RU2315024C2 - Method of molding building materials mainly containing magnesium oxide - Google Patents

Abstract

FIELD: molding building materials mainly containing magnesium oxide.

SUBSTANCE: proposed method includes the following stages: mixing of magnesium oxide powder with vegetable or mineral powder at definite ratio; adding water to mixture thus obtained for forming moist powder-like mixture; delivery of moist powder-like mixture to preheated casting mold; then, said moist mixture is heated and molded at temperature of from 80 C to 120 C and pressure of from 100 to 250 kgf/cm² for quick hardening of mixture, after which product is withdrawn from mold. Specification gives description of version of molding the building materials in frame-shaped casting mold of casting machine.

EFFECT: enhanced strength and refractoriness of material; avoidance of toxic vapor emissions in the course of sintering; low cost of materials manufactured by pressure molding or extrusion.

4 cl, 6 dwg, 1 tbl

Description

Technical field

The present invention relates to a method for forming building materials consisting mainly of magnesium oxide, and in particular, to a method for forming building materials consisting mainly of magnesium oxide, in which a mixture consisting mainly of magnesium oxide quickly cures in molding the machine, while the injection or extrusion form, each, have a heater, which helps to increase the strength of building materials. The method of the present invention has the advantage that double-sided molding and precise casting of such materials is feasible when the casting processes cannot be completed in the usual way, while the method of forming building materials is simplified and its processing time is reduced, and building materials are inexpensive and their production is increased .

State of the art

Typically, the structure includes a frame, and internal and external decoration. Various types of buildings are known. Typically, examples of frames include reinforced concrete, steel frames, wood, brick frames, and examples of external and internal finishes include plaster, wood, synthetic resin and foam.

The frame and interior and exterior decoration must have corrosion resistance, heat resistance, fire resistance, insulating properties, as well as sufficient strength to withstand the weight of the building and external influences.

Refractoriness of building materials is considered a very important property, but for most building materials there is a safety problem, namely, they are highly flammable and emit toxic fumes when heated to an extreme temperature, or higher, even if they are refractory, which leads to death from suffocation. Therefore, buildings containing traditional building materials are not safe. In particular, the above-mentioned disadvantages characterize synthetic resin products used as building materials.

Many attempts have been made to solve the safety problems arising in the event of a fire. For example, restrictions on compliance with building codes are being tightened. Building materials capable of resolving safety problems are materials consisting mainly of magnesium oxide.

Magnesium oxide, in accordance with the present invention, is used both as a main component of building materials, and in the case when a powder of plant origin, such as sawdust, is added to the magnesium oxide, and the resulting mixture is cured. The resulting building material has excellent physical properties. Moreover, magnesium oxide has a low weight and high strength, and is a non-flammable material. Thus, building materials, consisting mainly of magnesium oxide, help solve fire safety problems and do not emit toxic fumes.

However, despite the fact that magnesium oxide has various advantages, building materials, consisting mainly of magnesium oxide, are not produced commercially, but are created only experimentally, in small quantities. The reason for this is the difficulty in obtaining such building materials by a person skilled in the art.

The traditional method of forming building materials, consisting mainly of magnesium oxide, involves the steps of mixing magnesium oxide with sawdust, chloride as a curing agent, and water, feeding the resulting mixture into a mold, transporting the resulting casting to a room where a sufficiently high temperature is maintained to cure the mixture within a predetermined time, and removing the molded product from the mold (i.e., a method of casting concrete into the mold).

The traditional method is disadvantageous, since building materials are molded in several stages using many forms, this requires significant labor and human costs, as well as reduced production of building materials. Another inconvenience of the traditional method is that the two-sided molding and precise casting of such building materials cannot be completed due to the parameters of the curing process, in which the mixed material is cast into a mold.

As described above, even though magnesium oxide has various advantages, building materials, mainly consisting of magnesium oxide, are obtained, mainly due to the fault of the performer, in an unfavorable way, and are not widely used in construction due to the shortcomings of the traditional method of molding such materials, and only experimentally molded in small quantities.

