JPH0699160B2 - Multi-layer foam glass body and its manufacturing method - Google Patents

Description

TECHNICAL FIELD The present invention relates to a foam glass body that is frequently used as an interior, exterior material, exterior wall material, etc. of a building.

(Prior art and its problems) It is known to bond and integrate a foam glass layer and a dense glass layer as disclosed in JP-A-50-123108 and JP-B-60-12937. By coating the outer surface of the foamed glass layer with the dense glass layer, the surface hardness is remarkably improved, the scratch resistance is excellent, and the decorativeness with the unique luster and profound feeling of the glass is added.

Usually, the bulk specific gravity of the dense glass layer (that is, the true specific gravity of glass) reaches about 2.5, while the bulk specific gravity of the foamed glass layer is preferably less than 0.8 in consideration of heat insulation and light weight. The difference in specific gravity between the two layers exceeds 1.7, which gives rise to differences in physical properties, especially thermal properties.

For example, when the foamed glass body formed by integrating the foamed glass layer formed in the molding step with extremely high heat insulation and the dense glass layer having much better thermal conductivity than that when cooled in the slow cooling step, No matter how sufficiently the slow cooling operation is performed, there is a clear difference between the two layers until shrinkage and solidification, which naturally induces strain between both layers, resulting in insufficient adhesion at the interface.

The foamed glass body thus obtained is liable to be cracked from the interface due to a slight impact during use or repeated fatigue due to weathering.

JP-A-59-111948 discloses that a preformed foam glass body is provided with an intermediate layer mainly composed of a hydraulic substance filling the open pores, and a glaze layer is further coated and heat-welded together. There is. However, also in the foam glass body, it is clear that there is a difference in heat conduction between the dense intermediate layer made of ceramics or glass and the foam glass layer containing a large amount of gas. Since it is a material of expansion, strain between both layers is promoted.
Anchoring effect due to slight sealing is expected, but it does not fundamentally improve the adhesion between the two layers, production efficiency,
It lacks relevance in terms of economy.

JP-B-49-28251 discloses that in a foam glass body formed by applying a glaze to a foam glass, the impact strength is increased by setting the bulk specific gravity of the foam glass in contact with the so-called dense glass layer to which the glaze is applied to 0.4 or more. However, the adhesiveness, which is the object of the present invention, cannot be improved over the specific bulk specific gravity range, and the problem of peeling cannot be solved.

The present invention solves these problems and provides a multilayer foam glass body that can be manufactured easily and economically.

(Structure of the invention) The present invention comprises a dense glass layer adhered to and integrated with at least one surface of a foam glass layer having a bulk specific gravity of less than 0.8 through an intermediate foam glass layer having a bulk specific gravity of 0.8 to 1.8, wherein each glass layer is soda lime. Glass, borosilicate glass, or a multi-layer foam glass body which is a glass mainly composed of one or more of aluminosilicate glass, and a layer of a foam glass raw material composed of glass granules, a mixed granule of a foaming agent and a binder. , A layer of an intermediate foam glass raw material made of a mixed granulation of fine glass powder and a binder or further a foaming agent, and a layer of a dense glass raw material made of glass particles are sequentially laminated and then fired to integrally form these layers. Or glass fine powder,
A layer of a foam glass raw material made of a mixed granulation of a foaming agent and a binder, and a layer of a dense glass raw material made of glass particles are laminated, and at the same time as firing, or immediately after that, the upper surface of the dense glass layer is 0.1 kg to A process for producing a multi-layered foam glass body in which an intermediate foamed glass layer is formed in a portion of the foamed glass layer that is in contact with the dense glass layer by applying a pressure of 4 kg / cm ² , and these layers are integrally formed. .

In the present invention, a foam glass layer (hereinafter simply referred to as a foam layer)
As a raw material, colored or colorless glass with a particle size of 100 μm or less and a true specific gravity of around 2.5, that is, soda-lime-based glass, borosilicate-based glass, aluminosilicate-based glass, fine powder of coal stone, dolomite, carbon, etc. A powder, and a mixture prepared by adding or not adding an inorganic pigment, and adjusting the mixture are used. Further, a binder such as water glass is further added, and the particles are granulated to have a particle diameter of about 1/3 mm to several mm by a conventional granulating means.

