WO2020137987A1 - 耐火断熱組成物、耐火断熱組成物スラリー、耐火断熱ボード及び耐火断熱構造体 - Google Patents
耐火断熱組成物、耐火断熱組成物スラリー、耐火断熱ボード及び耐火断熱構造体 Download PDFInfo
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- WO2020137987A1 WO2020137987A1 PCT/JP2019/050394 JP2019050394W WO2020137987A1 WO 2020137987 A1 WO2020137987 A1 WO 2020137987A1 JP 2019050394 W JP2019050394 W JP 2019050394W WO 2020137987 A1 WO2020137987 A1 WO 2020137987A1
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- 239000011592 zinc chloride Substances 0.000 description 1
- 235000005074 zinc chloride Nutrition 0.000 description 1
- 239000011787 zinc oxide Substances 0.000 description 1
- 235000014692 zinc oxide Nutrition 0.000 description 1
Images
Classifications
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- 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
- C04B14/10—Clay
-
- 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
- C04B28/14—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 calcium sulfate cements
-
- 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
- C04B28/02—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 hydraulic cements other than calcium sulfates
- C04B28/06—Aluminous cements
- C04B28/065—Calcium aluminosulfate cements, e.g. cements hydrating into ettringite
-
- 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
- C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
- C04B38/08—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by adding porous substances
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J9/00—Working-up of macromolecular substances to porous or cellular articles or materials; After-treatment thereof
- C08J9/36—After-treatment
- C08J9/40—Impregnation
-
- 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
- E04B1/74—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls
- E04B1/76—Heat, sound or noise insulation, absorption, or reflection; Other building methods affording favourable thermal or acoustical conditions, e.g. accumulating of heat within walls specifically with respect to heat only
- E04B1/78—Heat insulating elements
- E04B1/80—Heat insulating elements slab-shaped
-
- 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
-
- 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
- C04B2103/00—Function or property of ingredients for mortars, concrete or artificial stone
- C04B2103/10—Accelerators; Activators
-
- 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
- C04B2103/00—Function or property of ingredients for mortars, concrete or artificial stone
- C04B2103/20—Retarders
- C04B2103/22—Set retarders
-
- 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
- C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
- C04B2111/00482—Coating or impregnation materials
- C04B2111/00534—Coating or impregnation materials for plastic surfaces, e.g. polyurethane foams
-
- 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
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2201/00—Foams characterised by the foaming process
- C08J2201/02—Foams characterised by the foaming process characterised by mechanical pre- or post-treatments
- C08J2201/038—Use of an inorganic compound to impregnate, bind or coat a foam, e.g. waterglass
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08J—WORKING-UP; GENERAL PROCESSES OF COMPOUNDING; AFTER-TREATMENT NOT COVERED BY SUBCLASSES C08B, C08C, C08F, C08G or C08H
- C08J2325/00—Characterised by the use of homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an aromatic carbocyclic ring; Derivatives of such polymers
- C08J2325/02—Homopolymers or copolymers of hydrocarbons
- C08J2325/04—Homopolymers or copolymers of styrene
- C08J2325/06—Polystyrene
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
- Y02W30/00—Technologies for solid waste management
- Y02W30/50—Reuse, recycling or recovery technologies
- Y02W30/91—Use of waste materials as fillers for mortars or concrete
Definitions
- the present invention relates to a fireproof insulation composition, a fireproof insulation composition slurry, a fireproof insulation board, and a fireproof insulation structure for constructing a fireproof insulation structure of a building.
- heat insulating materials and refractory materials are used in buildings, and as the heat insulating material, polyurethane foam, polystyrene foam, and phenol foam, which are resin foams that have a high heat insulating effect, are lightweight, and have good workability, are used. Inorganic fiber aggregates such as glass wool and rock wool, which are inexpensive, are also used.
- resin foam is an organic substance, it burns when a fire occurs and often causes damage to spread due to fire spread, so countermeasures are required.
- inorganic fiber aggregates such as glass wool and rock wool are mainly composed of non-flammable materials, but they tend to have higher thermal conductivity than resin foams and are inferior in heat insulation properties. Since it is in a shape, there is a problem that a puncture feeling is felt and workability is poor. Furthermore, conventionally, a method has been adopted in which the fiber aggregate is packed in a plastic bag at the time of construction, and this is fitted between the pillar and the outer wall of the house, but there is a gap or it falls off over time. There was a problem to do.
- heat insulating materials made of resin foam with nonflammability are already on the market.
- a non-combustible heat-insulating board having a structure in which one or both surfaces of a phenol foam board are laminated with non-combustible materials such as aluminum foil, aluminum hydroxide paper, and gypsum-based board material can be used.
- non-combustible materials such as aluminum foil, aluminum hydroxide paper, and gypsum-based board material
- the surface facing the flame does not burn during a fire, but the heat melts the phenolic foam inside, creating a cavity, and the problem that the board itself falls off and spreads fire can be solved. In other words, it is not a material that satisfies the fireproof structural specifications stipulated by the Building Standards Act.
- a foam is formed with an alkali metal carbonate, an isocyanate, water and a reaction catalyst.
- Technology related to heat insulating materials Patent Document 1
- Patent Document 2 A technique related to an injection material for tunnel ground improvement, which is a curable composition consisting of one or more inorganic compounds selected from the group consisting of acid salts and phosphates, water and isocyanates.
- Patent Document 2 is developed for ground improvement and is not intended to obtain heat insulation.
- the conventional method of reacting an isocyanate with an aqueous solution of 30% or more of an alkali metal carbonate as in Patent Document 1 a large amount of unreacted water remains by using a large amount of water. It is considered that the heat insulating property is not so large because it needs to be dried and the resulting foam has a large cell size.
- synthetic resin foam particles obtained by forming a coating of sepiolite and an aqueous organic binder containing a water-soluble resin as a main component and subjecting it to a surface treatment
- a technique relating to heat-insulating coated granules which is further coated with a coating material composed of an inorganic powder and an aqueous inorganic binder containing water glass having an alkali metal silicate as a main component and dried and cured Patent Document 3
- At least a part of the surface of the synthetic resin foam was filled with a silica-based inorganic material composed of one or a mixture of two or more of calcium silicate, magnesium silicate, aluminum silicate, and aluminosilicate.
- Patent Document 4 A technique (Patent Document 4) related to an inorganic-containing synthetic resin foam is disclosed.
- Patent Document 4 A technique (Patent Document 4) related to an inorganic-containing synthetic resin foam is disclosed.
- the conventional technology using these silicates it is difficult to maintain the shape as a heat insulating board because the resin foam melts and the binding force of the filled silicate itself is lost due to combustion. ..
