KR100845020B1 - Making method of non-combustible vermiculite panel - Google Patents
Making method of non-combustible vermiculite panel Download PDFInfo
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- KR100845020B1 KR100845020B1 KR1020070070305A KR20070070305A KR100845020B1 KR 100845020 B1 KR100845020 B1 KR 100845020B1 KR 1020070070305 A KR1020070070305 A KR 1020070070305A KR 20070070305 A KR20070070305 A KR 20070070305A KR 100845020 B1 KR100845020 B1 KR 100845020B1
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B3/00—Producing shaped articles from the material by using presses; Presses specially adapted therefor
- B28B3/02—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein a ram exerts pressure on the material in a moulding space; Ram heads of special form
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
- B28B11/24—Apparatus or processes for treating or working the shaped or preshaped articles for curing, setting or hardening
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
- C04B14/02—Granular materials, e.g. microballoons
- C04B14/04—Silica-rich materials; Silicates
- C04B14/14—Minerals of vulcanic origin
- C04B14/18—Perlite
- C04B14/185—Perlite expanded
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
- C04B14/02—Granular materials, e.g. microballoons
- C04B14/04—Silica-rich materials; Silicates
- C04B14/20—Mica; Vermiculite
- C04B14/202—Vermiculite
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
- C04B14/02—Granular materials, e.g. microballoons
- C04B14/04—Silica-rich materials; Silicates
- C04B14/20—Mica; Vermiculite
- C04B14/204—Mica; Vermiculite expanded
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
- C04B28/24—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing alkyl, ammonium or metal silicates; containing silica sols
- C04B28/26—Silicates of the alkali metals
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- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
- E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
- E04B1/62—Insulation or other protection; Elements or use of specified material therefor
- E04B1/92—Protection against other undesired influences or dangers
- E04B1/94—Protection against other undesired influences or dangers against fire
- E04B1/941—Building elements specially adapted therefor
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- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/20—Resistance against chemical, physical or biological attack
- C04B2111/28—Fire resistance, i.e. materials resistant to accidental fires or high temperatures
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Abstract
Description
운모광물에 속하는 질석은 버미큘라이트(vermiculite)라고도 하며, 화학성분은 CMg, Fe3 +, Al3(Al,Si)4O10(OH)2·4H2O 로써, 알루미늄·마그네슘·철의 수산화규산염으로 된 점토광물이다. Also known as vermiculite is vermiculite (vermiculite) belonging to the mica mineral and chemical composition CMg, Fe 3 +, Al 3 (Al, Si) 4 O 10 (OH) 2 · As 4H 2 O, aluminum, magnesium, iron hydroxide silicate It is a clay mineral.
질석은 산(酸)에 쉽게 분해되고, 양이온 교환능력이 크며 다공질로 되어 있다.Vermiculite is easily decomposed into acids, has a large cation exchange capacity, and is porous.
특히, 가열시 결정층 사이의 수분이 증발됨과 동시에 격자층이 팽창하여 부피가 증가하며 무기질재료의 특성인 내화성과 팽창으로 인하여 단열충진재로 이용이 가능한 친환경적인 재료이다.In particular, it is an environmentally friendly material that can be used as a thermal insulation filler due to the evaporation of moisture between the crystallization layer and the expansion of the lattice layer and the volume of the inorganic layer.
본 발명은 위와 같은 질석의 특징을 이용하여 선박 불연재 등과 같은 저밀도의 질석불연판넬의 제조방법에 관한 것이다.The present invention relates to a method for producing a low density vermiculite non-combustible panel such as a ship nonflammable using the above characteristics of vermiculite.
질석 판넬에 관한 기술로는 질석, 석회석분말, 합성수지를 혼합한 후 압착 성형시킨 '건축용 질석판넬의 제조방법'(한국 공개특허공보 특1996-0010571)이 출원된 바 있다.As a technology for the vermiculite panel, a method of manufacturing a vermiculite panel for construction, which is formed by mixing vermiculite, limestone powder, and synthetic resin and then compression molding has been filed (Korean Patent Laid-Open Publication No. 1996-0010571).
위와 같은 기술은 질석의 열에 의한 팽창 특성을 이용하기 전의 기술로써, 방음 및 방습 효과 및 내열성의 향상을 가져왔으나 불연재로 사용될 수 있을 정도의 열적 특성을 갖지는 못했다.The above technique is a technique before utilizing the thermal expansion characteristics of vermiculite, which has improved sound insulation and moisture proofing effect and heat resistance, but did not have enough thermal characteristics to be used as a nonflammable material.