Further, as a raw material for the intermediate foam glass layer (hereinafter, simply referred to as an intermediate layer), the same glass powder as described above, to which an inorganic pigment and a fine powder of a foaming agent are added and mixed as needed, are used and granulated as described above.

The bulk specific gravity of the foam layer and the intermediate layer depends on the type and amount of the foaming agent,
It can be appropriately adjusted within the scope of the present invention by selecting the softening temperature of glass, the type and amount of the inorganic pigment, the firing conditions and the like.

When a non-granulated raw material is used in the foam layer, it is extremely bulky and has a large amount of entrapped air inside, but the entrained air remains and expands during the firing process, causing coarse bubbles, cavities, and the interface with the intermediate layer. Has a wavy shape instead of being flat, and further, the high-foamed layer locally penetrates the intermediate layer and directly contacts the dense glass layer, but by using the granulation raw material, such a harmful effect is Will be resolved. In addition, the product has a large tendency to form open cells when a non-granulated raw material is used, but when the granulated raw material is used, almost all become independent bubbles,
Therefore, water absorption resistance and water permeability resistance are remarkably improved.

Even in the intermediate layer, the use of the granulating raw material eliminates locally fragile portions due to non-uniform sintering as in the case of using non-granulated raw particles for the same reason as described above, and a homogeneous layer is formed. It is formed.

Further, since these granulation raw materials are rich in fluidity, they can be easily put into a mold or the like in a later step and a flat layer can be easily formed.

In addition, in forming the intermediate layer, the granulation raw material may be appropriately mixed with coarse-grained glass to add a taste.

As the glass particles as a raw material of the dense glass layer (hereinafter simply referred to as a dense layer), the same glass as the glass used for the foam layer and the intermediate layer is selected, but the thermal expansion coefficient thereof is the foam layer,
It is important that it is close to the middle layer. Particle size is 1/3 mm
If the above materials are used, the glass is softened and melted, and it is easy to form a dense layer having a bubble specific gravity (that is, true specific gravity) of about 2.5 without bubbles.

Various means can be adopted for the firing of these multilayer foam glass body raw materials. For example, the foam layer raw material is put into a steel mold so as to have a desired thickness and laid, and then the intermediate layer raw material and further the dense layer raw material are filled so as to have a desired thickness, A multilayer foam glass body can be simultaneously and integrally formed by firing and foaming in a heating furnace at an appropriate temperature in the range of 700 ° C. to 1000 ° C., or by applying an appropriate pressure during or immediately after firing.

Further, means for filling the foaming layer raw material in the lower portion between the pair of running heat-resistant belts, the intermediate layer raw material in the middle portion, and the dense layer raw material in the upper portion, and continuously guiding it to a heating furnace for firing and foaming. By taking the above steps, it is possible to easily and economically form a multilayer foam glass body simultaneously and integrally and continuously.

In addition, according to another means for simultaneously producing a multilayer foam glass body, a foam layer raw material and a dense layer raw material are laminated and filled in a mold, or a foam layer is formed under a pair of upper and lower heat resistant belts. use material, filled with raw materials for the dense layer to the upper, the firing during foaming or immediately after in the furnace, depending on the bulk density and the like of the foam layer of the foamed layer be added to a pressure of 0.1~4kg / cm ² An intermediate layer having a thickness of 0.5 mm or more and a bulk specific gravity of 0.8 or more is formed at the interface in contact with the dense layer. If the pressure is excessively applied, the foamed layer itself will be densified, so that the range of 1 to ³ kg / cm ² is more preferable.

The pressure applying means is not specified, but in the latter case, for example, a plurality of pressing rollers may be pressed from above the dense layer via the heat resistant belt.

The total thickness of the multilayer foam glass body thus formed is preferably in the range of approximately 30 mm to 125 mm. Ie 30 mm
When it is less than the above range, the characteristic function of the multilayer foam glass body, that is, the heat insulating property cannot be effectively exhibited. If it is about 125 mm, it is thick enough to cut off heat in a normal building and does not need to be thicker than that. The trend is toward lighter and higher floors, which makes handling and construction difficult.

Of course, the thickness is not particularly limited, it may be less than 30 mm if weight is more important than heat insulation, and may be around 10 mm in some cases, especially in special places where heat insulation is required.
May exceed 125 mm.

