【発明の詳細な説明】
本発明は諸性能の優れた軽量体組成物に係り詳
しくは衝撃強さ及び曲げ強さ等機械的強度の優れ
た無機−有機複合系の軽量体を得るものである。
本発明者らは、以前よりアルカリ硅酸塩の結合
力並びに不然性能等の特性を生かして軽量体を得
る研究に従事しており、既に耐水性、圧縮強さ、
耐火性などの優れた軽量材入り発泡硬化型の軽量
体を創作してきた。しかしながら、それらは完全
無機質材で形成されており、堅くもろい性質を十
分に克服出来ず、さらに比較的フレキシビリテイ
の高い素材と租み合わせた場合にクラツクが入り
易かつたり、又一方耐水性も今一つ十分ではなか
つた。
本発明者らは係る粒状軽量材入の軽量体を得る
に際し、種々機械的強度向上のための方策を講
じ、ここに該軽量体自体の耐火性、不然性、圧縮
強さ等の性能を損なうことなく、曲げ強さ、衝撃
強さのごとき機械的強度の向上並びに一層耐水性
の優れた組成物を完成するに至つたものである。
即ち、本発明は、一般式
R2O・nSiO2（但し、Ｒはアルカリ金属または、
第四級アンモニウム、ｎは1.5〜7.0の正数）で示
される硅酸塩の水溶液、該硅酸塩水溶液の硬化性
成分、粒状軽量体及び重合して合成樹脂を形成す
る水溶性モノマーまたはオリゴマーから本質的に
成るものであり、前記４成分以外に、該合成樹脂
の重合を促進する目的で上記水溶性合成樹脂モノ
マーまたはオリゴマーの重合用触媒を配合でき
る。この組成物は注形もしくは塗付などの方法に
より軽量体を形成するが、機械的強度とりわけ曲
げ強さ、衝撃強さに著しい効果がみられ、併せて
耐水性もかなり向上することがわかつた。以下、
本発明につき詳述する。
本発明に用いる硅酸塩の水溶液とは上述のごと
きSiO2／R20モル比が1.5〜7.0の範囲に有るアル
カリ硅酸塩で、使用形態は水溶液状を呈しＲがア
ルカリ金属とりわけナトリウムの場合には通常水
ガラスと称呼されているものである。つぎに、該
硅酸塩水溶液の硬化性成分は、通常水ガラスの硬
化剤として使用されるものが使用でき、フツ化
物、硅フツ化物、リン酸塩、ホウ酸塩、セメン
ト、酸化亜鉛、亜硫酸カルシウムなどを例示でき
る。また粒状軽量材とは有機質、無機質の材質を
問わず使用できるもので例えば塩化ビニル、フエ
ノール、ユリア、スチレン、ウレタン、エチレン
等の合成樹脂の粒状発泡体もしくは粒状粉砕物、
合成ゴムの粒状発泡体や粉砕物のごとき有機質軽
量材、ヒル石、膨張頁岩、パーライト、シリカバ
ルーン、粒状発泡シリカ等の無機質発泡体、この
他無機質人工軽量骨材やALCの粉砕物などを掲
げることができる。さらに、重合して合成樹脂を
形成する水溶性モノマーまたはオリゴマーとして
は、フルフラール誘導体、ビニルイソブチルエー
テル、ビニルピロリドン等のビニル誘導体、ε−
アミノカプロラクタム、フエノール、メラミン、
ホルムアルデヒドなどが例示でき、本発明組成物
の必須配合成分として欠かすことができないもの
である。ここで上記、水溶性モノマーまたはオリ
ゴマーは分子量が概ね1000以下の形態で用いる。
本発明の前記必須成分以外に各々の目的に応じ
て配合される上記水溶性モノマーまたはオリゴマ
ーの合成樹脂の重合用触媒としては、酸性触媒、
塩基性触媒、過酸化水素、フツ化ホウ素、ヨウ
素、アミノカプロン酸など通常上記合成樹脂の重
合用触媒として使用されるものが例示できる。
本発明は上述のごとき組成物よりなるものであ
るが、その配合比は硅酸塩水溶液の固形分10重量
部に対して該硅酸塩水溶液の硬化性成分約１〜50
重量部、粒状軽量体約５〜100重量部及び重合し
て合成樹脂を形成する水溶性モノマーまたはオリ
ゴマーを約２〜100重量部配合するものである。
この時上記硬化性成分が約１重量部より少ないと
きは軽量体の耐水性が若干もろくなり、又、約50
重量部を越えると、過剰に残存する未反応物が悪
い影響を及ぼすこととなり、粒状軽量材が少ない
と軽量性が損なわれ、又、多と機械的強度がもろ
くなる。又、水溶性モノマー及びオリゴマーから
重合される合成樹脂が約２重量部未満の時は機械
的強度向上の効果が現れにくく、一方、約100重
量部を越えると耐火性、防火性等に支障ができ
る。又、前記４成分と共に、配合できる粒状軽量
材の配合量は硅酸塩水溶液の固形分100重量部に
対して、約５〜50重量部で、また水溶性モノマー
及びオリゴマーから重合される合成樹脂の重合用
触媒は、該合成樹脂に対して、約0.1〜15重量％
とする。
このようにして得られる本発明組成物の無機有
機複合系固体形成物は注形によつてもしくは塗付
によつて、該組成物の発泡硬化機構により乾燥工
程を経て得られるものであるが、その作用構成は
不明であるにせよ、耐衝撃性、曲げ抵抗がすこぶ
るよくなり、耐水性、耐アルカリ性も非常に良好
で、かつ各種下地への付着性が良く、軽量体を得
るに際し、作業上何等支障がなく、予想外なこと
には軽量体の耐水性も若干向上することがわかつ
たことである。
以下実施例を示す。
実施例 １
Na2O・3.1SiO2から成るアルカリ金属硅酸塩水
溶液（固形分40％）100重量部に硅フツ化ナトリ
ウム５重量部、比重0.15の発泡パーライト（10〜
24メツシユ）15重量部、ビニルピロリドンモノマ
ーの20％水溶液20重量部並びに過酸化水素２重量
部を配合し約20秒撹拌した後300×300×15mmの型
枠に注入し約20℃の室内で24時間後軽量体を得
た。この軽量体の曲げ強さ、衝撃強さ等を測定し
たところ第１表に示すような結果になつた。
試験方法
曲げ強さ；JIS K6911に規定の方法による。
衝撃強さ：JIS K5400の耐衝撃性試験により500
ｇのおもりで初めて割れを生ずる高さを
求める。
耐水性：48時間水中浸漬後JIS K6911に定められ
る曲げ強さを測定する。
防火性：JIS A1321に規定の表面試験による。
実施例 ２
実施例１において重合用触媒の過酸化水素を除
いた以外は実施例１と全く同じ方法で軽量体を得
た。その結果第１表に示すごとくになつた
実施例 ３
Na2O・3.1SiO2から成るアルカリ金属硅酸塩水
溶液（固形分40％）100重量部に硅フツ化ナトリ
ウム５重量部、比重0.15の発泡パーライト（10〜
24メツシユ）15重量部、ε−カプロラクタム20重