이러한 기술에서 질석의 열에 의한 팽창 특성을 이용한 것으로 보이는, 질석, 세라믹결합재를 혼합한 후 가열, 진공 건조하여 제조되는 '내열제품 및 그 제조방법'(한국 공개특허공보 특2001-0034854)이 출원되었다.In this technology, a 'heat-resistant product and its manufacturing method' (Korean Patent Laid-Open Patent Publication No. 2001-0034854), which is produced by mixing vermiculite and ceramic binder and heating and vacuum-drying, which appears to utilize thermal expansion characteristics of vermiculite, has been applied .
또, 질석 원석을 소성시킨 다음 바인더를 혼합한 후 열간 프레스한 '질석소성품 및 이를 이용한 질석판넬'(한국 공개특허공보 특2001-0102690)이 출원되기도 하였다.In addition, a sintering vermiculite product and a vermiculite panel using the same, which have been fired after the vermiculite is calcined and then mixed with a binder, have been filed (Korean Patent Laid-Open Publication No. 2001-0102690).
그런데, 질석판넬 제조시 첨가되는 무기질바인더는 열에 경화될 뿐 아니라 성형몰드에 쉽게 접착되어 가열성형 후 성형몰드에서 제품을 분리하기가 곤란해 분리 및 절단 공정에 따른 생산 공정이 복잡해지고, 비용이 추가되는 문제점이 있었다.However, the inorganic binder added in the vermiculite panel is not only hardened by heat but also easily adhered to the molding mold, which makes it difficult to separate the product from the molding mold after heat molding, which complicates the production process according to the separation and cutting process and adds cost. There was a problem.
또, 가열된 성형몰드 바닥에 재료가 투입될 때 바닥면에서 재료의 경화가 발생되기 때문에 제품의 상부와 하부 밀도가 균일하지 못하는 문제점도 있었다.In addition, there is a problem that the density of the top and bottom of the product is not uniform because the hardening of the material occurs at the bottom when the material is put into the heated molding mold bottom.
또한, 질석의 고팽창성 및 성형몰드의 깊이에 대한 정확한 계산 부족으로 인해 성형몰드에 재료를 투입한 후 상판의 몰드를 이용하거나 다른 장치를 이용하여 일정한 압력으로 가압 후 다시 재료를 추가 투입하여 제품을 성형하므로 재료투입량이 일정하지 않게 되고, 이로 인해 제품 전체의 밀도 분포 및 평활도가 고르지 못한 문제점도 있었다.In addition, due to the high expansion of vermiculite and lack of accurate calculation of the depth of the molding mold, the material is added to the molding mold, pressurized using a mold of the top plate, or pressurized to a constant pressure using another device, and then the material is added again. Because of the molding, the input amount of the material is not constant, which causes a problem in that the density distribution and smoothness of the entire product are uneven.
위와 같은 기술 이외에 배합된 질석원료가 롤 방식의 압착을 통해 일정한 두께로 성형되는 연속공정이 가능한 제조공법의 경우, 프레스와 비교시 상대적으로 압력조절이 어려운 롤 압착방식을 이용하게 됨으로써 동일한 질석재료간 상호 접착이 요구되는 경우 과도한 무기질바인더의 사용으로 선박불연재로 이용될 시 가장 중요하게 고려대상이 되는 600 kg/cm3 이하의 저 밀도 질석불연판넬을 얻기가 어려운 문제점이 있으며, 이와 더불어 고가의 공정라인 설비로 인하여 제품의 단가가 상승하는 문제점이 있었다.In addition to the above technology, in the case of a manufacturing process in which the mixed vermiculite raw material is formed in a predetermined thickness through a roll method of pressing, a process of compressing the pressure is relatively difficult to control compared to a press. If mutual adhesion is required, it is difficult to obtain a low density vermiculite non-combustible panel of 600 kg / cm 3 or less, which is the most important consideration when used as a ship nonflammable material due to the use of excessive inorganic binders. There was a problem that the unit price of the product rises due to the line equipment.
본 발명의 질석불연판넬 제조방법은 위와 같은 문제점을 해소하기 위한 것으로, 가압프레스 방식을 활용하되 냉간 프레스 방식을 적용하여 프레스 공정에서의 무기질바인더의 경화를 방지함으로써 성형몰드에 제품이 접착되지 않게 하여 성형 후 제품을 분리하기 쉽게 함으로써 불필요한 분리 및 절단 공정 없이 질석불연판넬을 제조하려는 것이다.The method of manufacturing vermiculite non-combustible panel of the present invention is to solve the above problems, by using a press press method but by applying a cold press method to prevent the product from adhering to the molding mold by preventing the hardening of the inorganic binder in the pressing process. It is intended to make vermiculite non-combustible panels without unnecessary separation and cutting process by making the product easy to separate after molding.
