JPH0585857A - Composition for inorganic foam - Google Patents

Abstract

PURPOSE:To provide a composition for inorganic foam providing inorganic foam extremely advantageously usable as a building material, etc., capable of forming inorganic foam containing uniform cells of small size, having high compression strength and flexural strength, excellent heat insulating properties, high qualities, incombustibility and non-smoking properties. CONSTITUTION:A composition for inorganic foam consists of 100 pts.wt. main material comprising 20-65 pts.wt. aqueous solution of alkali metal silicate, 15-60 pts.wt. inorganic solid component and 3-65 pts.wt. filler, 0.05-5 pts.wt. powdery metallic soap and 2-30 pts.wt. blowing agent.

Description

Detailed Description of the Invention

[0001]

INDUSTRIAL APPLICABILITY The present invention is useful as, for example, a nonflammable and smokeless building material, and an inorganic foam capable of forming an inorganic foam having a small cell size and high compressive strength and bending strength. The present invention relates to a foam composition.

[0002]

2. Description of the Related Art In general, in this type of inorganic foam, density and cell size are important factors in its quality.

Conventional inorganic foams include those composed of an alkali metal silicate aqueous solution, an inorganic solid component, a filler and a foaming agent, which are lightweight and have a low thermal conductivity, and for example, a building material such as a heat insulating material. Was used for.

[0004]

However, the conventional inorganic foams have a cell size of 1 mm or more at a low density, particularly at a density of 250 kg / m ³ or less, which can be said to be fatal as a building material of this kind. There is a problem that the compressive strength, bending strength and heat insulating property are deteriorated.

The inventors of the present invention have conducted extensive studies in order to solve the above-mentioned problems, and as a result, by adding a powdery metal soap in a predetermined ratio to the main material of the inorganic foam. It was found that the cell size of the formed inorganic foam can be reduced and high compressive strength and bending strength can be imparted, and the present invention has been completed.

The object of the present invention is to reduce the bubble size,
It is an object of the present invention to provide a composition for an inorganic foam, which has high compressive strength, bending strength, and excellent heat insulation and is capable of forming a noncombustible and smokeless inorganic foam of high quality.

[0007]

In order to achieve the above-mentioned object, the present invention provides an alkali metal silicate aqueous solution 20-6.
5 parts by weight, 15 to 60 parts by weight of inorganic solid components, and 100 parts by weight of a main material consisting of 3 to 65 parts by weight of a filler, 0.05 to 5 parts by weight of powdered metal soap, and 2 to 30 parts by weight of a foaming agent. The gist is a composition for an inorganic foam, which comprises a part.

Here, as the alkali metal silicate aqueous solution, an aqueous solution of potassium silicate, sodium silicate, or a mixture thereof is used.

The composition of such an aqueous solution is SiO ₂ and K
₂ O, SiO ₂ and Na ₂ O, or SiO ₂ and K ₂ O +
Na ₂ O having a molar ratio of 1.0 to 3.0
And the concentration of the aqueous solution is preferably in the range of 30 to 60%.

As the above inorganic solid components, amorphous SiO _{2 of 2 to} 98% by weight and Al ₂ O ₃ 98 to ₂ % by weight are used.
An oxidation mixture containing is used.

As such an oxidizing mixture, for example, dust generated during the production of metakaolin, corundum or mullite, crushed bauxite, fly ash, etc. can be used.

For example, in the case of dust from a corundum manufacturing furnace, 20 to 80% by weight of amorphous SiO ₂ and Al ₂ O ₃ 8
An oxidation mixture consisting of 0 to 20% by weight is contained in an amount of 50% by weight or more, and the balance is Fe ₂ O ₃ , TiO ₂
Etc.

As the above-mentioned filler, pulverized or finely divided inorganic substances such as rock powder, basalt, mica, silica sand, glass powder, alumina, aluminum hydroxide, talc, calcium carbonate, kaolin and other clays, fiber materials Various other inert or water-insoluble minerals can be used. These fillers are appropriately selected according to the use of the inorganic foam, and are used alone or as a mixture.

