WO2019216470A1 - Method for manufacturing light-weight building material using perlite - Google Patents

Method for manufacturing light-weight building material using perlite Download PDF

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Publication number
WO2019216470A1
WO2019216470A1 PCT/KR2018/005576 KR2018005576W WO2019216470A1 WO 2019216470 A1 WO2019216470 A1 WO 2019216470A1 KR 2018005576 W KR2018005576 W KR 2018005576W WO 2019216470 A1 WO2019216470 A1 WO 2019216470A1
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Prior art keywords
pearlite
weight
expanded pearlite
lightweight
raw material
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PCT/KR2018/005576
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French (fr)
Korean (ko)
Inventor
이정학
김영건
Original Assignee
주식회사 펄라이트코리아
주식회사 아이에스세라텍
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Publication of WO2019216470A1 publication Critical patent/WO2019216470A1/en

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
    • B28B23/02—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects wherein the elements are reinforcing members
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B14/02—Granular materials, e.g. microballoons
    • C04B14/04—Silica-rich materials; Silicates
    • C04B14/14—Minerals of vulcanic origin
    • C04B14/18—Perlite
    • C04B14/185—Perlite expanded
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B20/00—Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups C04B14/00 - C04B18/00 and characterised by shape or grain distribution; Treatment of materials according to more than one of the groups C04B14/00 - C04B18/00 specially adapted to enhance their filling properties in mortars, concrete or artificial stone; Expanding or defibrillating materials
    • C04B20/02—Treatment
    • C04B20/04—Heat treatment
    • C04B20/06—Expanding clay, perlite, vermiculite or like granular materials
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B20/00—Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups C04B14/00 - C04B18/00 and characterised by shape or grain distribution; Treatment of materials according to more than one of the groups C04B14/00 - C04B18/00 specially adapted to enhance their filling properties in mortars, concrete or artificial stone; Expanding or defibrillating materials
    • C04B20/10—Coating or impregnating
    • C04B20/1055—Coating or impregnating with inorganic materials
    • C04B20/1074—Silicates, e.g. glass
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/24—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing alkyl, ammonium or metal silicates; containing silica sols
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/92—Protection against other undesired influences or dangers
    • E04B1/94—Protection against other undesired influences or dangers against fire
    • E04B1/941—Building elements specially adapted therefor
    • E04B1/942—Building elements specially adapted therefor slab-shaped
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • E04C2/288—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and concrete, stone or stone-like material
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/20—Resistance against chemical, physical or biological attack
    • C04B2111/28—Fire resistance, i.e. materials resistant to accidental fires or high temperatures
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/40—Porous or lightweight materials
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/52—Sound-insulating materials
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2201/00—Mortars, concrete or artificial stone characterised by specific physical values
    • C04B2201/30—Mortars, concrete or artificial stone characterised by specific physical values for heat transfer properties such as thermal insulation values, e.g. R-values

Definitions

  • the present invention relates to a method for manufacturing lightweight building materials using pearlite, and more particularly, to light weight and heat insulation, as well as fire resistance and sound absorption, and to improve water absorption, which is a disadvantage of pearlite having environmentally friendly properties, to prevent strength degradation and durability.
  • the present invention relates to a method for manufacturing lightweight building materials using pearlite by maximizing utilization value as lightweight building materials.
  • the pearlite expanded by calcination after calcination of volcanic stone at 900 ⁇ 1200 °C is composed of small particles, resulting in 90% or more of porosity, and the unit volume weight is light spherical with micropores up to 0.03 ⁇ 0.25.
  • it has the advantage of having an operating temperature of about 600 ° C. and a high sound absorption property due to its fire resistance, it has a limitation that it is not suitable as an external finishing material because of its hygroscopic property of absorbing moisture, which lowers the strength after molding.
  • the present invention was created in view of the above-mentioned problems in the prior art, and has been created to solve this problem, and has excellent light weight and heat resistance as well as fire resistance and sound absorption, and improves water absorption, which is a disadvantage of pearlite having environmentally friendly properties, and prevents the strength from falling.
  • the main purpose of the present invention is to provide a method for manufacturing lightweight building materials using pearlite, which maximizes the utilization value as lightweight building materials by improving durability.
  • the present invention is a means for achieving the above object, the step of preparing an expanded pearlite raw material that is the base of the lightweight building material; Molding the expanded pearlite raw material to form a base; Laying a stainless steel mesh network on the molded substrate; Re-injecting the expanded pearlite raw material on the substrate on which the stainless steel mesh network is installed to form a lightweight non-combustible material; Forming a coating on the surface of the lightweight non-combustible material; It provides a method for manufacturing a light-weight building materials using a pearlite comprising a; sintering and drying the lightweight non-combustible material formed with a coating.
  • the step of preparing the expanded pearlite raw material is a process of making expanded pearlite by pulverizing the pearlite ore, high temperature treatment; Making a ceramic binder in a suspension or paste state; Coating expanded pearlite with a ceramic binder; It is also characterized by the process of drying the coated expanded pearlite.
  • the process of making the ceramic binder is a compound oxide powder by mechanically pulverizing the composite oxide produced during copolymerization after slowly inducing a copolymerization reaction by heating by adding alkali sodium silicate in a weight ratio of 1: 6-7 to the ceramic powder Obtaining a step; And a step of preparing a ceramic binder having high adhesion and hardness by adding and stirring 0.2-0.5 parts by weight of nano silica sol and 20-30 parts by weight of distilled water to 100 parts by weight of the composite oxide powder to the composite oxide powder. There is this.
  • the present invention it is possible to obtain the effect of maximizing the utilization value as lightweight building materials by preventing moisture loss and improving durability by improving water absorption, which is a disadvantage of pearlite, which is excellent in fire resistance and sound absorption, as well as light weight and heat insulation, as well as fire resistance and sound absorption. have.
  • FIG. 1 is a schematic process diagram showing a method for manufacturing a lightweight building material using pearlite according to the present invention.
  • 2 to 5 is a test report showing the results of the characteristic test of the lightweight building material sample according to the present invention.
  • a method for manufacturing a lightweight building material using pearlite comprising: preparing expanded pearlite raw material serving as a base of lightweight building material; forming the base by molding the expanded pearlite raw material; Step of laying a steel mesh net, Re-inflating expanded pearlite raw material on the substrate on which the stainless steel mesh net is formed and forming a lightweight non-combustible material, Forming a film on the surface of the light non-combustible material, Lightweight formed film Sintering and drying the non-combustible material.
  • the pearlite (perlite) used in the present invention is finely crushed minerals selected from the group consisting of pearlite, obsidian, pumice, etc. and then heated to high heat (900 ⁇ 1200 °C), the volatile content contained gasified and softened
  • the internal pores are formed by the expansion of the inside, and the expansion is about 10 to 20 times the original volume. The expansion is due to the volatile content of the pearlite contained in the crude perlite rock, which is called expanded pearlite.
  • Such pearlite is a kind of rhyolite rock, and it is also called pearl rock with light gray with pearlescent to dark gray, brown, green and black, and it is evaporated when the binding water evaporates at 870 ⁇ 1100 °C although it depends on the structure of the rock. Pressure is used commercially to expand each granular particle about 10 to 20 times into circular vitreous particles.
