JPH01317148A - Production of inorganic lightweight construction material - Google Patents

Abstract

PURPOSE:To obtain a high-quality lightweight construction material outstanding in heat resistance and thermal insulation, causing no maldeformation, producible by continuous production line system by press molding followed by hot curing of granules prepared by admixing lightweight aggregate such as calcined vermiculite with water-glass. CONSTITUTION:Granules are prepared by blending inorganic lightweight aggregate comprising calcined vermiculite and/or calcined silas with a mixture comprising water-glass and its curing agent. The amounts to be blended (based on 100 pts.wt. of the inorganic lightweight aggregate) are: 50-200 pts.wt. for the water-glass and 3-35 (pref. 3-30) pts.wt. for the water-glass curing agent. And the water content of said granules is 10-50 (pref. 20-40)wt.% said granules are put to press molding (at 0.5-5.0kg/cm<2>) through a continuous system such as roll press method, heating, drying and curing with e.g., infrared rays, thus obtaining the objective dry-pressed inorganic lightweight construction materials.

Description

[Detailed Description of the Invention] (Industrial Application Field) The present invention relates to a method for producing inorganic lightweight building materials.
More specifically, it relates to a completely new method for continuously manufacturing the building material.

Moreover, the resulting building materials are not only lightweight, but also have excellent heat resistance and insulation properties, and do not emit toxic gases.
Accordingly, the present invention is directed to a new and superior method for efficiently producing building materials with superior properties.

(Conventional technology) As buildings become taller and the number of apartment buildings increases, fire resistance and
There is a need for technology that can efficiently produce building materials that are lightweight, have excellent thermal insulation and soundproofing properties, and have excellent physical strength. Conventionally, inorganic lightweight building materials were disclosed in JP-A-60-16]380.
As seen in JP-A-61-98846, etc., an inorganic lightweight aggregate is mixed with an inorganic adhesive such as water glass or pol-1-land cement, and the mixture is dried, hardened, and molded while being packed in a mold. However, as an adhesive, water glass or Pace 1, which is made by adding approximately the same amount of water to cement, has been used. For this reason, it took time to dry and harden, which had the major drawback of interrupting assembly line operations in the manufacturing process.13 For example, in the conventional method, aggregates and adhesives were left in the formwork for a certain period of time. °
C. to about 100.degree. C. for curing and drying, or at room temperature for several days.

Furthermore, when moisture is removed, the molded product shrinks and deforms. Therefore, in order to improve the shortcomings in this process, a technology has been proposed in which lightweight inorganic aggregate is bond-molded using a fast-acting organic adhesive (Japanese Patent Application Laid-Open No.
7-140357), it cannot be said to be the best in terms of fire resistance and combustion gas generation issues, and the aggregate obtained here is granular, so to speak, it is the material of aggregate, and it is not the best. In order to produce the building material according to the invention, the granules must be placed in a mold and molded according to the conventional method described above, and therefore, the above-mentioned drawbacks are unavoidable even in this technique.

(Problem to be solved by the invention) All of the above-mentioned conventional technologies inevitably have the decisive drawback of not being able to process continuously. However, organic materials cannot be used because of the pollution and safety issues that have recently come into focus, such as the generation of toxic gases.

Therefore, the present invention has set as a new object the production of lightweight building materials using inorganic materials.

In other words, the purpose of the present invention is to bond inorganic lightweight aggregate with an inorganic adhesive to produce inorganic lightweight building materials, to form it in a short time, to enable continuous and targeted work, and to
The objective is to reduce shrinkage and deformation during drying and curing, and to produce a product with excellent physical properties.

(Means for Solving the Problems) In order to solve the above problems in a method of bonding inorganic lightweight aggregates with an inorganic adhesive, the inventors reduced the moisture content of the adhesive as much as possible, Furthermore, we have continued to conduct research to establish a manufacturing method that enables continuous flow work by uniformly distributing adhesive on the aggregate surface and molding it in a short time.

As a result of the research, when we specifically selected an inorganic lightweight building material mainly composed of calcined vermiculite and/or calcined whitebait, and mixed it with hydraulic lath and a water glass hardening agent, we unexpectedly found that the fluidity deteriorated. A smooth powder was obtained. What was even more surprising was that after the powder obtained in this way was continuously put into a mold and pressure-molded, the hair was taken out and heated, and it was completely bonded and solidified. We have newly discovered that there is no problem even if the work is performed continuously without interruption.

