JP2009012437A - Mold for inorganic foam molded article, and method for molding the article - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for easily and efficiently molding an inorganic foam molded article having desired dimensional shape, foaming magnification and physical properties, and to provide a mold therefor. <P>SOLUTION: The mold comprises the molding side plates and a molding bottom plate each of which is separably joined, and a molding lid plate which fittingly closes the foam molding space formed by the side and bottom plates to enable molding of the inorganic foam molded article having desired dimensional shape, foaming magnification and physical properties. The material of the mold is iron, aluminum or stainless steel, and the peeling layers and electromagnetic induction heating bodies are disposed on the inside and outside faces of the mold, respectively. The molding method includes: pouring a solution containing high-molecular weight siloxane and silanol salt into the foam molding space of the above mold; heating and foaming after fittingly closing; and separating respective molds to take out the article. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a molding die and a molding method for an inorganic foam molded product, which can easily and efficiently mold an inorganic foam molded product with various standards using a siloxane and silanol salt multi-molecular weight solution. is there.

  Insulating heat insulating plates for buildings, heat insulation materials for cooling and heating equipment, etc. In addition to foaming moldability, cold insulation and trays and boxes are also cheaper in price, and foam polystyrene, foamed urethane and foamed phenol, Synthetic resin materials such as foamed polyethylene, foamed polypropylene, and foamed ABS have been used and produced and consumed in enormous amounts.

  However, since these synthetic resin materials use various chemical agents and chemical foaming agents not only at the synthesis stage but also at the time of molding, some of these are not only volatilized or eluted during production or consumption, Since resin materials do not collapse or decompose even in the natural environment, most of them are recovered and reused when discharging enormous amounts after consumption, and most of them must be incinerated. Due to the newly increased generation of smoke, toxic gases, and dioxins, pollution is extremely expanded to the atmosphere, water, and soil today, and environmental cleanup and environmental conservation are the top priorities. Has reached.

  For this reason, on the other hand, although substitution to a molded product by a biodegradable resin material made of polylactic acid, starch, aliphatic polyester or the like has been attempted, the biodegradable resin material has heat resistance, water resistance, durability, etc. Due to inferior physical properties and high price, it is only used as a cushioning material or agricultural film material, and its use in molded products is substantially unsuitable.

  In view of such circumstances, the inventor once dissolved alkali oxides of natural rocks and inorganic industrial wastes, particularly coal incineration ash and silicon wafer wastes, into alkali silicate to form sodium silicate. In the presence of hydrofluoric acid, boric acid, etc., a solid compound composed of a siloxane and a silanol salt in the form of a complex compound obtained by increasing the molecular weight of siloxane and silanol salt to a molecular weight of about 4,000 to 8,000. A siloxane and silanol salt multi-molecular weight solution having a composition of 45 to 75% by weight and a water content of 25 to 55% by weight is poured into a mold having a required size and shape, and the mold is sealed. In addition, by heating at least 200 ° C., the foaming ratio is about 2 to 15 times with the creation of heat-fusible properties, the promotion of siloxane bonds and the evaporation of moisture. It forms a lot of prior application to investigate that inorganic foamed molded article may form.

  However, when a siloxane and silanol salt multi-molecular weight solution is heated to form an inorganic foamed molded product, the creation of a heat-fusible property by heating and the promotion of siloxane bonding produce a strong fusing property. Therefore, the inorganic foamed molded product to be molded is strongly fused to the inner surface of the molding die, so that it is impossible to perform die cutting after molding. For this reason, a release film using a release material such as normal tetrafluoroethylene or silicon is formed on the entire inner surface of the mold by molding, but even in an inorganic foam molded product having a simple shape such as a flat plate, Even in the case of using a molding die with a molding die A and a closing lid B as shown in FIG. 6A, or a molding die with a molding bottom die C and a molding lid die D as shown in FIG. Since the internal pressure accompanying it is added to the molding die to give physical properties such as compression resistance, foam-molded inorganic foam molded products are foam-molded in a state of pressing inside the molding die. However, it is extremely difficult to remove the mold from the mold, and if the unreasonable mold is removed, the inorganic foam molded product is damaged, and the production efficiency is very bad. The thickness is about 15 mm to 60 mm like the heat insulating plate material for buildings. When requested to The, it must be prepared in the mold of each size and shape.