The reason for this is that all efforts are concentrated on the initial task of molding building materials, mainly consisting of magnesium oxide, in order to reduce the weight of the concrete product. The main idea, according to which building materials, consisting mainly of magnesium oxide, are molded by the injection process as a concrete structure, is widely known from the literature.

In fact, the basic idea is considered acceptable, since the cement does not cure even if it is heated and compressed in the mold after it is mixed with various powders and water. However, the inventor of the present invention has conducted many studies in order to improve the molding method of building materials consisting primarily of magnesium oxide, resulting in improved molding of building materials containing magnesium oxide instead of cement in commercial quantities.

In the course of these studies, the inventor has created several useful inventions that have received the following patents, and the present invention is based on the inventions of these patents.

1. Korean Patent No. 109507: Device for the continuous molding of building materials and a method for molding them.

2. Korean Patent No. 085731: Device for the continuous molding of building materials from concrete.

3. Korean Patent No. 102883: A device for the continuous molding of building materials.

4. Korean Patent No. 102884: A device for the continuous molding of building materials.

5. Korean Patent No. 102885: Device for the continuous molding of building materials from concrete.

6. Patent US 5756131: Device for continuous casting of building materials.

7. JP 2620057: A device for the continuous casting of building materials.

8. Chinese Patent No. 43518: Device for continuous casting of building materials.

9. Chinese Patent No. 44712: Device for continuous casting of building materials.

10. Korean Patent No. 109503: Method for molding a concrete PC panel and device for molding it.

11. JP patent No. 2780874: Method for forming a concrete PC-panel and a device for its molding.

12. China Patent No. 43642: Method for molding a concrete PC panel and device for molding it.

13. Indian Patent No. 181764: Method for molding a concrete PC panel and device for its molding.

14. Patent AU 687070: Method for molding a concrete PC panel and device for molding it.

SUMMARY OF THE INVENTION

The present invention was created to solve the above problems noted in the analysis of the prior art. The aim of the present invention is to provide a method for molding building materials consisting of non-combustible magnesium oxide having a melting point of 2850 ° C as a main component, and from a powder of vegetable or mineral origin as an additional component, where a mixture of magnesium oxide with a powder of vegetable or mineral origin mixes with water and cures during compression molding, injection molding or extrusion process, as a result of which can be obtained oitelnye materials with excellent physical properties and economic efficiency.

Another object of the present invention is a method for forming building materials, consisting mainly of magnesium oxide, in which an increase in productivity is achieved due to simplification of the technology and reduction of the time required for forming building materials, for example, by eliminating the process of transporting the mixture to the room for curing. Thus, fewer workers can efficiently and quickly mold building materials than with the conventional method of molding building materials.

Based on the present invention, a method for molding building materials consisting essentially of magnesium oxide is claimed, comprising the steps of mixing magnesium oxide with a powder of vegetable or mineral origin in a predetermined ratio to form a mixture; adding water to this mixture to obtain a wet powder mixture; introducing a wet powder mixture into a concave frame shape consisting of a frame shape and a preheated lower injection mold, and heating and compressing the wet powder mixture with a preheated upper injection mold, and curing the mixture, and removing the resulting product from the injection machine.

Further, in accordance with the present invention, a method for forming building materials, consisting mainly of magnesium oxide, comprising the steps of obtaining a mixture by mixing a powder of magnesium oxide with a powder of vegetable or mineral origin; selectively adding water to said mixture in such an amount that the mixture can be used in a pressure molding method to produce a wet mixture, for example a mortar; supplying the wet mixture from the high pressure nozzle through the inlet to the inside of the molding machine; curing this mixture by means of a heater located in each of the injection molds and removing the resulting product from the molding machine.

In addition, this invention provides a method for molding building materials, consisting mainly of magnesium oxide, comprising the steps of mixing a powder of magnesium oxide with a powder of vegetable or mineral origin to form a mixture; selectively adding water to said mixture in such an amount that the resulting wet mixture can be used in a pressure compression method; extruding the wet mixture to give the product the desired shape using an extruder, and passing the resulting product through a heater located in front of the outlet of the extruder to cure the resulting product.