또, 가열되지 않은 성형몰드를 사용함으로써 성형몰드 바닥에 먼저 접촉하는 재료가 먼저 경화되지 않게 함으로써 제품의 상,하부 밀도를 균일하게 하려는 것이다.In addition, by using an unheated molding mold, the material contacting the bottom of the molding mold is not cured first, so that the upper and lower densities of the product are made uniform.
또한, 상부 몰드 또는 하부몰드가 중간몰드와 함께 암수 형태로 조립됨으로써 판넬 전체에 걸쳐 일정한 압력을 부여하여 프레스되도록 하여 제품 전체의 밀도 및 표면의 평활도를 균일하게 하고, 불필요한 추가 재료 주입 공정이 필요없는 질석불연판넬을 제조하려는 것이다.In addition, the upper mold or the lower mold is assembled together with the intermediate mold in the shape of male and female to apply a constant pressure throughout the panel to press to uniform the density and surface smoothness of the entire product, eliminating unnecessary additional material injection process To manufacture vermiculite non-combustible panels.
또한, 질석판넬 제조시 최대 난점으로 꼽히는 건조시간을 적외선히터를 포함하는 적외선조사장치를 이용함으로써 건조 시간을 단축시켜 제품 생산 속도를 향상시키려는 것이다.In addition, by using an infrared irradiation apparatus including an infrared heater, the drying time, which is considered to be the biggest difficulty in manufacturing vermiculite panels, is to shorten the drying time to improve the product production speed.
본 발명의 질석불연판넬 제조방법은 위와 같은 과제를 해결하기 위해, 팽창 질석과, 무기질바인더와, 팽창 펄라이트와, 무기배합제와, 물을 혼합, 교반하여 혼합물을 제조하는 혼합물제조단계와; 성형몰드를 준비한 후 성형몰드에 준비된 혼합물을 투입한 후 성형몰드를 가압 프레스하여 성형품을 제조하는 프레스성형단계와; 성형단계에서 수득된 성형품을 성형몰드에서 탈형한 후 롤 방식의 이동식 가압 열풍실에서 열풍 건조하는 열풍건조단계와; 열풍건조단계에서 열풍 건조된 성형품을 가열 건조하는 적외선건조단계; 적외선건조단계에서 가열 건조된 제품을 절단하여 질석불연판넬을 제조하는 절단단계;로 구성된다.In order to solve the above problems, the vermiculite non-combustible panel manufacturing method of the present invention comprises the steps of preparing a mixture by mixing and stirring expanded vermiculite, inorganic binder, expanded pearlite, inorganic compound, and water; A press molding step of preparing a molding mold, putting a prepared mixture into the molding mold, and then pressing the molding mold to produce a molded article; A hot air drying step of demolding the molded product obtained in the molding step from the molding mold and then hot air drying in a roll type pressurized hot air chamber; An infrared ray drying step of heating and drying the molded article hot-air dried in the hot air drying step; It consists of a cutting step of producing a vermiculite non-combustible panel by cutting the product heat-dried in the infrared drying step.
아울러 혼합물은 팽창 질석 100 중량 %와, 팽창 질석 대비 80 ~ 90 중량 %의 무기질바인더와, 팽창 질석 대비 5 ~ 10 중량 %의 팽창 펄라이트와, 팽창 질석 대비 1 ~ 3 중량 %의 무기배합제와 팽창 질석 대비 2 ~ 10 중량 %의 물이 혼합되어 형성된 것을 특징으로 한다.In addition, the mixture contains 100% by weight of expanded vermiculite, 80 to 90% by weight of inorganic binder relative to expanded vermiculite, 5 to 10% by weight of expanded pearlite relative to expanded vermiculite, and 1 to 3% by weight of inorganic compound compared to expanded vermiculite and expanded Characterized in that formed by mixing 2 to 10% by weight of water compared to vermiculite.
또, 물은 혼합물 전체 중량대비 4 % 정도 혼합되는 것을 특징으로 한다.In addition, the water is characterized in that about 4% of the total weight of the mixture is mixed.
또, 성형몰드는 상부몰드와 중간몰드, 하부몰드로 구성되어 있으며, 각각이 배치되어 암수 형태를 갖는 것을 특징으로 한다.In addition, the molding mold is composed of an upper mold, an intermediate mold, a lower mold, each of which is characterized in that it has a male and female form.