量部を配合し実施例１と全く同じ方法で軽量体を
得た。その結果第１表に示すごとくになつた。
実施例 ４
〔（CH3）4N〕20.31SiO2から成る硅酸塩水溶液
（固形分40％）100重量部に硅フツ化ナトリウム５
重量部、比重0.15の発泡パーライト（10〜24メツ
シユ）15重量部、ビニルピロリドンモノマーの20
％水溶液20重量部並びに過酸化水素２重量部に配
合し実施例１と全く同じ方法で軽量体を得た。そ
の結果第１表に示すごとくになつた。
実施例 ５
〔（CH3）4N）20.39SiO2からなる硅酸塩水溶液
（固形分40重量％）100重量部にリン酸ナトリウム
５重量部、比重0.15の発泡パーライト（10〜24メ
ツシユ）15重量部、ε−アミノカプロラクタム20
重量部並びにフツ化ホウ素２重量部を配合し実施
例１と全く同じ方法で軽量体を得た。その結果第
１表に示すごとくになつた。
実施例 ６
Na2O・3.1SiO2から成るアルカリ金属硅酸塩水
溶液（固形分40％）100重量部に硅フツ化ナトリ
ウム５重量部、比重0.15の発泡パーライト（10〜
24メツシユ）15重量部、37％ホルマリン水溶液40
重量部、97％フエノール20重量部を配合し実施例
１と同様の方法によつて成形し試験を行つた。そ
の結果第１表に示すごとくになつた。
比較例
実施例２において、ビニルピロリドンを配合し
ないで実施例１と全く同じ方法で軽量体を得第１
表に示す結果を得た。
【表】DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a lightweight body composition with excellent performance, and more specifically, to obtain an inorganic-organic composite lightweight body with excellent mechanical strength such as impact strength and bending strength. . The present inventors have been engaged in research to obtain a lightweight body by taking advantage of the properties of alkali silicates, such as their binding strength and natural performance, and have already achieved high water resistance, compressive strength,
We have created lightweight foam-curing bodies containing lightweight materials with excellent fire resistance. However, they are made entirely of inorganic materials, which cannot sufficiently overcome their hard and brittle properties, and they tend to crack easily when combined with relatively flexible materials. It still wasn't enough. In obtaining such a lightweight body containing granular lightweight material, the present inventors took various measures to improve mechanical strength, thereby impairing the performance of the lightweight body itself such as fire resistance, naturalness, compressive strength, etc. This has led to the completion of a composition that has improved mechanical strength such as bending strength and impact strength, and even better water resistance.
That is, the present invention is based on the general formula R 2 O・nSiO 2 (wherein R is an alkali metal or
An aqueous solution of a silicate represented by quaternary ammonium (n is a positive number from 1.5 to 7.0), a curable component of the aqueous silicate solution, a granular lightweight body, and a water-soluble monomer or oligomer that polymerizes to form a synthetic resin. In addition to the above-mentioned four components, a catalyst for the polymerization of the water-soluble synthetic resin monomer or oligomer can be blended in order to promote the polymerization of the synthetic resin. This composition can be formed into a lightweight body by methods such as casting or painting, and it has been found that it has remarkable effects on mechanical strength, especially bending strength and impact strength, and also significantly improves water resistance. . below,
