JPS6251232B2 - - Google Patents

Description

[Detailed description of the invention] The present invention uses ferroalloy dust such as ferrosilicon dust of silicic acid industrial waste and lithium silicate solution as main materials, and as an auxiliary material,
Foamed inorganic materials such as foamed perlite, foamed vermiculite, shirasu balloons, and foamed glass are bound together using a slurry-like caking agent made by adding appropriate amounts of calcium carbonate, white carbon, and kaolin and kneading them. , relates to inorganic molded panels that are formed into plate shapes using molds and fired.

In recent years, there has been a demand for building materials that are non-combustible and lightweight, and various inorganic building materials have become commercially available, but many of them are inferior in terms of weight and strength, which poses a major problem in practical use. It's summery.

The present invention is an inorganic lightweight panel completed as a result of many years of research in order to eliminate these drawbacks.

One of the main materials is ferroalloy dust, which is industrial waste from the ferrosilicon manufacturing industry.The main component is amorphous silicon dioxide, which is highly reactive, and is a white to gray-white fine powder. Also,
Lithium silicate solution is a clear colloid liquid.
The heat resistance is close to that of silica sol, the adhesive strength is close to that of water glass, and the water resistance is superior to that of water glass. Excellent, and heat resistance is approx.
It has the property of being able to withstand temperatures of 1000℃.

The present invention first uses 60 parts by weight of the above-mentioned ferroalloy dust and 100 to 50 parts by weight of lithium silicate as main materials, and further contains 20 to 10 parts by weight of calcium carbonate and 15 to 10 parts by weight of white carbon. Add 20 to 10 parts by weight of kaolin and knead until homogeneous to make a slurry-like kneading solution. Next, 120 to 60 parts by weight of one or more types of foamed inorganic particles such as foamed perlite, foamed barculite, and shirasu balloons are added to this, and the mixture is sufficiently kneaded to cause the kneading liquid to adhere to the entire surface of the foamed inorganic particles. .

Next, put this into a formwork to form it into a panel shape,
After forming by applying even pressure from above, it is removed from the mold or placed in a sintering furnace while still in the mold and sintered and solidified at 200℃ to 600℃ for 10 to 30 minutes. Complete.

Alternatively, the molded kneaded material is first hardened by heating at 200 to 400°C for 5 to 10 minutes in a high frequency heating furnace, and then sintered in a sintering furnace at 300 to 400°C for 10 to 20 minutes. The result is a high-quality panel.

In either case, when removed from the formwork after sintering, the lithium silicate and ferroalloy dust react, and auxiliary materials such as calcium carbonate are involved, producing complex reaction products. In this way, a strong ceramic-like foamed compound is produced, and a panel in which the foamed inorganic particles are firmly connected and cured is completed.

In addition, when molding is performed in a mold, an inorganic fiber sheet such as asbestos cloth or glass fiber sheet is placed on the bottom of the mold in advance, and the slurry is poured on top of it. When covered with an inorganic fiber sheet and sintered, an inorganic lightweight panel reinforced with an inorganic fiber sheet on one or both sides of the panel is created.

This panel is made of a caking material that is hardened by a three-dimensional chemical reaction between the main material and the sub-material at high temperatures.
The foamed inorganic particles are firmly bonded to each other, forming a homogeneous and lightweight inorganic panel with a high surface hardness as a whole.

The apparent specific gravity of the panel varies depending on the type and blending ratio of the main material, sub-materials, and foamed inorganic particles.
It is approximately 0.3 to 0.5 and is extremely lightweight. Its fire retardant properties are extremely good.In addition to the foamed inorganic particles containing ceramic-like fine closed cells, the caking material also generates fine closed cells due to the properties of the lithium silicate it contains during sintering. As a whole, it forms a non-combustible, fire-resistant, inorganic heat insulating layer. This heat-resistant and insulating property is much better than that of water glass, and even when one side of the panel is heated, it is extremely slow to transfer heat to the other side, especially when heated to high temperatures of 800℃ to 1000℃. When the foamed inorganic particles are heated, the inside of the foamed inorganic particles becomes ceramic and covers the surface of the caking material, so that excellent fire resistance can be exhibited.

Example 1 Lithium silicate 35 (Nissan Chemical, molar ratio 3.5)
100 parts by weight Silica flour 60 〃 Calcium carbonate powder 10 〃 Kaolin 20 〃 White carbon 10 parts by weight Mix the above materials and knead them uniformly to form a slurry. 120 parts by weight of expanded perlite (Toho Perlite No. 4) was added to this and mixed. Next, the mixture is poured into a mold with an asbestos sheet lined at the bottom, formed into a panel with a thickness of 25 mm, and then sintered in a sintering furnace at 400°C for 10 minutes.

The obtained panel had a specific gravity of 0.35 to 0.40, a compressive strength of 6 to 9 Kg/cm ² , and exhibited excellent fire resistance.

Example 2 Lithium Silicate 35 (Nissan Chemical) 100 parts by weight Silica flour 60 Calcium carbonate powder 20 Kaolin 20 White carbon 10 A panel was manufactured using the above materials in the same manner as in Example 1.

The resulting panels have a specific gravity of 0.41-0.46 and a compressive strength of 8.
~12Kg/cm ² , demonstrating excellent fire resistance.

Example 3 Lithium silicate 35 (Nissan Chemical) 50 parts by weight Silica flour 60 〃 Calcium carbonate powder 10 〃 Kaolin 10 〃 White carbon 10 parts by weight To the mixture of the above materials, 60 parts of expanded perlite (Toho Perlite No. 5) was added. Added and kneaded. This kneaded material was placed in a mold in the same manner as in Example 1, and the thickness was 20 mm.
After molding into millimeter-sized panels, they are placed in a high-frequency heating furnace.
After being heated and hardened at 250°C for 10 minutes, it was transferred to a sintering furnace and heated at 400°C for 5 minutes.

The resulting panels have a specific gravity of 0.40-0.47 and a compressive strength of 5.
It was ~7Kg/ ^cm2 .

Example 4 Lithium silicate 45 (Nissan Chemical, molar ratio 4.5)
50 parts by weight Silica flour 60 〃 Calcium carbonate 10 〃 Kaolin 10 parts by weight White carbon 15 〃 The manufacturing method is the same as in Example 3.

The resulting panels have a specific gravity of 0.41-0.48 and a compressive strength of 5.
It was ~7Kg/ ^cm2 .

Claims (1)

[Claims] 1. Using ferroalloy dust and lithium silicate solution as main materials, adding calcium carbonate powder, white carbon, and kaolin as auxiliary materials, and kneading the slurry-like binding material, foamed inorganic particles such as foamed pearlite are produced. An inorganic lightweight panel made by caking, forming into a panel shape, and sintering.