JPH0648861A - Composition for inorganic foamed body - Google Patents

Abstract

PURPOSE:To decrease and control the foaming time of the compsn. and to stabilize quality of the foamed body by compounding a specified amt. of copper or copper compd. to the principal material consisting of alkali metal silicate soln., inorg. solid component, and filler. CONSTITUTION:This compsn. for inorg. foamed body consists of 100 pts.wt. of the principal material, 0.01-5 pts.wt. of copper or water-insoluble copper compd., and 2-30 pts.wt. of foaming agent. The principal material consists of 20-65 pts.wt. of alkali metal silicate aq. soln., 15-60 pts.wt. of inorg. solid component, and 0-65 pts.wt. of filler. Instead of the copper or water-insoluble copper compd., 0.01-5 (X10<-3>) pts.wt. of water-soluble copper compd. may be used. By compounding these compds. into the principal material, the foaming time of the compsn. for inorg. foamed body is decreased and a uniform inorg. foamed body having specified density can stably be produced.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an inorganic foam composition for forming an inorganic foam useful as a nonflammable and smokeless building material.

[0002]

2. Description of the Related Art Conventionally, in manufacturing an inorganic foam of this type, the time required from immediately after mixing the constituent materials of the composition for an inorganic foam to the completion of foaming varies depending on the type of the inorganic solid component. It ranged from 10 seconds to several hours. On the other hand, the time required for the inorganic foam to be sufficiently cured immediately after mixing the constituent materials of the same composition also varies depending on the type of the inorganic solid component or the ambient temperature during curing. At a temperature of 25 ° C., the range was from several minutes to several tens of hours.

[0003]

However, if the foaming time is longer than the curing time, the mixed composition will start to cure or will cure again during foaming to obtain a homogeneous inorganic foam having a predetermined density. Therefore, there is a problem that a stable production of an inorganic foam cannot be performed.

Thus, in the production of the inorganic foam,
The foaming time of the composition for an inorganic foam must be shorter than the curing time of the composition, and the shortening of the foaming time is also necessary for shortening the manufacturing time of the inorganic foam. That is, by shortening and controlling the foaming time of the composition for an inorganic foam, it is possible to improve the quality stability and productivity of the inorganic foam.

As a result of intensive studies in view of the above points, the present inventors have found that copper or water-insoluble copper is added to an inorganic foam main material composed of an alkali metal silicate aqueous solution, an inorganic solid component and a filler. By compounding a compound or a water-soluble copper compound in a predetermined ratio, the foaming time of the composition for an inorganic foam can be shortened, and the foaming time of the composition must be shorter than the curing time of the same composition. After finding out what to obtain, the present invention has been completed.

The object of the present invention is to solve the above-mentioned problems of the prior art, to shorten and control the foaming time, and to produce a homogeneous inorganic foam having a predetermined density very stably. The present invention is intended to provide a composition for an inorganic foam, which can be made of:

[0007]

In order to achieve the above-mentioned object, the first aspect of the present invention is to provide 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 filling. Base material 100 consisting of 0 to 65 parts by weight of agent
The gist is a composition for an inorganic foam, which comprises 1 part by weight, 0.01 to 5 parts by weight of a copper or water-insoluble copper compound, and 2 to 30 parts by weight of a foaming agent.

Next, the second invention is 100 parts by weight of a main material consisting of 20 to 65 parts by weight of an aqueous alkali metal silicate solution, 15 to 60 parts by weight of an inorganic solid component, and 0 to 65 parts by weight of a filler, and a water-soluble material. The gist is a composition for an inorganic foam, which comprises 0.01 to 5 (× 10 ⁻³ ) parts by weight of a copper compound and 2 to 30 parts by weight of a foaming agent.

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 +
The molar ratio of Na ₂ O is 1.0 to 3.0, and the concentration of the aqueous solution is preferably 30 to 60% by weight.

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

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

For example, corundum furnace dust is amorphous S
50% by weight or more of an oxidation mixture composed of 20 to 80% by weight of iO _{2 and} 80 to 20% by weight of Al ₂ O ₃ is contained, and the balance is Fe ₂ O ₃ , TiO _{2, and the} like.

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

As the foaming agent, so-called sodium perborate and hydrogen peroxide solution are advantageous. The amount of the foaming agent is appropriately determined depending on the density of the inorganic foam, the strength of the inorganic foam to be obtained, and the type of the foaming agent.

In the first invention of the present invention, the copper used as the foaming accelerator is preferably a fine powder. Further, examples of the water-insoluble copper compound include copper (I) oxide and copper (II) oxide.

Further, in the second invention, the water-soluble copper compound used as the foaming accelerator is copper (I) chloride or copper (I) chloride.
I) and their hydrates, copper (I) sulfate, copper sulfate (I
I) and their hydrates.