  • the expanded pearlite is porous at low density, has good absorption ability, and has properties such as light weight, heat insulation, heat insulation, sound absorption, non-toxicity, and non-flammability, making it a lightweight building material such as heat-resistant material, soundproof material, lightweight aggregate, and heat insulating material. It is widely used.
  • the expanded pearlite raw material when the expanded pearlite raw material is manufactured, a ceramic binder is used, and by specially processing such a ceramic binder, it can be configured to suppress hygroscopicity, which is a limitation of the expanded pearlite, which is not shown in the prior art.
  • the polymerization of the sodium silicate copolymer used in the manufacture of the ceramic binder is polymerized using a reactive emulsifier, that is, an inorganic emulsifier capable of covalent bonding with a polymer, and is prepared by adding nano silica sol to the polymerization step.
  • a reactive emulsifier that is, an inorganic emulsifier capable of covalent bonding with a polymer
  • the step of preparing the expanded pearlite raw material is a process of making expanded pearlite by pulverizing, high-temperature processing pearlite ore; Making a ceramic binder in a suspension or paste state; Coating expanded pearlite with a ceramic binder; Drying of the coated expanded pearlite.
  • the process of making the expanded pearlite is made by swelling the high-temperature heating to 900 ⁇ 1200 °C after grinding the pearlite ore.
  • the alkali powder sodium silicate is added to the ceramic powder in a weight ratio of 1: 6-7 to slowly induce a copolymerization reaction while heating, and then composite oxide powder is mechanically pulverized. Obtaining a step; And adding 0.2-0.5 parts by weight of nano-silicon sol and 20-30 parts by weight of distilled water to the composite oxide powder to 100 parts by weight of the composite oxide powder to prepare a ceramic binder having high adhesion and hardness.
  • the ceramic powder is used as an inorganic emulsifier to prevent particle destruction and pore blockage of the expanded pearlite during hot processing, and serves to significantly reduce hygroscopicity by strengthening hydrophobicity around the pores.
  • the sodium silicate and the copolymerization reaction should be made gradually and uniformly, so that the ceramic powder and sodium silicate should be mixed evenly to achieve uniform dispersion after mixing in the above weight ratio.
  • the nano-silica sol is added to increase the interfacial adhesion when coating the expanded pearlite as a component added to increase the bonding and dispersibility at the same time, if it exceeds 0.5 parts by weight, the viscosity and coating adhesion is lowered to less than 0.2 parts by weight When added, it should be limited to the above range because it can not increase the bondability and dispersibility.
  • the agitated mixture of dichloroethane and methylene chloride in a weight ratio of 1: 1 is intended for dimensional stabilization during expansion pearlite molding to suppress defects due to volume change and to enhance sound absorption;
  • the dimethylpolysiloxane is composed of a heat-resistant siloxane bond (Si-O-Si) and an organic methyl group to increase the thermal oxidation stability, chemical resistance and water repellency, in particular to minimize the hygroscopicity to enhance durability.
  • the process of coating the expanded pearlite with the ceramic binder is a process of spraying the ceramic binder in a suspension or paste state onto the expanded pearlite and then mixing it uniformly to coat the expanded pearlite.
  • the process of drying the coated expanded pearlite is a process of drying the expanded pearlite coated with a ceramic binder using hot air or microwave.
  • forming the base by forming the expanded pearlite raw material is dried in the state in which the expanded pearlite raw material, that is, the ceramic binder is coated using the conveyor 100 and the forming roller 200, as shown in FIG. It is a step of forming a substrate by rolling the expanded perlite raw material to the conveyor 100 while rolling to the molding roller 200.
  • roller-type molding equipment Since the roller-type molding equipment is widely used in the art, a detailed description of the configuration of the molding equipment itself will be omitted, and only a conceptual description will be given.
  • a heating line (heater) is built in the forming roller 200 so as to increase the degree of freedom of molding so that the heating temperature can be freely and easily controlled during molding.
  • the reason for adopting the molding roller method without using the injection method is that the thickness of the substrate can be freely adjusted during the molding of the substrate, the pressing force can be adjusted by varying the weight of the pressing roller, and the uniform pressing force can be secured. This is because the quality of the base material can be improved.
  • the step of installing the stainless steel mesh network is a step of constructing to be a kind of reinforcement by building a surface of the base material using a stainless steel mesh net so as not to rust, so as to have a strong and durable durability like a building.
  • the stainless steel mesh network is configured to be continuously processed by being supplied after molding the substrate in the middle of the conveyor 100 through the mesh network feed roller 300.
  • water-soluble epoxy resin can be used to increase the fixing force, that is, the bonding force, of the stainless steel mesh network, thereby preventing layer separation at the interface, and to secure the initial bonding strength at the interface, and to ensure water resistance and weather resistance.
  • the water-soluble epoxy resin is added to maximize the adhesive force while maintaining a stable adhesion at the interface to implement peeling inhibition and to enhance weather resistance.
  • titanium dioxide is added to enhance the water resistance and moisture resistance by strengthening the resistance to water by bonding with the epoxy resin.
  • alumina is an oxide of aluminum is added to improve the heat resistance as well as the strength of building materials, that is, durability.
  • anhydrous gypsum is a calcium sulfate salt having no crystal water and is added to secure initial strength.
  • the ursolic acid is added to increase the durability by strengthening the bonding strength on the surface of the powder particles by replacing the organic thickener with powder having excellent needle absorption.
  • metaphosphate is added to enhance the antioxidant function at the interface
  • ammonium alginate is added to adjust the binding stability and viscosity of the composition.
  • the step of forming a lightweight non-combustible material is a building material in which the base material and the surface layer are integrated by forming the surface layer on the substrate by re-inserting the same expanded pearlite raw material described above on the substrate on which the stainless steel mesh network is installed, In other words, it is a step to complete a lightweight non-combustible material.
  • the expanded perlite raw material is sprayed onto the substrate moving in the conveyor 100 through the raw material feeder (400).
  • the expanded pearlite raw material completely covers the stainless steel mesh network, and is formed through the material forming roll 500 to have a thickness corresponding to that of the substrate, thereby building materials having a substrate-stainless steel mesh network-surface layer structure, that is, a lightweight non-combustible material. Will complete.
  • the material forming roll 500 has a heating wire (heater) built-in to be configured to be capable of hot pressing.
  • the forming of the film on the surface of the light weight non-combustible material is a step of rolling after supplying the coating material through the coating material feeder 600 and spraying the coating layer with a predetermined thickness.
  • the coating material is a liquid, more precisely It is used by mixing the ceramic binder and natural seed powder in the suspension or paste in a weight ratio of 1: 0.2.
  • the reason for using the natural stone powder is the crack resistance and erosion resistance described above, but it is possible to produce the desired color, in particular texture expression is also intended to improve the appearance quality.
  • the sericite is added to increase the adhesion area by increasing the adhesion area to the surface and thereby increase the binding property to increase durability
  • silicon nitride in which amorphous nanoparticle-sized boron nitride is dispersed It suppresses the occurrence of minute cracks and may be added to enhance corrosion resistance.
