JPH0433735B2 - - Google Patents

Description

[Detailed Description of the Invention] [Industrial Application Field] The present invention relates to foam glass that is mainly used for interior, exterior, and wall materials of buildings, and has particularly excellent impact resistance and machinability as well as load resistance. This invention relates to foam glass consisting of a foam layer and a shell layer, which has excellent scratch resistance.

[Conventional technology]

It is conventionally known to form a shell layer on the foam layer of foam glass. JP-A-50-123108 describes a method for producing foam glass and ceramics consisting of a glass or ceramic foam layer and a vitreous shell layer.
Glass pieces for forming a skin layer and glass fine powder to fill between the glass pieces are placed on the bottom of the mold, and a material to form a foam layer is filled on top of the mold and heated to form foam glass or ceramics. Disclosed. In addition, JP-A-60-166239 discloses that a shell layer with a porosity of 1 to 30 vol% and a porous layer with a porosity of 70 to 95 vol% are integrally bonded to form laminated foam glass.
The shell layer is formed by granulating a raw material mainly consisting of fine glass powder into island shapes, while filling the spaces between the island-like parts with other raw materials mainly consisting of fine glass powder in powder form. It is disclosed that

[Problem that the invention seeks to solve]

Generally, by forming a shell layer, strength such as bending and tensile strength can be increased. However, in the above-mentioned known technology, when attempting to divide or cut a foam glass body, the skin layer is formed so densely that the skin layer must be removed in advance along the line to be cut during foam glass production. The latter has a porosity of 30 vol% or less, that is, the true specific gravity of glass is 2.5, while the apparent specific gravity is
It also has a dense skin layer of 1.75 or higher. By making the skin layer denser in this way, it is highly rigid, but if it receives a local impact from the outside, cracks will occur in that area and the cracks will develop in the surrounding area, sometimes resulting in bubble glass. leading to total collapse.

Needless to say, it is inferior in machinability and tends to cause cracks that deviate from the cutting line during the cutting process, significantly reducing production yield.

Therefore, it was necessary to make the bulk specific gravity of the shell layer lower than those of these known examples, and to provide it with porosity capable of absorbing external impact force.

On the other hand, when the bulk specific gravity of the skin layer is lowered, the surface hardness is not necessarily sufficient, and a new problem arises in that it is relatively easily damaged by, for example, a knife edge.

An object of the present invention is to provide foam glass that has excellent impact resistance and cutting workability, and also has excellent surface hardness and thus has scratch resistance.

[Means to solve the problem]

The present invention is formed integrally from a foam layer and a shell layer having a higher bulk specific gravity covering at least one side of the foam layer, and the shell layer is formed of a base phase formed by fusion of glass fine powder or glass fine powder and inorganic pigment fine powder. Particle size 0.5~5.2
The present invention provides foam glass in which glass grains having a shell layer with a content of 15 to 30 vol% are scattered therein.

In the present invention, the particle size is 150mm as the raw material for the foam layer.
Below, fine powder of a colored or colorless ordinary glass with a true specific gravity of around 2.5, such as soda lime glass, borosilicate glass, aluminosilicate glass, etc., is mixed with fine powder of a blowing agent such as limestone, dolomite, or carbon, and further an inorganic pigment. Mix and prepare with or without addition. These are further added with a binder such as water glass and processed by conventional granulation methods to produce particles with a particle size of 1/10 mm to several
Granulate to about mm.

As a raw material for forming the base phase of the shell layer, a mixture of the same glass powder as described above and fine powders of an inorganic pigment and a blowing agent as required is used and granulated in the same manner as described above.

As another raw material for the shell layer, ordinary colored or colorless glass particles with a particle size of 0.5 to 5.2 mm are used. The glass particles are uniformly mixed with the granulation raw material in a volume ratio range described below, and this is used as a raw material for forming a shell layer.

The bulk specific gravity of these foam layers and shell layers depends on the type and amount of foaming agent, the softening temperature of glass, the type and amount of inorganic pigment, or the amount of glass grains mixed in the skin layer.
It can be adjusted as appropriate by selecting firing conditions and the like.

When a non-granulated raw material is used in the foam layer, it is extremely bulky and contains a large amount of air mixed in. However, during the firing process, the mixed air remains and expands, resulting in coarse foam, the formation of cavities, and the formation of crusts. There are disadvantages such as the interface with the foam layer becoming wavy instead of flat, and furthermore, the foam layer locally penetrates the skin layer and is exposed on the surface, but by using granulated raw materials, such problems can be avoided. The harm will be eliminated.

Furthermore, when a non-granulated raw material is used, the product has a strong tendency to form open cells, but when a granulated raw material is used, most of the cells become closed cells, and therefore the water absorption resistance and water permeability resistance are significantly improved.

