JPS602277B2 - Manufacturing method for lightweight building materials - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention is directed to a method for making highly porous, lightweight inorganic building materials.

Demand for lightweight inorganic building materials has been increasing in recent years as they are used as soundproofing materials, heat insulating materials, and light panel materials.

Conventionally, this type of inorganic building material has been manufactured by using light materials for aggregate or by creating voids inside the material.

The latter method includes a foaming method in which gas is generated through a chemical reaction after compounding and becomes porous, and a foaming method in which a superfoaming agent such as a surfactant is added to cement, gypsum, water glass, etc. and compressed. A method is known in which the material is made into super-foam by air injection or air treatment, and then solidified in that state (Mochikai Sho 54-145734). However, with conventional methods, sufficient foaming may not be produced, or even if sufficient foaming is achieved, the weight of the inorganic material may cause the foam to break or recombine, resulting in non-uniformity or solidification. Sometimes air bubbles move to the upper layer,
Unevenness occurred in the density of the product. Therefore, the inventors conducted research to improve these drawbacks and to find a method for producing an even lighter inorganic building material.

As a result of research on material selection, foaming mechanism, prevention of defoaming, prevention of shrinkage during fixation, and reinforcement of the bending strength of the final product, the present invention was completed. More specifically, the purpose of this research is to make the size of bubbles finer and more uniform during foaming, and to increase the bubble ratio, that is, to increase overrun, to select materials for this purpose, and to improve foaming. After foaming, the foam walls are strengthened to increase foam retention and the foam is not destroyed by the weight of aggregates, etc., and the independence of the foam is maintained, allowing the foam to recombine and form non-uniformly sized bubbles. The present invention was achieved through research on the selection of foaming agents suitable for the purpose, foam strengthening methods, hardening agents for the main ingredient, blending methods of these materials, mixing order, etc. In the process of carrying out this research, even if foaming agents were added to the slurry consisting of cement, filler, aggregate, etc., foaming would not be sufficient if the specific gravity of the entire liquid was initially heavy. However, the foam was non-uniform and movement of the foam was observed during solidification, and it was found that the product aimed at by the present invention could not be obtained by this foaming treatment method.

As a result of various studies, it has been found that the object of the present invention can be achieved by solving the following problems.

[1] Obtain a liquid with an inorganic component composition that allows foaming to occur extremely easily, and the standard for ease of foaming at this time is an overrun of 200% or more. Physical and chemical strengthening of the foam in the foam is achieved, and the subsequent addition of a base agent, aggregate, etc. gives the foam strength to prevent the foam from collapsing. A slurry consisting of a hardening agent, filler, aggregate, etc. is added and mixed, and then the entire product is solidified. An aqueous solution of water glass was selected as an inorganic substance that easily foams, and a superfoaming agent made of a protein partial hydrolyzate or a synthetic surfactant was added to it to strengthen the foam. It has been found that the objective can be achieved by adding a substance that causes the water glass aqueous solution (sol-like material) to slowly gel continuously before, during and after foaming.

This slowly gelling substance, which is a mixture of an effective gelling agent, an aqueous solution of water glass, and a foaming agent, is easy to foam and can be foamed to an overrun of 200% or more with a simple super foam treatment. A similar product is obtained. The water glass referred to in the present invention is N
It is a concentrated aqueous solution of hydrated sodium silicate represented by a20.nSi02.xH20, and is usually commercially available as No. 1, No. 2, and No. 3 depending on the water content, but all are viscous liquids.

If left as is, it will not foam due to its high viscosity, so dilute it with water to a desired viscosity. Taking water glass No. 3 as an example, the degree of dilution with water is 1.5 to 3. Double the ship's ship capacity is appropriate. If too much water is used, the foam not only becomes weaker but also tends to shrink during solidification, so it is preferable that the amount of water used is as small as possible without interfering with the superfoam treatment. Foaming agents suitable for water glass aqueous solutions include those whose main component is peptides, which are partially hydrolyzed proteins with enzymes, alkalis, or acids, anionic synthetic surfactants, and nonionic synthetic surfactants. Suitable for use or in combination.

To further explain the slow-release gelling agent as used in the present invention, it refers to a gelling agent that, after addition of the gelling agent, uniformly increases the viscosity of the entire liquid and gradually progresses to gelation.