  The present invention has been made in order to solve the above-mentioned problems. The present invention injects a siloxane and silanol salt multi-molecular weight solution into a mold that can be detached from the joint, and then applies the required pressure and foaming to the mold cover plate. Molding method and molding method for an inorganic foamed molded product that can easily and efficiently mold an inorganic foamed molded product having the required dimensions, shape, foaming ratio and physical properties by heating after insertion and closing so as to be foam-molded to a thickness Is to provide.

  The technical means used by the present invention in order to solve the above-mentioned problems is a molded side plate that can be moved so that it can be joined and detached so that it can be molded into the required size, shape, expansion ratio and physical properties of the inorganic foam molded product. And a molded bottom plate, and a molded lid plate that can be fitted and closed in a foam molding space joined and formed by the molded side plate and the molded bottom plate. A molding die in which a release layer made of ethylene or silicon resin is formed and an electromagnetic induction heating body is disposed on the outer side thereof is used.

  Then, the molding side plate and the molding bottom plate of the molding die are joined to form a foam molding space for foam molding to the size and shape of the inorganic foam molded product, and then a siloxane and silanol salt polymolecular weight solution is injected at a required volume ratio. Then, the molding cover plate is press-fitted into the inner volume that can be formed to the required foaming ratio, thickness and physical properties of the foamed molded product, and heated at a temperature of 240 to 300 ° C. Made of silicon oxide, foamed into an inorganic foam molded product with the required size, shape, expansion ratio, and physical properties, and thus the molding side plate that forms the mold is joined horizontally and the molding lid is removed vertically. In addition, the present invention resides in a molding method and a molding die for an inorganic foamed molded product having a configuration in which the inorganic foamed molded product on the molded bottom plate is removed manually or by an adsorbing tool.

  According to the present invention, the foam molding space for foam molding to the shape and shape of the inorganic foam molded product can be easily joined by joining with the respective molding side plate and molding bottom plate, and the inside of the foam molding space where the joint is formed. Each of the molding lid plates that can be fitted and closed is formed with a release layer made of tetrafluoroethylene or silicon material on the inner surface, and an electromagnetic induction heating body is arranged on the outer side to form a molding die. Therefore, after forming the desired foam molding space and injecting the required volume of siloxane and silanol salt multi-molecular weight solution into the interior, the molding cover plate is inserted and closed with the required foaming ratio and molding thickness. In addition, an inorganic foam molded article having a desired dimensional shape and expansion ratio can be foamed only by heating at 240 to 300 ° C. with an electromagnetic induction heater.

  A release layer is formed inside the molding side plate, the molding bottom plate, and the molding lid plate forming the foam molding space. By removing the molding side plate in the horizontal direction and the molding lid plate in the vertical direction, respectively. In addition, it can be easily peeled off without applying excessive stress to the inorganic foamed molded product and is placed on the molded bottom plate, and the inorganic foamed molded product is once molded into a silicon oxide state by moisture evaporation. Moreover, since it is not plastically deformed, it can be molded manually or by an adsorbing tool even at a high temperature.

  In addition, in the present invention, without reducing the temperature of the molding die composed of the molding side plate, the molding bottom plate, the molding lid plate, etc., the foam molding space is formed again, and the siloxane and silanol salt multi-molecular weight solution is injected in a required volume. In addition, by repeatedly inserting and closing with a molding cover plate and repeating heating and foaming, foaming can be performed in a very short time, and since the mold can be formed by detachment, an inorganic foamed molded product can be produced with extremely high production efficiency.

  Further, in the present invention, the expansion ratio, the foam molding thickness, and the resistance to resistance are determined by the injection volume of the siloxane and silanol salt multimolecular weight solution into the foam molding space and the ratio of the substantial foam molding space volume due to the insertion and closure degree of the molding cover plate. This is a method and a molding die for an inorganic foam molded product having many features, such as the physical properties such as compressive strength being freely adjustable.