The present invention will be explained in detail. The aqueous solution of silicate used in the present invention is an alkali silicate having a SiO 2 /R 2 0 molar ratio in the range of 1.5 to 7.0 as described above, and is used in the form of an aqueous solution in which R is an alkali metal, particularly sodium. In this case, it is usually called water glass. Next, as the hardening components of the silicate aqueous solution, those commonly used as hardening agents for water glass can be used, such as fluorides, fluorosilicates, phosphates, borates, cement, zinc oxide, sulfites, etc. Examples include calcium. Furthermore, granular lightweight materials can be used regardless of organic or inorganic materials, such as granular foams or granular crushed products of synthetic resins such as vinyl chloride, phenol, urea, styrene, urethane, and ethylene;
Organic lightweight materials such as granular foams and crushed products of synthetic rubber, inorganic foams such as vermiculite, expanded shale, perlite, silica balloons, and granular foamed silica, and other inorganic artificial lightweight aggregates and crushed products of ALC. be able to. Furthermore, water-soluble monomers or oligomers that polymerize to form synthetic resins include furfural derivatives, vinyl derivatives such as vinyl isobutyl ether, vinyl pyrrolidone, and ε-
aminocaprolactam, phenol, melamine,
Examples include formaldehyde, which is indispensable as an essential component of the composition of the present invention. Here, the above-mentioned water-soluble monomer or oligomer is used in a form having a molecular weight of approximately 1000 or less. In addition to the above-mentioned essential components of the present invention, catalysts for polymerizing the synthetic resin of the water-soluble monomers or oligomers that are blended according to each purpose include acidic catalysts,
Examples of the catalyst include basic catalysts, hydrogen peroxide, boron fluoride, iodine, and aminocaproic acid, which are commonly used as catalysts for the polymerization of the above synthetic resins. The present invention consists of the composition as described above, and the blending ratio is about 1 to 50 parts by weight of the curable component of the silicate aqueous solution to 10 parts by weight of the solid content of the silicate aqueous solution.
About 5 to 100 parts by weight of a granular lightweight body and about 2 to 100 parts by weight of a water-soluble monomer or oligomer that is polymerized to form a synthetic resin are blended.