  • the step of sintering and drying the coated lightweight non-combustible material is carried out at a temperature of 150-180 ° C. to form the coated lightweight non-combustible material through a sintering furnace in the form of a tunnel kiln or microwave tunnel kiln to ensure robust durability for final production. Drying step.
  • the hygroscopicity that is, the water repellency (water resistance) is excellent at 98% to confirm that the present invention achieves the object.
  • Example 1 In preparing the specimen material of Example 1, it was prepared by further adding an interfacial bond strengthening agent and silicon nitride in which sericite powder and boron nitride were dispersed in the coating material.

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Abstract

The present invention relates to a method for manufacturing a light-weight building material using perlite and, more specifically, to a method for manufacturing a light-weight building material using perlite, wherein perlite, which is excellent in view of fire resistance and sound absorption as well as lightweight and heat insulation and has environmentally friendly characteristics, is modified in terms of water absorption, acting as a drawback, thereby preventing a decrease in strength and attaining enhanced durability, and thus the usability of the perlite as a lightweight building material is maximized.

Description

펄라이트를 이용한 경량건축자재의 제조방법Method for manufacturing lightweight building materials using pearlite
본 발명은 펄라이트를 이용한 경량건축자재의 제조방법에 관한 것으로, 보다 상세하게는 경량성과 단열성은 물론 내화성과 흡음성까지 우수하고 친환경 특성을 갖는 펄라이트의 단점인 수분흡수성을 개량하여 강도 저하를 막고 내구성을 향상시킴으로써 경량 건축자재로서의 활용가치를 극대화시킨 펄라이트를 이용한 경량건축자재의 제조방법에 관한 것이다.The present invention relates to a method for manufacturing lightweight building materials using pearlite, and more particularly, to light weight and heat insulation, as well as fire resistance and sound absorption, and to improve water absorption, which is a disadvantage of pearlite having environmentally friendly properties, to prevent strength degradation and durability. The present invention relates to a method for manufacturing lightweight building materials using pearlite by maximizing utilization value as lightweight building materials.
일반적으로, 건축물의 시공에 있어서 건축자재(내,외장재, 단열재 등), 특히 단열재로 사용되고 있는 것은 값이 싸고, 시공이 간편하며, 단열성이 뛰어난 발포 폴리스티렌(EPS)과 발포 폴리우레탄(EPU)이 주를 이루고 있다.In general, in the construction of the building materials used for building materials (internal, exterior, thermal insulation, etc.), in particular, as a heat insulating material is cheap, easy to construct, and excellent foam insulation polystyrene (EPS) and foamed polyurethane (EPU) is excellent It is a state.
이들 재료들은 100kg/m3 이하의 경량이면서 단열성이 탁월하여 각종 건축물의 단열재 또는 샌드위치 판넬의 심재 등으로 대량으로 사용되고 있으나, 화재시 쉽게 연소하여 화염을 전파하고 또한 유독가스를 발생하는 등 내열성, 난연성에서 매우 취약한 단점을 가지고 있다.These materials are light weight and less than 100kg / m 3 and have excellent thermal insulation, so they are used in large quantities as insulation materials for various buildings or cores of sandwich panels. Has a very weak disadvantage.
이에, 이러한 문제를 해결하기 위해 난연성을 갖는 다양한 형태의 건축자재(내,외장재 또는 단열재 등)가 개발되었으며, 대표적인 것으로는 유리섬유, 석면/암면재, 방염처리된 폴리에스테르계 섬유재, 폴리올레핀계 발포재 등이 있다.In order to solve this problem, various types of building materials (inner, exterior materials or insulation materials) having flame retardancy have been developed, and typical examples are glass fiber, asbestos / rock material, flame retardant polyester fiber material, and polyolefin type. Foam materials and the like.
하지만, 이들은 단열성 및 흡음성이 미흡하거나 혹은 경량성 및 환경친화성이 결여되어, 건축용 재료로 이상적인 경량성, 난연성, 단열성, 경제성 등을 동시에 만족시키지 못하는 문제점이 있다.However, they have insufficient insulation and sound absorption, or lack of light weight and environmental friendliness, and thus have a problem in that they do not satisfy ideal light weight, flame retardancy, heat insulation, economic efficiency, and the like as building materials.
이와 같은 이유로 최근에는 팽창성 무기물인 펄라이트(Perlite)와 규조토, 황토분말 및 활성탄 등의 무기물과, 바인더로서 규산나트륨 및 알루미나졸 등과 같은 액상의 무기 바인더와 열경화성 페놀수지를 병용·혼합하여 고온에서 압축 성형한 경량의 내화성 단열재 혹은 건축자재들이 개시(disclosure)되고 있다.For this reason, in recent years, compression molding at high temperature was carried out by mixing and mixing expandable inorganic materials such as perlite, diatomaceous earth, ocher powder and activated carbon with liquid inorganic binders such as sodium silicate and alumina sol and thermosetting phenol resins as binders. One lightweight fire resistant insulation or building material has been disclosed.
그런데, 화산석으로 된 진주암을 900~1200℃로 소성한 후 분쇄하여 소성 팽창한 펄라이트는 작은 입자로 구성되어 공극율이 90% 이상 나타나며, 단위용적중량은 0.03~0.25 까지 미세공극을 가지는 경량 구상형이고, 내화성으로 600℃정도의 사용온도와 높은 흡음성을 갖는 장점이 있음에도 불구하고, 수분을 흡수하는 흡습성이 있어 성형 후 강도가 저하되기 때문에 외부마감재로는 적합하지 못하다는 한계를 가지고 있다.By the way, the pearlite expanded by calcination after calcination of volcanic stone at 900 ~ 1200 ℃ is composed of small particles, resulting in 90% or more of porosity, and the unit volume weight is light spherical with micropores up to 0.03 ~ 0.25. Although it has the advantage of having an operating temperature of about 600 ° C. and a high sound absorption property due to its fire resistance, it has a limitation that it is not suitable as an external finishing material because of its hygroscopic property of absorbing moisture, which lowers the strength after molding.
본 발명은 상술한 바와 같은 종래 기술상의 제반 문제점들을 감안하여 이를 해결하고자 창출된 것으로, 경량성과 단열성은 물론 내화성과 흡음성까지 우수하고 친환경 특성을 갖는 펄라이트의 단점인 수분흡수성을 개량하여 강도 저하를 막고 내구성을 향상시킴으로써 경량 건축자재로서의 활용가치를 극대화시킨 펄라이트를 이용한 경량건축자재의 제조방법을 제공함에 그 주된 목적이 있다.The present invention was created in view of the above-mentioned problems in the prior art, and has been created to solve this problem, and has excellent light weight and heat resistance as well as fire resistance and sound absorption, and improves water absorption, which is a disadvantage of pearlite having environmentally friendly properties, and prevents the strength from falling. The main purpose of the present invention is to provide a method for manufacturing lightweight building materials using pearlite, which maximizes the utilization value as lightweight building materials by improving durability.