As the foaming agent, so-called sodium perborate, hydrogen peroxide solution, or inactivated or non-inactivated form of aluminum powder is advantageous. The amount of the foaming agent is appropriately determined depending on the density of the foam, the strength of the foam to be obtained, and the type of the foaming agent.

The above-mentioned metal soap refers to metal salts other than alkali metal salts such as fatty acids and aromatic acids. The main metal soaps are
Aluminum, manganese, cobalt, lead, calcium,
Soaps such as chromium, copper, iron, mercury, magnesium, zinc and nickel are listed.

Examples of the fatty acids and aromatic acids forming these metal soaps include stearic acid, lauric acid,
Examples thereof include ricinoleic acid, naphthenic acid, 2-ethylhexylic acid, and salicylic acid. You may use these metal soaps individually or in mixture of 2 or more types.

In the present invention, such a metal soap is blended with respect to a nonflammable and smokeless inorganic foam in order to improve the compressive strength and bending strength, or the heat insulating property.

The blending ratio of the composition for an inorganic foam according to the present invention is 20 to 65 parts by weight of an aqueous alkali metal silicate solution,
Inorganic solid component 15 to 60 parts by weight, and filler 3 to 65
The main component is 100 parts by weight, the powdery metal soap is 0.05 to 5 parts by weight, and the foaming agent is 2 to 30 parts by weight.

Here, the mixing ratio of the alkali metal silicate aqueous solution, which is the main material of the inorganic foam, the inorganic solid component and the filler is appropriately determined depending on the use and density of the inorganic foam.

In the present invention, the powdery metal soap is blended in an amount of 0.05 to 5 parts by weight with respect to 100 parts by weight of the main material of the inorganic foam.

Here, the mixing ratio of the metal soap is 0.05.
If the amount is less than parts by weight, the amount of addition is small, so that the cell size of the inorganic foam formed is, for example, about 2 mm at a density of 250 kg / m ³ , and at a density of less than 250 kg / m ³ , However, it is not preferable because it does not exhibit sufficient strength and heat insulation.

On the other hand, if the mixing ratio of the powdery metal soap exceeds 5 parts by weight, the viscosity of the composition for an inorganic foam becomes too high to form an inorganic foam having a uniform cell size. It is not preferable. It is not preferable that the amount of metal soap exceeds 5 parts by weight from the viewpoint of nonflammability and smokelessness.

From the composition for an inorganic foam according to the present invention,
In order to produce an inorganic foam as a building material, first, an inorganic solid component that is a solid component in the composition, a filler, and a powdered metal soap, and if necessary, an appropriate amount of a pigment are added and mixed. Then, an aqueous solution of an alkali metal silicate, which is a liquid component, is added to this, and the mixture is kneaded until the solid component is sufficiently dispersed. After that, a foaming agent is added and kneading is performed until it is sufficiently dispersed.

The inorganic foam raw material kneaded product thus obtained is then poured into a predetermined mold and heated from room temperature to 100 ° C. for 1 to 4 hours to form an inorganic foam having a predetermined shape. is there.

[0025]

According to the above-mentioned composition for an inorganic foam, powdery metal soap is prescribed for the main material of the inorganic foam comprising the alkali metal silicate aqueous solution, the inorganic solid component and the filler, and the foaming agent. By blending in a ratio, an inorganic foam containing uniform and small-sized cells can be formed, and its compressive strength, bending strength and heat insulating property can be greatly improved.

[0026]

EXAMPLES Next, examples of the present invention will be described together with comparative examples.

Examples 1 to 6 K ₂ O 15.3 wt%, Na ₂ O 7.7 wt%, S
44.9 parts by weight of an aqueous solution of potassium sodium silicate having a composition of 24.9% by weight of iO _{2 and} 52.1% by weight of H ₂ O, 22.5 parts by weight of metakaolin, and 22.5 parts of filter dust during corundum production. 100 parts by weight of the main material composed of 1 part by weight, 6.0 parts by weight of talc, and 4.1 parts by weight of mica, powdered calcium stearate as metal soap (Examples 1 to 3) and powdered aluminum stearate. (Examples 4 to 6) were blended in the proportions shown in Table 1.

