JPS63252932A - Production of foamed glass board - Google Patents

Abstract

PURPOSE:To inexpensively obtain lightweight and beautiful foamed glass board useful as building materials, having excellent heat resistance and heat insulating properties, by calcining and expanding a mixture of glass powder, specific inorganic powder and a gas blowing agent. CONSTITUTION:30-80wt.% glass powder obtained by grinding waste glass, etc., is blended with 5-60wt.% inorganic powder comprising one or more selected from quartz, feldspar, clay minerals and artificial lightweight minerals consisting essentially of SiO2 and/or Al2O3, screened by a sieve with 100 meshes and adjusted to particle size to pass about 90% particles to give powder A. Then the component A is mixed with (B) a gas blowing agent comprising NaNO3 and/or Na2CO3 and (C) 0-40wt.% viscosity modifier such as B2O3 and calcined at 700-900 deg.C to melt the glass powder and the inorganic powder and to expand the blend by gas. Then the expanded material is cooled and solidified to form foamed glass board.

Description

[Detailed Description of the Invention] [Field of Industrial Application] The present invention provides a method for producing a lightweight and beautiful board that has excellent heat resistance and heat insulation properties, mainly using scrap glass such as plate glass and bottle glass. In particular, the present invention relates to a method of manufacturing a foam glass board that is most suitable for use as a building material.

[Prior art and its problems] Conventional foam glass is made by adding a foaming agent to powdered glass powder, stirring it, placing it in a mold, and then heating it to melt it.
Furthermore, it is heated to foam and melt, and then,
It was manufactured by slow cooling. The foam glass produced by this method has excellent heat insulation properties due to its numerous bubbles, is fire resistant, and is beautiful, making it ideal for architectural use. However, foam glass is difficult and expensive to manufacture;
In addition, because large pieces cannot be manufactured, it is not yet widely used in construction, despite its excellent properties. A technique has been developed in which glass powder is mixed with dolomite and heated for the purpose of improving the foaming state of foam glass (Japanese Patent Publication No. 61-2618). This method is effective in simplifying the foaming process and reducing costs. However, none of the conventional methods can efficiently produce large foam glass boards. The biggest cause is the cracking of the sintered body that occurs during cooling. Therefore, in the conventional method,
3×6 version used as architectural pod, i.e. 900X
It is not possible to manufacture a product with a size of 1800mm. Cracks occur due to thermal contraction that occurs during cooling. Heat shrinkage is
Reduce Na20 and 20 contained in glass powder to 5
It can be reduced by increasing i02, B2O2, Am2, and O3.

Scrap glass cannot be used as a raw material whose ingredients have been specified, and this method increases the raw material price and cannot be used for construction boards. Scrap glass is mostly soda glass and contains about 10% Na2O and several percent 20%. Na2O cannot be easily removed from crushed glass glass.

Moreover, Na2O has the function of lowering the softening and melting temperature of glass, and if it is removed from the raw materials, the heating temperature will become high and the manufacturing cost will increase. For example, soda glass has Na2O
Since the content of Na2 is high, it softens at about 700℃, but Na2
Borosilicate glass with low O content has a softening point of 900°C
The temperature will increase by 200°C.

It is important that inexpensive foamed glass boards use inexpensive scrap glass as a raw material, are easy to manufacture, and can be manufactured in large sizes in a short time.

The present invention satisfies the above-mentioned requirements for conventional foam glass ports by adding and mixing inexpensive powder to glass powder. Therefore, an important object of the present invention is that although inexpensive scrap glass can be used as a raw material, it can minimize cracking during the cooling process, and large boards can be manufactured in a short time, reducing both raw material costs and manufacturing costs. An object of the present invention is to provide a method for manufacturing a foamed glass board that can be mass-produced at low cost while reducing the amount of damage.

Another important object of the present invention is to provide a method for manufacturing foamed glass boards that can effectively recycle a huge amount of scrap glass by using scrap glass as a raw material for construction boards, which are used in large quantities. It is on offer.

