阅读说明：本技术 一种阻燃性建筑用轻量面板及其制造方法 (Flame-retardant lightweight panel for building and manufacturing method thereof ) 是由 全一郎 于 2019-07-10 设计创作，主要内容包括：本发明涉及一种阻燃性建筑用轻量面板及其制造方法,其特征在于,通过在金属加工工程中排出的金属废料、废石膏等工业废料中组合蛭石和耐火性材料、耐热性材料,从而不仅改善了耐热性等,而且还改善了耐冲击性等物理特性。另外,在通过组合各种耐热性成分来制造耐热性面板时,能够选择金属废料作为单一材料,因此在选择耐热性材料方面具有非常有利的优势,并且在回收工业废料方面,也具有降低制造成本等优势。(The present invention relates to a flame-retardant lightweight panel for buildings and a method for manufacturing the same, wherein physical properties such as impact resistance are improved in addition to heat resistance by combining vermiculite, a fire-resistant material, and a heat-resistant material with industrial waste such as metal waste and waste gypsum discharged from a metal working process. In addition, when a heat-resistant panel is manufactured by combining various heat-resistant components, metal scraps can be selected as a single material, and thus there are advantages in that a heat-resistant material is very advantageously selected, and there are advantages in that manufacturing costs are reduced in recycling industrial scraps, and the like.)

1. A flame-retardant lightweight panel for construction, characterized in that,

the waste metal material comprises 50-65 parts by weight of waste gypsum, 50-55 parts by weight of feldspar and 45-50 parts by weight of vermiculite relative to 100 parts by weight of waste metal material discharged in a metal processing engineering, wherein the waste metal material contains aluminum oxide (Al)₂O₃)、MgO·Al₂O₃Sodium chloride (NaCl), aluminum nitride (AlN), metallic aluminum (Al), Silica (SiO)₂) Ferroferric oxide (Fe)₃O₄) Iron oxide (FeO), magnesium oxide (MgO),

the metal waste, the waste gypsum, the feldspar and the vermiculite are respectively powder crushed by 100 meshes, and a surface treating agent consisting of inorganic pigment, mica, vermiculite and garnet powder in the same weight ratio is used for coating.

2. The flame retardant lightweight panel for construction according to claim 1,

the inorganic pigment is at least one or more inorganic pigments selected from titanium oxide, cobalt oxide, barium oxide, nickel oxide, chromium oxide, and zirconium oxide.

3. A method for manufacturing a flame-retardant lightweight panel for construction, characterized in that,

a) a first step of crushing 50 to 65 parts by weight of waste gypsum, 50 to 55 parts by weight of feldspar, and 45 to 50 parts by weight of vermiculite with respect to 100 parts by weight of metal scrap discharged in a metal working process, mixing the crushed materials with a particle size of 100 meshes, and molding the mixture into a panel shape;

b) a second step of forming a coating layer having a thickness of 1 to 2 mm on the surface of the molded article molded in the first step by using a surface treatment agent comprising an inorganic pigment, mica, vermiculite and garnet powder, and then drying the coating layer; and

c) and a third step of firing the molded article coated with the surface treatment agent in the second step at 1000 to 1400 ℃.

4. The method of claim 3, wherein the flame retardant lightweight panel for construction is produced by the method of claim,

the scrap metal contains aluminum oxide (Al)₂O₃)、MgO·Al₂O₃Sodium chloride (NaCl), aluminum nitride (AlN), metallic aluminum (Al), Silica (SiO)₂) Ferroferric oxide (Fe)₃O₄) Iron oxide (FeO), magnesium oxide (MgO).

5. The method of claim 3, wherein the flame retardant lightweight panel for construction is produced by the method of claim,

the surface treating agent of the second step is composed of inorganic pigment, mica, vermiculite and garnet powder in the same weight ratio.

6. The method of claim 5, wherein the flame retardant lightweight panel for construction is produced by the method of claim,

the inorganic pigment is at least one or more inorganic pigments selected from titanium oxide, cobalt oxide, barium oxide, nickel oxide, chromium oxide, and zirconium oxide.

Technical Field

The present invention relates to a flame-retardant lightweight panel composition for construction, and more particularly, to a flame-retardant lightweight panel for construction, which combines metal processing waste, waste gypsum, and a fire-resistant material, which are industrial waste, and a method for manufacturing the same.