또한, 적외선건조단계는 적외선히터가 설치된 적외선 조사장치에 의해 가열 건조되어 열전도율이 낮은 질석과 무기질바인더의 수분을 빠른 시간 내에 제거하여 경화시키도록 되어 있는 것을 특징으로 한다.In addition, the infrared drying step is characterized in that it is heated and dried by an infrared irradiator equipped with an infrared heater to remove and harden the moisture of the vermiculite and inorganic binder having a low thermal conductivity within a short time.
본 발명에 의해, 프레스 공정에서의 무기질바인더의 경화를 방지함으로써 성 형몰드에 제품이 접착되지 않게 하여 성형 후 제품을 분리하기 쉽게 함으로써 불필요한 분리 및 절단 공정 없이 질석불연판넬을 제조할 수 있다.According to the present invention, the vermiculite non-combustible panel can be produced without unnecessary separation and cutting processes by preventing the product from adhering to the molding mold by preventing hardening of the inorganic binder in the pressing process, thereby making it easy to separate the product after molding.
또, 가열되지 않은 성형몰드를 사용함으로써 성형몰드 바닥에 먼저 접촉하는 재료가 먼저 경화되지 않게 함으로써 제품의 상,하부 밀도가 균일해진다.In addition, by using the unmolded molding mold, the material contacting the bottom of the molding mold is not cured first, so that the density of the upper and lower parts of the product becomes uniform.
또한, 상부 몰드 또는 하부몰드가 중간몰드와 함께 암수 형태로 조립됨으로써 판넬 전체에 걸쳐 일정한 압력을 부여하여 프레스됨으로써 제품 전체의 밀도 및 표면의 평활도가 균일해지고, 불필요한 추가 재료 주입 공정이 필요없는 질석불연판넬이 제공된다.In addition, as the upper mold or the lower mold is assembled together with the intermediate mold in the shape of male and female, press and apply a constant pressure throughout the panel to uniformize the density and surface smoothness of the entire product, and do not require unnecessary additional material injection process vermiculite nonflammable Panels are provided.
또한, 질석판넬 제조시 최대 난점으로 꼽히는 건조시간을 적외선히터를 포함하는 적외선조사장치를 이용함으로써 건조 시간을 단축시켜 제품 생산 속도가 향상된다.In addition, by using an infrared irradiation device including an infrared heater, the drying time, which is considered to be the biggest difficulty in manufacturing vermiculite panels, shortens the drying time, thereby improving the product production speed.
즉, 가열되지 않은 암수 형태의 성형몰드를 이용하여 예비성형 함으로써 일정한 압력과 내외부의 균일한 온도를 부여함으로써 제품의 품질과 생산성을 향상시킬 수 있을 뿐만 아니라 적외선히터를 포함하는 적외선 조사장치를 이용함으로써 열전도율이 극히 낮은 질석의 무기질바인더의 수분을 빠른 시간 내에 제거하여 경화시켜 연속제조공정을 이룰 수 있는 질석불연판넬의 제조방법이 제공되는 것이다.In other words, by preforming using unheated male and female molding molds, by providing a constant pressure and a uniform temperature inside and outside, it is possible to improve product quality and productivity as well as by using an infrared irradiation device including an infrared heater. It is to provide a method for producing a vermiculite non-combustible panel that can achieve a continuous manufacturing process by removing the moisture of the inorganic binder of vermiculite of extremely low thermal conductivity within a short time to cure.
이하 본 발명의 질석불연판넬의 제조방법에 대해 상세히 설명하면 다음과 같다.Hereinafter, the method for preparing the vermiculite nonflammable panel of the present invention will be described in detail.
1. 혼합물제조단계1. Mixing step
팽창 질석과, 무기질바인더와, 팽창 펄라이트와, 무기배합제를 혼합 교반하여 혼합물을 제조한다.The mixture is prepared by mixing and stirring the expanded vermiculite, the inorganic binder, the expanded pearlite, and the inorganic compounding agent.
팽창질석(Vermiculite)은 운모가 풍화 또는 변질되어 생성된것으로 함유하고 있는 수분이 탈수되면 팽창하여 늘어나는 성질을 가지며 1400 도 정도의 온도에 대해 내화성을 갖는 것으로 알려져 있다.Vermiculite is produced by weathering or deterioration of mica, and it is known that it expands and expands when moisture contained therein is dehydrated and has a fire resistance to a temperature of about 1400 degrees.
팽창펄라이트는 천연유리를 조각으로 분쇄한 것을 주로 말하며, 조각에 형성된 얇은 공기막으로부터 반사에 의해 진주와 같은 빛을 발하기도 한다.Expanded pearlite mainly refers to the crushing of natural glass into pieces and sometimes emits pearl-like light by reflection from the thin air film formed on the pieces.