Furthermore, the present invention provides a method for manufacturing a foamed glass board that can produce a foamed glass board with physical properties that are comparable to those of conventional foamed glassboards.

[Means for solving conventional problems] The present invention uses 30 to 80 wt% of glass powder obtained by pulverizing glass.
and 5 to 60 wt% of inorganic granular material containing at least one of quartz, feldspar, clay mineral, and artificial lightweight aggregate, the main components of which are either or both of 5i02 and A-203.
, a gas blowing agent, and 0 to 40 wt% of a viscosity modifier are mixed, and this is fired at 700°C to 900°C to melt the glass powder and inorganic powder, and the gas blowing agent is used to cause gas foaming. , cool and solidify.

The most suitable glass powder is scrap glass made by crushing plate glass or bottle glass.

The present invention mixes inorganic powder and granules such as artificial lightweight aggregate, quartz, feldspar, and clay minerals containing either or both of 5i02 and AfL203 as main components with glass powder. If the amount is too high, the strength will decrease or the original beauty of the glass will be lost, so it is usually 5 to 60 wt%, preferably 10 to 60 wt%.
Adjusted to a range of 40 wt%.

These inorganic powder particles and glass powder preferably contain 10
The particle size is adjusted so that 90% of the particles pass through a 0-mesh sieve, and more preferably, 90% of the particles pass through a 200-mesh sieve. If the raw material has m grains and the particle size is too large, it is preferable to mix the raw material with a mixer with a grinding function such as a ball mill.

Quartz has 5102 as its main component, and impure quartzite such as waxite, shale, and bentonite can be used for this. Feldspar is a rock-forming silicate mineral, in which 5i02, A and 03 are combined, and in addition, K and Na.

KAQSi308 bound with Ca, NaAQSi308
, Ca AQ S i 20B can be used.

Clay minerals include those whose main component is magnesium produced from hydrated silica, such as kaolinite, halloysite, and pyrophyllite.
Furthermore, those containing micaceous or marginal stone powder can be used. The most suitable material for clay minerals is white clay made by refining clay with water and mainly containing Afl, 03.5i02,
Or about 70% 5i02, about 10-20% A magazine, 03
, besides 20, Ma2O, Fe2O, CaOlMgO
, T r 02, etc. can be used.

Artificial lightweight aggregates include, for example, shale rock, clay, slate,
Fly ash etc. in rotary kiln 1000-12
Products manufactured by heating and firing at 00℃, such as mesalite (
The product name and ingredients will be described later), etc. can be used. These artificial lightweight aggregates contain 50wt% or more of 5i02, A magazine 2033~
Contains 30 wt% gold.

As the blowing agent, any material that can be thermally decomposed to generate gas during heating and firing, such as sodium nitrate, soda ash, or dolomite, can be used. The larger the mixing amount of the blowing agent, the lower the specific gravity of the product, and the smaller the mixing amount, the heavier the product. Therefore, the mixing amount is usually 0.5 to 20 wt%, taking into account the required specific gravity and degree, or the specific gravity of the raw materials to be mixed.

The viscosity modifier adjusts the amount of foaming and the diameter of foamed particles by changing the viscosity of the raw material in its molten state. By adding this, it is possible to lower the melting temperature of the raw material and also to make the foaming state uniform. The viscosity modifier includes B
In addition to various fluxes for firing such as 2O2 and Na2AQFe, and boric acid, dolomite and TiO2
, calcium carbonate, talc, etc. can also be used.

Furthermore, the present invention does not directly mix white clay or the like with the glass powder as a raw material, but instead foams and sinters the white clay, soda ash, and sodium nitrate, and then mixes the sintered inorganic powder obtained by pulverizing this with the glass powder. It can also be baked.

In this case, a mixture of fired inorganic powder and unfired inorganic powder can be used. When the fired inorganic powder is mixed with the raw material glass powder and fired, it is possible to obtain a homogeneous product with less uneven melting during firing.

Moreover, quartz, feldspar, kaolinite, etc. may not be directly mixed with the raw material glass powder, but may be sintered once and then crushed and mixed with the raw material glass powder as an inorganic powder.