본 발명은 상기한 목적을 달성하기 위한 수단으로, 경량건축자재의 베이스가 되는 팽창 펄라이트 원료를 제조하는 단계; 상기 팽창 펄라이트 원료를 성형하여 기재(Base)를 형성하는 단계; 성형된 기재 위에 스테인리스스틸 메쉬망을 포설하는 단계; 스테인리스스틸 메쉬망이 포설된 기재 위에 팽창 펄라이트 원료를 다시 투입한 후 성형하여 경량 불연 자재를 형성하는 단계; 경량 불연 자재의 표면에 피막을 형성하는 단계; 피막이 형성된 경량 불연 자재를 소결 건조하는 단계;를 포함하는 펄라이트를 이용한 경량건축자재의 제조방법을 제공한다.The present invention is a means for achieving the above object, the step of preparing an expanded pearlite raw material that is the base of the lightweight building material; Molding the expanded pearlite raw material to form a base; Laying a stainless steel mesh network on the molded substrate; Re-injecting the expanded pearlite raw material on the substrate on which the stainless steel mesh network is installed to form a lightweight non-combustible material; Forming a coating on the surface of the lightweight non-combustible material; It provides a method for manufacturing a light-weight building materials using a pearlite comprising a; sintering and drying the lightweight non-combustible material formed with a coating.
이때, 상기 팽창 펄라이트 원료를 제조하는 단계는 펄라이트 원석을 분쇄, 고온처리하여 팽창 펄라이트를 만드는 과정; 서스펜션(Suspension) 혹은 페이스트(Paste) 상태의 세라믹 바인더를 만드는 과정; 세라믹 바인더로 팽창 펄라이트를 코팅하는 과정; 코팅된 팽창 펄라이트를 건조하는 과정으로 이루어진 것에도 그 특징이 있다.At this time, the step of preparing the expanded pearlite raw material is a process of making expanded pearlite by pulverizing the pearlite ore, high temperature treatment; Making a ceramic binder in a suspension or paste state; Coating expanded pearlite with a ceramic binder; It is also characterized by the process of drying the coated expanded pearlite.
또한, 상기 세라믹 바인더를 만드는 과정은 세라믹 분체에 알카리인 규산나트륨을 1:6-7의 중량비로 첨가하여 가열하면서 공중합반응을 서서히 유도한 후 공중합시 생성되는 복합산화물을 기계적으로 분쇄하여 복합산화물 분체를 얻는 스텝과; 상기 복합산화물 분체에 복합산화물 분체 100중량부에 대해 나노 실리카졸 0.2-0.5중량부와 증류수 20-30중량부를 첨가 교반하여 부착성과 경도율이 높은 세라믹 바인더를 제조하는 스텝;으로 이루어진 것에도 그 특징이 있다.In addition, the process of making the ceramic binder is a compound oxide powder by mechanically pulverizing the composite oxide produced during copolymerization after slowly inducing a copolymerization reaction by heating by adding alkali sodium silicate in a weight ratio of 1: 6-7 to the ceramic powder Obtaining a step; And a step of preparing a ceramic binder having high adhesion and hardness by adding and stirring 0.2-0.5 parts by weight of nano silica sol and 20-30 parts by weight of distilled water to 100 parts by weight of the composite oxide powder to the composite oxide powder. There is this.
본 발명에 따르면, 경량성과 단열성은 물론 내화성과 흡음성까지 우수하고 친환경 특성을 갖는 펄라이트의 단점인 수분흡수성을 개량하여 강도 저하를 막고 내구성을 향상시킴으로써 경량 건축자재로서의 활용가치를 극대화시키는 효과를 얻을 수 있다.According to the present invention, it is possible to obtain the effect of maximizing the utilization value as lightweight building materials by preventing moisture loss and improving durability by improving water absorption, which is a disadvantage of pearlite, which is excellent in fire resistance and sound absorption, as well as light weight and heat insulation, as well as fire resistance and sound absorption. have.
도 1은 본 발명에 따른 펄라이트를 이용한 경량건축자재의 제조방법을 보인 모식적인 공정도이다.1 is a schematic process diagram showing a method for manufacturing a lightweight building material using pearlite according to the present invention.
도 2 내지 도 5는 본 발명에 따른 경량건축자재 시료의 특성 테스트 결과를 보인 시험성적서이다.2 to 5 is a test report showing the results of the characteristic test of the lightweight building material sample according to the present invention.
이하에서는, 첨부도면을 참고하여 본 발명에 따른 바람직한 실시예를 보다 상세하게 설명하기로 한다.Hereinafter, with reference to the accompanying drawings will be described in detail a preferred embodiment according to the present invention.
본 발명 설명에 앞서, 이하의 특정한 구조 내지 기능적 설명들은 단지 본 발명의 개념에 따른 실시예를 설명하기 위한 목적으로 예시된 것으로, 본 발명의 개념에 따른 실시예들은 다양한 형태로 실시될 수 있으며, 본 명세서에 설명된 실시예들에 한정되는 것으로 해석되어서는 아니된다.Prior to the description of the present invention, the following specific structures or functional descriptions are merely illustrated for the purpose of describing embodiments according to the inventive concept, and the embodiments according to the inventive concept may be implemented in various forms, It should not be construed as limited to the embodiments described herein.
또한, 본 발명의 개념에 따른 실시예는 다양한 변경을 가할 수 있고 여러 가지 형태를 가질 수 있으므로, 특정 실시예들은 도면에 예시하고 본 명세서에 상세하게 설명하고자 한다. 그러나, 이는 본 발명의 개념에 따른 실시예들을 특정한 개시 형태에 한정하려는 것이 아니며, 본 발명의 사상 및 기술 범위에 포함되는 모든 변경물, 균등물 내지 대체물을 포함하는 것으로 이해되어야 한다.In addition, embodiments in accordance with the concepts of the present invention may be modified in various ways and may have various forms, specific embodiments will be illustrated in the drawings and described in detail herein. However, this is not intended to limit the embodiments in accordance with the concept of the present invention to a specific disclosed form, it should be understood to include all modifications, equivalents, and substitutes included in the spirit and scope of the present invention.
본 발명에 따른 펄라이트를 이용한 경량건축자재의 제조방법은 경량건축자재의 베이스가 되는 팽창 펄라이트 원료를 제조하는 단계, 상기 팽창 펄라이트 원료를 성형하여 기재(Base)를 형성하는 단계, 성형된 기재 위에 스테인리스스틸 메쉬망을 포설하는 단계, 스테인리스스틸 메쉬망이 포설된 기재 위에 팽창 펄라이트 원료를 다시 투입한 후 성형하여 경량 불연 자재를 형성하는 단계, 경량 불연 자재의 표면에 피막을 형성하는 단계, 피막이 형성된 경량 불연 자재를 소결 건조하는 단계를 포함한다.According to the present invention, there is provided a method for manufacturing a lightweight building material using pearlite, the method comprising: preparing expanded pearlite raw material serving as a base of lightweight building material; forming the base by molding the expanded pearlite raw material; Step of laying a steel mesh net, Re-inflating expanded pearlite raw material on the substrate on which the stainless steel mesh net is formed and forming a lightweight non-combustible material, Forming a film on the surface of the light non-combustible material, Lightweight formed film Sintering and drying the non-combustible material.