이러한 팽창펄라이트는 평소 3 ~ 4 % 의 수분을 함유하고 있으며, 화재시에 820 ~ 1100 도의 온도에 노출되면 체적이 약 15 ~ 20배 정도 팽창하는 특성이 있다.Such expanded pearlite usually contains 3 to 4% of water, and when the fire is exposed to a temperature of 820 ~ 1100 degrees, the volume is expanded by about 15 to 20 times.
무기질바인더는 각 혼합 재료간 결착력을 증대시키는 것으로 시멘트, 석고, 규산나트륨과 같은 규산염, 점토 등을 사용하며 특히 규산소다를 사용하는 것이 바람직하다.Inorganic binders are used to increase the binding strength between the mixed materials, and cement, gypsum, silicate such as sodium silicate, clay, and the like, and sodium silicate is particularly preferable.
무기배합제는 무기질의 배합제로 공지되어 있는 여러 가지 보강재 내지는 골재, 안료, 고착제, 초기점착성 부여제 등을 사용할 수 있다.The inorganic compound may use various reinforcing materials or aggregates known as inorganic compounding agents, aggregates, pigments, fixing agents, initial tackifiers, and the like.
이중 충격흡수 성능을 높이기 위해서는 카오린을, 제품 강도를 증진시키기 위해서는 탄산칼슘이 적합하다.Kaolin is suitable to increase the double shock absorption performance, and calcium carbonate to enhance the product strength.
또, 여러 재료를 섞어 형성할 수 도 있다.It is also possible to form a mixture of various materials.
즉, 카오린과 탄산칼슘을 적정 비율로 혼합한 재료를 무기배합제로 사용할 수도 있는 것이다.In other words, a material obtained by mixing kaolin and calcium carbonate in an appropriate ratio may be used as the inorganic compounding agent.
한편, 위와 같은 재료는 물과 함께 혼합되어 혼합물이 형성되는데, 본 출원의 발명자는 반복적인 실험을 통해 불연 성능을 가질 수 있는 최적의 혼합 비율을 찾아내었다.On the other hand, the above materials are mixed with water to form a mixture, the inventors of the present application has found the optimum mixing ratio that can have a non-combustible performance through repeated experiments.
구체적으로 혼합물은, 팽창 질석 100 중량 %와, 팽창 질석 대비 80 ~ 90 중량 %의 무기질바인더와, 팽창 질석 대비 5 ~ 10 중량 %의 팽창 펄라이트와, 팽창 질석 대비 1 ~ 3 중량 %의 무기배합제와 팽창 질석 대비 2 ~ 10 중량 %의 물이 혼합되어 형성될 경우 가장 불연 성능이 우수해지는 것을 알 수 있었다.Specifically, the mixture includes 100% by weight of expanded vermiculite, 80 to 90% by weight of inorganic binder relative to expanded vermiculite, 5 to 10% by weight of expanded pearlite relative to expanded vermiculite, and 1 to 3% by weight of inorganic mixture based on expanded vermiculite. 2 to 10% by weight of water compared to the expanded vermiculite was found that the most non-combustible performance is formed.
2. 프레스성형단계2. Press molding step
성형몰드를 준비한 후 성형몰드에 준비된 혼합물을 투입한 후 성형몰드를 가압 프레스하여 성형품을 제조한다.After the molding mold is prepared, the prepared mixture is introduced into the molding mold, and the molding mold is pressed to prepare a molded article.
여기서 성형몰드는 상부몰드(10)와 중간몰드(20), 하부몰드(30)로 구성하는 것이 바람직하며, 상부몰드(10), 중간몰드(20), 하부몰드(30)는 각각이 배치되어 도 2에서 보는 바와 같이 암수 형태를 갖도록 배치되는 것이 바람직하다.Here, the molding mold is preferably composed of an
도 2에서는 중간몰드(20)와 하부몰드(30) 사이에 혼합물(40)이 담겨져 있는 상태가 도시되어 있으며, 도 3은 프레스가 완료된 후 성형품(41)이 형성된 상태가 도시되어 있다.In FIG. 2, a state in which the
또한, 본 발명의 성형몰드를 프레스할 때는 가열 가압 프레스하지 않고, 냉간가압 프레스하는 특징을 갖는다.Moreover, when pressing the shaping | molding mold of this invention, it does not have a hot press, but cold press press has the characteristics.