Then, this blend was thoroughly kneaded using a hand mixer in a container having a volume of 1000 cc.
Then, 10.0 parts by weight of hydrogen peroxide solution having a concentration of 10% by weight was added as a foaming agent to 100 parts by weight of the main material and mixed to prepare an inorganic foam composition according to the present invention.

Here, a filter for corundum production
Dust is 50% by weight of amorphous SiO ₂ and Al ₂ O ₃
25% by weight and the balance Fe ₂ O ₃ and TiO _{2 and the} like.

Next, after the foaming of the composition for an inorganic foam was completely completed, the composition was cured by heating in an oven at 50 ° C. for 4 hours.

After the curing was completed, the formed inorganic foam was cooled to room temperature in the container and taken out from the mold. Cut the obtained inorganic foam into a size of 50 mm × 50 mm × 50 mm,
After sufficiently dried in an oven at 50 ° C, density, bubble size, and compressive strength (according to JIS A9514)
Was measured, and the obtained results are summarized in Table 1.

Comparative Examples 1 to 3 These comparative examples are almost the same as those in Examples 1 to 3 above, except that the amount of powdery calcium stearate added is outside the range of the present invention. There is a point.

The inorganic foam compositions of these comparative examples were molded in the same manner as in Example 1 above.

After the curing was completed, the formed inorganic foam was cooled to room temperature in the container and taken out from the mold. After cutting this inorganic foam into a predetermined size, the density, cell size, and compressive strength were measured in the same manner, and the obtained results are also shown in Table 1.

[0035]

[Table 1]

As is clear from the results shown in Table 1 above, according to the compositions for inorganic foams of Examples 1 to 6 of the present invention, the inorganic foam composed of the alkali metal silicate aqueous solution, the inorganic solid component, and the filler was used. Since the metal soap is blended in a predetermined ratio with respect to the main material of the body and the foaming agent, there is no change in the density, yet it is possible to form an inorganic foam having a small cell size, Therefore, the compressive strength was high and the heat insulating property was improved.

On the other hand, in the inorganic foams of Comparative Examples 1 to 3 in which the amount of the powdery metal soap added was out of the range of the present invention or not added at all, the bubble size was large, and therefore the compression was performed. The strength was extremely low, and improvement of heat insulation was impossible.

Although detailed description is omitted, the bending strength of the inorganic foams obtained from the compositions for inorganic foams of Examples 1 to 6 and Comparative Examples 1 and 3 was measured. The inorganic foams of Examples 1 to 6 had high flexural strength, while the inorganic foams of Comparative Examples 1 to 3 had low flexural strength.

[0039]

The composition for an inorganic foam according to the present invention comprises:
As described above, 20 to 65 parts by weight of the alkali metal silicate aqueous solution, 15 to 60 parts by weight of the inorganic solid component, and the filler 3
To 65 parts by weight of the main material, 0.05 to 5 parts by weight of powdered metal soap, and 2 to 30 parts by weight of a foaming agent, According to this, it is possible to form a high-quality non-combustible and smoke-free inorganic foam which has uniform and small size bubbles, has high compressive strength and bending strength, and has excellent heat insulation. The obtained inorganic foam has an effect that it can be used extremely advantageously as a building material or the like.

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Claims (1)

[Claims] 1. An alkali metal silicate aqueous solution of 20 to 65 parts by weight, an inorganic solid component of 15 to 60 parts by weight, and a filler 3.
A composition for inorganic foams, which comprises 100 parts by weight of a main material consisting of ˜65 parts by weight, 0.05 to 5 parts by weight of powdered metal soap, and 2 to 30 parts by weight of a foaming agent.