KR101737811B1 - Expanded mortar and method for fabricating thereof and repair material method - Google Patents

Abstract

The present invention relates to a fire-resistant and fire-proofing work for preventing heat loss caused by external influences, a core material of a composite panel and a fireproof door core, a frozen warehouse flooring material, For the purpose of construction, the present invention is advantageous in that, in addition to mixing magnesium oxide and magnesium sulfate as a main raw material at a constant weight ratio, a light-weight filler of various materials can be selected according to the required use for the purpose of improving the heat insulating performance After construction, self-foaming by the catalyst enabled the formation of a micro-air layer with an expansion of about 2 to 4 times the initial thickness, thereby improving the insulation performance.
In order to prevent the deterioration of the workability due to the initial sudden foaming reaction, the bubble formation inhibitor was used to induce foaming in the late stage of construction, and abnormal bubble growth was suppressed to achieve uniform bubble generation. It has the advantage of shortening the air due to the reduction of the curing time compared to the conventional wet product, and it is a fire-retardant insulation excellent in thermal conductivity than EPS, which is a typical flammable insulating material.

Description

FIELD OF THE INVENTION [0001] The present invention relates to an inorganic foamed mortar having excellent fire resistance and excellent heat insulating performance, a method for manufacturing the inorganic foamed mortar, and an improved method for repairing inorganic foamed mortar using the same.

The present invention relates to an inorganic foamed mortar having fire resistance and excellent heat insulating performance, a method for manufacturing the same, and a repair method for repairing an inorganic foamed mortar using the same. More particularly, the present invention relates to a heat- Inorganic foamed mortar having fire resistance and excellent heat insulation performance to improve fire resistance and fire resistance including heat insulation performance such as fire retardant door core material, fire retardant door core material, and insulation panel performance of composite panel, and manufacturing method thereof and inorganic foam This relates to a repair method of a mortar.

Generally, most of the conventional incombustible mortars for insulation are made of foamed concrete mixed with cement mortar and animal foaming agent at a certain ratio and porosity of inorganic foam lightweight such as vermiculite or perlite, and EPS grains mixed with gypsum and cement Gypsum plaster-based free-mixing mortar is generally used.

In particular, gypsum plaster-based mortar has the advantage of excellent thermal insulation and spraying workability compared to foamed concrete, but it has a higher thermal conductivity than EPS and urethane foam, It is true that there is a limit. Despite the advantages of excellent nonflammability of gypsum plaster-based mortar, it is said that the reason why the consumer prefers flammable organic insulation material is because of the above-mentioned reason.

Also, the porous lightweight aggregate used in the gypsum plaster mortar does not participate in the reaction but acts as a simple aggregate, resulting in a marked increase in the water-gypsum-cement ratio, which makes the mechanical properties very weak.

These insulation materials are easily broken even after curing due to their poor mechanical properties, causing air pollution due to scattering into the atmosphere, and problems of environmental pollution such as vermiculite used as an insulating material and fungal growth due to excessive moisture absorption characteristics of perlite It causes.

Examining the prior art of refractory insulation mortar using porous lightweight stone, Patent No. 10-0326614 is expected to produce toxic gas in case of fire due to excessive use of organic matter such as organic lightweight aggregate, latex, synthetic fiber, There is no occurrence, but the strength of the coating composition itself is too weak, so that after the curing, the coating composition may be crumbled and contamination of the inside air by dust generation may occur.

In addition, the registered patents 10-0693859 and 10-0807244 use a silicate-based non-cementitious composition because it is difficult to secure a sufficient pot life due to occurrence of sudden occurrence and a large amount Of the silicate system is required. This may cause deterioration of the heat insulating property. In addition, Japanese Patent Registration No. 10-1145871 discloses a spraying material using a latent hydraulic material such as heavy oil and bottom ash and an organic binder. However, it is difficult to apply the insulating material because of its low thermal insulation property, and heavy metals in the bottom ash are volatilized, And Patent Application No. 10-2004-0082094 fails to apply it as a heat insulating material utilizing the voids of heavy oil.

On the other hand, Patent Registration No. 10-0760040 proposes a method of producing a foamed ceramic by a method similar to the present invention, but in order to prevent re-shrinkage after foaming, a separate and rapid gelling step, which is required to be exposed to carbon dioxide or immersed in an acid solution, Therefore, it is different from the present invention because it is not suitable for spraying and uses the chemical reaction between the metal powder and hydrogen peroxide to realize the foam.