이러한 성형몰드의 형태는 기존의 성형몰드와는 구별되는 것으로 종래의 성형몰드의 경우 평평한 상부몰드(10) 또는 하부몰드(30)를 이용하여 가열 가압 성형할 때 일정한 압력이 혼합물에 가해지지 못해 제품의 기계적 강도가 균일하지 못하고, 표면이 거칠게 형성되는 것을 방지할 수 있게 된다.The shape of the molding mold is distinguished from the conventional molding mold, and in the case of the conventional molding mold, a constant pressure is not applied to the mixture when hot press molding using the flat
특히, 종래의 프레스 공정에서는 배합된 무기질바인더와 성형틀간 접착으로 성형몰드 탈형시 제품이 파손되는 문제점이 발생하나, 본 발명에서는 비가열식 프레스 방법을 적용하여 무기질바인더와 몰드간 접착을 방지하게 된다. In particular, in the conventional press process, there is a problem in that the product is damaged when the molding mold is demolded by the bonding between the blended inorganic binder and the molding die, but in the present invention, the non-heating press method is applied to prevent the bonding between the inorganic binder and the mold.
또한, 암수 형태를 갖도록 성형몰드를 형성함으로써 상부몰드(10) 또는 하부몰드(30)와 중간몰드(20)로부터 일정한 압력을 가하여 성형함으로써 판넬 전체에 걸쳐 고른 기계적 강도와 밀도를 유지할 수 있게 된다.In addition, by forming a molding mold to have a male and female form, by applying a constant pressure from the
3. 열풍건조단계3. Hot air drying step
프레스성형단계에서 수득된 성형품을 성형몰드에서 탈형한 후 롤 방식의 이동식 가압 열풍실에서 열풍 건조한다.The molded article obtained in the press molding step is demolded in a molding mold and then hot-air dried in a roll-type mobile pressurized hot air chamber.
가압 열풍실은 도 4에서 보는 바와 같이 양측에 가열가압롤러(50)가 설치된 열풍실에 성형품을 투입하여 압력을 가하면서 열풍을 가해 내부 수분을 제거한다.In the pressurized hot air chamber, as shown in FIG. 4, the hot air is applied to the hot air chamber in which the heating and
4. 적외선건조단계4. Infrared drying step
열풍건조단계에서 열풍 건조된 성형품을 가열 건조한다.In the hot air drying step, the hot air dried molded product is heated and dried.
이때, 가열 및 건조하는 방법은 적외선히터를 포함하는 적외선조사장치(60)에 의해 가열 건조하는 것을 특징으로 한다.At this time, the heating and drying method is characterized in that the heat drying by the
도면기호 70 은 적외선 조사실을 나타낸 것이고, 도면기호 80은 컨베이어 벨트다.
즉, 적외선히터를 포함하는 적외선조사장치(60)에 의해 열전도율이 낮은 질석과 무기질바인더의 수분을 빠른 시간 내에 제거하여 경화시키게 되는 것이다.That is, the
이러한 적외선히터를 포함하는 적외선조사장치(60)를 사용할 경우 열풍이나 전열식 방법에 의해 건조시킬 경우 질석의 낮은 열전도율로 인해 건조 경화 시간이 오래 소요되는 것에 비해 건조 경화 시간을 획기적으로 단축시킬 수 있게 된다.In the case of using the
본 출원의 발명자가 실험해 본 결과 적외선 조사장치를 이용할 경우 건조 경화 시간이 5 내지 10분에 불과하여 일반적인 열풍이나 전열식 건조 방법에 비해 3 내지 6배 빨리 완료되는 것을 확인하였다.As a result of experiments by the inventors of the present application, when the infrared irradiation apparatus is used, the drying curing time is only 5 to 10 minutes, and it is confirmed that it is completed 3 to 6 times faster than a general hot air or an electrothermal drying method.
5. 절단단계5. Cutting step
적외선건조단계에서 가열 건조된 성형품을 절단기를 이용하여 절단함으로써 질석불연판넬이 제조된다.Vermiculite non-combustible panel is manufactured by cutting a molded product heated in the infrared drying step by using a cutter.
이하에서 본 발명의 바람직한 실시예를 상세히 설명한다.Hereinafter, preferred embodiments of the present invention will be described in detail.
이하의 실시예들은 본 발명을 예증하기 위한 것으로 본 발명의 범위를 국한시키는 것으로 이해되어져서는 안될 것이다.The following examples are intended to illustrate the invention and should not be understood as limiting the scope of the invention.
<실시예 1> 질석불연판넬 제조1Example 1 Preparation of vermiculite nonflammable panel 1
팽창 질석 5 kg, 규산 소다 4.3 kg, 팽창 펄라이트 500 g, 카오린 200 g, 물 100 g 을 용기에 넣고 혼합한 후 교반시켜 혼합물을 제조하였다.5 kg of expanded vermiculite, 4.3 kg of sodium silicate, 500 g of expanded pearlite, 200 g of kaolin, and 100 g of water were placed in a container, mixed, and stirred to prepare a mixture.