When granulated raw materials are used to form the base phase of the crust layer, for the same reason as mentioned above, locally weak areas may occur due to non-uniform sintering, unlike when non-granulated raw granules are used. is eliminated, and a homogeneous base phase of the crust layer is formed, which evenly and firmly adheres to the scattered glass grains.

Furthermore, since these granulation raw materials and glass particles have high fluidity, they can be easily charged into a mold or the like in a subsequent step, and a flat layer can be easily formed.

Various means can be employed for firing these foam glass raw materials.

For example, a foamed layer is formed in a steel formwork, the raw material is poured and laid to the desired thickness, and then the raw material for forming the skin layer is filled on top of it to the desired thickness, and the material is placed in a heating furnace. Foamed glass can be simultaneously and integrally formed by firing and foaming at an appropriate temperature in the range of 700° C. to 1000° C., or by further applying appropriate pressure during or immediately after firing.

Alternatively, a foamed layer and a shell layer may be separately manufactured using the same heating means as described above, and then laminated and heat-fused to integrally form foam glass.

Furthermore, it is easy to do so by filling the lower part between the upper and lower running heat-resistant belts with the material for forming the foam layer, and filling the upper part with the raw material for forming the shell layer, and then continuously introducing the material into a heating furnace for firing and foaming. Foam glass can be formed economically, simultaneously, integrally and continuously.

The total thickness of the foam glass thus formed is preferably in the range of approximately 30 mm to 125 mm. That is, if the thickness is less than 30 mm, the characteristic function of foam glass, that is, the heat insulation property cannot be effectively exhibited. If it is around 125mm, it is thick enough to block heat in normal buildings, and no more than that is necessary.
If the thickness is greater than that, the weight increases even though it is foam glass, which goes against the trend of lighter and higher-rise buildings and makes handling and construction difficult.

The bulk specific gravity of the foam layer is preferably in the range of 0.3 to 0.6. If it is less than 0.3, it will be too weak to be used as interior, exterior, or exterior wall materials for buildings, and if it exceeds 0.6, it will impair heat insulation, reduce lightness, and be inferior in handling and workability.

The bulk specific gravity of the skin layer is preferably in the range of 0.8 to 1.7, and the thickness is preferably in the range of 1.5 to 20 mm.

If the bulk specific gravity is less than 0.8, the density will be poor and mechanical strength such as bending strength will be insufficient, and in particular, chips and dents will easily occur due to external impact.
When it exceeds 1.7, the rigidity improves, but cracks are likely to occur and grow from localized external impacts, which may induce collapse of the entire foam glass.

In addition, related to the difference in bulk specific gravity between the foam layer and the shell layer, if the difference between the two layers is large, it is difficult to perform slow cooling uniformly, and distortion occurs between the two layers, causing external forces such as bending or impact to occur. On the other hand, since cracks are likely to occur at the interface between both layers, the difference should preferably be within 1.2.

The total thickness of the skin layer is related to the total thickness of the foam glass,
The thickness should be 1/4 or less of the total thickness of the foam glass in order not to impair its insulation properties, light weight, ease of handling, etc. It is also related to the bulk specific gravity of the skin layer, for example, in the case of a skin layer with a bulk specific gravity of 1.2, a thickness of 4 mm or around that has good impact resistance, and if the bulk specific gravity is lower than that, the thicker the better. ,
If the bulk specific gravity is higher than that, the thinner the material, the more effective the impact resistance tends to be, and the appropriate range is generally 1.5 to 20 mm, preferably 2 to 9 mm.

The shell layer has glass grains scattered in a base phase in which fine glass powder or inorganic pigments are fused together, thereby improving surface hardness and imparting scratch resistance.

Glass particles with a particle size of 0.5 to 5.2 mm are placed in the skin layer.
It is contained in a range of 15vol% to 30vol%.

Generally speaking, if the proportion of glass grains mixed in the shell layer is large, the surface hardness will improve and it will be effective for scratch resistance, but since it becomes difficult to cut foam glass, it must be kept at 30 vol% or less.

In penetration resistance tests, for example,
In the case of ALC, the penetration resistance R is as low as about 30 to 40 kg/cm ³ , that is, the surface hardness is low, so scratches are easily caused by knife edges and the like. In order to maintain a surface hardness to the extent that almost no scratches are observed even when the knife edge is brought into contact with a relatively strong force, a hardness of 120 kg/cm2 ^or more is required. Must be at least 15vol%.