Open No. 10-2015-0121329 was invented by the present applicant and is a foam prepared by modifying sodium silicate with organic acid by using a lightweight filler, a quick-setting agent, a foaming agent, etc., and separating the liquid phase and the solid phase separately So that the manufacturing process is complicated and cumbersome, and there is a disadvantage that the construction work on the site is inconvenient.

Most of the adiabatic mortar currently applied is generally made by mixing porous materials such as gypsum and cement with porous materials such as perlite, but it has a limit because it relies on a simple filler to lower the thermal conductivity.

In the case of inorganic insulating mortar which is conventionally used for general purpose, the present invention utilizes lightness and heat insulation of EPS or perlite of granular or crushed type, and is made by using the hydraulic property of gypsum and cement.

However, since it is superior in incombustibility, it has a remarkable thermal insulation characteristic compared with existing organic insulation material. Therefore, in view of energy efficiency, it is necessary to construct the insulation material at a thickness twice as thick as that of organic insulation material. Therefore, during the winter season, the hardening is delayed, There was a serious problem in which defects were generated and there was a problem in shortening the air due to the limitation of working thickness at the time of one time construction.

KR Patent Registration (B1) 10-0326614 (2002.02.19) KR Patent Registration Bulletin (B1) 10-0693859 (2007. 03. 06) KR Patent Registration (B1) 10-0807244 (Feb.

It is an object of the present invention to solve the above-mentioned problems, and it is an object of the present invention to provide a method for preparing a lightweight filler of a variety of materials according to the purpose of use, in addition to mixing magnesium oxide and magnesium sulfate as a main ingredient at a constant weight ratio, The present invention provides an inorganic foamed mortar having excellent fire resistance and excellent heat insulation performance by which a fine air layer can be formed by expansion of about 2 to 4 times the initial thickness by self-foaming by a post catalyst so as to improve the heat insulation performance.

It is another object of the present invention to provide a fire-retardant insulating material which is excellent in heat-insulation and anti-condensation work for preventing heat loss caused by external influences, core material of a composite panel and fireproof door core, freezing warehouse flooring, The present invention also provides an inorganic foamed mortar having excellent fire resistance and excellent heat insulating performance.

Another object of the present invention is to provide a process for producing a water-soluble material, which is capable of generating bubbles through a catalytic reaction by hydrogen peroxide water to realize weight reduction by expansion of the foam, and to solve the problem of bubbles which may be generated due to delay of hardening after bubbling, It is possible to realize a foam having a specific gravity of 0.1 g / cm 2 or less by using a high purity magnesium oxide and a fine powdery magnesium sulfate which are easy to control the curing rate relatively easily according to the mixing ratio of the core and the hardener, And to use reinforcements and additives in order to minimize the rebounding rate in the application of the lowering and spraying process.

In order to achieve the above object, the present invention provides a foam inhibitor comprising at least one of aluminum monophosphate, aluminum phosphate, magnesium phosphate, and calcium phosphate per 100 parts by weight of a slurry in which a filler is mixed in a hydraulic mordant powder, 10 parts by weight; 0.1 to 1.0 part by weight of a foaming catalyst comprising at least one of manganese dioxide, ferric oxide, and potassium iodide; 0.5 to 1.0 part by weight of a reinforcing material comprising at least one of nylon fiber, glass fiber, carbon fiber, aramid fiber, rock surface fiber and pulp; 0.5 to 3.0 parts by weight of an additive comprising at least one of HPMC, CMC, gum arabic, MC, xanthan gum; 3 to 10 parts by weight of a strength-increasing agent comprising at least one of a melamine resin, a emulsifying type EVA powder resin, a emulsifying type acrylic powder resin, and a water-soluble powder type resin such as gum arabic; 2 to 10 parts by weight of a foaming agent containing hydrogen peroxide; And a non-combustible inorganic foamed mortar having fire resistance and heat insulation performance.

The amount of the hydraulic mortar powder may be 50 to 350 parts by weight based on 100 parts by weight of the filler.

Also, the hydraulic mortar powder may contain 40 to 60 parts by weight of active magnesium oxide; And 40 to 60 parts by weight of magnesium sulfate.

Further, the magnesium sulfate may be any one of anhydrides, pentahydrate, hexahydrate, and octahydrate.