Brief Description of the Drawings

The above and other objects, features and preferences of the present invention will be better understood from the following detailed description, and the related drawings, where

1a-1c are schematic sectional views illustrating a phased operation of a compression molding machine used in a method for molding building materials consisting mainly of magnesium oxide in accordance with the present invention;

FIG. 2 is a sectional view of an injection molding machine used in a method for molding building materials consisting primarily of magnesium oxide in accordance with the present invention;

Figure 3 is a cross-sectional view of an extrusion molding machine used in a method for molding building materials consisting primarily of magnesium oxide in accordance with the present invention;

Figure 4 is a fragmentary view in the direction of the arrows along line AA of Figure 3.

The best embodiment of the invention

In accordance with the present invention, high-quality building materials are obtained using fine-grained magnesium oxide as the main component.

Further, the material of plant origin used as an additional component is selected from the group consisting of powdered wood waste, sawdust, powder of finely chopped straw, powder of rice straw, powdered leaves or stems of various plants, for example corn, and plant fibers, for example, chopped pulp or rice straw, according to the types of building material. Further, a material of mineral origin used as an additional component is selected from the group consisting of mineral powder, for example rock powder, volcanic ash, loose foamed perlite powders, and mineral fibers such as fiberglass, in accordance with physical properties such as strength, fire resistance , non-flammability, soundproofing and insulating properties, as well as wear resistance of this building material.

As mentioned above, under the powder of plant or mineral origin, used in the present invention as an additional component, is meant plant fibers, such as rice straw and cellulose, and mineral fibers, for example glass fiber.

The authors of the present invention conducted research on a method of forming building materials consisting mainly of magnesium oxide, as a result of which it was found that when the mixture obtained by mixing the magnesium oxide powder with a powder of vegetable or mineral origin and water is fed into a pre-heated injection mold and pressed, then there is a rapid change in the physical properties of the mixture. In other words, in contrast to expectations, magnesium oxide quickly cures with moisture in an injection mold at 100 ° C under a pressure of 100 kg / cm ² and acts on a powder of mineral or vegetable origin as a strong binder, thereby increasing the strength of the product. At the same time, the higher the pressure, the denser the structure.

Based on the fact that it was found that wet magnesium oxide is pressed and quickly cures when heated and pressure, while exhibiting significant adhesion, the inventors of the present invention have discovered a method for molding building materials consisting mainly of magnesium oxide by changing physical properties building materials under the influence of heat and pressure.

According to this invention, the ratio of magnesium oxide, as the main component, and powder of plant or mineral origin, as an additional component, depends on the characteristics and physical properties of the building material. In addition to the mixture, consisting mainly of magnesium oxide, various additives can be added in accordance with the required physical properties of the building material. For example, a hydrophobizing agent can be added to the mixture to improve the moisture-proofing properties of the building material, and additives can also be added to improve the ductility of the building material, which will vary depending on the molding method, such as compression molding, injection molding and extrusion molding.

Meanwhile, in accordance with the traditional method of forming building materials using magnesium oxide, chloride is used as a curing agent, but it has the ability to absorb moisture from the air, that is, deliviscence, and therefore the surface of the building material obtained in the usual way leaves a feeling of moisture . However, in accordance with this invention, the above disadvantages of the conventional method are eliminated by using a building material, consisting mainly of magnesium oxide, without a curing agent - chloride.

As described above, a method for forming building materials consisting mainly of magnesium oxide is characterized in that magnesium oxide is used as the main component, and fine-grained powder of plant origin, such as sawdust, or of mineral origin, such as volcanic ash, is selectively added to magnesium oxide.

In accordance with the claimed method of forming building materials, consisting mainly of magnesium oxide, magnesium oxide is used as the main component of the building material. If there is a need for a building material with a wood texture, then a powder of plant origin such as sawdust is added to magnesium oxide.

On the other hand, when building material is mainly characterized by non-flammability, heat and sound insulation, and low mass is required, then mineral powder such as slag or volcanic ash is added to magnesium oxide in combination with water in an appropriate ratio.

