JPS5835955B2 - Manufacturing method of inorganic fiberboard - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing an inorganic fiberboard that is lightweight and has excellent bending strength.

In recent years, lightweight aerated concrete, which is a lightweight cementitious insulation material, or lightweight aerated concrete containing steel has been used to form an inorganic insulation layer on the walls and ceilings of these buildings, subways, etc. However, lightweight aerated concrete generally has a porous surface, so it has poor insulation properties and does not have sufficient waterproof function.

In addition, urethane foam has been used on-site for insulation purposes, but it has recently become a problem because the material itself is organic and is flammable or highly susceptible to corrosion.

As a result of research to improve the technical content of heat insulating and non-combustible materials as described above and more broadly, the present invention has developed an extremely lightweight and non-combustible material by effectively applying an inorganic foamable composition that foams at room temperature. , we succeeded in obtaining an inorganic fiberboard with excellent heat insulation and workability.

That is, the present invention provides (a) an ionization constant (pK
a) an acid having a pH of 4.0 or less or/and an aqueous solution of a water-soluble acidic phosphate with a pH of 1.5 or less; (b) at least one basic powder selected from anhydrous alkali silicates and cement materials; ( C) a metal foaming agent, and (d) silica gel,
An inorganic fiberboard comprising a room-temperature foamable composition comprising at least one foaming stabilizer selected from zeolite, carbon black, activated carbon, talc, and mica, and a mixed layer of fibers and a non-foamable hydraulic composition was obtained. .

Such room-temperature foaming compositions have already been disclosed in Japanese Patent Application Laid-open No. 52-2 by the present applicant.
As detailed in No. 3126 and JP-A No. 52-81326, it is obtained by mixing the above-mentioned components (a) to (d) into a paste, and although it differs slightly depending on the preparation method, it is essentially normal. It has uniform closed cells in the range of 0.5 to 1071071, has low specific gravity, high strength, and exhibits excellent properties such as waterproofness, water resistance, chemical resistance, heat insulation, and flame resistance. be.

The above-mentioned room temperature foamable composition takes advantage of the acid-base reaction between the acid (or special acid salt) as the component (a) and the base as the component (b). ) by combining the ingredients,
The object is to obtain a material having a very low bulk specific gravity and various properties as a heat insulating material.If the ionization constant is 4.0 or less, it is difficult to obtain a foamed heat insulating material itself, and if the pH is 1.
If it exceeds 5, the concentration will be too small and the acid-base reaction will not proceed sufficiently, resulting in a marked drop in the water resistance and mechanical strength of the resulting heat insulating material.

A heat insulating material may be formed from this foamable composition by any method, including cast molding, lamination molding, spray molding, and overlay molding.

Furthermore, the fibers referred to in the present invention include both inorganic fibers and organic fibers, and include glass fibers, asbestos, rock wool, carbon fibers, quartz fibers, high silica fibers, aluminum silicate fibers, zirconia fibers, and whisker fibers. Examples include inorganic fibers such as polyamide fibers, organic fibers such as polypropylene fibers, etc., and their usage forms include monofilaments, strands such as chopped, and sheets, and these are used depending on the manufacturing method and mode. It is something that

Furthermore, the non-foaming hydraulic composition described in the present invention refers to a composition obtained by removing the metal foaming agent from the above-mentioned foamable composition, a composition obtained by removing the metal foaming agent and the foaming stabilizer, or a composition obtained by removing the cement material alone. It is also possible to use a mixture of any of the following: those containing essentially hydraulic cement substances are used, and any materials that harden by reacting with water can be used.

In the present invention, each substance as described above is prepared according to a specific method.

That is, the inorganic fiberboard shown in FIG. 1 is composed of a mixed layer 1 of fibers and a non-foamable hydraulic composition and a room-temperature foam layer 2, and is shown in FIGS. 2 to 4. Adjusted according to procedure.