In order to achieve the above-mentioned object, the present invention provides a method for producing a water-borne mordant, Adding a filler to the hydraulic mordant powder at a weight ratio of 30:70 to 70:30 to prepare a first mixture; Applying a strength enhancing agent to the primary mixture to increase the mechanical strength and to increase the adhesion strength to the base surface; Introducing into the primary mixture a blowing catalyst to improve the adiabatic properties of the mortar; Introducing a foam inhibitor into the primary mixture to facilitate the construction work and to generate uniform and fine bubbles; Mixing the mixture with a ribbon mixer for 15 to 30 minutes to prepare a pre-mixing type mortar powder, adding water in a total weight ratio of 50 to 150 by weight, and mixing the mixture with a paddle mixer for 3 to 5 minutes to prepare a slurry; Adding hydrogen peroxide solution having a concentration of 15 to 35% to the mixed slurry at a ratio of 2 to 8 by weight based on the total weight of the slurry, and mixing the slurry for 0.5 to 2 minutes to complete foamable mortar. A method for producing a nonflammable inorganic foamed mortar is disclosed.

As a process for producing the hydraulic mortar powder, a magnesium oxide having an average particle size of 3 탆 or less and a magnesium oxide having a particle size of 325 mesh or less To 60 weight ratio.

In addition, as a process for improving the heat insulation and fire resistance and preventing the cracks and deformation of the foam and improving the mechanical strength, it is also possible to use an expanded pyrite having a size of 0.1 to 1 mm and hard calcium carbonate, microporous silica Comprising one or more inorganic fillers having adiabatic properties such as fumed silica, carbonated calcium borosilicate, aerogels, fly ash, aluminum hydroxide, magnesium hydroxide, expanded vermiculite, diatomaceous earth, wollastonite, olivine, sericite, . ≪ / RTI >

Also, as a process for improving the heat insulation and fire resistance and preventing the cracks and deformation of the foam and improving the mechanical strength, it is possible to produce a reinforcing material having a heat insulating property, such as 5 mm diameter or shredded foam (EPS), nylon fiber, CMC, MC, xanthan gum, modified starch, etc., in order to control initial adhesion and slurry viscosity when adding or adding one or more of carbon fiber, aramid fiber, rock wool, pulp, Or one or more of the above.

The water-soluble powder may be added in an amount of 5 to 15 wt% based on 100 wt% of the first mixture.

Also, one or more of manganese oxide, ferric oxide and potassium iodide may be added to the foaming catalyst at a weight ratio of 0.1 to 1.0 based on 100 weight ratio of the first mixture.

Also, one or more of aluminum monophosphate, aluminum phosphate, magnesium phosphate, calcium phosphate and the like may be added as the foam inhibitor at a weight ratio of 1.0 to 5.0 based on 100 weight ratio of the primary mixture.

In order to accomplish the above-mentioned object, the present invention provides a method for producing a basic mortar powder, A raw material and a sub-material mixing step of mixing a filler having an adiabatic performance and improving the mechanical properties of the foam with a basic mortar; A mortar pre-mixing step of adding a catalyst, an inhibitor and a reinforcing agent, and an initial adhesion promoting agent to the mixture; Mixing the mortar pre-mixing with water to prepare a primary slurry; Adding a foaming agent for forming bubbles to the primary slurry, and finally mixing the foamed mortar; A mortar casting or spraying step in which a final mixed slurry is sprayed onto a base surface or cast into a mold to form uniform bubbles; Expanding the mortar foaming after the lapse of time; Which comprises a natural curing and a drying step, is disclosed in which a non-combustible inorganic foamed mortar having fire resistance and heat insulating performance is maintained.

Further, the method may further include a step of stirring the raw material of the paddle mixer into which the raw material and the raw material have been added, stirring the mixture with water, injecting the foaming agent, completing the secondary stirring, and injecting all the materials into the hopper, 50 mm / round.

In addition, the step of mixing the raw materials and the raw materials, stirring the mixture with water, and then injecting the raw material into the hopper, which is an equipment for spraying, and cross-injecting the blowing agent at the end nozzle of the sprayed hose, .

In order to solve the problem of bubbles which can be generated due to the delay of hardening after bubbling, the present invention provides a method of removing bubbles from a water- It is possible to realize a foam having a specific gravity of 0.1 g / cm 2 or less by using high purity magnesium oxide which is relatively easy to control the curing rate and excellent in light weight and magnesium sulfate in the form of fine powder depending on the mixing ratio of the curing agent.

In addition, the present invention uses reinforcing materials and additives to minimize the mechanical strength and minimize the rebounding rate when applying the spraying process. In this process, the amount of the curing agent to be added and the size It is possible to solve the problem by simultaneously using the catalyst and the inhibitor of the hydrogen peroxide solution as the blowing agent.