In particular, together with powders of plant or mineral origin, various powdery materials, such as fibrous material, can be added to magnesium oxide to obtain a building material. Further, the ratio in the mixture of magnesium oxide and powder of vegetable or mineral origin according to the present invention is not limited, since this ratio freely changes depending on the physical properties of the building material.

In other words, the mixed ratio of the components and the type of additional components serve to illustrate and not limit the present invention.

In addition, limiting the temperature and molding pressure to a specific value in the molding method of the building materials of this invention is neither preferred nor possible.

For example, when products are being molded that require large-sized molds, such as doors, the molding mixture is prone to drying due to the relatively long time it takes to fill the mold with the mixture, therefore, it is preferable to mold such molds at low temperature. With regard to pressure, in the manufacture of an insulating board or soundproof panel using light porous volcanic ash, it is preferable that they be manufactured under reduced pressure in order to prevent pores from flattening out of the volcanic ash.

It should be noted that all drawings use the same numbering to refer to similar or similar components.

According to a first embodiment of the invention, 20% by weight of sawdust and 30% by weight of water are added to 50% by weight of magnesium oxide powder to form a mixture. This mixture is fed into a conventional extrusion molding device, consisting of upper and lower injection molds, aged for 2-5 minutes at 100 ° C and a pressure of 100 kg / cm ² , and removed from this device. The resulting product has a flat surface and high strength, like a board.

According to a second embodiment of the present invention, a mixture having the same composition as in Example 1 is molded using the manufactured molding machine M.

In accordance with figa, the molding machine M, according to the present invention, contains the upper 1 and lower 2 injection mold, as well as the frame form 3. The upper form 1 is located in the upper part of the press, which moves vertically, and the frame form 3, fixed in the middle part of the press, has the same cross-sectional shape as the product profile. That is, when the product has a rectangular section, the frame shape 3 also has a hollow rectangular section, and when the product is a cylinder in the section, the frame shape 3 also has a hollow cylindrical section. Further, the part protruding from the bottom of the upper injection mold 1 has the same sectional shape as the hollow frame mold 3, and thus the upper injection mold 1 works like a piston. The lower mold 2 is located in the lower part of the press, moving vertically.

On figa-1B molding machine M is shown, provided that the product has a cylindrical profile. As follows from figb, the hollow cylindrical frame form 3 slides forward on the lower injection mold 2 and forms a concave injection mold assembly.

A mixture of magnesium oxide 5 with water and sawdust is fed into a concave injection mold, pressed by vertical movement of the upper injection mold 1, so that part of the mixture extruded from the upper injection mold 1 enters the hollow frame mold 3 like a piston and cures at elevated temperature for 2-5 minutes using heaters 4 located in the upper 1 and lower 2 injection molds. After the mixture 5 has cured in frame mold 3, the lower mold 2 in contact with the side wall of the mold 3 is separated from the mold and the upper mold 1 inserted into mold 3 is compressed until the resulting product is removed from 5 from mold 3. The resulting The product is characterized by non-flammability, smooth surface and high strength.

The same product with excellent physical properties can also be obtained using a different type of molding machine M, in which the lower mold 2 is stationary and the frame mold 3 moves vertically.

In accordance with a third embodiment of the present invention, there is provided a method for forming building materials consisting mainly of magnesium oxide, comprising the steps of preparing a mixture by mixing magnesium oxide powder with a powder of vegetable or mineral origin; adding water to this mixture in such an amount that the resulting mixture can be used for injection molding to obtain, for example, a liquid mortar; supplying the liquid mixture from the nozzle through the inlet to the inside of the mold assembly; curing said mixture by means of a heater located in each of the injection molds; removal of the resulting product from the mold.

Said mixture is cured with a heater located inside the mold, during or after the mixture is fed into the mold, and then removed from the mold. In this case, the mixture is thermoset in an injection mold equipped with a heater, as opposed to conventional injection molding of thermoplastics, in which the injection molded plastic is cooled. Additionally, in the case where the product is formed using a spray head, the heater 12 is arranged in an injection mold for the magnesium oxide mixture, as shown in FIG.