이러한 본 발명에서 사용되는 펄라이트(perlite)는 진주암, 흑요석, 경석 등으로 이루어진 군으로부터 선택된 광물을 미세하게 분쇄한 후 높은 열(900~1200℃)로 가열하면, 함유된 휘발성분이 가스화하여 연화된 입자의 내부에서 팽창하여 내부기공이 형성되며, 본래 부피의 약 10~20배 정도로 팽창하게 되는데, 팽창은 펄라이트 원료(the crude perlite rock)에 포함된 펄라이트의 휘발성분 때문이며, 이를 팽창 펄라이트라고 한다.The pearlite (perlite) used in the present invention is finely crushed minerals selected from the group consisting of pearlite, obsidian, pumice, etc. and then heated to high heat (900 ~ 1200 ℃), the volatile content contained gasified and softened The internal pores are formed by the expansion of the inside, and the expansion is about 10 to 20 times the original volume. The expansion is due to the volatile content of the pearlite contained in the crude perlite rock, which is called expanded pearlite.
이와 같은 펄라이트는 유문암질 암석의 일종으로, 진주광택을 가진 연회색에서 암회색, 갈색, 녹색, 검은색을 띔으로 진주암이라고도 하며, 암석의 조직에 따라 다르지만 870~1100℃ 정도에서 결합수가 증발하면서 생기는 증발압력이 각각의 과립입자를 원형의 유리질입자로 약 10배에서 20배 정도 팽창하여 상업적으로 사용된다.Such pearlite is a kind of rhyolite rock, and it is also called pearl rock with light gray with pearlescent to dark gray, brown, green and black, and it is evaporated when the binding water evaporates at 870 ~ 1100 ℃ although it depends on the structure of the rock. Pressure is used commercially to expand each granular particle about 10 to 20 times into circular vitreous particles.
이렇게 팽창된 펄라이트는 저밀도에 다공질이고, 흡수능력이 좋으며, 경량성, 단열성, 보온성, 흡음성, 무독성 및 불연성 등의 성질을 가지고 있어 내열재료, 방음재료, 경량골재 및 단열재료 등의 경량건축자재로 널리 이용되고 있다.The expanded pearlite is porous at low density, has good absorption ability, and has properties such as light weight, heat insulation, heat insulation, sound absorption, non-toxicity, and non-flammability, making it a lightweight building material such as heat-resistant material, soundproof material, lightweight aggregate, and heat insulating material. It is widely used.
다만, 종래 기술에서 문제점으로도 언급했듯이 흡습성이 좋기 때문에 강도 저하, 내구성 약화의 단점이 있으므로 본 발명은 이를 해결할 수 있는 방법적 접근을 주된 특징으로 한다.However, as mentioned as a problem in the prior art, the hygroscopicity is good, so that there is a disadvantage in strength reduction and durability deterioration.
즉, 본 발명에서는 팽창 펄라이트 원료를 제조할 때 세라믹 바인더를 사용하게 되는데, 이러한 세라믹 바인더를 특수가공함으로써 팽창 펄라이트가 갖는 한계인 흡습성을 억제하도록 구성할 수 있는데 이러한 개념은 선행기술들에 나타나 있지 않는 특징들이다.That is, in the present invention, when the expanded pearlite raw material is manufactured, a ceramic binder is used, and by specially processing such a ceramic binder, it can be configured to suppress hygroscopicity, which is a limitation of the expanded pearlite, which is not shown in the prior art. Features.
이를 테면, 세라믹 바인더 제조에 사용되는 규산나트륨 공중합체의 중합시 반응형 유화제, 즉 폴리머와 공유결합이 가능한 무기물 유화제를 사용하여 중합하고, 상기 중합단계에 나노 실리카졸을 투입하여 제조하는 것을 예시할 수 있다.For example, the polymerization of the sodium silicate copolymer used in the manufacture of the ceramic binder is polymerized using a reactive emulsifier, that is, an inorganic emulsifier capable of covalent bonding with a polymer, and is prepared by adding nano silica sol to the polymerization step. Can be.
보다 구체적으로, 상기 팽창 펄라이트 원료를 제조하는 단계는 펄라이트 원석을 분쇄, 고온처리하여 팽창 펄라이트를 만드는 과정; 서스펜션(Suspension) 혹은 페이스트(Paste) 상태의 세라믹 바인더를 만드는 과정; 세라믹 바인더로 팽창 펄라이트를 코팅하는 과정; 코팅된 팽창 펄라이트를 건조하는 과정으로 이루어진다.More specifically, the step of preparing the expanded pearlite raw material is a process of making expanded pearlite by pulverizing, high-temperature processing pearlite ore; Making a ceramic binder in a suspension or paste state; Coating expanded pearlite with a ceramic binder; Drying of the coated expanded pearlite.
이때, 상기 팽창 펄라이트를 만드는 과정은 펄라이트 원석을 분쇄한 후 900~1200℃로 고온 가열하여 팽창시킴으로써 이루어진다.At this time, the process of making the expanded pearlite is made by swelling the high-temperature heating to 900 ~ 1200 ℃ after grinding the pearlite ore.
그리고, 상기 세라믹 바인더를 만드는 과정은 세라믹 분체에 알카리인 규산나트륨을 1:6-7의 중량비로 첨가하여 가열하면서 공중합반응을 서서히 유도한 후 공중합시 생성되는 복합산화물을 기계적으로 분쇄하여 복합산화물 분체를 얻는 스텝과; 상기 복합산화물 분체에 복합산화물 분체 100중량부에 대해 나노 실리카졸 0.2-0.5중량부와 증류수 20-30중량부를 첨가 교반하여 부착성과 경도율이 높은 세라믹 바인더를 제조하는 스텝;으로 이루어진다.In the process of making the ceramic binder, the alkali powder sodium silicate is added to the ceramic powder in a weight ratio of 1: 6-7 to slowly induce a copolymerization reaction while heating, and then composite oxide powder is mechanically pulverized. Obtaining a step; And adding 0.2-0.5 parts by weight of nano-silicon sol and 20-30 parts by weight of distilled water to the composite oxide powder to 100 parts by weight of the composite oxide powder to prepare a ceramic binder having high adhesion and hardness.
여기에서, 상기 세라믹 분체는 무기성 유화제로 사용되는 것으로서 열간 가공시 팽창 펄라이트의 입자 파괴 및 기공 폐색을 방지하고, 기공 주변에서 소수성을 강화시켜 흡습성을 현저히 낮추는 역할을 하게 된다.Here, the ceramic powder is used as an inorganic emulsifier to prevent particle destruction and pore blockage of the expanded pearlite during hot processing, and serves to significantly reduce hygroscopicity by strengthening hydrophobicity around the pores.
이러한 효과를 극대화시키기 위해서는 규산나트륨과 공중합반응이 서서히 그리고 전체적으로 균일하게 이루어져야 하므로 세라믹 분체와 규산나트륨은 상술한 중량비로 혼합된 후 균일한 분산이 이루어질 수 있도록 균일하게 혼합되어야 한다.In order to maximize the effect, the sodium silicate and the copolymerization reaction should be made gradually and uniformly, so that the ceramic powder and sodium silicate should be mixed evenly to achieve uniform dispersion after mixing in the above weight ratio.