Background

In general, a sandwich panel, which is a panel using steel plates on both sides and a filler such as foam, polyurethane, glass fiber, mineral wool, etc. in the middle of the steel plates, is used for insulation, sound absorption, etc., and although foam and polyurethane have excellent insulation and sound insulation properties, they have poor heat resistance, so that a large amount of toxic gas is generated during a fire, thereby causing casualties, property loss, and air pollutants, and it is difficult to dispose of the wastes when the panel is aged and needs to be replaced, thereby causing environmental pollution.

In addition, glass fiber and mineral wool are non-combustible materials, which are advantageous for fire prevention and the like, but glass fiber dust, mineral wool dust, and the like are generated during the process of manufacturing a panel, which results in a bad working environment, and health problems such as dermatitis, skin cancer, and the like may be caused by repeated contact of workers with the dust. In developed countries such as the united states, mineral wool is found to be a carcinogen and is therefore of limited use.

Regarding a panel for construction, patent document 1(KR10-1206644B) discloses a corrugated high-elasticity panel that is flame-retardant and enhances adhesion, taking the prior art as an example The method is characterized in that a resin mixture mixed by 30 wt% of flame-retardant thermosetting melamine resin, 30 wt% of polyester resin, 30 wt% of epoxy resin, 8 wt% of inorganic ceramic and 2 wt% of ammonium chloride is impregnated with reinforcing fibers, an introduction groove (12) and a locking protrusion (14) are alternately formed on the upper surface of a panel on the side facing to a concrete structure (30), the lower surface of the panel on the side opposite to the upper surface of the panel is flat, and at least one of the left and right side surfaces of the introduction groove (12) is overlapped with at least one of the left and right side surfaces of the locking protrusion (14). Patent document 2(KR10-1551542B) discloses a nonflammable building panel The building board is formed by mixing and adhering main components of silica dioxide, alumina, lime, silica sand, fly ash, non-combustible paper scrap, stone powder and bamboo fiber of cement through inorganic adhesive water glass, and melamine resin with various patterns is adhered to the upper surface and the lower surface of the board to form an integral building board, and is characterized by being formed by mixing 30-40 wt% of the silica dioxide, 3-10 wt% of the alumina, 1-5 wt% of the lime, 1-3 wt% of the silica sand, 1-5 wt% of the fly ash, 10-20 wt% of the non-combustible paper scrap, 15-25 wt% of the stone powder, 3-10 wt% of the bamboo fiber and 10-20 wt% of the water glass.

Further, patent document 3(KR10-1731553B) discloses a multifunctional building materialEnergy composite board It includes: a core material molded from a binder containing a silicone component and a swellable mineral; and a metal foam attached to at least one surface of the core material, the silicone-based composition including: a nano silicate powder produced by hydrolyzing tetraethoxysilane to an acidic solution with a solvent containing 95 wt% or more of a lower alcohol having 1 to 4 carbon atoms, with any one neutral surfactant selected from the group consisting of polyoxyethylene octylphenyl ether, polyethylene oxide, polypropylene oxide, and polyethylene glycol, then dropping an alkali solution, and then filtering; and magnesium aluminum silicate, wherein the magnesium aluminum silicate has 20 to 50 parts by weight of magnesium aluminum silicate with respect to 100 parts by weight of nano silicate powder.

The applicant of the present invention manufactures a flame-retardant lightweight panel for construction by using industrial waste such as metal processing waste and waste gypsum, thereby not only further improving physical properties such as fire resistance, heat resistance and impact strength, but also facilitating recycling of industrial waste.

Disclosure of Invention

[ problem to be solved ]

The present invention relates to a flame-retardant lightweight panel for buildings and a method for manufacturing the same, and more particularly, to a flame-retardant lightweight panel for buildings and a method for manufacturing the same, which is advantageous in that physical properties such as fire resistance, heat resistance, and impact strength are further improved and industrial wastes such as waste gypsum are used, thereby facilitating recycling of the industrial wastes.

[ solution ]

The solution of the present invention for achieving the above object is a flame retardant lightweight panel for construction, comprising: the coating is prepared by coating 100 parts by weight of metal waste generated in metal processing engineering with 50-65 parts by weight of waste gypsum, 50-55 parts by weight of feldspar and 45-50 parts by weight of vermiculite by using a surface treating agent consisting of pigment, mica, vermiculite and garnet powder.

According to one side of the flame-retardant lightweight panel for buildings of the present invention, the flame-retardant lightweight panel for buildings is obtained by using industrial waste such as metal waste and waste gypsum generated in metal processing, and thus, the flame resistance, heat resistance, impact strength and other physical properties are further improved, and the recovery of industrial waste is facilitated.