These copper and copper compounds are usually used alone, but a plurality of types may be mixed and used.

The copper and the water-insoluble copper compound are effective even if added in any form.
It is most effective and desirable to add it as a fine powder.

In the case of a water-soluble copper compound, the effect is exhibited in any form, but since it is added in a very small amount, it may be added as an aqueous solution or as an inorganic solid component, a filler, etc. Addition in a state where the powder is uniformly dispersed and supported is most effective and desirable.

The composition for an inorganic foam according to the present invention is added to 100 parts by weight of a main material composed of 20 to 65 parts by weight of an alkali metal silicate aqueous solution, 15 to 60 parts by weight of an inorganic solid component, and 0 to 65 parts by weight of a filler. On the other hand, in the first invention, 0.01 to 5 parts by weight of copper or a water-insoluble copper compound is used as the foaming accelerator, and in the second invention, the water-soluble copper compound is used in the range of 0.01 to 5 (x) as the foaming accelerator. 10 ^-3 ) parts by weight, respectively. Further, in any case, the foaming agent is blended in a proportion of 2 to 30 parts by weight.

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

In the first invention, if the compounding ratio of copper or water-insoluble copper compound is less than 0.01 parts by weight,
Further, in the second invention, if the blending ratio of the water-soluble copper compound is less than 0.01 × 10 ⁻³ parts by weight, no sufficient effect of promoting foaming can be obtained, and the foaming rate does not change.

In the first invention, the compounding ratio of copper or the water-insoluble copper compound exceeds 5 parts by weight, or in the second invention, the compounding ratio of the water-soluble copper compound is 5 × 1.
If it exceeds 0 ^-3 parts by weight, the effect of promoting foaming is too great,
It is not suitable because the foaming time becomes too short and predetermined operations such as kneading and molding cannot be performed.

That is, the amount of the foaming accelerator added is in the range of 0.01 to 5 parts by weight (copper or water-insoluble copper compound) in the case of the first invention, and in the case of the second invention. , 0.
By varying each within the range of 01 to 5 (× 10 ^-3 ) parts by weight (water-soluble copper compound), the foaming rate can be arbitrarily changed and the foaming time can be shortened.

In order to produce an inorganic foam from the composition for an inorganic foam according to the present invention, first, in the first invention, an inorganic solid component, a filler, and a copper or copper component which are solid components in the composition. A solid foaming accelerator consisting of a water-soluble copper compound, and if necessary, an appropriate amount of a pigment are added and mixed, and then an aqueous solution of an alkali metal silicate which is a liquid component is added to the mixture so that the solid component is sufficiently mixed. Knead until dispersed.
Then, a foaming agent is added and kneading is carried out until it is sufficiently dispersed. In the second invention, an inorganic solid component which is a solid component in the composition, a filler and, if necessary, an appropriate amount of a pigment are added and mixed, and then a liquid component of alkali metal silicate is used. A liquid foaming accelerator consisting of an aqueous solution and an aqueous solution of a water-soluble copper compound is added and kneaded until the solid components are sufficiently dispersed. Then, a foaming agent is added and kneading is carried out until it is sufficiently dispersed. In addition, since the addition of the water-soluble copper compound is very small, it may be carried evenly in the powder such as the inorganic solid component or the filler, and in such a case, the water-soluble copper compound is added. The supported inorganic solid component or powder such as filler may be mixed as a solid component in the same manner as in the case of the first invention.

The first invention or the second invention thus obtained
The kneaded product for inorganic foam of the invention is then poured into a predetermined mold, and after foaming is completed, at room temperature or at room temperature to 100%.
The inorganic foam having a predetermined shape is formed by reacting and curing for 10 minutes to 4 hours by heating up to ℃.

[0028]

According to the above-mentioned composition for inorganic foam, copper, water-insoluble, as a foaming accelerator is added to the main material of the inorganic foam, which comprises the aqueous alkali metal silicate solution, the inorganic solid component and the filler, and the foaming agent. By blending a water-soluble copper compound or a water-soluble copper compound in a predetermined ratio, the foaming time of the composition for an inorganic foam can be shortened, and the foaming time of the composition must be shorter than the curing time of the composition. Thus, a homogeneous inorganic foam having a predetermined density can be stably produced.

[0029]

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

Examples 1 to 7 K ₂ O 15.3 wt%, Na ₂ O 7.7 wt%, S
An aqueous solution of alkaline salt water (A) having a composition of 24.9% by weight of iO _{2 and} 52.1% by weight of H ₂ O, metakaolin (B) as an inorganic solid component, talc (C) and mica as a filler (D). ) And 100 parts by weight of the main material as a foaming accelerator, copper fine powder (E1), copper oxide (II) (E2) or 0.05
M Copper (II) chloride dihydrate aqueous solution (E3) and 10 as a foaming agent
An aqueous solution (F) of hydrogen peroxide solution having a concentration of wt% was prepared for each example in the mixing ratio shown in Table 1.