The present invention utilizes this new knowledge, that is, until the mold is filled (instead of a highly viscous paste as in the conventional method).
Although it has free-flowing properties, if it is pressure-molded, it will adhere and solidify in a short period of time, two problems that are inherently incompatible.
They discovered a composition that has two properties (free-flowing properties and adhesive solidification) and completed further studies based on this new knowledge.

The main point of the present invention is that when a lightweight inorganic aggregate is bound with an inorganic adhesive to produce a lightweight inorganic building material, a thick water glass adhesive with a low water content is used for the selected aggregates, namely fired vermiculite, fired vermicelli, etc. Easy to distribute uniformly in whitebait by mixing;
When the water content of the mixture consisting of aggregate, water glass, and water glass hardening agent is 40% by weight or less, it becomes a powder with smooth fluidity, and when this powder is packed into a mold, it will flow. Because of its properties, it is easy to disperse uniformly, and secondly, when the powder packed in a mold is pressure-molded at a pressure of 0.5 to 5.0 kg/d, the molded product will not be deformed during operations such as movement and transportation. Or have physical strength to the extent that it will not break.
As a result, it is now possible to remove the press-molded product from the mold after completion of the pressurization and dry and harden it outside the frame, and as a result, it has become possible to continuously manufacture lightweight inorganic building materials, which was previously considered impossible. That's what happened.

Next, the present invention will be explained in more detail.

Calcined vermiculite as used in the present invention is made by firing vermiculite, and is commercially available as calcined vermiculite (hereinafter referred to as calcined vermiculite).
Moreover, baked whitebait is a product made by firing whitebait, and is commercially available as a whitebait balloon (hereinafter referred to as a whitebait balloon), and both are made of granular materials.

In the present invention, these may be used alone or in an appropriate combination. When 60% by weight or more of the inorganic lightweight aggregate used in the present invention is calcined vermiculite and/or shirasu balloons, the effects of the present invention can be further expected. Other blended aggregates include kaolin, fuyolite (commercial product fired from obsidian), and barley 1 to
Commonly used materials such as (commercially available), zeolite, talc, and limestone are widely used, whether fired or unfired. In addition,
Use of acid clay improves workability.

In addition, it is more effective to use Calcilla carbonate 11, mica (muscovite, phlogopite, rhodotite), etc. Also, glass fiber, rock wool, carbon fiber, pulp fiber,
Even when inorganic or organic fibers such as rice husk, hemp, rice straw, wheat straw, juro chips, etc., especially alkali-resistant fibrous materials are blended, excellent effects can be obtained.

The inorganic adhesive used in the present invention has water glass as its main component, and contains a hydraulic lath curing agent and other components if necessary.

What is water glass?Na70・IIS], 02・x15
It refers to an ITS standard product that is commercially available as a concentrated aqueous solution of mono-lithium silicate hydrate shown in There are silifluoride salts such as ~Rium 11, phosphates such as Matanesium phosphate 11, borates such as boric acid [~Rium], but in the present invention, slow-release curing agents are suitable. Particularly preferable are silicofluoride to lithium.Other examples include thulium polyphosphate, tris(1-helium) phosphate, di(s)-to-lium phosphate, sulfur(1-helium) phosphate,
Helium metaborate, potassium sulfate, magnesium sulfate, ammonium sulfate 11, calcium silicate, and zinc oxide A9 may also be added, for example, to improve the water resistance and whitening of the cured product.

When blending these raw materials to make powder J11, the d^ combination step does not necessarily require heating, and is usually 41M.
Even better results can be obtained if the temperature is 10°C or lower.

If the blended star of hydraulic lath is less than 65 weight yI 7%, especially less than 1 part of 50 weight, the binding force will be weak for 100 parts by weight of an inorganic lightweight aggregate mainly composed of ``L-forming vermiculae 1~ or/and shirasu balloons. If the amount is more than 200 parts by weight, the specific gravity of the concrete becomes heavy, which is undesirable. -4- For 100 parts by weight of the aggregate, the water glass hardening agent should be in an amount of 23 to 35 parts by weight, preferably 3 to 30 parts by weight. It is suitable in terms of the curing speed of hydraulic lath.

Water glass, a water glass hardening agent, and if necessary a small amount of water are added to an inorganic lightweight aggregate mainly composed of fired vermiculite 1 and/or shirasu balloons, and the mixture is mixed using a mixer.

