WO2009088173A2

WO2009088173A2 - Apparatus and method for manufacturing partitioned panel, and partitioned panel manufactured by the same

Info

Publication number: WO2009088173A2
Application number: PCT/KR2008/007849
Authority: WO
Inventors: Gil-Seob Song; Hayashi Kenzaburo; Tojo Hirofumi
Original assignee: Gil-Seob Song; Hayashi Kenzaburo; Tojo Hirofumi
Priority date: 2008-01-04
Filing date: 2008-12-31
Publication date: 2009-07-16
Also published as: WO2009088173A3; KR100975274B1; KR20090075416A

Abstract

The present invention generally relates to apparatus and methods for manufacturing a non¬ flammable liquid composition for wallboard, and the non-flammable liquid composition made by the same, and more specifically, to apparatus and methods for manufacturing a non-flammable liquid composition for wallboard which can provide versatility in its usage as a substantially absolute non-flammable liquid composition for wallboard, provide high efficiency with bw cost, and furthermore, contribute to improvement in productivity through a rapid chemical reaction, and the non-flammable liquid composition made by the same.

Description

APPARATUS AND METHOD FOR MANUFACTURING PARTITIONED PANEL, AND PARTITIONED PANEL MANUFACTURED BY THE SAME

Technical Field

[1] The present invention generally relates to apparatus and methods for manufacturing a non-flammable liquid composition for waϊboard, and the non-flammable liquid composition made by the same, and more specifically, to apparatus and methods for manufacturing a non-flammable liquid composition for waϊboard which can provide versatility in its usage as a substantially absolute non-flammable liquid composition for walboard, provide high efficiency with bw oost, and furthermore, contribute to improvement in productivity through a rapid chemical reaction, and the nonflammable liquid composition made by the same. Background Art

[2] In general, almost all the products used in our daily lives are chemical products prepared by mixing various chemical components.

[3] Such chemical products are widely used in the interior and exterior materials in oon- struction and building industry, in electronics, in home appliances, and in stationery products.

[4] For the chemical products in construction and building industry, such products can be categorized into structural members, ceiling and roofing materials, interior and exterior materials, open- structures, floor materials, insulators, glues and pastes, paints and vanishes, equipment commodities, or can be classified as non-flammable oon- struction materials (fireproof materials, non-flammable materials, fire-resistant materials), fire-protective materials, anti-pollution materials, waterproof materials, and anti-septic and anti-oorrosion materials according to specific purposes.

[5] For example, fibrous materials such as glass wool, rock wool, ceramic fiber or cellulose, synthetic woods using wood powder, or other composite construction materials are most widely used as ingredients of interior and exterior materials for construction industry in Korea, for the purpose of noise-absorption, insulation, fire- resistance, and frost prevention. There is a variety of construction materials used in the above-described purposes. In addition, the panels used for prefabricated building components include EPS (expanded polystyrene), urethane, MDF (Medium-density fiberboard), glass wool, concrete PC, ALC panel and so on.

[6] Furthermore, the above-described materials may be coated with coating materials to improve fire-resistance or non-flammability, and such coating materials may include inorganic adhesive and other coating material based on sodium silicate.

[7] Fbwever, such coated products have a drawback in that when the products coated with coating material are heated after carbonation, white powder tends to reach up to the surface that are coated or impregnated with the coating material to cause the easy exfoliation of the surface.

[8] In addition to the above products coated with coating material, silica gel or silica alkoxide are also used as a fire-resistant material; however, it is known that such materials cannot be used as a heat-resistant material at high temperature.

[9] Furthermore, fluorescein, which is an organic compound of Freon, has been reported that it has an improved heat-resistance (about 600⁰Q over the common synthetic resin; however, it is known that such fluorescein cannot be a heat-resistant material at high temperature, either.