아울러, 상기 나노 실리카졸은 결합성과 분산성을 동시에 높이기 위해 첨가되는 성분으로서 팽창 펄라이트를 코팅할 때 계면 밀착력을 증대시키기 위해 첨가되며, 0.5중량부를 초과하면 점도 및 코팅밀착력이 떨어지고 0.2중량부 미만으로 첨가되면 결합성과 분산성을 높일 수 없기 때문에 상기 범위로 한정되어야 한다.In addition, the nano-silica sol is added to increase the interfacial adhesion when coating the expanded pearlite as a component added to increase the bonding and dispersibility at the same time, if it exceeds 0.5 parts by weight, the viscosity and coating adhesion is lowered to less than 0.2 parts by weight When added, it should be limited to the above range because it can not increase the bondability and dispersibility.
덧붙여, 상기 세라믹 바인더를 제조하는 스텝에서 디크롤에탄과 메틸렌클롤라이드가 1:1의 중량비로 혼합된 교반물과 디메틸폴리실록산을 각각 상기 복합산화물 분체 100중량부에 대해 2.5-4.0중량부 및 3.5-6.5중량부 더 첨가할 수 있다.In addition, in the step of preparing the ceramic binder, 2.5-4.0 parts by weight and 3.5- parts of the mixture and the dimethyl polysiloxane were mixed with dichloroethane and methylene chloride in a weight ratio of 1: 1, respectively. 6.5 parts by weight may be further added.
이 경우, 상기 디크롤에탄과 메틸렌클롤라이드가 1:1의 중량비로 혼합된 교반물은 팽창 펄라이트 성형시 치수안정화를 꾀해 체적변화에 따른 불량을 억제하고, 흡음성을 강화시키기 위한 것이며; 상기 디메틸폴리실록산은 열에 강한 실록산 결합(Si-O-Si)과 유기질의 메틸기로 구성되어 있어 열산화 안정성, 내화학성과 발수성을 증대시켜, 특히 흡습성을 극소화시켜 내구성을 강화시키기 위한 것이다.In this case, the agitated mixture of dichloroethane and methylene chloride in a weight ratio of 1: 1 is intended for dimensional stabilization during expansion pearlite molding to suppress defects due to volume change and to enhance sound absorption; The dimethylpolysiloxane is composed of a heat-resistant siloxane bond (Si-O-Si) and an organic methyl group to increase the thermal oxidation stability, chemical resistance and water repellency, in particular to minimize the hygroscopicity to enhance durability.
그리고, 상기 세라믹 바인더로 팽창 펄라이트를 코팅하는 과정은 서스펜션 혹은 페이스트 상태의 세라믹 바인더를 팽창 펄라이트에 살포한 후 균일하게 믹싱하여 세라믹 바인더가 팽창 펄라이트를 코팅하도록 하는 과정이다.The process of coating the expanded pearlite with the ceramic binder is a process of spraying the ceramic binder in a suspension or paste state onto the expanded pearlite and then mixing it uniformly to coat the expanded pearlite.
또한, 상기 코팅된 팽창 펄라이트를 건조하는 과정은 세라믹 바인더가 코팅된 팽창 펄라이트를 열풍 혹은 마이크로웨이브를 이용하여 건조하는 과정이다.In addition, the process of drying the coated expanded pearlite is a process of drying the expanded pearlite coated with a ceramic binder using hot air or microwave.
한편, 팽창 펄라이트 원료를 성형하여 기재(Base)를 형성하는 단계는 도 1의 예시와 같이, 컨베어(100)와 성형롤러(200)를 이용하여 팽창 펄라이트 원료, 즉 세라믹 바인더가 코팅된 상태에서 건조된 팽창 펄라이트 원료를 컨베어(100)로 이송하면서 성형롤러(200)로 롤링하여 기재를 성형하는 단계이다.On the other hand, forming the base by forming the expanded pearlite raw material is dried in the state in which the expanded pearlite raw material, that is, the ceramic binder is coated using the conveyor 100 and the forming roller 200, as shown in FIG. It is a step of forming a substrate by rolling the expanded perlite raw material to the conveyor 100 while rolling to the molding roller 200.
이러한 롤러형 성형설비는 당해 분야에서 널리 사용되는 것이므로 성형설비 자체의 구성에 대해서는 구체적인 설명을 생략하며, 개념적인 설명만 하기로 한다.Since the roller-type molding equipment is widely used in the art, a detailed description of the configuration of the molding equipment itself will be omitted, and only a conceptual description will be given.
다만, 본 발명에서는 성형자유도를 높일 수 있도록 상기 성형롤러(200)에 발열선(히터)을 내장시켜 성형시 가열온도를 자유롭고 쉽게 조절할 수 있도록 한다.However, in the present invention, a heating line (heater) is built in the forming roller 200 so as to increase the degree of freedom of molding so that the heating temperature can be freely and easily controlled during molding.
특히, 사출 방식을 사용하지 않고 성형롤러 방식을 채택한 이유는 기재 성형시 기재의 두께를 자유롭게 조절할 수 있고, 눌러주는 롤러의 무게를 달리하여 누르는 힘을 조절할 수 있을 뿐만 아니라 균일한 가압력을 확보할 수 있어 기재의 품질을 향상시킬 수 있기 때문이다.In particular, the reason for adopting the molding roller method without using the injection method is that the thickness of the substrate can be freely adjusted during the molding of the substrate, the pressing force can be adjusted by varying the weight of the pressing roller, and the uniform pressing force can be secured. This is because the quality of the base material can be improved.
그리고, 스테인리스스틸 메쉬망을 포설하는 단계는 녹이 슬지 않도록 스테인리스스틸로 된 메쉬망을 사용하여 기재의 표면에 포설함으로써 일종의 철근 역할을 담당하여 건축물처럼 튼튼하고 견고한 내구성을 갖도록 구성하는 단계이다.In addition, the step of installing the stainless steel mesh network is a step of constructing to be a kind of reinforcement by building a surface of the base material using a stainless steel mesh net so as not to rust, so as to have a strong and durable durability like a building.
이때, 상기 스테인리스스틸 메쉬망은 메쉬망 공급롤러(300)를 통해 컨베어(100)가 진행하는 도중에 기재 성형 후 공급됨으로써 연속처리가 가능하도록 구성된다.At this time, the stainless steel mesh network is configured to be continuously processed by being supplied after molding the substrate in the middle of the conveyor 100 through the mesh network feed roller 300.