  It is composed of a molding side plate and a molding bottom plate that can be joined and detached to form a foam molding space of dimensions and shape for foam molding, and a molding lid plate that can be fitted and closed in this foam molding space. Using a molding die in which a release layer is formed and an electromagnetic induction heating body is coordinated on the outside, a required volume of siloxane and silanol salt multi-molecular weight solution is injected into the formed foam molding space, and then a molding cover plate Then, it is heated at 240 to 300 ° C. with an electromagnetic induction heating body, foam-molded and foam-molded, and the molding side plate and the molding lid plate are detached to mold the inorganic foam-molded product.

  In the following, embodiments of the present invention will be described in detail with reference to the drawings. FIG. 1 is a development explanatory view of a molding die in the present invention, FIG. 2 is a flowchart of the molding method of the present invention, Since 1 plays a main role, the description will be made based on the molding die 1. The molding die 1 forms a foam molding space 1A that matches the size and shape of the inorganic foam molded product 3 to be foam molded. The molding side plate 1B and the molding bottom plate 1C are used, and the molding side plate 1B and the molding bottom plate 1D are joined to form a foam molding space 1A, and are movable so that the foam molding space 1A can be disassembled by detachment. Is formed.

The molding die 1 in FIG. 1 is suitable for forming a flat plate-shaped or prismatic inorganic foam molded product 3, and the molding side plate 1B is composed of four sets of left and right and front and rear, and on the back of each molding side plate 1B. A moving piston 1C for attaching and detaching them in the horizontal direction is attached, and the other end of this moving piston 1C is connected to an appropriate hydraulic or electric cylinder.
Further, the foam molding space 1A is formed by joining the molding side plates 1B to each other and a molding bottom plate 1D that forms the bottom, and the molding bottom plate 1D is provided with a piston 1E so that it can move in the vertical and horizontal directions. It is desirable to keep it.

  Then, the molding lid plate 1F formed in a dimension shape that can be fitted and closed in the foam molding space 1A formed in the required dimension shape by the molding side plate 1B and the molding bottom plate 1D is provided to an appropriate position in the foam molding space 1A. In addition, it is arranged so as to be fitted and closed with a required pressure, a pressure piston 1G is provided on the back surface of the molded lid plate 1F, and the other end is connected to an appropriate cylinder. .

In addition, in the foam molding space 1A formed by the molding side plate 1B and the molding bottom plate 1D, the raw material siloxane and silanol salt multimolecular weight solution 2 are injected at a required volume ratio, and then inserted and closed by the molding lid plate 1F. When heat foaming is performed, the siloxane and silanol salt multi-molecular weight solution 2 is strongly bonded to the molding side plate 1B, the molding bottom plate 1D, or the molding lid plate 1F by creating strong heat-fusibility and promoting siloxane bonding. Thus, the inorganic foam molded product 3 cannot be formed.
For this purpose, a release layer 1H made of tetrafluoroethylene or a silicon material is formed on the inner side surfaces of the molded side plate 1B, the molded bottom plate 1D, and the molded lid plate 1F. As the release layer 1H, means for adhering the release material in the form of a film, coating formation or coating formation is proposed, but coating means is desirable from the viewpoint of repeated use and molding.

Further, on the outside of the molding side plate 1B, the molding bottom plate 1D or the molding lid plate 1F, the siloxane and silanol salt polymolecular weight solution 2 injected into the foam molding space 1A is heated to 240 to 300 ° C. to create heat-fusible properties. And an electromagnetic induction heating body 1K for foaming the inorganic foamed molded article 3 having an open cell structure by promoting siloxane bonding and moisture evaporation. The heating capacity of the electromagnetic induction heating body 1K is the injection capacity of the siloxane and silanol salt polymolecular weight solution 2 injected into the foam molding space 1A and its water composition ratio, or the size and shape of the inorganic foam molded product 3 to be foam molded. Etc. are determined concretely.
The electromagnetic induction heating body 1K heats the siloxane and silanol salt multimolecular weight solution 2 injected at a high temperature of 240 to 300 ° C., so that the external environment in which the molding die 1 is used. However, in order to prevent heat dissipation to the outside, it is desired that the electromagnetic induction heating body 1K is further covered with an appropriate heat insulating material 1L on the outer side.