Therefore, a gelling agent that is added to a water glass aqueous solution and quickly gels and causes a phenomenon of fixation is unsuitable. Addition of such a fast-acting gelling agent not only impairs the foaming properties but also does not improve the foam strength. For example, a gelling agent that clearly forms a fixed gel within 30 minutes after the gelling agent is added is not an effective gelling agent as used in the present invention. In other words, the slow-release gelling agent as used in the present invention has the effect of increasing foam retention and foam strength without interfering with foaming properties. Those suitable for this purpose include, for example, colloidal silica, magnesium biphosphate, monocalcium phosphate, and the like. Colloidal silica is a stable colloidal aqueous solution of silicic acid anhydride.Commercially available products contain silicic anhydride 2 to 21%, pH 9.9, and specific gravity 1.
．． It is a milky white sol type colloidal liquid with a molecular weight of 10 to 1.16. When a colloidal silica solution is added to a water glass aqueous solution, the pHIO.
5 or more, the viscosity gradually increases and weak gelation occurs. The appropriate amount of colloidal silica liquid to be used for water glass (product No. 3) when foaming is based on the above-mentioned commercial product standards, with 50 to 15 parts by weight of colloidal silica liquid per 10 parts by weight of water glass. It is a combination. Magnesium diphosphate, monocalcium phosphate, etc. are prepared using water glass (3
It is appropriate to use 3 to 2 parts by weight per 100 parts by weight. In addition, it is preferable for these salts to be dissolved or suspended in advance in water for diluting the water glass and then added to the water glass. It is also possible to use two or more of the above-mentioned fertilizing gelling agents in combination. After adding the above-mentioned foaming agent and anti-gelling agent to the water glass aqueous solution, foaming treatment (for example, using a mechanical tomato or the like) is carried out to obtain a foamy product up to an overrun of 200% or more.

Water glass and water glass hardening agent are added to this foam and mixed. The conventional method of foaming by adding a foaming agent to a slurry consisting of a base agent (cement, gypsum, water glass, etc.), an extender, a bone filler, water, etc. does not have good foaming properties, or does not produce bubbles. However, it has some drawbacks such as not being able to achieve uniformity. In the present invention, a foam having an overrun of 200% or more is prepared in advance, and the foam is mixed with a base material and a curing agent for the base resin afterwards. The meaning of separately creating a foam is that during or after the process of mixing a water glass aqueous solution, a foaming agent, and a slow-release gelling agent to form a seed foam, the liquid gradually changes from a sol state to a gel state, resulting in bubbles. The strength of the wall is strengthened,
The reason is that the bubbles remain stable even if the base material, hardening agent for the base material, aggregate, etc. are subsequently added. In the present invention, it is necessary to foam the foam with an overrun of 200% or more, that is, up to a 3 times volume ratio, because experimental results show that the foam cannot be homogenized with a lotus foam of less than 200%, and the final product may deteriorate. This is because it almost always does not bring about good results. It is preferable to select a composition or foaming treatment that foams to an overrun of 300% or more, that is, 4 times the volume ratio or more. Water glass/Aya effect I
After mixing the gelling agent, foaming agent, and water, it is preferable to carry out foaming treatment as soon as possible before gelation progresses.
Further, it is preferable to maintain the foamed material after foaming to promote gelation. The shelf life varies depending on the type of slow-release gelling agent and the amount used, but a retention period of several minutes to a few minutes is usually sufficient. It is not a good idea to leave this stick until you can see it solidify (turn white) with the naked eye. For example, in the case of magnesium biphosphate, which has a relatively fast gelling rate, it is preferable to start the next step within 2 to 3 hours, depending on the amount added, but in the case of colloidal silica, which has a slow gelling rate, it is left for several hours or more. It can be used even if it is - The main ingredients of the lightweight building material of the present invention are water glass and a water glass hardening agent. If the total weight of the water glass (No. 3 product) used for this building material is 100, the weight of the water glass (No. 3 product) used to make the foam must be 30 or less. The remaining 70 or more is used as the main ingredient. If water glass is used in a ratio higher than kneaded to make a foam, the amount of water added to obtain a viscosity suitable for super foam will increase, and the water content will increase during solidification, causing shrinkage during solidification. I don't like it. In addition, the water glass hardening agent that can be used in the present invention is 1
It is preferable that the curing reaction proceeds at a temperature of 00° C. or lower and that the curing reaction proceeds relatively slowly. Substances that meet this condition include silicofluoride metal salts such as sodium silicate, lucium silicofluoride, magnesium silicate, and zinc silicate, magnesium biphosphate, and ethyl silicate (manufactured by Nippon Colcourt Chemical Co., Ltd.).
Next, if necessary, it is possible to further mix fillers, light weight particles, pigments, etc. into the water glass as the main ingredient and the hardening agent for the water glass.