[10] In addition to the techniques described above, inorganic compound coating-material and other film-making compounds used to be applied onto products mainly for fireproof and non-flammability; however, such coating-material is eventually exfoliated easily from the products, which in turn, deteriorates the heat-resistance and non-flammability. Accordingly, such compounds are not appropriate enough to be used as a non-flammable insulator in nature. Disclosure of Invention Technical Problem

[11] Therefore, it is an object of the present invention to provide apparatus and methods for manufacturing a non-flammable liquid composition for waDboard which can provide versatility in its usage as a substantially absolute non-flammable liquid GO mposition for waDboard, provide high efficiency with bw cost, and furthermore, contribute to improvement in productivity through a rapid chemical reaction, and the non-flammable liquid composition made by the same. Technical Solution

[12] The above object is achieved by an apparatus for manufacturing a non-flammable liquid composition for waDboard, comprising: a reaction vessel for mixing and accommodating pure water and SiO (sffioon dioxide) for being mixed in the ratio of 4 to 1, shel powder heated at very high temperature for being mixed in the ratio of 0.3% -0.5% of the SiO , caustic soda for being mixed in the ratio of 30% -40% of the

2 pure water, and a mass of 30cc~50cc of activated odloid water; at least one sample extraction unit installed at the reaction vessel; a heating furnace having a heating burner mounted thereon for heating the reaction vessel; a door for opening and closing an aperture on one side of the reaction vessel; a plurality of safety valves installed at the reaction valve for adjusting the pressure inside the reaction vessel; a plurality of feedback lines for connecting the plurality of safety valves with the reaction vessel, respectively and for feeding bubbles flowing out of the reaction vessel back to the reaction vessel; a hopper for holding at least one ingredient selected from the pure water, the shel powder, caustic soda and the activated odbid water; and a supply unit connected to the hopper for feeding the material held inside the hopper into the reaction vessel, and the non-flammable liquid composition made by the same.

[13] Furthermore, the SiO may be fed into the reaction vessel while being held in a stainless material net of 25 mesh.

[14] The supply unit may comprise a forced circulation pump connected to the hopper, and a connector line connecting the forced circulation pump to the plurality of feedback lines.

[15] The above object is further achieved by a method for manufacturing a nonflammable liquid composition for walboard, comprising the steps of: preparing pure water and SiO for being mixed in the ratio of 4 to 1, shel powder heated at very high temperature for being mixed in the ratio of 0.3%~0.5% of the SiO , caustic soda for

2 being mixed in the ratio of 30%~40% of the pure water, and a mass of 30cc~50cc of activated colloid water; closing and heating the reaction vessel after putting the pure water, the SiO , and the activated colloid water into the a reaction vessel; feeding the caustic soda into the reaction vessel according to a predetermined temperature condition; stopping the heating of the reaction vessel according to the pressure inside the reaction vessel, and making the reaction continue by feeding the shel powder heated at very high temperature into the reaction vessel; and measuring the FH (potential of hydrogen) and specific weight of the samples extracted from the reaction vessel, and completing the reaction process after releasing the pressure inside the reaction vessel when the measurement meets a predetermined condition, and the nonflammable liquid composition made by the same.

[16] Moreover, the method may further comprise a step of inserting a material to be impregnated into the reaction vessel. Advantageous Effects

[17] Accordingly, the present invention can provide versatility of a substantially complete non-flammable liquid composition for waDboard, provide high efficiency with bw cost, and furthermore, contribute to improvement in productivity through a rapid chemical reaction. Brief Description of Drawings

[18] These and other features, aspects, and advantages of the present invention wil help for better understanding with regard to the following description, appended claims, and accompanying drawings, in which like components are referred to by like reference numerals. In the drawings:

[19] Fig. 1 shows the schematic construction of an apparatus for manufacturing a nonflammable liquid composition for walboard, according to the present invention; and

[20] Fig. 2 is a sectional view the main part of the Fig. 1.

Best Mode for Carrying out the Invention

[21] Hereinafter, preferred embodiments of the present invention wil be described in detail with reference to the accompanying drawings.