이 경우, 스테인리스스틸 메쉬망의 고정력, 즉 결합력을 높이면서 계면에서의 층분리를 억제하고, 계면에서의 초기 결합강도 확보 및 내수성과 내후성(耐候性)을 확보할 수 있도록 수용성 에폭시수지 4.5중량%와, 이산화티타늄(titanium dioxide) 2.5중량%와, 알루미나 8.5중량%와, 무수석고 4.5중량%와, 우르솔산(Ursolic acid) 3.5중량%와, 메타인산염 2.5중량%와, 알긴산암모늄 3.5중량% 및 나머지 물로 이루어진 계면결합강화제를 더 살포할 수 있다.In this case, 4.5% by weight of water-soluble epoxy resin can be used to increase the fixing force, that is, the bonding force, of the stainless steel mesh network, thereby preventing layer separation at the interface, and to secure the initial bonding strength at the interface, and to ensure water resistance and weather resistance. And, 2.5 wt% titanium dioxide, 8.5 wt% alumina, 4.5 wt% anhydrous gypsum, 3.5 wt% ursolic acid, 2.5 wt% metaphosphate, 3.5 wt% ammonium alginate, and The interfacial bond strengthening agent consisting of the remaining water can be further sprayed.
여기에서, 상기 수용성 에폭시수지는 계면에서의 안정적인 부착력을 유지하면서 접착력을 극대화시켜 박리억제성을 구현하고 내후성을 강화시키기 위해 첨가된다.Here, the water-soluble epoxy resin is added to maximize the adhesive force while maintaining a stable adhesion at the interface to implement peeling inhibition and to enhance weather resistance.
그리고, 상기 이산화티타늄은 에폭시수지와의 결합에 의해 물에 대한 저항성을 강화시켜 방수성, 방습성을 강화시키기 위해 첨가된다.In addition, the titanium dioxide is added to enhance the water resistance and moisture resistance by strengthening the resistance to water by bonding with the epoxy resin.
뿐만 아니라, 상기 알루미나(alumina)는 알루미늄의 산화물로서 내열성 향상은 물론 건축자재의 강도, 즉 내구성을 향상시키기 위해 첨가된다.In addition, the alumina (alumina) is an oxide of aluminum is added to improve the heat resistance as well as the strength of building materials, that is, durability.
나아가, 상기 무수석고(anhydrous gypsum)는 결정수를 갖지 않는 황산 칼슘염으로서 초기 강도 확보를 위해 첨가된다.Furthermore, the anhydrous gypsum is a calcium sulfate salt having no crystal water and is added to secure initial strength.
또한, 상기 우르솔산은 침상의 흡수성이 우수한 분체로 유기 증점제를 대체하여 분체 입자표면에서의 결합강도를 강고하게 하여 내구성을 높이기 위해 첨가된다.In addition, the ursolic acid is added to increase the durability by strengthening the bonding strength on the surface of the powder particles by replacing the organic thickener with powder having excellent needle absorption.
아울러, 상기 메타인산염은 계면에서의 산화방지 기능을 강화시키기 위해 첨가되고, 상기 알긴산암모늄은 조성물의 결합안정성과 점도 조절을 위해 첨가된다.In addition, the metaphosphate is added to enhance the antioxidant function at the interface, and the ammonium alginate is added to adjust the binding stability and viscosity of the composition.
다른 한편, 경량 불연 자재를 형성하는 단계는 스테인리스스틸 메쉬망이 포설된 기재 위에 앞서 설명한 동일한 팽창 펄라이트 원료를 다시 투입한 후 성형하여 기재 위에 표층을 형성함으로써 기재와 표층이 일체화된 하나의 건축자재, 즉 경량 불연 자재를 완성하는 단계이다.On the other hand, the step of forming a lightweight non-combustible material is a building material in which the base material and the surface layer are integrated by forming the surface layer on the substrate by re-inserting the same expanded pearlite raw material described above on the substrate on which the stainless steel mesh network is installed, In other words, it is a step to complete a lightweight non-combustible material.
이때, 팽창 펄라이트 원료는 원료공급기(400)를 통해 컨베어(100)를 타고 이동하고 있는 기재 위로 살포된다.At this time, the expanded perlite raw material is sprayed onto the substrate moving in the conveyor 100 through the raw material feeder (400).
그러면, 팽창 펄라이트 원료는 스테인리스스틸 메쉬망을 완전히 덮게 되고, 기재와 대응되는 두께를 갖도록 자재성형롤(500)을 통해 성형됨으로써 기재-스테인리스스틸 메쉬망-표층 구조를 갖는 건축자재, 즉 경량 불연 자재를 완성하게 된다.Then, the expanded pearlite raw material completely covers the stainless steel mesh network, and is formed through the material forming roll 500 to have a thickness corresponding to that of the substrate, thereby building materials having a substrate-stainless steel mesh network-surface layer structure, that is, a lightweight non-combustible material. Will complete.
이 경우에도 상기 자재성형롤(500)에는 발열선(히터)가 내장되어 있어 가열가압 성형이 가능하도록 구성되어야 함은 물론이다.In this case as well, the material forming roll 500 has a heating wire (heater) built-in to be configured to be capable of hot pressing.
또한, 이 과정에서 기재와 표층간 계면에서는 동일 재료이므로 열융합이 일어나면서 스테인리스스틸을 머금은 채 완전한 하나의 바디로 일체화되어 합체되게 된다.In this process, since the material is the same material at the interface between the substrate and the surface layer, heat fusion occurs and is integrated into one complete body with stainless steel.
그리고, 경량 불연 자재의 표면에 피막을 형성하는 단계는 피막원료공급기(600)를 통해 피막원료를 공급하여 표층에 일정두께로 살포한 후 롤링하는 단계이다.In addition, the forming of the film on the surface of the light weight non-combustible material is a step of rolling after supplying the coating material through the coating material feeder 600 and spraying the coating layer with a predetermined thickness.
여기에서, 상기 피막원료를 살포하여 피막을 형성하는 이유는 표면 크랙발생을 억제하고, 표면 침식을 방지하여 장수명화를 유지할 수 있도록 하기 위함이며, 이를 위해 상기 피막원료는 상술한 액상, 더 정확하게는 서스펜션 혹은 페이스트 상의 세라믹 바인더와 천연종석분말을 1:0.2의 중량비로 혼합하여 사용된다.Here, the reason for forming the film by spraying the coating material is to suppress the surface cracking, to prevent surface erosion to maintain long life, for this purpose, the coating material is a liquid, more precisely It is used by mixing the ceramic binder and natural seed powder in the suspension or paste in a weight ratio of 1: 0.2.
이때, 천연종석분말을 사용하는 이유는 상술한 내크랙성, 내침식성도 있지만, 원하는 색상 연출이 가능하고, 특히 질감표현도 가능하여 외관 품질을 높이려는 의도도 있는 것이다.At this time, the reason for using the natural stone powder is the crack resistance and erosion resistance described above, but it is possible to produce the desired color, in particular texture expression is also intended to improve the appearance quality.
나아가, 표면 내구성과 내침식성, 내크랙성을 더욱 강화시키기 위해 상기 피막원료 100중량부에 대해 세리사이트 분말 2.5중량부와, 무정형의 나노입자 크기의 질화붕소를 분산시킨 질화규소 3.5중량부를 더 첨가할 수 있다.Furthermore, in order to further enhance surface durability, corrosion resistance and crack resistance, 2.5 parts by weight of sericite powder and 3.5 parts by weight of silicon nitride in which amorphous nanoparticles of boron nitride are dispersed may be added to 100 parts by weight of the coating material. Can be.