Preferred substances as fillers in the present invention include kaolin,
These include silicic anhydride, silicic acid clay, and carbonates such as calcium carbonate and magnesium carbonate. As the aggregate, lightweight aggregates such as foamed shirasu and fly ash can be used. It should be noted that the main ingredient water glass, water glass hardening agent, filler, lightweight aggregate, pigment, etc. can be added separately to the above-mentioned foam, or from a work standpoint, it is better to mix them all together and make a slurry. It is also possible to incorporate it into foams.
The mixing operation at this time can be done by the fly-azusa method, which is enough to make the foam and other substances homogeneous. o When making the foam, the mixing ratio of each substance should be such that foaming is easy and the bubbles are uniform. For example, when colloidal silica is used, 50 to 15 parts by weight of colloidal silica to 10 parts by weight of water glass (product No. 3), protein Partial hydrolyzate (moisture 1
0% or less) 1 to 6 parts by weight or synthetic surfactant 0
．． 05 to 1 part by weight, and 50 to 20 parts by weight of water.

Also, when using a salt such as magnesium biphosphate or monocalcium phosphate as a slow-release gelling agent, the amount of slow-release gelling agent should be 3 to 2 parts by weight per 10 parts by weight of water glass (product No. 3). parts by weight, foaming agent in the same amount as above and water 10
0 to 25 parts by weight. In addition, when producing a foamy material, it is possible to appropriately add substances other than the above-mentioned water glass, twilling gelling agent, and foaming agent to the extent that they do not impede foaming properties. Next, the blending amounts of components such as base ingredients prepared separately will be described.

As for the amount of water glass used, the ratio of the amount used when making the foam and the amount used as the main ingredient was described above. The amount of curing agent used for water glass is determined by the type of curing agent, the required curing speed, the temperature during the reaction, etc.
For example, 3 to 2 parts by weight of sodium silicate is suitable for 10 parts by weight of water glass (product No. 3). In addition to the water glass and water glass hardening agent mentioned above, when fillers, lightweight aggregates, and pigments are added as necessary, the amount of these additions depends on the fluidity and uniformity of the final porous slurry (including foam). This may be done as appropriate to the extent that it does not interfere with this. The mixing ratio of the above-mentioned foam, the main ingredient water glass, and the water glass hardening agent is the weight ratio of water glass (product No. 3) (mixing limit amount 30:
70) Alternatively, the volume ratio of the water glass and the water glass hardening agent, which is a mixture of the solid material and the main agent, is 100:50 to 600.

As described above, the mixing ratio of the two differs depending on the specific gravity and strength of the final product and the intended use of the quality product. For example, when a certain degree of physical strength is required as a panel material, the mixing volume ratio of the foam and the base compound is preferably 100:10, but the non-combustible porous material is injected into the space of a building. When manufacturing by this method, physical strength is not required so much, so the mixing volume ratio of the two may be 100:400 or more.In this way, the mixing ratio of the two can be freely changed to create different properties. Another advantage and feature of the present invention is that it can be used to produce a wide variety of products.Solidification is carried out by leaving it at room temperature or by heating it at less than 100 qo. There are two methods: a method in which a molded product is made by putting the slurry in and solidifying it and then taking it out to make a molded product, a method in which this molded product is joined to another molded product, a method in which the slurry is poured into a hollow frame such as a metal material before solidification, and the slurry is used as a core material after solidification. It is possible to inject it into the spaces and voids of buildings and then solidify it to make it into a non-combustible soundproofing and insulation material.The lightweight building material obtained by the present invention has excellent durability despite being extremely lightweight. It can be widely used as a soundproofing material and a heat insulating material.

Note that the overrun in the present invention is determined by the following equation. Value (amount of insects before foaming) Tablet] Liquid before foaming* Volume and amount of foamy mass) xl.

〇 Weight of foam with the same volume as liquid volume before rear chamber foam) Test example
1 Dilute colloidal silica (made by Nissan Chemical) 3k9 with 3k9 water, add 3kg of water glass (product No. 3) and 30 ml of surfactant Lion Riporan 1400 (made by Lion), and make a foam of about 80 ml. A foam with an overrun of approximately 900% was obtained.