[22] Fig. 1 depicts the schematic construction of an apparatus for making a nonflammable liquid composition for walboard according to the present invention, and Fig. 2 is a sectional view of the main part of the Fig. 1.

[23] As shown in the drawings, the apparatus for making a non-flammable liquid composition for walboard according to a preferred embodiment of the invention comprises generally a reaction vessel (10), a heating furnace (20), and a hopper (30).

[24] The reaction vessel (10) is the place where pure water and SiO for being mixed in the ratio of 4 to 1, shel powder heated at very high temperature for being mixed in the ratio of 0.3%~0.5% of the SiO , caustic soda for being mixed in the ratio of 30%~40%

2 of the pure water, and a mass of 30cc~50cc of activated odbid water are mixed and accommodated. [25] Among such ingredients, especially the SiO is fed into the reaction vessel (10) while being held in a stainless material net (19) of 25 mesh. [26] Therefore, the SiO , which is the object to be decomposed, does not oome out from

2 where it is held because it is kept in the stainless material net (19) of 25 mesh, and can be decomposed quickly without leaning to one side from pressurization. [27] A door (11) is provided on one side of the reaction vessel (10) for opening and cbsing an aperture on the side of the vessel (10) so that a part of the above-mentioned ingredients and an object to be impregnated can go in and out of the reaction vessel (10).

[28] A pressure gauge (12), a thermometer (13), and a water inlet (14) are provided on the upper part of the reaction vessel (10). Pure water can be injected into the reaction vessel (10) through the water inlet (14). Here, pure water means water of 100% purity, in other word, the water with all of the natural ingredients contained in the water removed for the equalization of chemical reaction.

[29] A first, a second and a third safety valves (15a ~15c) are provided on the upper part of the reaction vessel (10) to adjust the pressure inside the reaction vessel (10). For example, the first, second and third safety valves (15a~15c) are used for the adjustment of 5kg/cnf , 3kg/cnf and 2kg/cnf of pressure, respectively. As a matter of fact, the present invention is not limited to these values, and accordingly, the range of operation and the number of the safety valves may be changed appropriately.

[30] The fist, second and third safety valves (15a~15c) are provided with a plurality of feedback lines (16a~16c) for connecting the safety valves (15a~15c) to the reaction vessel (10) and for feeding bubbles flowing out of the reaction vessel (10) back to the reaction vessel (10). The plurality of feedback lines (16a~16c) are combined into one line and then this line is connected to the reaction vessel (10).

[31] Next, there are two sample extraction units (17) provided on one side of the reaction vessel (10).

[32] The heating furnace (20) is provided under the reaction vessel (10) to heat the reaction vessel (10). As shown in the drawings, a heating burner (21) is installed at the heating furnace (20).

[33] The hopper (30) is a container to accommodate materials such as above-described shel powder or boron which can control PH and specific weight. This hopper (30) is connected to the reaction vessel (10) through a separate supply unit (40).

[34] The supply unit (40) comprises a forced circulation pump (41) that is connected to the hopper (30), and a connector line (42) for connecting the forced circulation pump (41) to the plurality of feedback lines (16a~16c). Accordingly, the material within the hopper (30), such as shel powder can be supplied into the reaction vessel (10) along the connector line (42) by the forced circulation pump (41).

[35] Next, a method for making a non-flammable liquid composition for waϊboard of the present invention wl be described.

[36] In particular, the present invention is completely different from the prior art in that shel powder that has been heated at very high temperature is used to make the non- flammable liquid composition. Here, the very high temperature means the temperature around 3000⁰C. [37] The non-flammable liquid composition for waϊboard of the present invention is made according to the foflowing method. [38] First, pure water and SiO that are to be mixed in the ratio of 4 to 1, shel powder heated at very high temperature for being mixed in the ratio of 0.3%~0.5% of the SiO ,

2 caustic soda for being mixed in the ratio of 30%~40% of the pure water, and a mass of 30cc~50cc of activated odbid water are prepared. The activated odbid water (nano water) means pure water of 99.999%, and such activated odbid water (nano water) act as a dispersant to disperse other ingredients. [39] Next, the door (11) of the reaction vessel (10) is opened to supply the SiO and the

2 activated odbid water into the reaction vessel (10), and at the same time the pure water is injected through the water inlet (14). Then, the reaction vessel (10) is cbsed tightly and is heated by turning on the heating burner (21).