상부몰드(10), 중간몰드(20), 하부몰드(30)를 준비한 후 도면에서 보는 것처럼 하부몰드(30) 위에 중간몰드(20)를 설치하고, 하부몰드(30)와 중간몰드(20) 사이의 공간에 혼합물을 투입한 후 그 위에 상부몰드(10)를 설치한 후 상부몰드(10)에 5,000 kg/의 압력을 가해 성형품을 제조하였다.After preparing the
이때, 중간몰드(20)와 하부몰드(30)에 의해 형성된 공간은 좌, 우 1 m의 크기로 형성되도록 하였다.At this time, the space formed by the
그런 다음 상부몰드(10), 중간몰드(20), 하부몰드(30)를 탈형한 후 양측에 롤러가 형성되어 있는 열풍실에 성형품을 투입하여 가압 롤러로 압력을 주면서 열풍 건조하였다.Then, after demolding the upper mold (10), the intermediate mold (20), the lower mold (30), the molded article was put into a hot air chamber in which rollers are formed on both sides, and hot air was dried while applying pressure with a pressure roller.
열풍실에서 나온 성형품을 정격출력 1 KW의 적외선히터가 설치된 적외선 조사실에 투입한 후 15분 동안 가열 건조하였다.The molded product from the hot air chamber was put into an infrared irradiation chamber equipped with an infrared heater with a rated output of 1 KW, and then heated and dried for 15 minutes.
이때, 최초 온도는 28도에서 승온을 시작하여 승온속도는 6.14 도/분 로 하여 200도까지 승온시켰다.At this time, the temperature was initially raised at 28 degrees, and the temperature was raised to 200 degrees at 6.14 degrees / min.
가열 건조가 끝난 성형품을 가로 세로 10 cm, 높이 15 cm 단위로 절단하여 본 발명의 질석불연판넬을 제조하였다.The vermiculite non-combustible panel of the present invention was prepared by cutting the molded product after heat drying in units of 10 cm and 15 cm in height.
이때, 적외선히터를 포함하는 적외선조사장치에 의한 성형품의 내부 및 표면온도는 표1과 같이 나타났다.At this time, the inside and the surface temperature of the molded article by the infrared irradiation device including the infrared heater are shown in Table 1.
표 1에서 보는 바와 같이 적외선히터를 포함하는 적외선조사장치에 의해 성형품을 가열, 건조할 경우 내부 및 표면 온도가 초단위로 급격하게 상승해 건조 시간이 획기적으로 단축되었다.As shown in Table 1, when the molded article was heated and dried by an infrared irradiation device including an infrared heater, the internal and surface temperatures rapidly increased in seconds, which drastically shortened the drying time.
<표 1> 적외선히터를 포함하는 적외선조사장치에 의한 성형품의 표면 및 내부 온도<Table 1> Surface and internal temperature of the molded article by the infrared irradiation device including the infrared heater
<실시예 2> 질석불연판넬 제조2Example 2 Preparation of Vermiculite Non-combustible Panel 2
실시예1과 동일하게 진행하되 적외선히터가 포함된 적외선 조사장치 대신 고온챔버에서 가열 건조하여 질석불연판넬을 제조하였다.Proceed in the same manner as in Example 1, but instead of the infrared irradiation apparatus including an infrared heater by heating in a high temperature chamber to prepare a vermiculite non-combustible panel.
<실시예 3> 질석불연판넬 제조3Example 3 Preparation of Vermiculite Nonflammable Panel 3
실시예1과 동일하게 진행하되 적외선히터가 포함된 적외선 조사장치 대신 적 외선조사만으로 가열 건조하여 질석불연판넬을 제조하였다.Proceed in the same manner as in Example 1, instead of the infrared irradiation device containing infrared heaters by heating only by infrared irradiation to prepare a vermiculite non-combustible panel.
<실시예 4> 질석불연판넬 제조4Example 4 Preparation of Vermiculite Nonflammable Panel 4
실시예1과 동일하게 진행하되 카오린 200 g 대신 탄산칼슘 200 g을 투입하여 질석불연판넬을 제조하였다.Proceed in the same manner as in Example 1 but instead of 200 g of kaolin was added to the calcium carbonate to prepare a vermiculite non-combustible panel.
<실험예 1> 가열 건조시 온도 비교<Experimental Example 1> Comparison of temperature during heat drying
실시예1 내지 실시예3에 의한 질석불연판넬 제조시 성형품의 가열, 건조할 때의 표면 및 내부 온도를 분 단위로 측정하여 비교하였다.In preparing the vermiculite non-combustible panel according to Examples 1 to 3, the surface and internal temperature of the molded product when heating and drying were measured and compared in minutes.