- Patent Document 5 A technique related to a foamed resin composite structure in which a filler material made of an organic substance having an oxygen index of greater than 21 is filled in a communication void formed between foamed beads in a foamed resin formed of a bead method polystyrene foam (Patent Document 5). ), or a technology relating to a composite molded article in which the voids of a thermoplastic resin foamed particle molded article having continuous voids of 5 to 60% are filled with a cement or gypsum cured product containing smectite (Patent Document 6) is known.
- Patent Document 5 since the communication voids are filled with the filling material that is an organic substance, it is not possible to expect improvement in the combustion resistance at the non-combustible level.
- Patent Document 5 is directed to an expanded polystyrene foam having a very solid void having a void ratio of about 3%, and it cannot be said that the void can be effectively used.
- Patent Document 6 preferably contains ettringite in its hardened product as cement, exemplifies it as a cement containing ettringite under the trade name, and describes that it contains smectite, which is considered to be one of the material separation reducing materials. There is.
- Patent Document 7 contains calcium aluminate having a CaO content of 40% by mass or more, gypsum, inorganic powder having a hollow structure with an average particle size of 20 to 60 ⁇ m, and waste glass foam powder with an average particle size of 20 to 130 ⁇ m.
- the composition is described, it is not intended to reduce the separation of materials, nor is it intended to improve the fire resistance in consideration of the crystal water content and crystal structure of talc, sepiolite and zeolite.
- the materials described in Patent Documents 7 and 8 are used for the purpose of covering the surface of the steel frame and protecting it from a fire, and are considered not to have great heat insulating properties.
- a fire-resistant coating composition comprising ettringite as a main component, and further containing an inorganic compound powder or titanium oxide powder which releases a non-combustible gas at 100 to 1000° C.
- a composition for use (Patent Document 9) is also known.
- a technology relating to a non-fired fire-resistant heat insulating material composed of heat-resistant aggregate, lightweight aggregate, alumina-based binder, silicon carbide, and reinforcing fiber is disclosed. Shirasu balloon as the lightweight aggregate and calcium aluminate as the alumina-based binder are disclosed. It is described (Patent Document 10).
- Japanese Unexamined Patent Publication No. 10-67576 Japanese Patent Laid-Open No. 8-92555 Japanese Patent Laid-Open No. 2001-329629 JP 2012-102305 A Japanese Patent No. 4983967 JP, 2005-199945, A Japanese Patent Laid-Open No. 2017-77994 JP-A-7-48153 JP, 7-61841, A JP-A-62-41774
- Patent Documents 9 and 10 are premised on being used as a fire-resistant heat insulating material in a high temperature region used in steelmaking and steelmaking, and have insufficient heat insulation under normal environment and fire resistance during a fire. Met. Therefore, there has been a demand for a method capable of achieving both heat insulation and fire resistance.
- a refractory heat insulating composition comprising 0.1 to 20 parts by mass of a fibrous inorganic clay mineral.
- a fireproof heat insulating board comprising a resin molded body having a continuous porosity of 25 to 70% by volume and the fireproof heat insulating composition slurry according to (5), which is filled in the voids of the resin molded body and solidified.
- a fireproof heat insulating structure including the fireproof heat insulating board according to (6).
- a fire resistant insulation board having both fire resistance and heat insulation can be obtained.
- composition contains a predetermined calcium aluminate, gypsum, and a fibrous inorganic clay mineral in a predetermined ratio. Is characterized by.
- the calcium aluminate is a hydration activity mainly composed of CaO and Al 2 O 3 obtained by mixing a calcia raw material and an alumina raw material or the like and firing them in a kiln or melting and cooling in an electric furnace. Is a general term for substances having.
- the calcium aluminate is not particularly limited, but amorphous calcium aluminate that is rapidly cooled after melting is preferable from the viewpoint of developing initial strength after curing.
- the CaO content of calcium aluminate is preferably 34% or more, more preferably 40% or more. If the CaO content is less than 34%, sufficient fire resistance is not exhibited.
- a part of CaO or Al 2 O 3 of calcium aluminate is an alkali metal oxide, an alkaline earth metal oxide, silicon oxide, titanium oxide, iron oxide, an alkali metal halide, an alkaline earth metal.
- a compound substituted with a group metal halide, an alkali metal sulfate, an alkaline earth metal sulfate, or the like can also be used, or a small amount of these can be solid-dissolved in those containing CaO and Al 2 O 3 as main components. Compounds can also be used.
- the vitrification rate of calcium aluminate is preferably 8% or more, more preferably 50% or more, most preferably 90% or more.
- the particle size of the calcium aluminate in terms of early strength development, preferably not less than Blaine specific surface area of 3,000cm 2 / g, 5,000cm 2 / g or more is more preferable. When it is 3,000 cm 2 /g or more, the initial strength development is improved.
- the Blaine specific surface area is a value measured according to JIS R5201:2015 (physical test method for cement).
- any of anhydrous gypsum, hemi-water gypsum, and dihydrate gypsum can be used and is not particularly limited.
- Anhydrous gypsum is a generic term for compounds represented by the molecular formula CaSO 4 which is anhydrous calcium sulfate
- hemi-water gypsum is a generic term for compounds represented by the molecular formula CaSO 4 .1/2H 2 O
- dihydrate gypsum Is a general term for compounds represented by a molecular formula of CaSO 4 .2H 2 O.
- the particle size of gypsum is preferably 1 to 30 ⁇ m, more preferably 5 to 25 ⁇ m, in terms of non-combustibility, initial strength development and proper working time.
- the average particle diameter is a value measured in a dispersed state using an ultrasonic device using a measurement laser diffraction type particle size distribution meter.
- the amount of gypsum used in the composition is preferably 70 to 250 parts by mass, more preferably 100 to 200 parts by mass, based on 100 parts by mass of calcium aluminate. If the amount of gypsum is less than 70 parts by mass or more than 300 parts by mass, sufficient fire resistance cannot be imparted.
- the fibrous inorganic clay mineral contained in the composition (hereinafter sometimes simply referred to as “fibrous mineral”) must have a water content of at least 5% or more in order to obtain heat insulation and fire resistance. ..
- the fibrous inorganic clay mineral imparts a material separation reducing effect to the composition and also improves fire resistance.
- FIG. 1 shows a schematic diagram of the crystal structure of a fibrous inorganic clay mineral (sepiolite in FIG. 1) (based on the structural model of Brauner and Preisinger, see JP-A-2004-59347 and JP-A-2002-338236).