According to the other side surface of the flame-retardant lightweight panel for buildings of the present invention, the lightweight panel for buildings is obtained by combining the metal component contained in the scrap metal and vermiculite, and thus the lightweight property, the insulating property, and the heat resistance due to the expansibility of the panel are further improved, and the impact resistance is also improved.

Another object of the present invention is to provide a method for manufacturing a flame retardant lightweight panel for construction, comprising: a) a first step of molding a mixture of 50 to 65 parts by weight of waste gypsum, 50 to 55 parts by weight of feldspar, and 45 to 50 parts by weight of vermiculite into a panel shape, based on 100 parts by weight of metal scrap discharged from a metal working process; b) a second step of coating the surface of the molded product molded in the first step with a surface treatment agent comprising a pigment, mica, vermiculite and garnet powder, and then drying the coated product; c) and a third step of firing the molded article coated with the surface treatment agent in the second step at 1000 to 1400 ℃.

[ Effect of the invention ]

According to the flame-retardant lightweight panel for buildings of the present invention, the combination of the metal component contained in the scrap metal and vermiculite provides excellent fire resistance, heat resistance, weight reduction of porosity and insulation properties, and further improves physical properties such as impact strength without generating toxic gas even in the event of fire.

In addition, in the case of manufacturing a heat-resistant and insulating building panel in which various materials are combined for the purpose of flame retardancy or heat resistance, metal scraps are selected as a single material, so that there is a great advantage in material selection, and recycling industrial scraps is advantageous not only in terms of environment but also in terms of reduction in manufacturing cost.

Drawings

FIG. 1 is an analysis table for testing heavy metal components contained in the panel of the present invention;

FIG. 2A is an image comparing panels manufactured by example and comparative example, respectively;

FIG. 2B is an image of a panel nailed for the purpose of impact resistance testing the panel of the present invention.

Detailed Description

The present invention will be described in detail below with reference to specific contents of embodiments of the present invention, examples, and test examples, but the following specific description is not intended to limit the present invention.

The lightweight fire-retardant building panel comprises 50-65 parts by weight of waste gypsum, 45-50 parts by weight of vermiculite and 50-55 parts by weight of feldspar based on 100 parts by weight of metal waste generated in metal processing engineering, and is coated with a surface treatment agent consisting of pigment, mica, vermiculite and garnet powder.

The scrap metal discharged from the metal processing step according to the present invention is, for example, scrap metal discharged from steps such as pretreatment, smelting and processing of a metal mineral such as aluminum ore, and contains alumina (Al) in most cases although the content of the constituent components thereof is different₂O₃) Spinel (MgO. Al)₂O₃) Sodium chloride (NaCl), aluminum nitride (AlN), metallic aluminum (Al), silica sand and clay mineral (SiO)₂) Ferroferric oxide (Fe)₃O₄) Iron oxide (FeO), magnesium oxide (MgO), from which the scrap metal discharged in the process is collected in the present invention can be obtained from tokyo metal (gold sea, the locus).

The scrap metal discharged in the metal working process contains various components having fire resistance, so that when manufacturing a heat-resistant and insulating building panel, that is, a fire-resistant panel in which various materials are combined for fire resistance or heat resistance, the scrap metal can be selected as a single material, thus having a very advantageous advantage in selecting the material, and the scrap metal contains oxides of metal components (Al, etc.), nitrides (AlN), iron, and magnesium, thereby further improving the heat resistance of the panel of the present invention, and in this case, the scrap metal is preferably pulverized in a size of about 100 mesh and then mixed.

The waste gypsum (CaSO)₄·2H₂O) is selected from the group consisting of desulfurized gypsum discharged from flue gas desulfurization processes or phosphate gypsum generated as a by-product in the process of reacting phosphate rock with sulfuric acid, which is used as an inorganic binder in various applications such as ceramic industry, molding gypsum for casting mold, gypsum board, etc., and is recycled in various fields, but there is still a problem of accumulation or leaving with the ground, and therefore, when it is affected by natural disasters such as typhoons, rainstorms, etc., these waste gypsums pollute the surrounding environment and seriously pollute the environment due to infiltration of leachate.

In the present invention, the waste gypsum not only serves as fire resistance but also serves as a molding aid because it has adhesive properties, and in this case, it is preferable to pulverize the waste gypsum to a size of about 100 mesh and mix it.