이 경우, 상기 세리사이트(Sericite)는 표면에 대한 접착면적을 넓혀주어 부착력을 배가시키고 이를 통해 바인딩성을 강화시켜 내구성을 증대시키기 위해 첨가되며, 무정형의 나노입자 크기의 질화붕소를 분산시킨 질화규소는 미소 크랙이 발생하는 것을 억제하며, 내침식성을 강화시키기 위해 첨가될 수 있다.In this case, the sericite is added to increase the adhesion area by increasing the adhesion area to the surface and thereby increase the binding property to increase durability, and silicon nitride in which amorphous nanoparticle-sized boron nitride is dispersed It suppresses the occurrence of minute cracks and may be added to enhance corrosion resistance.
마지막으로, 피막이 형성된 경량 불연 자재를 소결 건조하는 단계는 최종 제품화를 위해 견고한 내구성을 갖추도록 터널식 킬른 혹은 마이크로웨이브 터널킬른 형태를 갖는 소결로를 통해 피막이 형성된 경량 불연 자재를 150-180℃의 온도에서 건조시키는 단계이다.Finally, the step of sintering and drying the coated lightweight non-combustible material is carried out at a temperature of 150-180 ° C. to form the coated lightweight non-combustible material through a sintering furnace in the form of a tunnel kiln or microwave tunnel kiln to ensure robust durability for final production. Drying step.
이렇게 건조하게 되면 최종 제품화 된다.This drying results in a final product.
이하, 실시예에 대하여 설명한다.Hereinafter, an Example is described.
[실시예 1]Example 1
먼저, 20㎝×15㎝×4㎝ 크기의 시편 자재를 제조하였다.First, a specimen material having a size of 20 cm x 15 cm x 4 cm was prepared.
그리고, 상기 시편 자재에 대하여 첨부한 도 2 내지 도 5와 같이 불연성시험, 가스유해성 실험, 흡음성 실험을 진행한 결과, 모두 양호한 결과를 얻었다.In addition, as a result of performing the nonflammability test, the gas hazard test, and the sound absorption test, as shown in FIGS.
특히, 내흡습성, 즉 발수성(내수성)이 98%로 우수한 것으로 확인되어 본 발명이 목적하는 바를 달성하고 있음을 확인할 수 있었다.In particular, it was confirmed that the hygroscopicity, that is, the water repellency (water resistance) is excellent at 98% to confirm that the present invention achieves the object.
[실시예 2]Example 2
실시예 1의 시편 자재 제조시 계면결합강화제와, 피막원료에 세리사이트 분말과 질화붕소를 분산시킨 질화규소를 더 첨가하여 제조하였다.In preparing the specimen material of Example 1, it was prepared by further adding an interfacial bond strengthening agent and silicon nitride in which sericite powder and boron nitride were dispersed in the coating material.
실시예 2에 따른 계면에서의 분리억제성을 확인하기 위해 시편을 세운 상태에서 폭 중심을 해머로 10회 타격한 후 계면 분리 여부를 확인하였으며, 또한 시편을 수평하게 놓은 상태에서 표면 중심에 10회 타격하여 계면 분리 및 크랙 발생여부를 확인하였으나 계면분리나 크랙발생이 확인되지 않았다.In order to confirm separation inhibition at the interface according to Example 2, the width of the specimen was raised 10 times with a hammer and the interface was separated, and the interface was separated. It was confirmed that the interface separation and cracking occurred by hitting, but no interface separation or cracking was confirmed.

Claims (3)

  1. 경량건축자재의 베이스가 되는 팽창 펄라이트 원료를 제조하는 단계;Manufacturing an expanded pearlite raw material serving as a base of the lightweight building material;
    상기 팽창 펄라이트 원료를 성형하여 기재(Base)를 형성하는 단계;Molding the expanded pearlite raw material to form a base;
    성형된 기재 위에 스테인리스스틸 메쉬망을 포설하는 단계;Laying a stainless steel mesh network on the molded substrate;
    스테인리스스틸 메쉬망이 포설된 기재 위에 팽창 펄라이트 원료를 다시 투입한 후 성형하여 경량 불연 자재를 형성하는 단계;Re-injecting the expanded pearlite raw material on the substrate on which the stainless steel mesh network is installed to form a lightweight non-combustible material;
    경량 불연 자재의 표면에 피막을 형성하는 단계;Forming a coating on the surface of the lightweight non-combustible material;
    피막이 형성된 경량 불연 자재를 소결 건조하는 단계;를 포함하는 펄라이트를 이용한 경량건축자재의 제조방법.Sintering and drying the light-weight non-combustible material is a film formed.
  2. 청구항 1에 있어서;The method according to claim 1;
    상기 팽창 펄라이트 원료를 제조하는 단계는 펄라이트 원석을 분쇄, 고온처리하여 팽창 펄라이트를 만드는 과정; 서스펜션(Suspension) 혹은 페이스트(Paste) 상태의 세라믹 바인더를 만드는 과정; 세라믹 바인더로 팽창 펄라이트를 코팅하는 과정; 코팅된 팽창 펄라이트를 건조하는 과정으로 이루어진 것을 특징으로 하는 펄라이트를 이용한 경량건축자재의 제조방법.The step of preparing the expanded pearlite raw material is a process of making expanded pearlite by pulverizing the pearlite ore, high temperature treatment; Making a ceramic binder in a suspension or paste state; Coating expanded pearlite with a ceramic binder; A method of manufacturing lightweight building materials using pearlite, characterized in that the process of drying the coated expanded pearlite.
  3. 청구항 2에 있어서,The method according to claim 2,
    상기 세라믹 바인더를 만드는 과정은 세라믹 분체에 알카리인 규산나트륨을 1:6-7의 중량비로 첨가하여 가열하면서 공중합반응을 서서히 유도한 후 공중합시 생성되는 복합산화물을 기계적으로 분쇄하여 복합산화물 분체를 얻는 스텝과; 상기 복합산화물 분체에 복합산화물 분체 100중량부에 대해 나노 실리카졸 0.2-0.5중량부와 증류수 20-30중량부를 첨가 교반하여 부착성과 경도율이 높은 세라믹 바인더를 제조하는 스텝;으로 이루어진 것을 특징으로 하는 펄라이트를 이용한 경량건축자재의 제조방법.In the process of making the ceramic binder, sodium alkali silicate is added to the ceramic powder in a weight ratio of 1: 6-7 to gradually induce a copolymerization reaction while heating and mechanically pulverize the composite oxide produced during copolymerization to obtain a composite oxide powder. A step; Preparing a ceramic binder having high adhesion and hardness by adding and stirring 0.2-0.5 parts by weight of nano silica sol and 20-30 parts by weight of distilled water with respect to 100 parts by weight of the composite oxide powder to the composite oxide powder. Method for manufacturing lightweight building materials using pearlite.
PCT/KR2018/005576 2018-05-09 2018-05-15 Method for manufacturing light-weight building material using perlite WO2019216470A1 (en)

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KR102427316B1 (en) * 2021-11-04 2022-08-01 한국도시재생기술(주) Composite plate manufacturing method with excellent thermal conductivity and weight reduction by recycling waste perlite and waste synthetic resin

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