- the fibrous mineral is a kind of hydrous magnesium silicate mineral, and is a fibrous clay mineral characterized by having a crystal structure as shown in FIG. 1 and having pores inside the crystal. , Crystal water exists in the pores in the form of bound water or boiling water.
- the two-dimensional crystal structure forms a fibrous crystal structure in which bricks are alternately stacked.
- this unit crystal structure as shown in FIG. 1, there are 4 hydroxyl groups bonded to Mg atoms, 4 bonded water bonded to Mg atoms, and 8 zeolite water.
- FIG. 1 shows that there are eight pieces of zeolite water in the unit structure.
- the fibrous mineral has a specific surface area of 50 to 500 m 2 /g, a fiber length of 0.1 to 50 ⁇ m, and an aspect ratio of 0.1 to 50 ⁇ m, which varies depending on the type. It is preferably 5000.
- the specific surface area is a value measured according to the BET method and JIS Z8830:2013.
- Fibrous mineral is not particularly limited as typical is sepiolite ((OH 2) 4 (OH ) 4 Mg 8 Si 12 O 30 ⁇ 6 ⁇ 8H 2 O), palygorskite (attapulgite) ((OH 2) 4 (OH) 2 Mg 5 Si 8 O 20 ⁇ 4H 2 O), wollastonite, Rogurinaito and the like.
- sepiolite (OH 2) 4 (OH ) 4 Mg 8 Si 12 O 30 ⁇ 6 ⁇ 8H 2 O)
- palygorskite attapulgite
- wollastonite Rosgurinaito and the like.
- the water content of the fibrous mineral is preferably 7% or more, more preferably 9% or more.
- the upper limit of the water content is not particularly limited, but is preferably 30% or less, for example.
- the moisture content W can be calculated from the following formula by using the thermogravimetric analyzer (TGA) to raise the temperature of the fibrous mineral from 30° C. to 200° C. and using the mass X before the temperature rise and the decreased mass X 1 .
- the sample amount was 10 mg, the temperature rising rate was 5.0° C./min, and the measurement was performed under an air atmosphere.
- Water content W (mass %) X 1 /X ⁇ 100
- the amount of the fibrous mineral used in the composition is preferably 0.1 to 20 parts by mass, more preferably 3 to 15 parts by mass, based on 100 parts by mass of calcium aluminate and gypsum. If the amount of the fibrous mineral is less than 0.1 parts by mass, the fire resistance and heat insulation may not be improved, and if it exceeds 20 parts by mass, the fire resistance and heat insulation may be deteriorated.
- the fibrous mineral may be used by premixing it with calcium aluminate or gypsum, or may be used by preliminarily dispersing it in water.
- the present composition may further contain an inorganic powder having pores (hereinafter, sometimes simply referred to as “inorganic powder”).
- the inorganic powder is not particularly limited as long as it is a powder of an inorganic material having pores, and any powder can be used.
- Typical examples of the inorganic powder inorganic powder obtained from a foam made by heating a volcanic deposit represented by Shirasu balloon at high temperature, fly ash balloon generated from a thermal power plant, and obsidian, Inorganic powder obtained by firing pearlite or shale, and waste glass foam powder (recycled glass balloons) that has been subjected to particle size adjustment by firing after pulverizing waste such as glass bottles, etc. The above can be used.
- the inorganic powder excludes the above-mentioned calcium aluminate, gypsum, and fibrous inorganic clay mineral.
- the average particle size of the inorganic powder is preferably 1 to 150 ⁇ m, more preferably 15 to 100 ⁇ m.
- the average particle diameter is a value measured in a dispersed state using an ultrasonic device using a measurement laser diffraction type particle size distribution meter.
- the amount of the inorganic powder used in the composition is preferably 2 to 100 parts by mass, and more preferably 5 to 80 parts by mass, based on 100 parts by mass of calcium aluminate and gypsum.
- the amount of the inorganic powder is 2 parts by mass or more, the heat insulating property is improved, and when it is 100 parts by mass or less, the fire resistance is improved.
- the composition may further comprise a set retarder.
- the setting retarder is a substance that adjusts the pot life of the refractory insulation composition slurry.
- the setting retarder include an inorganic setting retarder and an organic setting retarder.
- the inorganic setting retarder include phosphate, silicofluoride, copper hydroxide, boric acid or salts thereof, zinc oxide, zinc chloride, zinc carbonate, and the like.
- organic setting retarders include oxycarboxylic acids (citric acid, gluconic acid, malic acid, tartaric acid, glucoheptonic acid, oxymalonic acid, lactic acid, etc.) or salts thereof (sodium salt, potassium salt, etc.), and sugar. And the like.
- the setting retarder excludes the above-mentioned calcium aluminate, gypsum, fibrous inorganic clay mineral, and inorganic powder having pores.
- the amount of the setting retarder used in the composition is preferably 0.02 to 2.0 parts by mass, and more preferably 0.05 to 1.0 part by mass, based on 100 parts by mass of calcium aluminate and gypsum.
- the amount of the setting retarder is 0.02 parts by mass or more, it becomes easy to adjust the required pot life, and when it is 2.0 parts by mass or less, the curing time does not become too long and curing failure occurs. Hateful.
- the composition may further contain a hydration enhancer.
- the hydration accelerator is a substance that promotes the reaction between calcium aluminate and gypsum, increases the amount of water of crystallization and improves fire resistance, and is not particularly limited.
- Examples of the hydration accelerator include hydroxides such as calcium hydroxide, alkali metal silicates, aluminum sulfate such as anhydrous aluminum sulfate, alkali metal carbonates such as sodium carbonate, nitrates, nitrites, and ordinary Portland cement.
- Various portland cements, various inorganic filler fine powders, etc. may be mentioned, and one or more of these may be used.
- the hydration accelerator excludes the above-mentioned calcium aluminate, gypsum, fibrous inorganic clay mineral, inorganic powder having pores, and set retarder.
- the amount of the hydration accelerator used in the composition is preferably 0.1 to 15 parts by mass, more preferably 0.5 to 10 parts by mass, based on 100 parts by mass of calcium aluminate and gypsum.
- the amount of the hydration accelerator is 0.1 part by mass or more, a sufficient hydration promoting effect is obtained, and when it is 15 parts by mass or less, a sufficient pot life is secured.
- the fire-resistant insulation composition slurry according to the embodiment of the present invention can be prepared by using water (tap water, etc.).
- the amount of water for preparing the slurry is not particularly limited, but is preferably 40 to 300 parts by mass, and more preferably 80 to 250 parts by mass, based on 100 parts by mass of calcium aluminate and gypsum.