The molding cover plate 1F is foam-molded while maintaining the desired compressive strength by adding the expansion ratio, molding thickness and internal pressure of the inorganic foam-molded product 3 to be foam-molded, as shown in FIG. The foam molding space 1A into which the silanol salt multi-molecular weight solution 2 has been injected is sufficiently inserted and closed, and the pressure is increased and moved to a range where the required increase in foaming 2A and internal pressure are applied by internal heating accompanying heating and foaming. The movement adjustment with the pressure piston 1G is achieved.
In such a case, the molding thickness varies depending on the specific use of the inorganic foam molded article 3, but the inner heat insulating material for building is about 15 mm even if it is thin, and about 60 to 80 mm if it is thick. Therefore, it is desirable that the formed lid plate 1F be formed with a substantial thickness that can be moved and adjusted to such a range.

  The inorganic foamed molded product 3 thus formed is required to have various widths, lengths and thicknesses depending on the purpose of use. As described above, the thickness, the foaming ratio and the physical properties are foamed. Although adjustment is possible by the injection volume of the siloxane and silanol salt polymolecular weight solution 2 injected into the molding space 1A and the substantial foam molding volume by the molding lid 1F fitted and closed in the foam molding space 1A, On the other hand, a variety of widths and lengths are required, but creating the molding side plate 1B, the molding bottom plate 1D, and the molding lid plate 1F capable of coping with them requires enormous burden on the installation cost. Is forced.

  A method for coping with such a problem is also considered in the present invention. As shown in FIG. 4, the molded bottom plate 1D is formed with a sufficiently large area that can be formed in various dimensions and formed, and the molding is performed. As the side plate 1B, by forming the formed side plate 1B capable of coping with the length of the inorganic foam molded product 3 to be formed, the four formed side plates 1B shown in FIG. The foamed molded product 3 can be formed, and the molded side plate 1B that is orthogonal to the opposing molded side plate 1B as shown in FIG. Since formation becomes possible, it can cope with preparation of the minimum shaping | molding side plate 1B based on the dimension of the inorganic foaming molded product 3 to foam-form. Of course, even in such a case, the molded lid plate 1F is formed to have a dimension and shape that can be fitted and closed in the foam molding space 1A to be joined.

  The molded side plate 1B, the molded bottom plate 1D, and the molded lid plate 1F are made of a siloxane and silanol salt multi-molecular weight solution at a heating temperature of 240 to 300 ° C. by an electromagnetic induction heating body 1K disposed on the outside. Since the inorganic foamed molded article 3 is foamed by heating, a material having excellent heating efficiency by electromagnetic induction is desired, and thus an iron plate material is usually used. However, due to technical progress of electromagnetic induction heating since recent years. It can also be used with aluminum plates and stainless steel.

The molded side plate 1B, the molded bottom plate 1D, the molded lid plate 1F, and the like thus formed are joined and detached by the moving piston 1C of the molded side plate 1B, the piston 1E of the molded bottom plate 1D, the pressure piston 1G of the molded lid plate 1F, and the like. Therefore, these are usually combined into an integral frame and formed as a molding die device as a whole.
Of course, when the siloxane and silanol salt multimolecular weight solution 2 is injected into the foam molding space 1A formed by joining the molding side plate 1B and the molding bottom plate 1D, an appropriate injector 2B for metering the required volume and It is desirable that an appropriate adsorbing tool 2C capable of adsorbing and molding the high-temperature inorganic foamed molded article 3 that has been heat-foamed is provided.

By the way, siloxane and silanol salt multi-molecular weight solution 2 which are raw materials for foaming inorganic foamed molded product 3 are practically used after being used in addition to fire resistance, non-flammability, light weight, heat insulation and safety. In addition, since the most characteristic feature is that it can be assimilated into soil, that is, it can be assimilated into soil, a silicon oxide state is desired.
For this reason, the siloxane and silanol salt multi-molecular weight solution is used to dissolve sodium oxide contained in a large amount in natural rocks and inorganic industrial wastes into alkali silicate so as to form sodium silicate once, hydrofluoric acid, boric acid, etc. In the presence of water, siloxane and silanol salt are foam-molded into a dense complex compound with a high molecular weight of about 4,000 to 8,000 in terms of molecular weight, and into an open cell structure due to the evaporation of water. Therefore, the solid content of siloxane and silanol salt is 45 to 75% by weight and the water content is 25 to 55% by weight. With the creation, promotion of siloxane bond and moisture evaporation, the expansion ratio is about 15 to 20 times when the moisture content is about 45 to 55% by weight. Approximately 8 to 15 times is prospect is 5 to about 35 wt%.