Furthermore, the present invention is a product manufactured as a foamed glass board, and it is also possible to crush cut ends or recycled products that are defective products, mix them with glass powder, and then fire the product. In this case, since the inorganic powder is already mixed in the fired and pulverized product, the amount of the inorganic powder to be mixed with the glass powder can be reduced by the amount contained in the mixed product. Therefore, in this specification, the mixed amount of 5 to 60 wt % of inorganic powder and granular material contained in a product includes inorganic powder and granular material that is once made into a product and is then ground again and added to glass powder.

Furthermore, glass powder, 5i02 and An20. Calcium silicate, calcium carbonate, etc. can also be mixed in addition to the inorganic powder containing as a main component.

[Preferred Examples] Examples of the present invention will be specifically described below, but the present invention is not limited to these Examples.

Example 1 69 parts by weight of glass powder obtained by crushing bottle glass, 9 parts by weight of soda ash as a blowing agent, 5 parts by weight of sodium nitrate, and 3 parts by weight of borax as a viscosity modifier are mixed in a ball mill. 90% of the raw material is passed through a 200 mesh sieve using a ball mill.
Adjust the particle size so that it can pass through. The powder mixed by pulverization with a ball mill has a 5102 content of 92.5 as an inorganic powder.
14 parts by weight of artificial lightweight aggregate having an Aα203 content of 5.7 wt% is mixed.

The mixed raw material powder is baked in a net conveyor kiln for 3 hours. The conveyor net of the net conveyor kiln was made by placing the mixed raw materials in a uniform thickness with a width of 900 mm, and firing at a firing temperature of 850° C. for 3 hours from the beginning to the exit. The obtained foamed glass board has a specific gravity of 0.35,
Tensile strength 3.4kgf/cm2, compressive strength 41kgf/
cm2 and bending strength of 28 kgf/cm2.

By the way, foam glass with a specific gravity of 2 has a compressive strength of 28.
kgf/cm2 and bending strength of 11 kgf/cm2, the foamed glass board produced by the method of the present invention showed superior properties compared to this.

Conventional foam glass with a specific gravity of 0.34 has a bending strength of 1
5 to 17 kgf/ctn2, the foamed glass board manufactured by the present invention of Example 1 was 30% stronger than this.

Also, the size of the conventional foam glass board is 606 x 45.
5 mm, and the heating and firing time was 5 to 10 hours, but according to the method of the present invention, a piece with a width of 900 mm could be manufactured without cracking in a kiln passage time of 3 hours.

The artificial lightweight aggregate was made from shale rock and was fired in a rotary kiln.

Example 2: 57 parts by weight of plate glass powder, 4 parts by weight of soda ash, 2 parts by weight of sodium nitrate, 5 parts by weight of flux containing about 40 wt% B2O3, and 14 parts by weight of the granules obtained by crushing the product manufactured in Example 1. Mix in a ball mill and add 5i02 to the resulting powder.
18 parts by weight of artificial lightweight aggregate containing 77.65 wt% and 20316.84 wt% of A-magazine were mixed, and the process was the same as in Example 1, except that the firing temperature was 790°C. A foam glass port was obtained.

This foam glass board has a tensile strength of 4. '2kgf/c
m2, compressive strength 511<g f/cm”, bending strength 3
It showed excellent characteristics of 8 kgf/cm2.

Example 3 50 parts by weight of bottle glass powder, sintered inorganic powder obtained by foaming and sintering white clay, soda ash, and sodium nitrate, and 5i0
A birthmark with 58.36 wt% of 2. 10.49wt% of 03
14 parts by weight of inorganic powder, 6 parts by weight of soda ash, 8 parts by weight of sodium nitrate, and 2 parts by weight of dolomite were mixed and ground in a ball mill, and 66.3 wt of 5i02 was added to the obtained powder.
, % and A magazine. A foamed glass port with a specific gravity of 0.45 was obtained in the same process as in Example 1, except that 20 parts by weight of artificial lightweight aggregate containing 23.2 wt% of 03 was mixed and the firing temperature was then set to 870°C.