The bulk specific gravity of the foam layer is preferably in the range of 0.2 to less than 0.8. If it is less than 0.2, it is fragile when used as an interior / exterior material or outer wall material of a building, and if it is 0.8 or more, the heat insulating property is impaired and the lightness is impaired, resulting in poor workability. The range is more preferably 0.3 to 0.6.

As described above, the specific gravity of the dense layer is around 2.5, and in order to maintain the hardness and abrasion resistance of glass and to fully exhibit its appearance characteristics, it is necessary to avoid the residual bubbles.

The bulk specific gravity of the intermediate layer is required to be 0.8 or more for good adhesion with the dense layer and 1.8 or less for good adhesion with the foam layer.

The thickness of the intermediate layer may be 0.5 mm or more in order to interpose between the dense layer and the foamed layer and improve the mutual adhesiveness. The intermediate layer may be colored by using various colored glasses so that it can be seen through the dense layer. In this case, a thickness of several mm is required. The thickness of the dense layer is also required to be 1 to several mm in order to improve the surface hardness and impart scratch resistance, and to take into account the profound feeling of the glass. Can appear.

The total thickness of the intermediate layer and the dense layer should be within 20 mm. When it exceeds 20 mm, it has excellent rigidity, but loses almost all elastic force and is fragile against external impact. In addition, the total thickness of the intermediate layer and the dense layer should be 1/4 or less of the total thickness in order not to impair the heat insulating property, light weight property and handling workability of the multilayer foam glass body.

In one aspect of the present invention, it is more effective if an appropriate portion of the foam glass body is previously coated with an adhesion-imparting agent to be reinforced with at least one kind of metal wire, metal net, punching metal or the like. No special means is required for these metallic materials by arranging them in a mold in advance when manufacturing a foam glass body, or by running them through the raw material between the upper and lower belts in continuous manufacturing. And can be easily integrated with the foam glass body.

As another aspect of the present invention, an intermediate layer and a dense layer may be formed on both sides of the foam layer of the foam glass body.
That is, when a foam glass body is manufactured, the raw material for the dense layer, the raw material for the intermediate layer, the raw material for the foamed layer, the raw material for the intermediate layer, and the raw material for the dense layer are charged in this order in the mold, or from the lower order in the continuous production. A foamed glass body integrally formed from these five layers can be formed by applying the above-mentioned manufacturing means by charging and stacking the raw materials in this order, and in particular, it can be a sufficient outer wall material.

Further, if surface irregularities are provided on at least one of the dense layer and the foamed layer, the adhesive area is increased when adhering to a wall surface as an exterior material to enhance the effect, and the surface irregularities are formed into a geometric pattern to form an outer surface. When used as, it becomes aesthetically pleasing.

These surface irregularities can be engraved by arranging irregularities on the bottom of the mold in advance, or by using a mesh heat-resistant belt to form mesh traces in continuous production, or arranging irregularities on the pressing lid surface. This can be done very easily by keeping it.

(Examples and Comparative Examples) Soda-lime glass waste as a raw material for the foam layer has a particle size of 100 μm.
10 parts of calcium carbonate as a foaming agent
0.7 wt% of powder having a particle size of 0 μm or less was added and mixed, and a small amount of water glass as a binder was further added and mixed to prepare a granulated product having a particle size of 0.5 to 2 mm by rolling granulation.

100 μm particle size of soda lime glass scraps as a raw material for the intermediate layer
Calcium carbonate is appropriately added to the crushed product below to add a small amount of water glass as a post-binder and mixed by tumbling to prepare a granule having a particle size of 0.5 to 2 mm. did.

Particle size of soda lime glass scrap as a raw material for dense layer 0.5-2 mm
The crushed one was prepared.

Raw material for foaming layer, raw material for intermediate layer, and raw material for dense layer are sequentially charged and stacked in a steel mold and placed in a heating furnace at 750 to 900 ° C for 20
By calcining for 60 minutes to 60 minutes, and further slowly cooling, the foam layer has a thickness of 42 mm, the middle layer 5 mm, and the dense layer 3 mm. The bulk specific gravity of the foam layer is 0.4, and the bulk specific gravity of the dense layer (that is, the true specific gravity).
Was obtained and the bulk specific gravity of the intermediate layer was 0.7 to 2.2.