At this time, it is preferable to mix the three components: hydraulic lath, water, and water glass hardening agent, and then mix this into the aggregate. The moisture content of the mixture obtained is between 10 and 50% by weight, preferably 20% by weight.
It is preferable to set it to 40% by weight. This water content is the minimum amount necessary to uniformly distribute the adhesive into the aggregate, and is also the amount suitable for the next step of pressure molding, and the amount suitable to prevent shrinkage and deformation during drying. It is. Even if a small amount of water is added to the water glass as necessary, the water content of the final mixture should be 10 to 50% by weight, preferably 20 to 50% by weight.
It must be processed so that the weight is within 40% weight. The most suitable moisture content is determined by the type of aggregate, the amount of water glass used, and the season.
A more preferable moisture content is usually 25-35% by weight.

When an inorganic lightweight aggregate mainly composed of calcined vermiculite and/or shirasu balloons, water glass, and a water glass hardening agent are mixed, and the water content of the mixture is 20 to 40% by weight, the water glass adhesive is It is easy to distribute uniformly on the surface of the grains of the aggregate, and water is absorbed into the grains, making the mixture a smooth powder with good dispersibility and fluidity. Before the adhesive hardens, this powder is packed into a mold using a continuous system such as a mobile pressure method or a roll press method, and is pressed at a pressure of 0.5 to 5.0 kg/cJ. The molded product is pressed and removed from the mold when the pressure gauge reaches a certain value.This molded product has sufficient physical strength to withstand movement or transportation of the molded product.Therefore, the present invention In this case, there is no need to dry and harden the molded product while it is packed in the mold, and the drying and hardening can be carried out after taking it out from the mold.The drying and hardening process can also be carried out by leaving the molded product at room temperature. A method of curing at a temperature may also be used.Furthermore, in the present invention, there is less water to be evaporated, and since the water is evaporated after molding, there is an advantage that shrinkage and deformation of the molded product is small, and furthermore, it is possible to form a large block molded product. This has the advantage that it is possible to cut this block to create building materials of a certain size.In addition, with the conventional method of using adhesive with a high moisture content, the molded product shrinks. It was difficult to obtain products with accurate dimensions.

Furthermore, according to the method of the present invention, even if the same material is used, molded products with different properties, that is, with different specific gravity and strength, can be obtained by adjusting the pressure during pressure molding.

The molded product obtained by the method of the present invention has an apparent specific gravity of 1.0 or less and is light, has fire resistance, heat insulation, and soundproofing properties, and has excellent physical strength, and can be used as flooring material, interior wall material, ceiling material, etc. In addition to interior building materials, it can also be used as exterior building materials such as exterior wall materials, cups, and roofing materials.

Examples will be described below.

Example 1 To 1000 g of a commercially available hydraulic lath (JISa standard product),
200 g of sodium silicofluoride was added as a water glass hardening agent and mixed to form an adhesive. To this adhesive, 1,400 g of calcined vermiculite (commercially available granular product), which is being stirred in a ribbon-type mixer, is gradually added and mixed and stirred at 10°C for 15 minutes, resulting in a smooth mixed powder with a water content of about 25% by weight. is obtained. Then, using a moving pressure method, this powder was packed into a mold with a size of 20 cm x 20 cm so that the thickness was as uniform as possible.
Pressure molding was carried out at a pressure of (20cm x 20cm
．． The molded product was an 8 cm rectangular parallelepiped, and was not deformed or damaged during operations such as moving it on a roll conveyor and manually transporting it to a warehouse. This molded product was dried and cured by heating. During this period, no shrinkage or deformation of the molded product was observed. After drying and curing, this rectangular parallelepiped molded product was subjected to 2.
Cut it with a saw to a thickness of 5cm, 20cm x
A plate-shaped building material measuring 20 cm x 2.5 cm was obtained. This material had excellent physical properties and sufficient ability to hold nails and wood blocks, making it suitable for wall materials. The apparent specific gravity of the molded product after drying and hardening was 0.50.