- the amount of water is 40 parts by mass or more, the filling into the voids becomes uniform and the fire resistance is improved, and when it is 300 parts by mass or less, the ettringite content in the cured product in the voids increases and the fire resistance increases. The property is improved.
- the resin molding is a resin having continuous voids, and has a void that can be filled with the slurry.
- the resin include foamed polyvinyl alcohol resin, foamed polyurethane resin, foamed polystyrene resin, foamed polyolefin resin, foamed phenol resin and the like.
- the continuous porosity of the resin molded product can be adjusted by the degree of pressurization during production.
- a resin molded product having continuous voids can be produced according to the method for producing a polystyrene foam using a bead method.
- the expanded polystyrene resin molded body is preferable in terms of versatility.
- the continuous porosity is 25% by volume or more, sufficient fire resistance can be imparted to the obtained board, and when it is 70% by volume or less, the board density is low, the thermal conductivity is low, and the heat insulating property is improved. ..
- the continuous porosity of the resin molded product can be determined by the following method, for example.
- a rectangular parallelepiped sample is cut out from a thermoplastic resin foamed particle molded article that has been left for 24 hours or more in an environment of a temperature of 23° C. and a relative humidity of 50%, and an apparent volume Va [cm 3 ] is determined from the external dimensions of the sample.
- the sample is submerged in a measuring cylinder containing ethanol at a temperature of 23° C. using a tool such as a wire net, and light vibration is applied to deaerate the air present in the voids in the molded body.
- the slurry filled in the continuous voids is hardened by the hydration reaction that produces hydration products.
- the continuous voids in the resin molding are filled with the hydration product.
- Hydration products include ettringite formed by the reaction of calcium aluminate and gypsum. Since ettringite has a large amount of water in its molecule as crystallization water, it dehydrates by heating, exhibits a fire extinguishing effect, and imparts incombustibility to the resin molded body.
- the embodiment of the present invention positively produces ettringite by using calcium aluminate having a CaO content of 34% or more, and improves the nonflammability of the resin molded body.
- the method for filling the resin-molded body with the refractory heat-insulating composition slurry is not particularly limited, but it is a method of filling by press-fitting with compressed air, decompression with a vacuum pump and suction, or installing the resin-molded body on a vibration table.
- a method of filling the inside of the void while applying a vibration of 30 to 60 Hz can be mentioned.
- the method of filling the voids while applying vibration is preferable from the viewpoint of quality stability.
- the method for curing the fire-resistant heat-insulating board after filling the void portion with the fire-resistant heat-insulating composition slurry is not particularly limited, but after filling, air-curing at room temperature or covering the board surface with a plastic film at room temperature. Examples include a method of curing in air.
- the refractory insulation board may be cured at a temperature of 30 to 50° C. to shorten the curing time.
- a non-woven fabric it is possible to further cover the entire board with a non-woven fabric, dispose a reinforcing material such as a grid-like fiber sheet on one or both sides of the board, or use the non-woven fabric and the fiber sheet together.
- the shape of the fireproof heat insulating board of the present invention is not particularly limited, but a length of 500 to 1000 mm, a width of 1000 to 2000 mm, and a thickness of 10 to 100 mm are preferable.
- the thickness is more preferably 50 to 100 mm. The smaller size makes the fireproof insulation board lighter and improves workability during installation.
- one or more kinds of various additives may be further used in the preparation of the present refractory insulation composition slurry within a range that does not affect the performance.
- additives include surfactants, air entraining agents, carbonization promoters, flame retardants, flame spread inhibitors, inorganic substances, rust inhibitors, antifreeze agents, shrinkage reducing agents, clay minerals, anion exchangers, etc. Are listed.
- Density refractory insulation board in that it does not impair the fire resistance and heat insulation, preferably 100 ⁇ 800kg / m 3, more preferably 200 ⁇ 500kg / m 3. If it is 100 kg/m 3 or more, sufficient fire resistance can be secured, and if it is 800 kg/m 3 or less, sufficient heat insulation can be obtained.
- the fire resistant insulation board described above can be used to build a fire resistant structure for a building.
- a fireproof structure for example, if it is shown in a layer structure from the outer wall side, it consists of a siding board, a moisture-permeable waterproof sheet, a fireproof insulation board, a structural plywood, and a reinforced gypsum board in that order.
- a structure having a space of about 100 mm (a space for accommodating a heat insulating material such as glass wool) is formed between the gypsum boards by a stud.
- Embodiments of the present invention provide a fire resistant insulation structure including a fire resistant insulation board.
- a fire resistant insulation board When constructing a refractory structure, depending on the required fireproof specifications, a plurality of the present fireproof insulating boards may be laminated and attached, or the present fireproof insulating board may be used in combination with a reinforced gypsum board.
- Example 1 A foamed resin molding having continuous voids (size: length 20 cm ⁇ width 20 cm ⁇ thickness 5 cm) was reinforced with alkali-resistant glass fibers, and a polyester non-woven fabric was further laminated. This was set in a vibration impregnation device, and the fire-resistant heat-insulating composition slurry having the composition shown in Table 1 was poured onto the upper surface of the molded body, vibration of 60 hertz was applied for 1 minute to impregnate the voids with the fire-insulating heat-insulating composition slurry, and the fire-insulating board Was manufactured. After filling, the refractory insulation board was taken out from the apparatus and cured at room temperature for 3 days. The cured fire-resistant heat-insulating board was evaluated for content of crystal water, fire resistance, shape retention, shape retention and thermal conductivity. The results are shown in Table 1.
- Foamed resin molded product A A commercially available polystyrene foamed bead (diameter: 1 to 5 mm) is filled in a molding machine (VS-500 manufactured by Daisen Kogyo Co., Ltd.) and heated by steam to form voids between foamed particles. In the state, the foamed particles were fused and manufactured. The continuous porosity was controlled by adjusting the degree of pressurization.
- CA3 Asahi Fonju made by AGC Ceramics Co., CaO: 37%, vitrification rate 12%, Blaine specific surface area 3500 cm 2 /g Calcium aluminate 4 (CA4): Denka high alumina cement manufactured by Denka, CaO: 26%, vitrification rate 13%, Blaine specific surface area 4660 cm 2 /g.
