and metering devices described here, it is possible to work with several components, for example three components, and a corresponding number of mixing and metering devices. In all of these cases, pneumatic, electric or hydraulic drive types can be used.

The amounts of components A and B can either be regulated in an arbitrarily adjustable volumetric ratio, for example A: B of 100: 5, or preferably 100: 15 to 100: 100, or it can be determined, for example by the choice of the container dimensions, in particular the Container diameter, fixed mixing ratios provided in one device.

Claims

claims

1. A process for the preparation of foam-forming compositions, based on inorganic, in particular phosphate, which are formed by reaction from at least two aqueous, predominantly inorganic components A and B, characterized in that the two components A and B are each fed to separate containers (9) or be made in them that the two components A and B through lines to a component mixing device

(6) continuously promoted and mixed in this within a few seconds and that the mixed mass is applied within a few seconds, after which the

Reaction between the two components A and B takes place.

2. The method according to claim 1, characterized in that the two components A and B are homogeneously mixed within less than ls, 5s or 10s and the mixed mass is placed on a base or in a cavity within seconds, it then by reaction between the two components.

3. The method according to claim 1 or 2 of two aqueous components which solidify within a time of 10 s to 10 min or a maximum of 60 min, but preferably in the range from 20 s to 5 min.

4. The method according to any one of claims 1 to 3, characterized in that the components A and B are each mixed separately in a container (9) and that the components from the container (9) of the component mixing device (6) are supplied.

5. The method according to any one of claims 1 to 4, in which three or more components are used instead of two components.

6. The method according to any one of claims 1 to 5, characterized in that it is carried out in a mobile device.

7. The device, in particular for carrying out a method according to claims 1 to 6, characterized in that containers (9) are provided which have floating pistons (18) acted upon by a medium and that devices are provided which have a mixing process of the two components allow in the containers (9).

8. The device, in particular for performing a method according to claims 1 to 6, characterized in that containers (9) are provided, the pistons of which are precisely controllable Devices can be moved, and that devices are provided which allow a mixing process of the components in the containers (9).

9. The device according to claim 7, characterized in that instead of the floating piston in a different way defined moving pistons, for example with the aid of mechanical devices such as spindles, are used.

10. Device according to one of claims 7 to 9, characterized in that the devices provided for the mixing process are dispersing disks (12).

11. Device according to one of claims 7 to 10, characterized in that the dispersing disks (12) after the mixing process from the container (9) are removable or fixed in such a way, for example by pulling on the lid of the container (9) that subsequently the components can be pressed out of the container (9) with the aid of floating pistons (18).

12. Device according to one of claims 7 to 11, characterized in that lines are provided through which the components can be conveyed to rapidly and intensely homogenizing mixing devices, to which means are connected to the desired mass within seconds on a base or in to bring a cavity, which then results in a reaction between the two components to set.

13. Device for carrying out a method according to one of claims 1 to 6, characterized in that pneumatic, hydraulic or electric drive types are used for the movement of the devices located on the mobile device.

14. The device, characterized in that this device is present in sub-assemblies, the first sub-assembly (Fig. 1) ensuring the delivery of at least two ready-mixed components even over longer distances through lines (4) and a second sub-assembly (Fig. 2) to carry out the method according to one of claims 1 to 6, an exact metering of the two components and a promotion to a component mixing unit (6).

15. The apparatus according to claim 14, characterized in that containers (9) with pistons are arranged in the second sub-assembly, the component conveyed in the relevant container (9) being used as the pressure medium, in particular by switching the flow from one side of the floating Piston on the other a filling and squeezing process is achieved in the respective dosing device at the same time.

16. The apparatus according to claim 15, characterized in that pistons are provided for metered and coordinated pressing of the components, which can be actuated either with the aid of mechanical devices, for example by spindles or rods, or by a quantity control of the pressed component, for example by a metering valve are.

17. Device according to one of claims 7 to 16, characterized in that the amount of components A and B in a customizable volumetric ratio of 5: 100, preferably 15: 100 to 100: 100 are adjustable or it is a fixed mixing ratio acts.

18. Device for a method according to any one of claims 7 to 17, characterized in that this mixing head is a static mixing head or a mixing chamber with a driven mixing unit.

19. Device according to one of claims 7 to 18, characterized in that it is designed to be mobile.

20. The apparatus according to claim 19, characterized in that it can be transported, for example, with a motor vehicle or is arranged on wheels or can be moved horizontally and vertically with the aid of a platform.

21. Device according to one of claims 7 to 20, characterized in that the metering by regulating the squeezed quantities, for example a metering valve, or by regulating the piston speed, for example by synchronizing the two pistons by a mechanical connection and adjusting the fixed mixing ratio by the piston size.