[40] During the heating process, the caustic soda is fed into the reaction vessel (10) based on the predetermined temperature oondition (about 40~50°Q by way of the thermometer (13). Right after the feed of the caustic soda into the reaction vessel, a chemical reaction starts.

[41] After the reaction starts, the first safety valve (15a) is opened when the pressure reaches, for example, 5 kg/cm² based on the pressure inside the reaction vessel (10). At this time, bubbles flowing out of the outlet of the first safety valve (15a) are fed along the feedback line (16a) back to the reaction vessel (10). Based on such construction, the pressure inside the reaction vessel (10) can be adjusted as desired.

[42] For example, when the pressure reaches 5kg/cnf , the heating of the reaction vessel

(10) by the heating burner (21) is stopped, and the shel powder that has been heated at very high temperature is fed through the hopper (30) and supply unit (40) to make the reaction continue.

[43] Thereafter, samples are extracted from the reaction vessel (10) through the two sample extraction unit (17) to measure the FH and specific weight from such samples.

[44] If the measurements meet a predetermined oondition, the pressure inside the reaction vessel (10) is released to complete the reaction process.

[45] Moreover, during the process, if a material to be impregnated is put into the reaction vessel (10) along with the above non-flammable ingredients, then the material can be completely impregnated with the non-flammable ingredients to make the material beoome a non-flammable product when the reaction oompletes (about 60 minutes). [46] [Experiment 1]

[47] The SiO and pure water in the ratio of 1 to 4 whose amount is determined by the amount of a non-flammable liquid composition to be prepared are fed into the reaction vessel (10), and at the same time the activated colloid water is injected into the reaction vessel (10), foflowed by the ignition of the heating burner (21) after cbsing the door (11).

[48] When the thermometer (13) indicates 45⁰C, the caustic soda is fed into the reaction vessel (10). Then, about 2~3 minutes later, reaction starts inside the reaction vessel (10).

[49] As the pressure inside the reaction vessel (10) goes up, the sound of the stir of the

SiO 2 is heard. When the pressure gauge at the third safety valve (15c) shows 2kg/cnf, the third safety valve (15c) is opened and bubbles flow out therethrough; however, these bubbles are fed along the feedback line (16c) back into the reaction vessel (10).

[50] Since the heating burner (21) is stl heating the reaction vessel (10), the pressure inside the reaction vessel (10) continues to go up.

[51] When the pressure reaches 3.5kg/cnf so that the second safety valve (15b) is opened to let a small amount of bubbles flow out, the operation of the heating burner (21) is stopped.

[52] Even after the halt of the heating burner (21) operation, natural reaction inside the reaction vessel (10) continues to cause the pressure to go up to 5kg/cnf so that the first valve (15a) is opened. At this time, boron or shel powder is fed through the hopper (30) and the supply unit (4). Then the pressure inside the reaction vessel (10) does not go up any more; however, the reaction inside the reaction vessel (10) stl continues.

[53] During the reaction, samples are extracted from the reaction vessel (10) through the two sample extraction unit (17) to measure the FH and specific weight. If the measurements meet a predetermined condition, the pressure inside the reaction vessel (10) is released to complete the reaction process.

