JPH0597538A - Lightweight inorganic building materials - Google Patents

Abstract

(57) [Summary] [Purpose] Light weight, fire resistance, heat insulation, and extremely low water absorption.
Provide an inorganic lightweight building material with high mechanical strength. Constituting fine hollow glass spheres having an average particle diameter of 40 to 600 μm and ultrafine particle powder having an average particle diameter of 5 nm to 300 nm and having water repellency, the ultrafine particle powder 3 per 100 parts by weight of the glass sphere. A lightweight inorganic building material comprising a molded body obtained by integrally joining 20 to 20 parts by weight of a mixture with an inorganic bonding agent.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a lightweight inorganic building material containing fine hollow glass spheres as a main component.

[0002]

2. Description of the Related Art Conventionally, building materials which are lighter in weight and have excellent mechanical strength have been required, and various inventions have been made. However, conventionally, water absorption of lightweight inorganic building materials has been a problem, and exterior materials have a problem of structural deterioration due to freeze-thaw reaction in cold regions. Surface treatment with paint and surface treatment with paint have been considered. When the base material is lightweight cellular concrete, the base material is alkaline in the treatment with the paint, and therefore the treatment agent must use an expensive alkali-resistant paint. Also, a water repellent,
The treatment with a waterproofing agent has a problem that it requires a secondary process such as long drying time after the treatment. Moreover, the occurrence of white flower after water absorption is also a problem. In the case of interior materials, if water stains are generated during construction, there is a risk of hygienic problems due to the generation of mold and mildew. Furthermore, water absorption leads to a decrease in heat insulation.

[0003]

SUMMARY OF THE INVENTION It is an object of the present invention to solve the above problems found in the prior art and to provide an inorganic lightweight building material having extremely low water absorption, light weight, fire resistance, heat insulation and mechanical strength. It is an issue.

[0004]

The present inventors have completed the present invention as a result of intensive studies to solve the above problems. That is, according to the present invention, an average particle size of 40-60
0 μm fine hollow glass spheres and average particle size 5 nm to 300
nm surface water-repellent ultrafine particle powder, and a molded body obtained by integrally bonding a mixture of 3 to 20 parts by weight of the ultrafine particle powder per 100 parts by weight of the glass sphere with an inorganic bonding agent. A lightweight inorganic building material is provided.

The lightweight inorganic building material of the present invention is prepared by adding an inorganic bonding agent to a raw material mixture consisting mainly of fine hollow glass spheres and surface-repellent ultrafine particle powder, and mixing this mixture under pressure. It is manufactured by molding into a shape.
The fine hollow glass spheres used in the present invention have an average particle size of 40 to 6
It has a diameter of 00 μm, preferably 60 to 160 μm, and shirasu balloon, pearlite or the like is used. The surface-repellent ultrafine particle powder used in the present invention has an average particle size of 5 to 300 nm, preferably 10 to 100 nm, and is a metal oxide such as silicon dioxide, aluminum oxide, titanium oxide, or magnesium oxide. Is mentioned. As a method for making the surfaces of these ultrafine particle powders water-repellent, conventionally known methods can be adopted. Examples of such a method include, for example, a method of reacting a hydrophilic silanol group (Si-OH) held by silicon dioxide with a silane coupling agent or a titanate coupling agent having an alkyl group or a haloalkyl group, There is a method of reacting a halosilane compound such as dimethyldichlorosilane and trimethylchlorosilane with a hydrophobic compound such as a silazane compound such as hexamethyldisilazane. Further, when the surface of the ultrafine powder is treated to be water-repellent, silicon dioxide can be easily treated with a silane cuffing agent, and a particularly effective effect can be seen. It is preferably used. For example, the ultrafine particle powder having a water repellent surface used in the present invention has a surface area of 10
Moisture absorption per 0 m ² is 5% under the condition of relative humidity 80%.
The surface treatment is performed to be less than mg, preferably less than 2 mg.