This foam glass board has a tensile strength of 5. Okgf/cm
2. Compressive strength 62kgf/cm2, bending strength 48kgf
/cm2, showing excellent properties.

Example 4 55 parts by weight of plate glass powder, a fired inorganic powder material obtained by foaming and sintering white clay, soda ash, and sodium nitrate and pulverizing the same, containing 58.36 wt% of 5i02 in magazine A, and 10.0% of 5i02. 4
13 parts by weight of inorganic powder containing 9 wt% gold, 5i02
72.0 wt% of A, 17 parts by weight of white clay containing 13.6 wt% of 03, 2 parts by weight of sodium nitrate as a blowing agent,
The viscosity modifier (38.8w) used as a flux in Example 2
t% B2O3) 10 parts by weight, N a 3
2 parts by weight of a clay conditioner containing about 98% by weight of A magazine F s and 1 part by weight of titanium oxide were mixed, and the specific gravity was 0 by the same process as in Example 1 except that the firing temperature was 820°C.
A foamed glass port of 28° was obtained.

This foam glass board has a tensile strength of 2.3kgf/
cm2, compressive strength 26kgf/cm2, bending strength 17
It exhibited excellent characteristics of kgf/cm2.

Example 5 56 parts by weight of plate glass powder, 118 parts by weight of clay mineral powder similar to clay [trade name B Clay (registered trademark)] 4 parts by weight of soda ash, 2 parts by weight of sodium nitrate, used in Example 2 4 parts by weight of a viscosity modifier, which is a flux, and 14 parts by weight of granules obtained by crushing the product manufactured in Example 1 are mixed to prepare a powder raw material,
The fired inorganic powder is made by foaming and sintering white clay, soda ash, and sodium nitrate at a ratio of 1 liter to 2 kg of this powder raw material, and pulverizing the resultant material, which contains 58.5% of 5IO2. 36w
A foamed glass port with a specific gravity of 0.53 was obtained by the same process as in Example 1 except that an inorganic powder containing 49 wt% of AM, 03 and IO was mixed and the firing temperature was then set to 790°C. Ta.

This foam glass board has a tensile strength of 5.3 kgf/cm
2. Compressive strength 34. Okgf/cm2, bending strength 9.7
It showed excellent characteristics with kgf/am2.

Example 6 A foamed glass board with a specific gravity of 0.53 was manufactured in the same manner as in Example 5 except that 2 parts by weight of soda ash was not used. This foamed glass board had a tensile strength of 7.4 kg.
f/cm2, compressive strength 69.7 kgf/cm2, bending strength 17. It showed excellent properties with O1cgf/cm2.

Example 7゜20 parts by weight of powder obtained by crushing the product manufactured in Example 1,
Powder of clay mineral similar to white clay [trade name B Clay (registered trademark)] 66 parts by weight 6 parts by weight of soda ash, 4 parts by weight of sodium nitrate, 15 parts by weight of the viscosity modifier which is the flux used in Example 2 A foamed glass port having a specific gravity of 0°62 was obtained in the same manner as in Example 5, except that the powder raw material was prepared by mixing the following.

This foam glass board has a tensile strength of 5. Okgf/cm
2. Compressive strength 48.5kgf/cm2, bending strength 13.
It showed excellent characteristics of 8 kgf/cm2.

Example 8 56 parts by weight of plate glass powder, 18 parts by weight of waxite, 2 parts by weight of sodium nitrate, viscosity modifier l which is the flux used in Example 2
Parts of ON, granules 1 obtained by crushing the product manufactured in Example 1
Mix 4 parts by weight to make a powder raw material, and make 2 kg of this powder raw material.
A foamed glass port with a specific gravity of 0.75 was obtained in the same manner as in Example 1, except that an artificial lightweight plaster (Mesalite) was mixed at a ratio of 1 liter to 1 liter of the foam, and the firing temperature was then set to 790°C.