[54] [Experiment 2]

[55] In the same way as the Experiment 1, nine rectangular lumbers of 6cmx6cmx 180cm,

9cmx9cmx 180cm and 12cmxl2cmx 180cm, three per each size were put in the reaction vessel (10) from the beginning of the reaction process. At about 35 minutes after the ignition of the heating burner (21), the pressure inside the reaction vessel (10) reached 2 atm (atmospheric pressure). So, the operation of the heating burner (21) was stopped; however, the natural reaction continued to make the pressure inside the reaction vessel (10) reach up to 3.2 atm. After 60 minutes, the liquid composition and the lumbers were removed from the reaction vessel (10) to another container and the lumbers were taken out of the liquid composition to dry under the sun. After seven days, these lumbers were put on the fire for burning test. The lumbers were carbonized but bleached.

[56] [Experiment 3]

[57] The filthy mud produced at the end of the sewage treatment was mixed with 1% of the non-flammable liquid composition of the present invention and 1% of cement. Then, the mixture was coagulated. As a result, the mixture turned into a hardened matter much like gravels. Before mixture and coagulation, the mud emitted a storing offensive smel; however, it became odorless after coagulation. As such, it was found that inorganic matters such as mud could be hardened by the non-flammable liquid composition of the present invention.

[58] [Experiment 4]

[59] The submarine mud produced by the reclamation for Busan New Port Project in

Busan, Republic of Korea, was mixed with 2% of the non-flammable liquid composition of the present invention and 2% of cement, and then the mixture was coagulated. Thereafter, the coagulated matters were submerged back into the sea, and it was found that neither dissolution nor discoloration had happened.

[60] [Experiment 5]

[61] The non-flammable liquid composition of the present invention was applied to the part from the midship to the bottom of a ship that had direct contact with sea water, and it was found that only the part coated with the liquid composition of the invention did not have any sea shels attached. In addition, only this part did not become rusty.

[62] [Experiment 6]

[63] The non-flammable liquid composition of the present invention was used as glue instead of conventional pastes for pasting wallpapers. Though it took bnger time for the liquid composition of the invention to dry than common organic glue; however, it was found that the non-flammable liquid composition of the invention could be used as inorganic glue as wel.

[64] [Experiment 7]

[65] In order to treat lime waste, which was the most difficult component of glass material among industrial wastes that cause environmental pollution and which was produced during the process of manufacturing various chemical components, there was no way other than using the non-flammable liquid composition of the present invention.

[66] As described above, the present invention provides versatility of a substantially complete non-flammable liquid composition for waϊboard, provides high efficiency with bw cost, and furthermore, contributes to improvement in productivity through a rapid chemical reaction.

[67] In particular, the non-flammable liquid composition according to the method of the present invention can significantly reduce the time required for subsidence and sedimentation during the chemical reaction over the prior art.

[68] In addition, the method of the present invention can be implemented regardless of the outside temperature, the sea temperature, the seasons or the like that affect chemical reactions.

[69] For example, it is known that in the case of generally known common reaction decomposition, it takes about 5~6 hours for reaction decomposition of one process, and thereafter, it takes more than 24 hours to appropriately measure the FH of the resulting chemicals, Fbwever, it is possible to cut the time required for the process down to about 60 minutes according to the present invention.

[70] As a result of the test on the lumber coated with the non-flammable liquid composition of the present invention by a lumber burn-test center, it was found that the value of formaldehyde of the lumber with the non-flammable liquid composition of the invention coated thereon was 1.6 mg/L which was significantly lower than conventional lumbers that had 13~ 14mg/L of formaldehyde at the beginning of burning. Especially, the lumber with the non-flammable liquid composition impregnated therein by pressurization was found that the value of formaldehyde was almost 0mg/L.

[71] Furthermore, according to the strength test by a concrete inspection agency, the conventional concrete showed a strength of 24.9, while the concrete with 1% of the nonflammable liquid composition of the present invention mixed therewith showed a strength of 40.2. For this test, the test machine by Shimazu was used.

[72] Moreover, when the non-flammable liquid composition of the present invention was applied to the bwer part of a foreign cargo ship anchored at a quay wall for repairs, the part with the non-flammable liquid composition applied thereon did not have any sea shel attached, thereby preventing corrosion of the part the ship.