Further, the raw material for the foam layer and the raw material for the dense layer are put into a steel mold and laminated, and appropriately fired in a heating furnace at 750 ° C. to 900 ° C. for 20 minutes to 60 minutes, and 1.5 kg / cm ² immediately before the firing is completed. With a pressure of 10 minutes from the upper surface of the dense layer, by further cooling the foam layer 46 mm, the intermediate layer 1 mm formed by compressing the foam layer, the dense layer 3 mm thickness, the bulk specific gravity of the foam layer 0.4, A multilayer foam glass body having a bulk density of 2.5 for the dense layer and a bulk density of 0.9 to 1.3 for the intermediate layer was obtained.

For comparison, a foam layer glass body having a thickness of 50 mm and a foam layer having a bulk density of 0.4 only, and a two-layer foam glass having a foam layer having a thickness of 47 mm and a dense layer having a thickness of 3 mm and having a bulk density of 0.4 and 2.5, respectively. Created the body.

A 20 mm × 50 mm sample (thickness direction) of these foamed glass bodies was pulled vertically in the thickness direction using a tensile strength tester, and the tensile fracture strength was measured.

The results are shown in the graph of FIG.

In the figure, a to f are multi-layer foam glass bodies, g to h are multi-layer foam glass bodies, i is the two-layer foam glass body, and J is the strength of the foam glass body consisting of only the foam layer. B to e, g and h having a specific gravity in the range of 0.8 to 1.8 show relatively high strength due to the rupture of the foam layer as in J, but a having a low bulk specific gravity of the intermediate layer is a at the interface between the intermediate layer and the dense layer. F, which is ruptured and has a high bulk specific gravity of the intermediate layer, is ruptured at the interface between the intermediate layer and the foam layer, and i without the intermediate layer is ruptured at the interface between the foam layer and the dense layer, and both show low strength. It is clear that the adhesion is poor.

(Advantages of the Invention) The present invention improves the adhesiveness between the dense layer and the foamed layer by providing the intermediate layer, and eliminates the conventional drawback that peeling easily occurs at the boundary portion. It has an effect of alleviating a remarkable difference in physical properties of layers, and is suitable as an interior / exterior material and an exterior wall material of a building. In addition, the dense layer has no bubbles, maintains the hardness and abrasion resistance of glass, and exhibits a profound appearance, luster, and smoothness, and has a decorative appearance.

[Brief description of drawings]

FIG. 1 is a graph showing the tensile breaking strength of the multilayer foam glass body of the present invention in comparison with the comparative example.

Claims (6)

[Claims] 1. A dense glass layer is adhered to and integrated with at least one surface of a foam glass layer having a bulk specific gravity of less than 0.8 via an intermediate foam glass layer having a bulk specific gravity of 0.8 to 1.8, wherein each glass layer is soda lime glass. A multi-layer foamed glass body, which is a glass mainly containing one or more of borosilicate glass and aluminosilicate glass. 2. The multilayer foam glass body according to claim 1, wherein the foam glass layer has a bulk specific gravity of 0.3 to 0.6, and the intermediate foam glass layer has a bulk specific gravity of 1.0 to 1.7. 3. The intermediate foam glass layer has a thickness of 0.5 mm or more, the dense glass layer has a thickness of 1 mm or more, and the total thickness of the intermediate foam glass layer and the dense glass layer is 20 mm or less. The multi-layer foam glass body according to claim 1 or 2. 4. A layer of a foamed glass raw material composed of a mixed granule of glass fine powder, a foaming agent and a binder, and a layer of an intermediate foamed glass raw material composed of a mixed granule of glass fine powder and a binder or further a foaming agent. A method for producing a multilayer foam glass body, wherein layers of dense raw material made of glass particles are sequentially laminated and then fired to integrally form these layers. 5. A layer of a foam glass raw material made of a mixed granulation of fine glass powder, a foaming agent and a binder and a layer of a dense glass raw material made of glass particles are laminated and then fired, or directly densified. The upper surface of the glass layer is 0.1 kg to 4 kg / c
A method for producing a multi-layered foam glass body, which comprises pressurizing with a pressure of m ² . 6. A dense glass layer upper surface 1kg / cm ² ~3kg / cm claims, characterized in that pressurizing at a pressure of ² paragraph 5, wherein the multilayer foamed glass body production method.