If necessary, the raw material mixture of the present invention may contain auxiliary inorganic particles such as kaolin, mica, wollastonite, talc and white carbon. The amount of the auxiliary inorganic particles to be blended is 50 parts by weight or less, preferably 30 to 40 parts by weight, based on 100 parts by weight of the fine hollow glass spheres, which has the effect of improving the moldability of the mixture and the physical strength of the molded product. Show. The average particle size of the auxiliary inorganic particles is 5 to 50 μm.
m, preferably 10 to 30 μm. Further, in the present invention, reinforcing fibers can be blended as needed to increase the strength of the molded body. Examples of the reinforcing fiber include vinylon fiber, acrylic fiber, aramid fiber, polyester fiber, polyamide fiber, cellulose fiber, cotton, carbon fiber, and other synthetic fibers and natural fibers, as well as metal fiber, alumina fiber, glass fiber, gypsum whiskers, and the like. Various metals and inorganic fibers are used. The content of the reinforcing fiber is 0.1 to 10 parts by weight, preferably 0.5 to 5 parts by weight, based on 100 parts by weight of the fine hollow glass spheres. The thickness of the fiber is 1 to 100 μm, preferably 3 to 60 μm, and the fiber length is 1 mm or more, preferably 3 to 20 m.
m. The blending ratio of the raw material mixture of the present invention is 3 to 20 parts by weight, preferably 5 to 15 parts by weight, of surface-repellent ultrafine particle powder per 100 parts by weight of fine hollow glass spheres. In the present invention, the raw material mixture is, as described above,
3 to 20 parts by weight, preferably 5 to 15 parts by weight, of the ultrafine particle powder whose surface has been made water repellent is contained, but when the content ratio is less than the above range, the obtained molded article has required water repellency. On the other hand, if it exceeds the above range, the water repellency can be obtained, but the strength of the molded article is remarkably reduced,
Practical strength cannot be obtained. Further, the above ultrafine particle powder,
The particle size is 5 to 300 nm, preferably 10 to 100
nm, which is a very bulky powder. When this powder is blended in the above blending amount, if the particle diameter exceeds the above upper limit, the surface area of the particles having a water repellent surface is reduced and the water repellency is lost. Further, it becomes difficult for the particles to be densely packed, and the strength decreases. Moreover, when powders are mixed, the fluidity is lowered and the workability is deteriorated. On the other hand, when the particle size is less than the above upper limit, the ratio of the particles to all particles in the molded article becomes high, and although water repellency is obtained, the strength is remarkably reduced and practical strength cannot be obtained.

As the inorganic bonding agent used in the present invention, any one can be used as long as it can integrally bond the above-mentioned raw material mixture. As such a material, a conventionally known inorganic polymer (for example, Polysilazane) can be mentioned, but it is particularly preferable to use a combination of water glass and a water glass curing agent. Examples of the water glass include aqueous solutions of alkali metal silicates such as sodium silicate, potassium silicate, and lithium silicate. For example, 11S 1 standard product, JIS 2 standard product, JIS
There are commercial products such as No. 3 standard products. As the water glass curing agent, conventionally known ones, for example, inorganic acids such as phosphoric acid and boric acid and salts thereof, silicofluorides such as sodium silicofluoride, zinc oxide and magnesium oxide, calcium carbonate, calcium sulfate, condensed phosphoric acid. Examples thereof include metal oxides such as aluminum, metal salts, and acetic acid esters.

In order to preferably produce the lightweight inorganic building material of the present invention, water glass and a water glass curing agent are mixed with a raw material mixture to obtain a non-slurry powdery material having fluidity, and the mixture is put into a mold. It is pressure molded and then cured. The use ratio of water glass is 30 to 150 parts by weight, preferably 40 to 130 parts by weight, in terms of solid content (alkali metal silicate), based on 100 parts by weight of the raw material mixture. When the proportion of water glass used is less than the above upper limit, the effect as a bonding material is poor, and the resulting molded body (building material) has a markedly reduced strength and is impractical. On the other hand, when the amount exceeds the upper limit, the fluidity of the raw material mixture is lowered, the mold is not uniformly filled, the resulting molded body has a density distribution, and a uniform molded body may not be obtained. .. The curing agent for water glass is 10 to 40 parts by weight, preferably 15 to 30 parts by weight, based on 100 parts by weight of the raw material mixture. When the amount of the curing agent used is less than the above lower limit value, the proportion of unreacted water glass increases, and thus the resulting building material tends to be broken at its ends, and practical strength cannot be obtained. On the other hand, when the amount exceeds the above upper limit, the curing reaction is fast and the workability is poor, and a good building material cannot be obtained.

In the present invention, a polymer binder may be used in combination in order to enhance the mechanical strength of the molded product. Examples of the polymer binder include water-soluble urea / formamide resins and guanamine resins, water-soluble polymers such as polyvinyl alcohol and polyvinylpyrrolidone, styrene / butadiene latex, acrylic latex, vinylidene chloride latex, and vinyl chloride. A polymer latex such as a system latex or a vinyl acetate latex is used. The polymer binder is used in an amount of 0.5 parts by weight or more, preferably 1 to 10 parts by weight in terms of solid content, based on 100 parts by weight of the raw material mixture. Since the incombustibility of the molded article will be impaired if the proportion of the polymer binder used increases, the proportion of the polymer binder used is preferably 5 parts by weight or less from the viewpoint of obtaining a noncombustible building material. In the lightweight inorganic building material of the present invention, the one containing a polymer binder is further improved in its mechanical strength, and the mechanical strength of the building material is adjusted by the kind and additive of the polymer binder. be able to.