Furthermore, if the particle size of the glass particles exceeds 5.2 mm, cracks are likely to occur along the glass grain boundaries when cutting the foam glass, making it difficult to cut along the planned cutting line.
If it is less than 0.5 mm, the required surface hardness cannot be obtained. However, after satisfying the above conditions, there is no problem in coexisting glass powder of less than 0.5 mm.
It will be readily understood that this does not depart from the invention.

Of course, the glass particles may vary in particle size within the range of 0.5 to 5.2 mm, and by changing the particle size or the color tone of the glass particles, it can be made elegant.

Within the scope of the present invention, it has excellent impact strength, bending strength, etc., as well as excellent scratch resistance and good machinability, and is therefore suitable for use as interior, exterior, and exterior wall materials for buildings.

In one embodiment of the present invention, one or both of the shell layer and foam layer of the foam glass is reinforced with at least one of metal wire, metal mesh, punched metal, etc. coated with an adhesion promoter in advance. Effective. These metal materials can be placed in a formwork in advance when manufacturing foam glass, or they can be inserted into the raw material between the upper and lower belts during continuous manufacturing without the need for special means. can be easily integrated with foam glass.

Conventionally, when reinforcing foam glass with metal materials, it has been pointed out that mutual adhesion is poor due to differences in mutual thermal shrinkage or oxidation of the metal. Alternatively, by using a metal material coated with resin such as acrylic, silica-based oxide powder, etc., the adhesive strength is significantly increased and the reinforcing effect is dramatically improved. Therefore, it is particularly suitable as an exterior wall material for buildings.

In another embodiment of the present invention, a shell layer may be formed on both sides of the foam layer of the foam glass. When manufacturing foam glass, these materials can be introduced into a mold in the order of the raw material for forming the shell layer, the raw material for forming the foam layer, and then the raw material for forming the shell layer, or in continuous production, the above raw materials can be introduced and laminated in the order from the lowest level. By applying the above-mentioned manufacturing means, it is possible to obtain a foam glass integrally formed from these three layers, which is particularly suitable as an exterior wall material.

It will be readily understood that, as a further embodiment of the present invention, the entire surface of the foam layer of the foam glass may be covered with a shell layer.

That is, for example, a foam glass body covered with a skin layer on both sides is first manufactured by the above-mentioned method, and then the surfaces on which the skin layer is not formed are held vertically and the raw material for forming the skin layer and the foam are placed in the mold. The glass body and then the raw material for forming the shell layer are charged in this order and fused together in a heating furnace, and this operation is repeated on other surfaces so that the entire surface is covered with the shell layer.

In the continuous production of foam glass, a similar method is used to first produce a foam glass body covered with a skin layer on both sides, and then to cover the surface of the foam glass body with no skin layer formed between the upper and lower heat-resistant belts. Holding them above and below, the raw material for forming the shell layer, the foam glass body, and the raw material for forming the shell layer are successively introduced from the bottom in this order, heated and fused together, and this operation is repeated for other surfaces as well. By repeating this process, the entire surface is covered with a shell layer, resulting in an extremely strong foam glass body.

Furthermore, if surface irregularities are provided on at least one of the shell layer and the foam layer, the adhesive area will increase and the effect will be enhanced when adhering to a wall surface as an exterior material, and the surface irregularities can be formed into a geometric pattern. If used as an external surface, it will be aesthetically pleasing.

These surface irregularities can be carved by placing irregularities on the bottom of the mold in advance, or by using a mesh-like heat-resistant belt to form mesh marks during continuous manufacturing, or by placing irregularities on the press lid surface. This can be done very easily by keeping it in place.

〔Example〕

As an example of implementation below, the bulk specific gravity of the foam layer is 0.4,
The total thickness is 50 mm or 100 mm, the bulk specific gravity of the skin layer is 0.9 to 1.6, the thickness of the skin layer is 2 to 20 mm, the particle size of glass grains in the skin layer is 0.1 to 6.7 mm, and the content of glass grains is 5 to 50 vol. % foam glass was subjected to a surface hardness test using penetration resistance of a steel rod and a cutting test.The results are detailed below.

Sample: Regular soda lime glass waste with particle size
Add and mix 0.7wt% of calcium carbonate powder of 150μm or less as a foaming agent to the powder crushed to 150μm or less, and then add a small amount of water glass as a binder and mix.The mixture is rolled and granulated to obtain particles with a particle size of 0.5~ A granulated raw material for a 2 mm foam layer was obtained.

Next, 1wt% of Bengara as a coloring agent was added to and mixed with soda lime glass waste crushed to a particle size of 150 μm or less, and a small amount of water glass was added and mixed as a binder, and the particles were granulated by rolling. A granulated raw material for forming a base phase of a shell layer of 0.5 to 2 mm was obtained.