- Ettringite 1 Ettringite powder obtained by hydrothermally synthesizing slaked lime, aluminum sulfate, and gypsum as starting materials, and drying the resulting powder, and the rate of crystal water: 46% Gypsum 1 (CS1): Type II anhydrous gypsum manufactured by Noritake Company, trade name D-101A, purity 95%, average particle size 20 ⁇ m Gypsum 2 (CS2): ⁇ -type semi-water gypsum manufactured by Noritake Company, trade name FT-2, purity 95%, average particle size 20 ⁇ m Gypsum 3 (CS3): Gypsum dihydrate manufactured by Noritake Company, trade name P52B, purity 95%, average particle size 20 ⁇ m Fibrous mineral (F1): Sepiolite manufactured by TOLSA, trade name: PANGEL AD, water content: 13.2%, fiber length 5 ⁇ m, fiber diameter 0.1 ⁇ m, specific surface area 270 m 2 /g Fibrous mineral (F2): pa
- a mixture was prepared by adding gypsum to 100 parts by mass of calcium aluminate shown in Table 1, and to 100 parts by mass of the mixture, 100 parts by mass of fibrous mineral and 100 parts by mass of water were added.
- a slurry was prepared by stirring for 5 minutes. The prepared slurry was poured on the upper surface of the foamed resin molded body so as to have a volume of 810 cm 3 (1.1 times the void volume of the resin molded body).
- synthetic ettringite 100 parts by mass of synthetic ettringite was mixed with fibrous minerals at a predetermined ratio to prepare a mixture, and 100 parts by mass of water was added to 100 parts by mass of the mixture, and the mixture was added for 5 minutes. A slurry was prepared by stirring.
- Continuous porosity The continuous porosity of the foamed resin molding was determined.
- a sample is cut out from a foamed resin molded product that has been left for 24 hours or more in an environment of a temperature of 23° C. and a relative humidity of 50%, and an apparent volume (Va) is obtained from the outer dimensions of the sample (length 10 cm ⁇ width 10 cm ⁇ thickness 5 cm).
- the sample is submerged in a graduated cylinder containing ethanol at a temperature of 23° C. using a wire net, and light vibration is applied to deaerate the air present in the voids in the molded body. Then, the water level rise is read in consideration of the volume of the wire mesh, and the true volume (Vb) of the sample is measured.
- Continuous porosity V(%) [(Va-Vb)/Va] ⁇ 100 Content of water of crystallization (amount of water of crystallization): 20g was sampled from a fireproof insulation board, the free water and the foam in the cured product were dissolved with acetone, filtered, and the residue was washed well with acetone, and the environment was kept at 25°C. It was vacuum dried in a desiccator for 48 hours. The amount of water of crystallization was determined by measuring the amount of mass reduction of the dried cured product in the range of 50 to 200° C.
- the water of crystallization in the present specification means water chemically or physically bound to the refractory heat insulating board except for free water such as acetone that can be removed by drying.
- Fire resistance An exothermic test using a cone calorimeter shown in ISO-5660-1:2002 was carried out to easily evaluate the fire resistance. It is preferable that a test piece of 10 cm in length ⁇ 10 cm in width ⁇ 5 cm in thickness is used, and that the total calorific value when the heating time is 20 minutes is 8 MJ/m 2 or less in terms of having fire resistance (noncombustible). ..
- Thermal conductivity Measured by a rapid thermal conductivity meter (box type probe method) using a test piece of 10 cm in length ⁇ 5 cm in width ⁇ 5 cm in thickness obtained from a fireproof heat insulating board.
- Shape retention The case where there was no cracks, cracks, collapses, defects, or shrinkage on the test body after the combustion test using a cone calorimeter was evaluated as ⁇ , and the case where cracks, cracks, collapses, or defects were confirmed was evaluated as x.
- Shape retention rate The shape retention rate was measured by comparing the volume of the test body after the combustion test with a cone calorimeter with the volume of the test body before the test.
- the amount of gypsum (CS) is parts by mass relative to 100 parts by mass of calcium aluminate (CA).
- the amount of fibrous mineral (F) is based on 100 parts by weight of a mixture of calcium aluminate (CA) and gypsum (CS).
- Experiment No. 1-23 was obtained by mixing 5 parts by mass of the fibrous mineral (F1) and 5 parts by mass of the fibrous mineral (F2) with 100 parts by mass of the mixture of calcium aluminate (CA) and gypsum (CS). use.
- Example 2 The type and amount of inorganic powder shown in Table 2 and the fibrous mineral based on 100 parts by mass of calcium aluminate (CA1) and 120 parts by mass of gypsum (CS1) and 100 parts by mass of a mixture of calcium aluminate and gypsum. 7 parts by mass of (F1) and 100 parts by mass of water were added to prepare a refractory heat insulating composition slurry in the same manner as in Experimental Example 1, and the performance was evaluated. The results are shown in Table 2.
- Inorganic powder 1 (Material used) Inorganic powder 1 (P1): Silas balloon manufactured by Axis Chemicals, trade name: MSB-301, average particle size 50 ⁇ m
- Inorganic powder 2 (P2): Silas balloon manufactured by Axis Chemicals, trade name: ISM-F015, average particle diameter 22 ⁇ m
- Inorganic powder 3 (P3): Silas balloon manufactured by Axis Chemicals, trade name: MSB-5011, average particle size 96 ⁇ m
- Inorganic powder 4 (P4): fly ash balloon manufactured by Tomoe Kogyo Co., Ltd., trade name: Cenolite SA, average particle size 80 ⁇ m
- Inorganic powder 5 (P5): waste glass foam powder manufactured by DENNERT POROVER GMBH, trade name: Poraver (0.04-0.125 mm particle size product), average particle size 90 ⁇ m
- the amount of the inorganic powder (P) is 100 parts by mass based on 100 parts by mass of the mixture of calcium aluminate (CA) and gypsum (CS).
- Experiment No. 2-13 was used by mixing 7 parts by mass of the inorganic powder (P1) and 7 parts by mass of the inorganic powder (P4) with 100 parts by mass of the mixture of calcium aluminate (CA) and gypsum (CS).
- Example 3 The type and amount of the setting retarder shown in Table 3, and the fibrous form, with respect to 100 parts by mass of calcium aluminate (CA1), 120 parts by mass of gypsum (SC1), and 100 parts by mass of the mixture of calcium aluminate and gypsum. 7 parts by mass of mineral (F1) and 100 parts by mass of water were added to prepare a refractory insulation composition slurry in the same manner as in Experimental Example 1, and the performance was evaluated. The results are shown in Table 3.
- R1 Reagent first grade sodium citrate Setting delay agent
- R2 Reagent first grade Tartaric acid setting retarder
- R3 Reagent first grade Sodium gluconate
- the amount of the setting retarder (R) is based on 100 parts by mass of the mixture of calcium aluminate (CA) and gypsum (CS).
- the work life can be adjusted while maintaining excellent fire resistance, shape retention, and heat insulation property by the fact that the fire resistant heat insulating composition further contains a setting retarder.