In the case of obtaining a building material according to the present invention, a non-slurry fluid powder-granular mixture is filled in a molding die, taken out from the molding die after pressure molding, and the pressure molded body is cured at room temperature or under heating. Let In this pressure molding, the molded body can be cured in the molding die, but since the pressure molded body is a solid material and is easy to handle, the molded body is taken out from the molding die and Hold at room temperature or under heating to cure. In the present invention, when the molded body is cured under heating, the heating temperature is 30 ° C. or higher, preferably 80 ° C. or lower, and the curing time is usually 1 to 5 hours. The heat-cured product of the molded product can be used as a product as it is, but in order to further advance the curing reaction and improve the mechanical strength, it is at room temperature or a temperature around room temperature for 3 to 10 days, preferably about 5 to 8 days. Hold and use. The building material may have any shape such as a block body, a columnar body, and a tubular body in addition to the plate-like body.

[0011]

EFFECTS OF THE INVENTION The building material of the present invention has remarkably reduced water absorption, which has been a problem in the past. When used as an interior building material, it is possible to prevent the generation of stains and mildew, and It is possible to prevent deterioration of heat insulation due to water absorption. Furthermore, it is possible to prevent the occurrence of white smelt after absorbing water, and it is also excellent in mechanical strength. The building material of the present invention is advantageously used as an interior material, floor material, ceiling material, lining material, etc. in the field of construction.

[0012]

EXAMPLES Next, the present invention will be described in more detail by way of examples.

Examples 1 to 3 and Comparative Examples 1 to 3 Shirasu balloon (average particle size: about 100 μm), surface-hydrophobicized silicon dioxide (average primary particle size: about 16 nm, B)
ET surface area: 110 m ² / g, moisture absorption at relative humidity 80%: 0.10% by weight), water glass (JIS No. 3 product) and water glass curing agent were uniformly mixed as shown in Table 1 to obtain fluidity. To obtain a non-slurry granular material, and then to fill these mixtures into a molding die (length: 400 mm, width: 400 mm, height: 50 mm) up to a height of 15 mm, and press-mold using a pressing plate. Then, the molded product was taken out of the mold and cured under the curing conditions shown in Table 1. Then, it was cured under the curing conditions shown in Table 1. The water repellency of the molded product thus obtained was observed, and the water absorption was also measured. The results are shown in Table 1. (All compounding amounts are shown in parts by weight)

The water repellency and water absorption of the molded product were evaluated as follows. (Water repellency) As a method of evaluating water repellency, the obtained molded product was kept at an angle of 60 degrees from the horizontal plane, and water was added from above to 60 °
It was dripped at g / min for 1 minute, and the state of water droplets on the surface of the molded product was observed and evaluated according to the following criteria. Yu: Water spilled down on the surface of the compact. Good: Some water did not flow down from the surface of the molded body, and maintained a water drop state. No ... Absorbed on the surface of the molded product and became a stain. (Water absorption rate) As a method for evaluating the water absorption rate, JIS A520
According to 9-1981 ceramic tile, a 24-hour water absorption test was conducted. (Bending strength) As an evaluation method of bending strength, JISA14
08 (test piece size; width 5 cm, fulcrum distance 15 cm,
The test speed was 5 mm / min).

[0015]

[Table 1]

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Claims (4)

[Claims] 1. An ultrafine particle powder comprising fine hollow glass spheres having an average particle diameter of 40 to 600 μm and surface water repellent ultrafine particles having an average particle diameter of 5 nm to 300 nm, and the ultrafine particle powder per 100 parts by weight of the glass sphere. A lightweight inorganic building material comprising a molded body in which a mixture of 3 to 20 parts by weight of a body is integrally bonded with an inorganic bonding agent. 2. The inorganic lightweight building material according to claim 1, wherein the surface-repellent ultrafine particle powder is silicon dioxide treated with a silane coupling agent. 3. The lightweight inorganic building material according to claim 1, wherein the mixture contains auxiliary inorganic particles and / or reinforcing fibers. 4. The inorganic lightweight building material according to claim 1, wherein the inorganic bonding agent comprises water glass and a water glass curing agent.