Furthermore, glass particles with a particle size of 0.1 to 6.7 mm are prepared and mixed with the granulation raw material to reduce the glass particles in the shell layer to 0 to 6.7 mm.
The blending ratio was adjusted to 50 vol% and used as a raw material for the skin layer.

Next, the granulated raw material for the foam layer and the raw material for the shell layer are placed in a steel mold to the desired thickness, and then heated in a heating furnace at 750-900℃ for 20-40 minutes. By appropriately firing and slowly cooling, a foam glass having a foam layer with a bulk specific gravity of 0.4 and a shell layer with a bulk specific gravity of 0.6 to 1.9 was obtained.

The following tests were conducted on the obtained foam glass.

Steel rod penetration test: A steel rod of 4 mmφ was penetrated from above at a speed of 5 mm/min into a foam glass specimen with a width of 15 cm, a length of 15 cm, and a thickness of 50 mm and 100 mm, which was held with the skin layer facing upward. The maximum resistance was measured.

Cutting test; width 40cm, length 40cm, thickness 50mm and
A 100 mm foam glass test piece was cut with a resinoid cutting wheel containing corundum as an abrasive grain, and the occurrence of chips and cracks was observed and graded from A to D from good to bad.

The results are shown in Figures 1 to 3 and Table 1.

Figure 1 shows the total thickness of 50mm and the bulk specific gravity of the skin layer.
1.0, a graph showing the steel rod penetration resistance of foam glass with a thickness of 8 mm in which glass particles with particle diameters of 1 mm and 1.7 mm were contained in the shell layer at various volume ratios. The penetration resistance increases rapidly up to around 15vol% of glass particles, and thereafter increases gradually as the amount of glass particles increases. This bending tendency is similar for other glass particle sizes, and in general, when the content of glass particles in the shell layer is 15 vol% or more, the penetration resistance R is 120
Kg/cm ² or more, which indicates that the scratch resistance is excellent.

Figure 2 shows a total thickness of 50 mm and bulk specific gravity of the skin layer.
1.0 and 1.2, foam glass with a thickness of 8 mm, containing 20 vol% of glass grains in the skin layer, and varying the glass grain size, and the bulk specific gravity of the skin layer.
This is a graph showing the penetration resistance of a steel bar when the glass particle size is similarly varied with 1.0 and 30 vol% glass particles.The penetration resistance increases rapidly until the glass particle size reaches around 0.5 mm, and after that, it continues to increase. It is on a gradual increase. A similar bending tendency is also evident when the glass particle content is varied, and in general, the penetration resistance R exceeds 120 kg/cm ² when the glass particle diameter is 0.5 mm or more, and therefore the scratch resistance decreases. It is clear that it is superior.

Figure 3 shows a total thickness of 50 mm, glass particle diameters of 1 mm and 1.7 mm in the shell layer, and a glass particle content of 20 vol%.
The relationship between the thickness of the skin layer and the penetration resistance is shown when the bulk specific gravity of the skin layer is 1.0, and a simple tendency for penetration resistance to increase as the thickness of the skin layer increases is observed.

Table 1 shows the steel rod penetration test for various types of foam glass.
The results of the cutting test are shown according to the rankings appended to the table. In terms of penetration resistance, the bulk specific gravity is 0.8 to 1.7, the content of glass particles in the shell layer is in the range of 2 to 20 mm, 15 vol% or more, and the particle size is 0.5 mm.
The above are good. On the other hand, as the number of glass grains increases and the grain size increases, cutting performance tends to gradually deteriorate. It is clear that the following ranges are good.

〔Effect of the invention〕

As described above, the foam glass of the present invention has high impact strength and
It has excellent bending strength, etc., excellent scratch resistance, and is easy to cut, so it can be effectively applied as an interior material, exterior material, exterior wall material, etc. of buildings.

[Brief explanation of drawings]

1 to 3 are graphs of penetration resistance related to scratch resistance showing an example of the implementation of the present invention.

【table】

【table】

【table】

【table】

Claims (1)

[Scope of Claims] 1. It is integrally formed of a foam layer and a shell layer having a higher bulk specific gravity covering at least one side of the foam layer, and the shell layer is made of glass fine powder or glass fine powder and inorganic pigment fine powder fused together. A foam glass characterized in that glass grains having a grain size of 0.5 to 5.2 mm and a content of 15 to 30 vol% in a shell layer are scattered in a base phase. 2. The foam glass according to claim 1, wherein the foam layer has a bulk specific gravity of 0.3 to 0.6, and the skin layer has a bulk specific gravity of 0.8 to 1.7. 3. Claim 1, characterized in that granules mainly composed of glass fine powder are used as the raw material for forming the foam layer and the raw material for forming the base phase of the shell layer, respectively.
Bubble glass according to items 1 to 2.