- Example 4 With respect to 100 parts by mass of calcium aluminate (CA1), 120 parts by mass of gypsum (SC1), and with respect to 100 parts by mass of a mixture of calcium aluminate and gypsum, 0.07 parts by mass of a set retarder and a hydration accelerator were used. The types and amounts shown in Table 4, 7 parts by mass of the fibrous mineral (F1), and 100 parts by mass of water were added to prepare a fireproof heat insulating composition slurry in the same manner as in Experimental Example 1, and the performance was evaluated. The results are shown in Table 4.
- ACC1 Reagent first grade calcium hydroxide hydration accelerator 2
- ACC2 Denka common portland cement hydration accelerator 3
- ACC3 Reagent first grade sodium carbonate hydration accelerator 4( ACC4): Reagent first grade anhydrous aluminum sulfate
- the amount of the hydration accelerator (ACC) is based on 100 parts by mass of the mixture of calcium aluminate (CA) and gypsum (CS).
- Example 5 120 parts by mass of gypsum (CS1) was added to 100 parts by mass of calcium aluminate (CA1) to prepare a mixture, and fibrous mineral (F1) was added to 100 parts by mass of the mixture of calcium aluminate and gypsum. 7 parts by mass and the amount of water shown in Table 5 were added to prepare a refractory heat insulating composition slurry in the same manner as in Experimental Example 1, and the performance was evaluated. The results are shown in Table 5.
- the amount of water is 100 parts by weight with respect to 100 parts by weight of a mixture of calcium aluminate (CA) and gypsum (CS).
- CA calcium aluminate
- CS gypsum
- Example 6 120 parts by mass of gypsum (CS1) to 100 parts by mass of calcium aluminate (CA1), 7 parts by mass of fibrous mineral (F1) to 100 parts by mass of the mixture of calcium aluminate and gypsum, and 100 parts by mass of water.
- CS1 gypsum
- CA1 calcium aluminate
- F1 fibrous mineral
- Foamed resin molded product B A commercially available polystyrene foamed bead (diameter: 1 to 5 mm) is filled in a molding machine (manufactured by Daisen Co., Ltd.: VS-500) and heated by steam to form voids between the foamed particles. In the state, the foamed particles were fused and manufactured. The continuous porosity was controlled by adjusting the degree of pressurization.
- Foamed resin molding C Commercially available polystyrene foamed beads (diameter 1 to 5 mm) are filled in a molding machine (VS-500 manufactured by Daisen Kogyo Co., Ltd.) and heated by steam to form voids between foamed particles. In the state, the foamed particles were fused and manufactured. The continuous porosity was controlled by adjusting the degree of pressurization.
- Foamed resin molded product D A commercially available polystyrene foamed bead (diameter: 1 to 5 mm) is filled in a molding machine (VS-500 manufactured by Daisen Kogyo Co., Ltd.) and heated by steam to form voids between foamed particles. In the state, the foamed particles were fused and manufactured. The continuous porosity was controlled by adjusting the degree of pressurization.
- Foamed resin molding E A commercially available polystyrene foamed bead (diameter: 1 to 5 mm) is filled in a molding machine (VS-500 manufactured by Daisen Kogyo Co., Ltd.) and heated by steam to form voids between foamed particles. In the state, the foamed particles were fused and manufactured. The continuous porosity was controlled by adjusting the degree of pressurization. Continuous porosity 69.4%, density of polystyrene foam bead molding 10.5 kg/m 3 , thermal conductivity of polystyrene foam bead molding 0.033 W/mK
- Example 7 A fireproof heat insulating board (length 1000 mm x width 1000 mm x thickness 25 mm) was made from the fireproof heat insulating composition of Experiment Nos. 1-7, 1-9, and 4-1 to obtain the fireproof structure shown in FIGS. It was assembled and installed in the refractory furnace. The size of the fire resistant structure was 2200 mm in width and 1200 mm in length. In the test, the combustion state of the refractory structure after completion of the test was confirmed by changing the type and thickness of the refractory insulation composition of the refractory insulation board. In addition, when boards were installed with different thicknesses, the number of boards installed was changed. The results are shown in Table 7.
- the refractory structure is installed in a refractory furnace, heating is performed on the siding board side simulating the outer wall, and flame is added from a gas burner (total 5 units).
- the refractory structure was heated for 1 hour with a standard heating curve according to ISO 834. Then, the heating was stopped and the state of being installed in the refractory furnace was maintained for 3 hours. The structure was removed from the refractory furnace, the siding board on the heating side was peeled off, and the combustion state was confirmed.
- the thickness of the fireproof insulation board corresponds to the thickness X in Fig. 3.
- a fireproof heat insulating board having fire resistance and heat insulating properties can be obtained.
- the embodiments of the present invention can contribute to the construction of buildings, vehicles, aircraft, ships, refrigeration equipment, and refrigeration equipment having high fire safety.