[73] In addition, when 1% of the non-flammable liquid composition of the present invention was added to the heat-resistant caster bowl for 1400⁰C of common furnace material as an interior material of hot melting furnace, the structure could withstand up to 2700⁰C. In this case, the temperature of the exterior wall was 6O⁰C.

[74] Additionally, the present non-flammable liquid composition is effective as an anti- dispersant agent of asbestos dust, and as a dioxin preventative, so that it has universal usage not only in the field of PCB decomposition but also in our daily lives.

[75] For example, the filthy mud produced at the end of the sewage treatment that was cbsely related to our daily lives used to be dumped into the sea until the ocean disposal was banned by the law in February 2008 in Korea. Fbwever, the nonflammable liquid composition of the present invention makes it possible to turn such mud into an odorless and harmless hardened matter in the form of gravels, thereby removing the need of ocean disposal.

[76] The present invention has been described in detail. Fbwever, it should be understood that the detailed description and specific examples, while indicating preferred embodiments of the invention, are given by way of lustration only, since various changes and modifications within the spirit and scope of the invention wl become apparent to those skiled in the art from this detailed description.

Claims

[1] . An apparatus for manufacturing a non-flammable liquid composition for waDboard, comprising: a reaction vessel for mixing and accommodating: pure water and SiO (sfficon dioxide) for being mixed in the ratio of 4 to 1, shel powder heated at about 3000⁰C for being mixed in the ratio of 0.3%~0.5% of the SiO , caustic soda for

2 being mixed in the ratio of 30%~40% of the pure water, and a mass of

30cc~50cc of activated colloid water; at least one sample extraction unit installed at the reaction vessel; a heating furnace having a heating burner mounted thereon for heating the reaction vessel; a door for opening and cbsing an aperture on one side of the reaction vessel; a plurality of safety valves installed at the reaction valve for adjusting the pressure inside the reaction vessel; a plurality of feedback lines for connecting the plurality of safety valves with the reaction vessel, respectively and for feeding bubbles flowing out of the reaction vessel back to the reaction vessel; a hopper for holding at least one ingredient selected from the pure water, the shel powder, the caustic soda, and the activated colloid water; and a supply unit connected to the hopper for feeding the ingredient held inside the hopper into the reaction vessel. [2] The apparatus of Claim 1, wherein the SiO is fed into the reaction vessel while being held in a stainless material net of 25 mesh. [3] The apparatus of Claim 1, wherein the supply unit comprises: a forced circulation pump connected to the hopper, and a connector line connecting the forced circulation pump to the plurality of feedback lines. [4] A non-flammable liquid composition for waDboard manufactured by the apparatus of any one of the Claims 1 to 3. [5] A method for manufacturing a non-flammable liquid composition for waDboard, comprising the steps of: preparing pure water and SiO for being mixed in the ratio of 4 to 1, sheD powder heated at about 3000⁰C for being mixed in the ratio of 0.3% -0.5% of the SiO ,

2 caustic soda for being mixed in the ratio of 30%~40% of the pure water, and a mass of 30cc~50cc of activated oαfloid water; dosing and heating the reaction vessel after putting the pure water, the SiO , and the activated odloid water into the a reaction vessel; feeding the caustic soda into the reaction vessel according to a predetermined temperature condition; stopping the heating of the reaction vessel according to the pressure inside the reaction vessel, and making the reaction continue by feeding the shel powder heated at very high temperature; and measuring the FH (potential of hydrogen) and specific weight of the samples extracted from the reaction vessel, and completing the reaction process after releasing the pressure inside the reaction vessel when the measurement meets a predetermined condition. [6] The method of Claim 5, further comprising a step of inserting a material to be impregnated into the reaction vessel. [7] A non-flammable liquid composition for waDboard manufactured by the method of Claim 5 or 6.