In addition, the present invention enables expansion by about two to three times or more the initial thickness by autogenous foaming by a catalyst, thereby improving the heat insulating performance by pores generated, securing sufficient working time by using an inhibitor, It is possible to realize a new type of foamed mortar having fire resistance, fire resistance and excellent heat insulating performance, which has the same heat insulating property as existing organic insulating material by suppressing the formation of abnormal bubbles.

In addition, there is an advantage that the initial curing time can be shortened dramatically compared with the conventional working method, and that the thermal conductivity of conventional inorganic insulating mortar is 0.045 ~ 0.045 W / mK or 0.035 ~ 0.040 W / mK However, the product according to the present invention can be replaced with a foamable flammable resin such as styrofoam or foamed polyurethane excellent in heat insulation effect, because it is possible to realize the group (less than 0.034 W / mK) according to the selection of the filler and the amount of foaming It is very advantageous to manufacture heat insulation material which can minimize damage caused by fire, and which has remarkable workability as well as economy.

1 to 4 show an embodiment of the inorganic foamed mortar having fire resistance and excellent heat insulation performance according to the present invention, a method for manufacturing the same, and a repair method for an inorganic foamed mortar using the same.
Brief Description of the Drawings Fig. 1 is a schematic view showing a process of working an inorganic foamed mortar according to the present invention,
Fig. 2 is a view showing a working process according to Fig. 2,
3 is a process plan view showing another working process of the inorganic foamed mortar according to the present invention,
Fig. 4 is a process flow chart according to Fig.

Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings.

It is to be understood that the present invention is not limited to the disclosed embodiments, but may be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, It is provided to inform.

Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. In the drawings, the same reference numerals are used to designate the same or similar components throughout the drawings. In the following description of the present invention, a detailed description of known functions and configurations incorporated herein will be omitted when it may make the subject matter of the present invention rather unclear.

1 and 2 show an embodiment of the inorganic foamed mortar having fire resistance and excellent heat insulating performance according to the present invention, a method for manufacturing the same and a method for repairing an inorganic foamed mortar using the same.

The inorganic foamed mortar according to the present invention having fire resistance and excellent heat insulating performance comprises at least one of aluminum monophosphate, aluminum phosphate, magnesium phosphate and calcium phosphate per 100 parts by weight of the slurry in which the filler is mixed in the hydraulic hard mortar powder as the main material 1 to 10 parts by weight of a foaming inhibitor; 0.1 to 1.0 part by weight of a foaming catalyst comprising at least one of manganese dioxide, ferric oxide, and potassium iodide; 0.5 to 1.0 part by weight of a reinforcing material comprising at least one of nylon fiber, glass fiber, carbon fiber, aramid fiber, rock surface fiber and pulp; 0.5 to 3.0 parts by weight of an additive comprising at least one of HPMC, CMC, gum arabic, MC, xanthan gum; 3 to 10 parts by weight of a strength-increasing agent comprising at least one of a melamine resin, a emulsifying type EVA powder resin, a emulsifying type acrylic powder resin, and a water-soluble powder type resin such as gum arabic; 2 to 10 parts by weight of a foaming agent containing hydrogen peroxide; .

The amount of the hydraulic mortar may be 50 to 350 parts by weight based on 100 parts by weight of the filler.

Also, the hydraulic mortar powder may contain 40 to 60 parts by weight of active magnesium oxide; And 40 to 60 parts by weight of magnesium sulfate.

It is preferable that the magnesium sulfate is any one of anhydrides, pentahydrate, hexahydrate, and octahydrate.

In other words, inorganic mineral with excellent thermal insulation property, mainly made of hydraulic mordant consisting of magnesium oxide and magnesium sulfate, and filler of 5 mm diameter or crushed EPS, which is also excellent in heat insulation property, improve water resistance, A water-soluble powder resin, a reinforcing material for improving the mechanical strength of the mortar, a thickening agent for adjusting initial adhesion and viscosity, a catalyst for foaming agent and foaming agent for expanding and expanding sufficient bubbles for the purpose of improving heat insulation, And an inhibitor for generating uniform and fine bubbles.

The present invention is a new type of adiabatic mortar that differentiates it from other products by improving the heat insulating property and the workability unlike the existing adiabatic mortar. Magnesium oxide, which is one of the important components of the present invention, is generally cured by ionic reaction with magnesium chloride, ammonium phosphate, magnesium sulfate and the like together with water. Among the above curing agents, magnesium chloride shows strong basicity and ammonium phosphate causes rapid curing of the mortar, which makes it difficult to control the curing rate. Therefore, it is easy to control the curing reaction rate, and it is not necessary to control the special temperature and humidity because it is less harmful, so it is easy to store the raw material and it is preferable to apply magnesium sulfate which is safe in the manufacturing process because of its neutrality. Respectively.