In addition, the injection molding machine comprises upper and lower injection molds 10a and 10b so as to perform double-sided molding, and an inlet 11 located on one of the sides. The mixture is fed from the nozzle through the inlet 11 into the injection molding machine. Additionally, the upper and lower forms 10a and 10b each have a built-in heater 12.

According to a third embodiment, the heaters 12, located in the upper and lower injection molds 10a and 10b, preheat the molds 10a and 10b to a certain temperature before the mixture is fed into the molding machine, then the mixture using the high pressure pump located at the edge nozzles are fed into the molding machine through the inlet 11. However, it is preferable that the end of the nozzle moves away from the inlet 11 immediately after the mixture has been supplied to the injection mold, until the mixture begins to fast. fall into the mold, in order to prevent clogging of the nozzle during heating and curing of the mixture at the end of the nozzle. The mixture fed to the injection mold is quickly cured by heat, and the final product is formed in a short period of time.

In accordance with a fourth embodiment of the present invention, there is provided a method for forming building materials consisting mainly of magnesium oxide, comprising the steps of preparing a mixture by mixing magnesium oxide powder with a powder of vegetable or mineral origin; selectively adding water to this mixture in such an amount that the resulting mixture can be used for extrusion, to obtain, for example, a liquid mortar; extruding the liquid mixture into the desired form using an extruder; and passing, by means of a supercharger, the product formed through a heating device located in front of the outlet of the extruder to cure the final product.

It is important that during the extrusion process in accordance with the present invention, sawdust or vegetable powder and water are mixed to form a mixture with magnesium oxide in a form suitable for extrusion. The mixture thus obtained is extruded through an ordinary extruder.

In particular, the heating device 22 is located directly in front of the outlet of the extruder, so that the extruded product enters the heating device 22 and quickly cures to produce the final product.

According to a fourth embodiment of the present invention, the resulting product has a smooth surface and a dense structure, since it is subjected to high pressure during the extrusion process, and also has a good appearance and is used in building materials of complex shape corresponding to a high-precision configuration.

The heating device 22 includes a tunnel type duct 23 and a plurality of heaters 24. Each of the heaters 24 is controlled by a temperature sensor (not shown) and is secured, separately from the others, in the duct 23, so that a different temperature can be set inside the duct. In particular, the heating device 22 is long enough so that the mixture is heated to a degree sufficient to cure it. Further, it is preferable that the heat-shielding curtain 26 is located in the opening of the heating device 22 so as to prevent leakage of heat into the atmosphere. In addition, at the end of the box is a supercharger 27, designed to pump out moisture and gases released from the mixture.

The extruded mixture is conveyed by a conveyor belt 21 to a heating device 22, where it quickly cures under the influence of heat to the desired hardness. At the same time, spaced-apart heaters 24 appropriately control the process so that the mixture cures under optimal conditions and as quickly as possible.

The building material obtained by the above procedure is non-flammable and has a smooth surface.

Industrial applicability

As described above, the present invention provides a new method for forming building materials consisting primarily of magnesium oxide, which provides the best use of the beneficial qualities of magnesium oxide.

Therefore, the present invention has the following advantages.

In accordance with this invention, the method of forming building materials, consisting mainly of magnesium oxide, helps to reduce the number of fires. Traditional building materials, including mainly plastics and adhesive resins, are the main cause of death due to suffocation by toxic fumes released during combustion. The present invention takes into account these disadvantages, known from the prior art, and the primary objective of the invention is a method of molding building materials containing non-combustible powder of magnesium oxide and non-toxic powder of plant origin. Such building materials are both non-combustible and do not emit toxic gas, which allows you to save many human lives.

Another advantage of the method according to this invention is the speed of production of building materials, since heating during pressing, extrusion or injection molding quickly cures the mixture. Additionally, the invention has such advantages as increased productivity and reduced labor costs, since transportation and storage are excluded, and the time required for sufficient curing of the mixture is reduced due to the rapid curing of the mixture, in contrast to the traditional method of molding concrete.