When the inorganic foam molded product 3 is molded using the molding die 1 thus formed, as shown in the molding process schematic diagram of FIG. 5, the molding bottom plate 1D and the molding are formed on the molding bottom plate 1D in the joining step 20 first. A foam molding space 1A conforming to the desired size and shape of the inorganic foam molded article 3 is joined and formed with the side plate 1B, and a required volume ratio of siloxane and silanol salt multimolecular weight solution 2 is injected in the injection step 21. Inject using 2B or the like.
Thus, in the fitting and closing step 22, the molded lid plate 1F is fitted and closed so that the required internal pressure is applied in the heating foam space 1A formed by bonding, and in the heating step 23, the molding side plate 1B and The electromagnetic induction heating state 1K coordinated with the molding bottom plate 1D is heated at a temperature of substantially 240 to 300 ° C. to be foam-molded to a required dimensional shape, expansion ratio and physical properties.

In addition to the foam molding, the inorganic foam molded article 3 that has been foam-molded is molded into the bottom plate 1D by removing the molding side plate 1B in the horizontal direction and the molding lid plate 1F in the vertical direction in the separation step 24. Presents the state of being placed on top.
Thus, the inorganic foamed molded product 3 is produced by manually molding or molding the inorganic foamed molded product 3 by the adsorbing tool 2C or the like in the molding step 25. From the viewpoint of facilitating unloading workability, the molded bottom plate 1D can be moved to an appropriate position.

  By preparing the molding die 1 and the molding die device, the desired inorganic foamed molded product 3 can be easily and efficiently molded.

  It is expansion | deployment explanatory drawing of a shaping die.   It is a flowchart of a shaping | molding method.   It is explanatory drawing which shows the foam increase of a foam molding space.   It is an illustration figure of joining formation of a shaping | molding side board.   It is a shaping | molding process schematic.   It is explanatory drawing of the conventional molding die.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Molding die 1A Foam molding space 1B Molding side plate 1C Molding side plate moving piston 1D Molding bottom plate 1E Molding bottom plate piston 1F Molding lid plate 1G Molding lid plate pressure piston 1H Peeling layer 1K Electromagnetic induction heating element 1L Insulating material 2 Siloxane and Silanol salt multi-molecular weight solution 2A Foam increase 2B Syringe 2C Adsorber 20 Joining process 21 Injection process 22 Insertion blockage process 23 Heating process 24 Release process 25 Molding process 3 Inorganic foam molded product

Claims (3)

  In order to be able to be molded to the size and shape, expansion ratio and physical properties of the inorganic foam molded product, the molded side plate and the molded bottom plate are movable so that they can be joined and detached from each other, and the foam molding formed between the molded side plate and the molded bottom plate is joined. It consists of a molded lid plate that can be inserted and closed, and an iron plate, an aluminum plate, or a stainless steel plate is formed with a release layer made of tetrafluoroethylene or silicon resin on the inner side, and an electromagnetic induction heating element is arranged on the outer side. A mold for forming an inorganic foam molded product, characterized in that it is provided.   The molding side plate and the molding bottom plate of the molding die are joined to form a foam molding space having a size and shape of an inorganic foam molded product, and then a siloxane and silanol salt multi-molecular weight solution is injected at a required volume ratio, The molding lid is press-fitted into and closed within the volume that can be formed according to the expansion ratio and the thickness and physical properties of the foamed molded product, and thus heated at a temperature of 240 to 300 ° C. to form a silicon oxide state with an open cell structure. In addition, foaming is performed on an inorganic foamed molded product having the required dimensions, shape, expansion ratio, and physical properties, and the molding side plate forming the molding die is detached in the horizontal direction and the molding lid plate in the vertical direction, and the inorganic on the molding bottom plate. A method for molding an inorganic foam molded article, wherein the foam molded article is taken out manually or by an adsorber.   The method for molding an inorganic foam molded article according to claim 2, wherein the siloxane and silanol salt multi-molecular weight solution is injected at a required volume ratio using an injector.

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