At this time, if the above-mentioned curable component is less than about 1 part by weight, the water resistance of the lightweight body becomes slightly brittle;
If the amount exceeds the weight part, unreacted substances remaining in excess will have a negative effect, and if the granular lightweight material is small, the lightness will be impaired and the mechanical strength will become brittle. In addition, when the amount of synthetic resin polymerized from water-soluble monomers and oligomers is less than about 2 parts by weight, the effect of improving mechanical strength is difficult to appear, whereas when it exceeds about 100 parts by weight, fire resistance and fireproofing properties are affected. can. In addition, the amount of the granular lightweight material that can be blended with the above four components is about 5 to 50 parts by weight based on 100 parts by weight of the solid content of the silicate aqueous solution, and synthetic resin polymerized from water-soluble monomers and oligomers. The polymerization catalyst is approximately 0.1 to 15% by weight based on the synthetic resin.
shall be. The inorganic-organic composite solid formed product of the composition of the present invention obtained in this manner is obtained by casting or painting, and through a drying step using the foaming and curing mechanism of the composition, Although its mechanism of action is unknown, it has extremely good impact resistance and bending resistance, very good water resistance and alkali resistance, and has good adhesion to various substrates. There were no problems, and unexpectedly it was found that the water resistance of the lightweight body was also slightly improved. Examples are shown below. Example 1 100 parts by weight of an aqueous alkali metal silicate solution (solid content 40%) consisting of Na2O .
Mix 15 parts by weight of 24 mesh), 20 parts by weight of a 20% aqueous solution of vinylpyrrolidone monomer, and 2 parts by weight of hydrogen peroxide, stir for about 20 seconds, then pour into a 300 x 300 x 15 mm mold and store in a room at about 20°C. After 24 hours, a light body was obtained. The bending strength, impact strength, etc. of this lightweight body were measured and the results are shown in Table 1. Test method Bending strength: Based on the method specified in JIS K6911. Impact strength: 500 by JIS K5400 impact resistance test
Find the height at which a crack occurs for the first time with a weight of g. Water resistance: Measure the bending strength specified in JIS K6911 after immersing in water for 48 hours. Fire resistance: Based on surface test specified in JIS A1321. Example 2 A lightweight body was obtained in exactly the same manner as in Example 1 except that hydrogen peroxide as a polymerization catalyst was omitted. The results were as shown in Table 1. Example 3 To 100 parts by weight of an aqueous alkali metal silicate solution (solid content 40%) consisting of Na 2 O. Foamed perlite (10~
A lightweight body was obtained in exactly the same manner as in Example 1 by blending 15 parts by weight of 24 mesh and 20 parts by weight of ε-caprolactam. The results were as shown in Table 1. Example 4 100 parts by weight of a silicate aqueous solution (solid content 40%) consisting of [(CH 3 ) 4 N] 2 0.31SiO 2 and 5 parts by weight of sodium fluorosilicate
15 parts by weight of expanded perlite (10-24 mesh) with a specific gravity of 0.15, 20 parts by weight of vinylpyrrolidone monomer
% aqueous solution and 2 parts by weight of hydrogen peroxide to obtain a lightweight body in exactly the same manner as in Example 1. The results were as shown in Table 1. Example 5 [(CH3) 4N ) 2 100 parts by weight of a silicate aqueous solution (solid content 40% by weight) consisting of 0.39SiO2 , 5 parts by weight of sodium phosphate, and expanded perlite (10 to 24 meshes) with a specific gravity of 0.15. 15 parts by weight, ε-aminocaprolactam 20
A lightweight body was obtained in exactly the same manner as in Example 1 by adding 2 parts by weight and 2 parts by weight of boron fluoride. The results were as shown in Table 1. Example 6 100 parts by weight of an aqueous alkali metal silicate solution (solid content 40%) consisting of Na 2 O.
24 mesh) 15 parts by weight, 37% formalin aqueous solution 40
parts by weight and 20 parts by weight of 97% phenol were blended, molded in the same manner as in Example 1, and tested. The results were as shown in Table 1. Comparative Example In Example 2, a lightweight body was obtained in exactly the same manner as in Example 1 without adding vinylpyrrolidone.
The results shown in the table were obtained. 【table】