Abstract
Description
ガラス化率χ(%)=100×(1-S/S0)
含水率W(質量%)=X1/X × 100
連続空隙率V[%]=〔(Va-Vb)/Va〕×100
耐火構造体を構築する際、必要とする耐火仕様によっては、本耐火断熱ボードを複数枚重ねて貼り付けてもよく、本耐火断熱ボードを強化セッコウボードと併用して使用してもよい。
連続空隙を有する発泡樹脂成形体(サイズ:縦20cm×横20cm×厚み5cm)の下部に耐アルカリ性ガラス繊維で補強を施し、更にポリエステル製不織布を重ねた。これを振動含浸装置にセットし、成形体上面に表1に示す配合の耐火断熱組成物スラリーを流し込み、60ヘルツの振動を1分間与え空隙内に耐火断熱組成物スラリーを含浸して耐火断熱ボードを製造した。充填後、装置から耐火断熱ボードを取り出し、3日間常温で養生した。養生した耐火断熱ボードについて、結晶水の含有量、耐火性、形状保持性、形状保持率及び熱伝導率を評価した。結果を表1に示す。
発泡樹脂成形体A:市販されているポリスチレン発泡ビーズ(直径1~5mm)を成形機(株式会社ダイセン工業製:VS-500)に充填し、スチームにより加熱して、発泡粒子間に空隙を有する状態で発泡粒子同士を融着させて製造した。連続空隙率は加圧度合いを調整することで制御した。連続空隙率36.8%、ポリスチレン発泡ビーズ成形体の密度10.5kg/m3、ポリスチレン発泡ビーズ成形体の熱伝導率0.033W/(m・K)
カルシウムアルミネート1(CA1):CaO:43%、Al2O3:53%となるように調整し、電気炉で溶融・急冷した非晶質カルシウムアルミネート、ガラス化率98%以上、ブレーン比表面積6050cm2/g
カルシウムアルミネート2(CA2):デンカ社製アルミナセメント1号、CaO:36%、ガラス化率15%、ブレーン比表面積4570cm2/g
カルシウムアルミネート3(CA3):AGCセラミックス社製アサヒフォンジュ、CaO:37%、ガラス化率12%、ブレーン比表面積3500cm2/g
カルシウムアルミネート4(CA4):デンカ社製デンカハイアルミナセメント、CaO:26%、ガラス化率13%、ブレーン比表面積4660cm2/g
エトリンガイト1(ET1):消石灰と硫酸アルミニウム及び石膏を出発原料とし、水熱合成したものをろ過、乾燥し得られたエトリンガイト粉末、結晶水率:46%
セッコウ1(CS1):ノリタケカンパニー社製II型無水セッコウ、商品名D-101A、純度95%、平均粒子径20μm
セッコウ2(CS2):ノリタケカンパニー社製β型半水セッコウ、商品名FT-2、純度95%、平均粒子径20μm
セッコウ3(CS3):ノリタケカンパニー社製二水セッコウ、商品名P52B、純度95%、平均粒子径20μm
繊維状鉱物(F1):TOLSA社製セピオライト、商品名:PANGEL AD、含水率:13.2%、繊維長5μm、繊維径0.1μm、比表面積270m2/g
繊維状鉱物(F2):Active Minerals International社製パリゴルスカイト(アタパルジャイト)、商品名:MIN-U-GEL 200、含水率:9.8%、繊維長5μm、繊維径0.1μm、比表面積270m2/g
繊維状鉱物(F3):関西マテック社製ウォラストナイト、商品名:KTP-H02、含水率:2.0%、繊維長75μm、繊維径10μm、比表面積4200cm2/g
非繊維状鉱物(N1):クニミネ工業社製ベントナイト、商品名:クニゲルV1、結晶水率:3.5%、比表面積60m2/g
水:水道水
カルシウムアルミネート100質量部に対してセッコウを表1に示す量加えて混合物を調製し、前記混合物100質量部に対して繊維状鉱物を表1に示す種類と量、水を100質量部を加え、5分間攪拌してスラリーを調製した。調製したスラリーは810cm3(樹脂成形体空隙量に対して1.1倍)となるように発泡樹脂成形体上面に流し込んだ。合成エトリンガイトについては合成エトリンガイト100質量部に対して繊維状鉱物を所定割合となるように混合した混合物を作製し、前記混合物100質量部に対して水を100質量部となるように加え、5分間攪拌してスラリーを調製した。
連続空隙率:発泡樹脂成形体の連続空隙率を求めた。温度23℃、相対湿度50%の環境下で24時間以上放置した発泡樹脂成形体からサンプルを切り出し、該サンプルの外形寸法(縦10cm×横10cm×厚さ5cm)より見かけ体積(Va)を求め、該サンプルを温度23℃のエタノールの入ったメスシリンダー中に金網を使用して沈め、軽い振動等を加えることにより成形体中の空隙に存在している空気を脱気する。そして、金網の体積を考慮して水位上昇分を読み取り、該サンプルの真の体積(Vb)を測定する。求められたサンプルの見かけ体積(Va)と真の体積(Vb)から、次式により連続空隙率(V)を求めた。
連続空隙率V(%)=〔(Va-Vb)/Va〕×100
結晶水の含有量(結晶水量):耐火断熱ボードから20gサンプリングし、アセトンで硬化体中の自由水と発泡体を溶解し、ろ過した後、残渣物をよくアセトンで洗浄し、25℃の環境下、デシケータ中で48時間真空乾燥した。乾燥した硬化物を熱分析装置(昇温速度:10℃/分、空気中)で50~200℃の範囲の質量減少量を測定することで結晶水量とした。尚、本明細書における結晶水とは、アセトン等の乾燥によって除去できる自由水を除く、該耐火断熱ボード中に含まれる化学的或いは物理的に結合された水のことを言う。
耐火性:ISO-5660-1:2002に示されたコーンカロリーメータによる発熱試験を実施し、耐火性を簡易的に評価した。縦10cm×横10cm×厚さ5cmの試験体を用い、加熱時間が20分間のときの総発熱量が8MJ/m2以下であることが、耐火性(不燃である)を有する点で、好ましい。
熱伝導率:耐火断熱ボードから得られた縦10cm×横5cm×厚み5cmの試験体を用いて迅速熱伝導率計(ボックス式プローブ法)で測定した。
形状保持性:コーンカロリーメータによる燃焼試験後の試験体に亀裂、割れ、崩壊、欠損箇所、収縮がない場合を○、亀裂、割れ、崩壊、欠損箇所が確認された場合を×とした。
形状保持率:コーンカロリーメータによる燃焼試験後の試験体の体積を試験前の試験体の体積と比較することで形状保持率を測定した。
繊維状鉱物(F)の量は、カルシウムアルミネート(CA)とセッコウ(CS)の混合物100質量部に対する質量部。
実験No.1-23は、カルシウムアルミネート(CA)とセッコウ(CS)の混合物100質量部に対して、5質量部の繊維状鉱物(F1)と5質量部の繊維状鉱物(F2)を混合して使用。
カルシウムアルミネート(CA1)100質量部に対して、セッコウ(CS1)120質量部、カルシウムアルミネートとセッコウの混合物100質量部に対して、無機粉末を表2に示す種類と量と、繊維状鉱物(F1)を7質量部と、水を100質量部とを加え、実験例1と同様に耐火断熱組成物スラリーを調製し、性能を評価した。結果を表2に示す。