The Vermiculite (Vermiculite) according to the present invention generally refers to hydromicas, which are deterioration products of phlogopite or biotite, and when rapidly heated at high heat, moisture in the Vermiculite layer is evaporated into water vapor and generates pressure, which is released to cause separation and expansion, thereby having lightweight property of very low density, and having excellent insulating property, incombustibility, soundproofing property and effect of absorbing physical impact.

Generally, fire retardant and heat resistant panels are required to have a certain strength to satisfy building applications, but the higher the strength, the more easily broken by impact, and therefore it is necessary to improve the impact resistance of building panels.

The feldspar includes various kinds of feldspar such as orthoclase, soda feldspar and ashlar feldspar, but in the present invention, soda feldspar (Na) is preferably used₂O·Al₂O₃·6SiO₂) And (4) combining. Feldspar has the property of swelling when heated to about 1200 c, and is therefore widely used as an inorganic refractory.

The pigment is preferably selected from at least one or more of titanium oxide, cobalt oxide, barium oxide, nickel oxide, chromium oxide and zirconium oxide, and is mixed in an amount of about 1 to 5 parts by weight, and in this case, the feldspar, vermiculite and pigment are also pulverized in a size of about 100 meshes and then mixed.

According to the flame-retardant lightweight panel for buildings of the present invention, the lightweight property and the insulating property of the panel are improved by the porosity generated by the interaction between the metal component (AI) contained in the metal scrap and the soda feldspar, and the lightweight property generated by the expansion of vermiculite by heating, and the impact resistance of the panel is improved by manufacturing the panel for buildings with improved heat resistance through the metal and the refractory material, especially by using the vermiculite in combination.

In addition, a method for manufacturing a flame retardant lightweight panel for construction according to the present invention includes: a first step of mixing and molding components of a panel; a second step of coating the surface of the molded article molded in the first step with a surface treatment agent and then drying the coated article; and a third step of firing the molded product obtained in the second step at 1000 to 1400 ℃.

In the first step of the present invention, the components of the panel are mixed by pulverizing the components into about 100 mesh size, mixing 50 to 65 parts by weight of waste gypsum, 50 to 55 parts by weight of feldspar, and 45 to 50 parts by weight of vermiculite with respect to 100 parts by weight of scrap metal discharged in the metal working process, and molding the mixture into a panel shape using the mixed mortar.

According to the second step of the present invention, the surface of the plate-shaped molded article molded in the first step is coated by using a surface treatment agent comprising a pigment selected from at least one of titanium oxide, cobalt oxide, barium oxide, nickel oxide, chromium oxide and zirconium oxide, a mica powder, a vermiculite powder and a garnet powder in the same weight ratio to form a coating layer of about 1 to 2 mm, and then dried.

According to the third step of the present invention, the molded article coated with the surface treatment agent in the second step is fired at 1000 to 1400 ℃ and, in this case, preferably at 1350 ℃.

Examples

A mortar for molding was prepared by mixing 65 parts by weight of waste gypsum, 55 parts by weight of feldspar, and 45 parts by weight of vermiculite with respect to 100 parts by weight of metal scrap (tokyo metal, seiko, japan) discharged in a metal working process, each crushed in a size of 100 mesh.

After the molding mortar was molded into a plate-shaped molded product using a mold, a coating layer having a thickness of about 1 to 2 mm was formed on the surface of the molded product using a surface treatment agent composed of a pigment, a mica powder, a vermiculite powder and a garnet powder in the same weight ratio, and then dried, and then placed in an electric furnace, and fired at 1350 ℃ for about one hour, and then cooled at normal temperature, the flame-retardant lightweight panel for buildings according to the present invention was manufactured through the above processes, and then a test analysis of the heavy metal content of the manufactured panel was requested, and fig. 1 shows the result (test result sheet).

Comparative examples

The mortar for molding, which was combined with the components other than vermiculite among the components of the examples, was molded into a plate-shaped molded product by a mold, and then fired at 1350 ℃ for about one hour in an electric furnace, and then cooled at room temperature, thereby producing a flame-retardant lightweight panel for buildings according to the present invention.

Test examples

Fig. 2A shows images of panel samples manufactured by the examples and comparative examples, respectively, and fig. 2B is an impact resistance improvement test performed on the panel samples manufactured by the examples, showing an image whose surface is not broken even if nailed on the panel thereof.

As shown in fig. 2B, the flame-retardant lightweight panel for buildings according to the present invention is judged to have improved impact resistance by the result that the periphery of the surface or the like is not crushed when the surface is nailed.