Mesalite includes AQ20], Fe2O3, Fe01M
g O-Ca O, Na 20, K2O, L, O
.
Crushed%, approximately 2% by weight, approximately 1.5% by weight, approximately 2.5% by weight,
0.2 to IO weight % can be used.

This foam glass board has a tensile strength of 9.4 kgf/cm
2. Compressive strength: 37.4 kgf/cm2, bending strength: 23.
It showed excellent characteristics of 1 kg f/cm2.

Example 9 A foamed glass port having a specific gravity of 0.74 was produced in the same manner as in Example 8 except that bentonite was added to the quadruple mold.

This foam glass board has a tensile strength of 10.7 kgf/c
It exhibited excellent properties with rn2, compressive strength of 48.4 kgf/crn2, and bending strength of 33.3 kgf/cm2.

Example 10° Artificial lightweight plaster with apparent specific gravity of 0. A foamed glass board having a specific gravity of 0.64 was manufactured in the same manner as in Example 8, except that the foamed glass board having a specific gravity of 0.64 was used.

The foamed glass boards manufactured in Examples 5 to 10 had water absorption rates of 10.9%, 11.5%, and 18% in order.
．． 9%, 8.0%, 12.0%, and 27.0%, which are extremely low compared to 45.7% for conventional foam glass and 30-40% for ALC plates, and are extremely excellent in freeze-thaw tests. It showed the following characteristics.

That is, while the ALC board broke after 1O cycles, the foamed glass boards manufactured in Examples 9 and 10 popped out or broke after 90 cycles, and the product obtained in Example 3 broke after 260 cycles. The product obtained in Example 6 suffered from pop-out after 320 cycles, while the product obtained in Example 1 showed no abnormality in 560 cycles of the freeze-thaw test.

Furthermore, the specific gravity of the ALC board is 0. 5, with a tensile strength of 4 to 7 kgf/cm2 and a compressive strength of 35 to 40 kgf/cm2.
cm2 and bending strength of 8 to 12 kgf/cm2, the foamed glass board produced by the method of the present invention showed extremely superior properties in terms of tensile strength, compressive strength, and bending strength compared to the ALC board.

Furthermore, the board manufactured by the method of the present invention is much more beautiful than a concrete ALC board, and can be used as an indoor building material.

Figures 1 to 3 show the tensile strength, compressive strength, and bending strength with respect to the bulk specific gravity of the board manufactured by the method of the present invention.
As shown in the figure. As shown in these drawings, the board manufactured by the method of the present invention exhibited light yet strong characteristics. However, the strength of the board manufactured by the present invention varies somewhat depending on the raw material, but when the specific gravity is determined by adjusting the expansion ratio and the amount of artificial lightweight paste mixed, it almost follows the curves shown in Figures 1 to 3. It showed similar characteristics.

[Brief explanation of the drawing]

1 to 4 are graphs showing the characteristics of foamed glass boards manufactured by the method of the present invention.

Claims (5)

[Claims] (1) 30 to 80 wt% of glass powder obtained by crushing glass;
5 to 60 wt% of inorganic granular material containing at least one of quartz, feldspar, clay mineral, and artificial lightweight aggregate, the main component of which is either or both of SiO_2 and Al_2O_3
, a gas foaming agent, and 0 to 40 wt% of a viscosity modifier are mixed, and this is fired at 700°C to 900°C to melt the glass powder and inorganic powder, and the gas foaming agent is used to foam the mixture, followed by cooling. A method for manufacturing foam glass boards that hardens. (2) The method for producing a foamed glass board according to claim 1, wherein the glass powder is made by pulverizing scrap glass. (3) The method for producing a foamed glass board according to claim 1, wherein at least one of feldspar, kaolinite, white clay, waxite, and bentonite is used as the inorganic powder. (4) The method for producing a foamed glass board according to claim 1, wherein the inorganic powder is made of shale rock as a raw material and fired. (5) The method for manufacturing a foamed glass board according to claim 1, wherein either or both of sodium nitrate and soda ash is used as the foaming agent.