First, for each example, the inorganic solid component (B), the fillers (C) and (D), and the foaming accelerator (E
1) or (E2) is put in a container and mixed using a hand mixer, and then an alkali metal silicate aqueous solution (A) and, if the foaming accelerator is (E3), this (E3) is added together. Kneaded well. After that, a foaming agent (F) was added to each of the examples, and the mixture was quickly kneaded and then poured into a predetermined mold. After visually confirming completion of foaming, sealing was performed, and the temperature was adjusted to 50
The foamed molded product was cured in an oven at ℃.

Here, the time from immediately after casting to visually confirming the completion of foaming is measured as the foaming time,
In addition, the time from immediately after casting to the completion of curing was measured as the curing time and shown in Table 1 below.

After the curing was completed, the formed inorganic foam was cooled to room temperature in the container and taken out from the container. The obtained inorganic foam was cut into a size of 50 mm × 50 mm × 50 mm with a band saw, and the density was measured.

Further, the appearance of the inorganic foam was visually observed, and those having uniform and almost spherical cells were evaluated as ◯ (good), and those having nonuniform or flat shape were evaluated as x (bad). The results of density and appearance are also shown in Table 1.

Comparative Examples 1 to 7 These comparative examples are almost the same as those of the compositions for inorganic foams of Examples 1 to 7 above, except that in Comparative Example 1, first, the foaming accelerator is used. There is no addition of. Next, in Comparative Examples 2, 4 and 6, the amount of the foaming accelerator added was smaller than that in the range of the present invention, and in Comparative Examples 3, 5 and 7, the amount of the foaming accelerator added was conversely large. There is a point.

With respect to the compositions for inorganic foams of these comparative examples, the inorganic foams were molded in the same manner as in Examples 1 to 7 above, and the foaming time and the curing time were measured. The density of the obtained inorganic foam was measured and the appearance was observed, and the obtained results are summarized in Table 1 below.

In Comparative Examples 3, 5 and 7,
Immediately after adding the foaming agent, foaming occurred instantaneously, sufficient kneading could not be performed, and an inorganic molded body having a predetermined shape could not be formed.

[0038]

[Table 1] As is clear from the results in Table 1 above, according to the inorganic foam compositions of Examples 1 to 7 according to the present invention, the foaming time was sufficiently shorter than the curing time in each case, and therefore the predetermined density was obtained. It is possible to stably produce a homogeneous inorganic foam having, and according to Examples 1 to 7, the cells are almost spherical and homogeneous in all cases, and the appearance quality is clearly higher than that of the comparative example. It was possible to form an excellent inorganic foam.

Moreover, according to the embodiment of the present invention, the foaming time can be freely controlled by increasing or decreasing the amount of the foaming accelerator added within the range of the present invention.
It is clear that it can greatly contribute to the productivity and production stability of the inorganic foam.

[0040]

The composition for an inorganic foam according to the present invention comprises:
As described above, the first aspect of the present invention is as follows. First, 100 parts by weight of a main material consisting of 20 to 65 parts by weight of an aqueous alkali metal silicate solution, 15 to 60 parts by weight of an inorganic solid component, and 0 to 65 parts by weight of a filler, copper or It is composed of 0.01 to 5 parts by weight of a water-insoluble copper compound and 2 to 30 parts by weight of a foaming agent,
The second invention is that the alkali metal silicate aqueous solution 20-65.
Parts, 15 to 60 parts by weight of the inorganic solid components, and a main member 100 parts by weight consisting of fillers from 0 to 65 parts by weight, the water-soluble copper compound 0.01~5 (× 10 ^-3) parts by weight, foaming Agent 2
According to the present invention, in any case, the foaming time of the composition for an inorganic foam can be shortened, and the foaming time of the composition is always higher than the curing time of the composition. Not only can it be shortened, but the foaming time can be controlled freely, and a homogeneous inorganic foam with a specified density can be manufactured very stably, and the quality of the inorganic foam can be stabilized. The effect of improving productivity and productivity can be achieved.

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Claims (2)

[Claims] 1. An alkali metal silicate aqueous solution 20 to 65 parts by weight, an inorganic solid component 15 to 60 parts by weight, and a filler 0.
To 65 parts by weight of the main material, 0.01 to 5 parts by weight of copper or a water-insoluble copper compound, and blowing agents 2 to 3
A composition for an inorganic foam, which comprises 0 part by weight. 2. An alkali metal silicate aqueous solution 20 to 65 parts by weight, an inorganic solid component 15 to 60 parts by weight, and a filler 0.
To 65 parts by weight of the main material, 0.01 to 5 (× 10 ⁻³ ) parts by weight of a water-soluble copper compound, and a foaming agent 2 to
An inorganic foam composition comprising 30 parts by weight.