Separately, 7 kg of water glass (product No. 3) 70k9 sodium sulfuride and kaolin 30k9 were mixed to prepare a base ingredient formulation.
Also, Shirasuba in the lightweight bone village. I used white runes. The above three materials were mixed in the volume ratio shown in the table below, poured into a frame of 300 side x 300 side x 100 skin, and the surface was scraped, allowed to harden at room temperature, and removed from the frame after 10 days to determine the degree of shrinkage. 30 things cape x 30 yards x low (indicates the contraction side for 300 legs within the frame of a pig), apparent specific gravity (Y/Y), bending strength ([9/Y), thermal conductivity (Kcal/skin h) ℃) was investigated. The results are shown in the table below. The products in Table Test Groups 1, 2, and 3 have low strength, but have a light specific gravity and are porous, similar to inorganic hard styrene quartz.
It can be used as a noncombustible heat and sound insulation material for buildings.

The products in test areas 3, 4, and 5 were used as core materials, and the products in test areas 5,
Products 6, 7, and 8 have high strength and are suitable as building materials alone or in combination. In this way, by changing the blending ratio of the base ingredient and the foam, products with various physical properties can be produced. Example 1 Water glass (product No. 3) for 50 hours, colloidal silica (Nissan Chemical) for 50 hours, water for 50 hours, and sodium alkylbenzene sulfonate for 1 night were stirred into foam for about 1.5 hours (overrun approx. 1000 minutes). %) of foam was obtained.

Mix 1400 g of water glass, 8002 g of kaolin, and 150 g of sodium silicate to make a slurry of the main ingredient mixture, and immediately mix it with the previous foam to form a formwork of 30 x 30 m x 3 x 3 x Pour the mixture and leave it at room temperature for 2 hours, then heat at 70:00 for 30 minutes to solidify. Specific gravity 0.52 3
A lightweight building material with 0 mosquitoes x 30G ship x 3W ship was obtained. Example 5 minutes of magnesium diphosphate and 22 hours of wheat protein partial hydrolyzate (commercial product Sunhoma 33) were suspended in 120 cc of water, 50 hours of water glass (Product No. 3) was added thereto, and the mixture was foamed. A foam of 1.0% (overrun approximately 520%) was obtained.

After leaving this at room temperature (approximately 20 degrees Celsius) for 1 hour, water glass (product No. 3) 1400 ml, kaolin 400 ml, calcium carbonate 200 ml, magnesium biphosphate 100 ml, ethyl silicate 40 ml (Nippon Colcoat Chemical Co., Ltd.) After 50 minutes, the mixture was mixed with a slurry containing 100 tons of titanium oxide, poured into a formwork, and solidified at room temperature to obtain a lightweight building material with a specific gravity of 0.55. Example 3 50 hours of water glass (product No. 3), 30 hours of colloidal silica, 5 hours of monobasic calcium phosphate, 1 night of surfactant IJ Poran 1400 (manufactured by Lion), and 50 hours of water were mixed and foamed for about 7 hours. 2 (overrun approx. 500%)
) was obtained.

Immediately, 800 g of water glass (product No. 3), 50 g of sodium silicofluoride, 50 g of ethyl silicate (Nippon Colcoat Chemical Co., Ltd.), 200 g of kaolin, and 500 g of Shirasu Balloon were mixed into this foam, and the mixture was poured into a frame and solidified. At the very least, it was used as a core material. Example 4 Water glass lk9
(Product No. 3) diluted with 1.5k9 water, 800 g of colloidal silica, 30 g of magnesium biphosphate, 30 g of wheat protein partial hydrolyzate (commercial product Sanhoma 33), and 50 g of household detergent (Dash made by Lion). The mixture was mixed and foamed until the volume reached about 22㎜ (overrun about 1000%).

Claims (1)

[Scope of Claims] 1. (a) an inorganic slow-release gelling agent consisting of one or more substances selected from water glass, (b) colloidal silica, magnesium biphosphate, and monobasic calcium phosphate; (c) A foaming agent and (d) water are mixed, then foamed to obtain a foam with an overrun of 200% or more, water glass and a water glass hardening agent are further mixed with this foam, and the necessary A manufacturing method for lightweight building materials characterized by adding fillers, lightweight aggregates, pigments, etc., and solidifying them. 2. The method for producing a lightweight building material according to claim 1, wherein the foam has an overrun of 300% or more. 3. The method for producing lightweight building materials as set forth in claims 1 and 2, which comprises solidifying the lightweight building materials within a predetermined framework.