無機粉末1(P1):アクシーズケミカル社製シラスバルーン、商品名:MSB-301、平均粒子径50μm
無機粉末2(P2):アクシーズケミカル社製シラスバルーン、商品名:ISM-F015、平均粒子径22μm
無機粉末3(P3):アクシーズケミカル社製シラスバルーン、商品名:MSB-5011、平均粒子径96μm
無機粉末4(P4):巴工業社製フライアッシュバルーン、商品名:セノライトSA、平均粒子径80μm
無機粉末5(P5):DENNERT PORAVER GMBH社製廃ガラス発泡体粉末、商品名:Poraver(0.04-0.125mm粒度品)、平均粒子径90μm
実験No.2-13は、カルシウムアルミネート(CA)とセッコウ(CS)の混合物100質量部に対して、7質量部の無機粉末(P1)と7質量部の無機粉末(P4)を混合して使用。
カルシウムアルミネート(CA1)100質量部に対して、セッコウ(SC1)120質量部、カルシウムアルミネートとセッコウの混合物100質量部に対して、凝結遅延剤を表3に示す種類と量と、繊維状鉱物(F1)を7質量部と、水を100質量部とを加え、実験例1と同様に耐火断熱組成物スラリーを調製し、性能を評価した。結果を表3に示す。
凝結遅延剤(R1):試薬1級 クエン酸ナトリウム
凝結遅延剤(R2):試薬1級 酒石酸
凝結遅延剤(R3):試薬1級 グルコン酸ナトリウム
ゲル化時間:調製した耐火断熱組成物スラリーをポリビーカーに入れ、これを断熱容器に入れ、測温抵抗体を差し込んだ。記録計により混練を終了した直後の温度に対して、モルタルの硬化に伴う発熱によって2℃温度が上昇した時間を、ゲル化時間とした。
カルシウムアルミネート(CA1)100質量部に対して、セッコウ(SC1)120質量部、カルシウムアルミネートとセッコウの混合物100質量部に対して、凝結遅延剤0.07質量部と、水和促進剤を表4に示す種類と量と、繊維状鉱物(F1)を7質量部と、水100質量部とを加え、実験例1と同様に耐火断熱組成物スラリーを調製し、性能を評価した。結果を表4に示す。
水和促進剤1(ACC1):試薬1級 水酸化カルシウム
水和促進剤2(ACC2):デンカ社製 普通ポルトランドセメント
水和促進剤3(ACC3):試薬1級 炭酸ナトリウム
水和促進剤4(ACC4):試薬1級 無水硫酸アルミニウム
カルシウムアルミネート(CA1)100質量部に対して、セッコウ(CS1)120質量部を加えて混合物を調製し、カルシウムアルミネートとセッコウの当該混合物100質量部に対して、繊維状鉱物(F1)を7質量部と、水を表5に示す量とを加え、実験例1と同様に耐火断熱組成物スラリーを調製し、性能を評価した。結果を表5に示す。
カルシウムアルミネート(CA1)100質量部に対して、セッコウ(CS1)120質量部、カルシウムアルミネートとセッコウの当該混合物100質量部に対して繊維状鉱物(F1)を7質量部と、水100質量部とを加え発泡樹脂成形体の空隙率を表6に示すよう変えて実験例1と同様に耐火断熱組成物スラリーを調製し性能を評価した。結果を表6に示す。
発泡樹脂成形体B:市販されているポリスチレン発泡ビーズ(直径1~5mm)を成形機(株式会社ダイセン工業製:VS-500)に充填し、スチームにより加熱して、発泡粒子間に空隙を有する状態で発泡粒子同士を融着させて製造した。連続空隙率は加圧度合いを調整することで制御した。連続空隙率25.3%、ポリスチレン発泡ビーズ成形体の密度10.5kg/m3、ポリスチレン発泡ビーズ成形体の熱伝導率0.033W/m・K
発泡樹脂成形体C:市販されているポリスチレン発泡ビーズ(直径1~5mm)を成形機(株式会社ダイセン工業製:VS-500)に充填し、スチームにより加熱して、発泡粒子間に空隙を有する状態で発泡粒子同士を融着させて製造した。連続空隙率は加圧度合いを調整することで制御した。連続空隙率43.9%、ポリスチレン発泡ビーズ成形体の密度10.5kg/m3、ポリスチレン発泡ビーズ成形体の熱伝導率0.033W/m・K
発泡樹脂成形体D:市販されているポリスチレン発泡ビーズ(直径1~5mm)を成形機(株式会社ダイセン工業製:VS-500)に充填し、スチームにより加熱して、発泡粒子間に空隙を有する状態で発泡粒子同士を融着させて製造した。連続空隙率は加圧度合いを調整することで制御した。連続空隙率58.7%、ポリスチレン発泡ビーズ成形体の密度10.5kg/m3、ポリスチレン発泡ビーズ成形体の熱伝導率0.033W/m・K
発泡樹脂成形体E:市販されているポリスチレン発泡ビーズ(直径1~5mm)を成形機(株式会社ダイセン工業製:VS-500)に充填し、スチームにより加熱して、発泡粒子間に空隙を有する状態で発泡粒子同士を融着させて製造した。連続空隙率は加圧度合いを調整することで制御した。連続空隙率69.4%、ポリスチレン発泡ビーズ成形体の密度10.5kg/m3、ポリスチレン発泡ビーズ成形体の熱伝導率0.033W/m・K
実験No.1-7、1-9、及び4-1の耐火断熱組成物で耐火断熱ボード(縦1000mm×横1000mm×厚さ25mm)を作製し、図2~3に示す耐火構造体になるように組み上げて耐火炉に設置した。耐火構造体のサイズは横2200mm×縦1200mmとした。試験は、耐火断熱ボードの耐火断熱組成物の種類と厚みを変えて試験終了後の耐火構造体の燃焼状態を確認した。尚、厚みを変えてボードを設置する場合は設置枚数を変えることで行った。結果を表7に示す。
図2の側面図及び図3の上面図に示すように、耐火構造体を耐火炉に設置し、加熱は外壁を模擬したサイディングボード側で行い、ガスバーナー(トータル5基)から加炎し、ISO 834に準拠した標準過熱曲線で耐火構造体を1時間加熱した。その後、加熱を止めて耐火炉に設置した状態を3時間維持した。耐火炉から構造体を取り外し、加熱側のサイディングボードを剥がして燃焼状態を確認した。
Claims (7)
- CaO含有量が34%以上のカルシウムアルミネート100質量部に対してセッコウを70~250質量部、前記カルシウムアルミネートとセッコウの合計100質量部に対して、含水率が5%以上である繊維状無機粘土鉱物0.1~20質量部を含む耐火断熱組成物。
- 空孔を有する無機粉末を含む請求項1記載の耐火断熱組成物。
- 凝結遅延剤を含む請求項1~2記載のうちいずれか1項記載の耐火断熱組成物。
- 水和促進剤を含む請求項1~3記載のうちいずれか1項記載の耐火断熱組成物。
- 請求項1~4記載のうちいずれか1項記載の耐火断熱組成物と水を混合した耐火断熱組成物スラリー。
- 連続空隙率が25~70体積%の樹脂成形体と、前記樹脂成形体の空隙部に充填され固化した請求項5記載の耐火断熱組成物スラリーとを含む耐火断熱ボード。
- 請求項6記載の耐火断熱ボードを含む耐火断熱構造体。
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