Further, this invention has an economic advantage. In particular, numerous non-toxic waste products of plant origin, such as sawdust, finely chopped straw and corn stalks, are reused and there is no need for separate processing of these waste products. Moreover, the building materials of the present invention are easy to knock and cut, which allows them to be used instead of wood, preserving forests. Accordingly, this invention can reduce wood consumption and reduce logging, and also contributes to the protection of forests that produce clean water and fresh air.

Further, in accordance with the present invention, the mixture is fed into a concave frame mold and pressed by the upper injection mold so that a part of the mixture extruded from the upper injection mold enters the hollow frame mold like a piston, and the lower injection mold is separated from the frame mold and the upper injection mold nested in a frame form is compressed further until the resulting product is removed from the frame form. Therefore, the resulting product has a good appearance and is used in building materials of complex shape, where a high-precision configuration is required.

The present invention is illustrated in an illustrative manner, and it should be understood that the terminology used is based on description and not limitation. In light of the foregoing, numerous modifications and variations of the present invention are possible. Therefore, it should be understood that in the scope of the attached claims, this invention can be implemented otherwise than specifically noted.

Table of experimental data. example MgO Vermiculite Mineral Powder sawdust water Temperature ° C pressure kg / cm ² Curing Time (min) the properties The compressive force, kgf / cm ² (the weight.%) four fifty twenty thirty 80 200 50 / for the door Flame retardation - 5 thirty 40 thirty 120 10 3 ~ 5 / for heat insulating and soundproof panels flammability - 6 35 35 thirty 80 one hundred 2 ~ 5 / cast after heat holding flammability 98 7 fifty twenty thirty 80 one hundred As above flammability 95 8 35 35 thirty 80 one hundred 60 Flame retardation 101 9 fifty twenty thirty 80 one hundred fifty Flame retardation 97 10 35 35 thirty 80 250 2-5 flammability 107 eleven fifty twenty thirty 80 250 As above flammability 102 12 35 35 thirty 80 250 60 Flame retardation 109 13 fifty twenty thirty 80 250 fifty Flame retardation 106 Introduction to fourteen 35 35 thirty 120 one hundred preliminary ignited 99 heating and aging grazing capacity after 4 min fifteen fifty twenty thirty 120 one hundred As above flammability 96 16 35 35 thirty 120 one hundred Heating 2 min and heat exposure 3 min Flame retardation 102 17 fifty twenty thirty 120 one hundred As above Flame retardation 97 eighteen 35 35 thirty 120 250 Introduction by preheating and holding after 4 min flammability 106 19 fifty twenty thirty 120 250 As above flammability 102 twenty 35 35 thirty 120 250 Heating 2 min and heat exposure 3 min Flame retardation 109 21 fifty twenty thirty 120 250 As above Flame retardation 107

Claims (3)

1. A method of forming building materials, consisting mainly of magnesium oxide, comprising the steps of: mixing a powder of magnesium oxide with a powder of vegetable or mineral origin in a certain ratio to obtain a mixture; adding water to the resulting mixture to form a wet powder mixture; feeding the wet powder mixture into a preheated injection mold, heating and pressing said wet mixture at a temperature of from 80 to 120 ° C at a pressure of from 100 to 250 kg / cm ² to ensure rapid curing of the mixture; and removal of the resulting product from the mold. 2. A method of forming building materials, consisting mainly of magnesium oxide, comprising the steps of: mixing a powder of magnesium oxide with a powder of vegetable or mineral origin in a certain ratio to obtain a mixture; adding water to the resulting mixture to form a wet powder mixture; feeding the wet powder mixture into a frame injection mold of an injection machine consisting of a mold and a preheated lower mold, heating and pressing said wet mix at a temperature of from 80 to 120 ° C at a pressure of from 100 to 250 kg / cm ² after the bottom part of the upper mold is included in the frame mold in order to quickly harden the mixture; and dredging the resulting product from the molding machine. 3. Building material, mainly containing magnesium oxide and obtained by the method according to one of claim 1 or 2.

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