<표 2> 가열 건조방법의 차이에 따른 표면 및 내부 온도 비교<Table 2> Comparison of surface and internal temperature according to differences in heating and drying methods
상기 실험결과, 고온챔버, 단일 적외선조사장치, 적외선히터를 포함하는 적외선조사장치에 의한 온도상승효과를 실험한 결과, 적외선히터를 포함하는 적외선조사장치에 의해 질석판넬이 함유하는 수분 증발을 촉진하여 질석판넬의 내외부를 고르게 가열하고 경화시간을 획기적으로 단축시키는 것으로 확인되었다.As a result of the experiment, the temperature rising effect of the infrared irradiation device including the high temperature chamber, the single infrared irradiation device, the infrared heater was tested, and the water vapor contained in the vermiculite panel was promoted by the infrared irradiation device including the infrared heater. It was found that the inside and outside of the vermiculite panel was evenly heated and the curing time was significantly shortened.
본 발명은 상기에서 특정한 실시 예에 관련하여 도시하고 설명하였지만, 이하의 특허청구의 범위에 의해 마련되는 본 발명의 정신이나 분야를 벗어나지 않는 한도 내에서 본 발명이 다양하게 개조 및 변화될 수 있다는 것을 본 발명이 속하는 분야에서 통상의 지식을 가진 자는 용이하게 인지할 수 있음을 밝혀두고자 한다.While the invention has been shown and described with respect to specific embodiments above, it will be appreciated that the invention can be modified and modified in various ways without departing from the spirit or scope of the invention as set forth in the following claims. It will be apparent to those skilled in the art that the present invention can be easily recognized.
아울러, 본 발명의 질석불연판넬은 저밀도 불연판넬로 선박용 불연재료 이용됨이 가장 바람직하나 이에 한정되는 것은 아니며 각종 건물 내외장재 및 차량 및 기차 등의 내외장재로도 사용될 수 있다.In addition, the vermiculite non-combustible panel of the present invention is a low-density non-combustible panel is most preferably used as a non-flammable material for ships, but is not limited thereto, and can also be used as interior and exterior materials of various buildings, interior and exterior materials, vehicles and trains.
도 1은 본 발명의 질석불연판넬 제조방법을 도시한 공정흐름도.1 is a process flow diagram illustrating a method for preparing a vermiculite non-combustible panel of the present invention.
도 2는 본 발명의 질석불연판넬 제조방법에서 프레스 성형 전을 나타낸 단면 개략도.Figure 2 is a schematic cross-sectional view showing before press molding in the vermiculite non-combustible panel manufacturing method of the present invention.
도 3은 본 발명의 질석불연판넬 제조방법에서 프레스 성형 후를 나타낸 단면 개략도.Figure 3 is a schematic cross-sectional view showing after the press molding in the vermiculite non-combustible panel manufacturing method of the present invention.
도 4는 본 발명의 질석불연판넬 제조방법에서 열풍건조단계를 나타낸 공정 개략도.Figure 4 is a process schematic showing the hot air drying step in the vermiculite non-combustible panel manufacturing method of the present invention.
도 5는 본 발명의 질석불연판넬 제조방법에서 적외선건조단계를 나타낸 공정 개략도.Figure 5 is a process schematic showing the infrared drying step in the vermiculite non-combustible panel manufacturing method of the present invention.
<도면의 주요 부분에 대한 부호설명><Code Description of Main Parts of Drawing>
10 : 상부몰드 20 : 중간몰드10: upper mold 20: middle mold
30 : 하부몰드` 40 : 혼합물30: lower mold `40: mixture
41 : 성형품 50 : 가열가압롤러41: molded article 50: heating press roller
60 : 적외선히터를 포함하는 적외선조사장치60: infrared irradiation device including an infrared heater
70 : 적외선 조사실 80 : 컨베이어 벨트70: infrared irradiation chamber 80: conveyor belt
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KR102645800B1 (en) * | 2023-03-06 | 2024-03-12 | 김순원 | Flame retardant light stone having multi-color pattern, Manufacturing method of the same and interior and exterior materials for construction |
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KR101073787B1 (en) | 2011-03-22 | 2011-10-13 | 동화개발 주식회사 | The product method for vermiculite board |
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KR102645800B1 (en) * | 2023-03-06 | 2024-03-12 | 김순원 | Flame retardant light stone having multi-color pattern, Manufacturing method of the same and interior and exterior materials for construction |
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