FIG. 2 shows an example in which an inorganic fiberboard is obtained using a fiber sheet as a starting material. A rolled fiber sheet 3 is spread over a screen 5 by a roller 4, and a non-foamable hydraulic composition 6 is mixed. After being uniformly impregnated onto the fiber sheet 3 with a doctor knife 7 and dried, the room-temperature foamable composition 2 is mixed with the four essential components in a mixing device 8, and the non-foamable hydraulic composition 6 is coated with a doctor knife 1 on the surface layer. After being uniformly applied and foamed and cured, the further rolled fiber sheet 3 is
The room-temperature foam layer 2 is entirely coated with the room-temperature foam layer by the roller 4, and the non-foaming composition 6 is mixed and uniformly impregnated onto the fiber sheet 3 using a doctor knife T to obtain an inorganic fiberboard. .

Note that the doctor knife 7 in the figure is an instrument for uniformly applying the liquid composition, and it is also possible to use a coating instrument such as a roller or curtain flow, and the same applies below.

In FIG. 3, an inorganic fiberboard is obtained using a mixture of fibers and a non-foaming hydraulic composition as a starting material, and the fiber strands 9 and the non-foaming hydraulic composition 6 are mixed in a mixing tank 10. , the room-temperature foamable composition 2 is uniformly applied onto the screen 5 using a doctor knife, and after drying, the room temperature foamable composition 2 is transferred to the mixing device 11.
The essential components are mixed and applied uniformly to the surface layer of the fiber-containing non-foamable hydraulic material using a doctor knife 1. After foaming and curing, the fiber strands 9 and the non-foamable hydraulic composition 6 are further mixed in a mixing tank 10. Then, it is applied uniformly onto the room-temperature foam layer using a doctor knife 7.

FIG. 4 shows an example in which an inorganic fiberboard is obtained using fiber strands as a starting material. Monofilament or chopped fiber strands 9 are sprayed 13 in the form of mist onto a screen 5 by a blower 12, and then as shown in FIG. Inorganic fiberboard can be obtained using exactly the same method.

Specific examples and blending ratios of the room-temperature foamable composition used in the production method of the present invention include component (b): water glass cullet, quicklime, dolomite plaster, Portland cement,
Based on basic powder such as alumina cement, fly ash cement, calcium borate, etc., add hydrochloric acid, chromic acid, nitric acid, phosphoric acid, chloroacetic acid, maleic acid, alanine as component (a) to 100 parts by weight of basic powder such as alumina cement, fly ash cement, calcium borate, etc. , 20 to 150 parts by weight of an aqueous solution of an acid such as chloroamine, acidic aluminum orthophosphate, or acidic zinc pyrophosphate, Mg, Ca, Cr, Mn, Fe, Ni, Cu, Z as component (C)
n.

2 to 15 parts by weight of a blowing agent such as At or Si and (d
2 to 40 parts by weight of the foaming stabilizer as a component () may be used.

In addition, as mentioned above, the non-foaming hydraulic composition is one that has a cement substance as a basic component, and may contain only the cement substance alone, or may include the above-mentioned component (a) or (d) in the cement substance.
Component (a) can be blended, and anhydrous alkali silicate powder can also be blended, and the blending ratio is based on the cement material, and the blending ratio is about 150 parts by weight of component (a) per 100 parts by weight of the cement material.
Preferably, the amount of component ('d) is about 40 parts by weight or less, and the amount of anhydrous alkali silicate is about 50 parts by weight or less.

Furthermore, when the combination of the fiber sheet or strand and the non-foaming hydraulic composition is placed above and below the room-temperature foaming cured material layer, the blending ratio of the fiber sheet or strand with the non-foaming hydraulic composition is determined by the impregnating ratio. Alternatively, the amount of the non-foaming composition is desirably about 50 to 500 parts by weight per 10 parts by weight of the fiber sheet or strand without being taken in the form of a mixture.

When constructing a fiberboard using such a composition, the thickness of the composite fiber layer when composited is 0.5 to 3 times the thickness of 10M based on the room temperature foam cured material layer. If it is too thin, the bending strength and waterproofness will decrease, and if it is too thin, it will tend to have problems with lightness, heat insulation, workability, etc.