Example 2 To 000 g of commercially available water glass (JTSa standard product), 35% sodium tetrapolyphosphate was added as a water glass hardening agent.
g, 200 g of 1-lium silicofluoride, and 35 g of magnesium sulfate were added and mixed to prepare an adhesive. This adhesive
While cooling, the mixture is gradually added to 580 g of a Shirasu balloon which is being stirred in a ribbon type mixer, and mixed and stirred for about 15 minutes to obtain a free-flowing mixed powder with a moisture content of about 35% by weight. Next, this powder was packed into a mold with a size of 20 cm x 20 cm using a roll press method so that the thickness was as uniform as possible at 2.1 kg/c++? Pressure molded at a pressure of When the pressure gauge reached a constant predetermined value, the pressurization was stopped and the molded product was taken out. The molded product obtained was a rectangular parallelepiped with dimensions of 20 cm x 20 cm x 6.5 cm. This molded product was transferred to a warehouse and heated to dry and harden. During this period, no shrinkage or deformation of the molded product was observed. This rectangular parallelepiped molded product was cut with a saw to a thickness of 2.0 cm, 20 cm x 20 cm x 2. A plate-shaped building material of Ocm was obtained. This material has excellent fire resistance, heat insulation, and sound insulation properties, and also has physical strength, making it suitable as a core material for boards, panel materials, etc. The apparent specific gravity of this molded product after drying and hardening was 0.40.

121 Example 3 To 1000 g of commercially available water glass (JIS No. 3 standard product),
50 g of water, 1-lium 2 silifluoride as a water glass hardening agent
00g, and further mixed with 35g of sodium tetrapolyphosphate and 35g of ammonium sulfate to prepare an adhesive. 700g of fired vermiculite (commercial product in granular form) and Shirasu balloon (commercial product in granular form) are stirred in a ribbon-type mixer.
200. ,, Gradually add to a mixture of 100 g of Fuyorai 1~ (obsidian fired product, granular commercial product) and 100 g of Calcilla carbonate A, mix and stir for about 15 minutes, and a smooth powder of the mixture with a moisture content of about 30% by weight is obtained. 19.

Next, this powder was continuously packed into a mold with a size of 20 cm x 20 cm so that the thickness was as uniform as possible]
, Okg/ant pressure. When the value of the pressure H1 became constant at a predetermined value, the pressurization was stopped and the molded product was taken out. The resulting molded product is 20cm x 20cm
X] It was a rectangular parallelepiped with a size of 1 cm. This molded product was transferred to a warehouse and heated to dry and harden. During this period, no shrinkage or deformation of the molded product was observed. This rectangular parallelepiped molded product was cut with a saw to obtain a plate-shaped building material measuring 20 cm x 20 cm x 1 and 0 cm. This material has excellent fire resistance, heat insulation, and soundproofing properties, and is suitable for core materials such as panel materials and ceiling materials. The apparent specific gravity of this molded product after drying and hardening was 0.35.

Example 4 1000g of water glass (JIS No. 3 standard product) as adhesive
, trisodium phosphate 35g, ammonium sulfate 35g
, magnesium sulfate 35g, and sodium silicofluoride 2
Excellent molded products were continuously produced by repeating the same process as in Example 3, except that 00g of the powder was used and a mixture of mica powder and carbon fiber was used instead of calcium carbonate.

(Effect of the invention) The present invention mixes an inorganic lightweight aggregate mainly composed of calcined vermiculite and/or calcined whitebait with a thick water glass adhesive with a low moisture content to obtain a powder with a low moisture content. This method continuously molds powder containing adhesive under pressure, eliminating the traditional process of hardening and binding it while it is in a mold for a long time, making it possible to perform continuous flow work. This is a manufacturing method for lightweight inorganic building materials. Furthermore, the method of the present invention has the advantage that products with different properties such as specific gravity and physical strength can be produced by adjusting the pressure during pressure molding without shrinking or deforming during drying and curing. There is. Therefore, the method of the present invention is efficient and economical as a manufacturing method for inorganic lightweight building materials, and in addition, high quality products without deformation can be obtained, and it can be said to be a superior manufacturing method compared to conventional methods. .

Agent Patent Attorney 1) Parent Male procedural correction band August 24, 1999

Claims (1)

[Claims] (1) 100 parts by weight of an inorganic lightweight aggregate mainly composed of calcined vermiculite and/or calcined whitebait, 50 to 200 parts by weight of water glass, and 3 to 35 parts by weight of a water glass hardening agent, with a water content of 20 to 40. A method for producing an inorganic lightweight building material, which is characterized by obtaining a powder of % by weight, then continuously press-molding the powder, and drying and curing it by heating.