The inorganic fiberboard obtained in this way has a tough surface,
It has high bending strength, is thermally lightweight, has non-combustible heat insulation properties, and is much easier to handle than conventional molded plates.

Examples A room-temperature foamable composition is prepared by the following (a) formulation, while a non-foamable hydraulic composition is prepared by the following (b) formulation.

(a) Mixed aluminum orthophosphate (concentration 40%) 10K
Sodium p-silicate cullet (S102/Na2O molar ratio 3.2) lK
y Portland cement 5: Zinc powder 0.2: Activated carbon
To 0.5! iI (b) blended Portland cement 2 Alumina cement I Ky-zeolite 0.3. Kp Glass fiber strand (fiber length 5 whips) 0.3 K7 Next, according to the method shown in Figure 3 of the drawing Herbal Medicine, first, about 2 strands of the composition of (B) was placed in a wooden frame with inner dimensions of 500 x 500 x 330 m covered with a polyethylene sheet. After applying it evenly and drying to the touch, apply the composition of (a) to a thickness of about 4w11 on the surface, and the composition of (i) foams and hardens after 60 minutes to a thickness of about 15M. After confirming that the composition was 200 mm thick, the composition (b) was applied uniformly to a thickness of about 2 yym.

After 24 hours, the obtained inorganic fiberboard was taken out and its physical properties were measured, and the following results were obtained.

Bulk specific gravity: 0.71 Thermal conductivity: 0.10 kcal/mh 'C bending strength: 25 hours/d Water permeability: 0.4 ml (according to JIS A 6910)

[Brief explanation of drawings]

Figure 1 is a cross-sectional view of the inorganic fiberboard of the present invention, and Figures 2-
FIG. 4 shows a flow sheet of the method for manufacturing the inorganic fiberboard shown in FIG.

Claims (1)

[Scope of Claims] 1. On the surface of the fiber sheet or on the surface covered with fiber strands, (a) cement material alone, or (b) cement material, anhydrous alkali silicate, and the following (
A non-foaming hydraulic composition, which is a mixture consisting of component a) and/or component (d), is uniformly impregnated and applied, and after drying to the touch, a room-temperature foamable composition consisting of the following components (a) to (d) is applied. An inorganic fiber characterized by uniformly foaming and curing a composition, further coating a fiber sheet or fiber strand on the room temperature foaming and curing layer, and uniformly impregnating and coating the surface of the non-foaming hydraulic composition. Method of manufacturing the board. (a) At least one acidic aqueous solution selected from a pH 1.5 or less aqueous solution of an acid with an ionization constant (pKa) of 4.0 or less at 25°C, and a water-soluble acidic phosphate aqueous solution pH 1.5 or less; ( b) At least one basic powder selected from anhydrous alkali silicates and cement substances; (c) Metal blowing agents; (d) At least one selected from silica gel, zeolite, carbon black, activated carbon, talc and mica. foam stabilizer. 2 Fiber strands and (a) cement material alone, or (b) cement material, anhydrous alkali silicate, and the following (
Component a) and/or a non-foaming hydraulic composition which is a mixture consisting of component (a) are mixed to form a layer of uniform thickness, and after drying to the touch, from the following components (a) to (d). A method for producing an inorganic fiberboard, comprising uniformly foaming and curing a room temperature foaming composition, and further coating the room temperature foaming cured layer after mixing fiber strands and the non-foaming hydraulic composition. . (a) At least one acidic aqueous solution selected from a pH 1.5 or less aqueous solution of an acid with an ionization constant (pKa) of 4.0 or less at 25°C, and a water-soluble acidic phosphate aqueous solution pH 1.5 or less; ( b) At least one basic powder selected from anhydrous alkali silicates and cement substances; (c) Metal blowing agents; (d) At least one selected from silica gel, zeolite, carbon black, activated carbon, talc and mica. foam stabilizer.