A method of producing a foamed mortar having fire resistance, fire resistance and excellent heat insulating performance according to the present invention will be described below.

(S10) of producing a hydraulic mortar powder as a main raw material; (S20) of mixing a raw material and a raw material for mixing a filler having an adiabatic performance and improving mechanical properties of the foam with a basic mortar; A mortar pre-mixing step (S30) in which a catalyst, an inhibitor, a reinforcement, and an initial adhesion promoting agent are added and mixed; A step (S40) of preparing a primary slurry by mixing the mortar pre-mixing with water; A step (S50) of preparing a foamed mortar in which a foaming agent for forming bubbles is added to the primary slurry, followed by final mixing; And a step (S60) of pouring or spraying the mortar so as to form uniform bubbles by spraying the final mixed slurry on the base surface or casting the mold on the mold.

Specifically, the present invention relates to a method for producing hydraulic basic mortar powder, which comprises mixing active magnesium oxide and magnesium sulfate pulverized to a size of 325 mesh or less by using active magnesium oxide and pulverizer having an average particle size of 3 microns or less, Mixing the filler with the basic mortar, adding the catalyst, the inhibitor and the reinforcement, the initial cohesion enhancer and mixing, the step of preparing the primary mixed slurry with water, the addition of the foaming agent to form the bubbles A final mixing step, a step of spraying the final mixed slurry onto the base surface, or a step of casting the slurry into a mold to form uniform bubbles.

The mixing step may be carried out in such a manner that the filler, the basic mortar powder, the catalyst, the inhibitor, and the reinforcing material are put into the mixer, and the mixture of the filler, the hydrated basic mortar powder, The mixture is homogeneously mixed with an appropriate amount of water to keep the desired slump according to the working conditions. At this time, when 100 parts by weight of the filler is used as a standard, it is advantageous that the amount of the hydraulic base mortar is 50 to 350 parts by weight.

Preferably 100 to 250 parts by weight is advantageous and most preferably 150 to 200 parts by weight is advantageous. When the hydraulic basic mortar is contained in an amount of 50 parts by weight or less, the mechanical strength of the foam is low, By weight or more, it is possible to provide a foamed ceramic excellent in mechanical strength, but it is preferable to add the foamed ceramic in the above ratio because the cost of the raw material is increased and the thermal conductivity is lowered.

It should be noted in the mixing process that the amount of the hydraulic base mortar may vary depending on the type of the filler selected so that the mixing ratio is not specified.

Therefore, it is advantageous for the mixture to maintain 10 to 20 parts by weight of the slump, preferably 13 to 17 parts by weight, more preferably 15 to 17 parts by weight, and the slump is preferably 10 parts by weight or less In case of low flowability, self-leveling property is not available during casting and uniform casting is difficult. It is difficult to transfer to the discharge port when using the spraying equipment, and there is a possibility that expansion due to sufficient foaming due to early curing during the foaming process is not possible It is difficult to achieve the object of the present invention. When the slump is more than 20 parts by weight, the fluidity is too high, so that the initial adhesive force is lowered and the rebound phenomenon due to the lowering of adhesion force with the base surface is increased, It is impossible to expect a uniform bubble generation due to the collapse of the slump and the foaming, It is desirable to keep the above.

Magnesium oxide for providing a hydraulic base mortar may be selected from lightly active magnesium oxide having a purity of 96% or less or a magnesium oxide having a purity of less than 3 microns and a purity of less than 3 microns. In consideration of the mechanical strength and the curing rate of the foam, It is preferable to use a product, and magnesium sulfate can be selected from anhydrides, pentahydrate, hexahydrate, octahydrate, and preferably, heptahydrate.

In particular, sodium sulfate is advantageously pulverized to a size of 325 mesh or less in order to improve the reactivity before mixing with magnesium oxide and the dissolution performance by water.

As an inhibitor for obtaining uniform and fine bubbles in order to improve the heat insulation property, phosphoric acid may be generally selected to use phosphoric acid, but phosphoric acid is not preferable as a liquid phase additive for premixed products and exhibits the same effect or more As an alternative, aluminum monophosphate or aluminum phosphate, magnesium phosphate or calcium phosphate may be selected.

The inhibitors may be used alone or in combination of two or more. It is advantageous to add each inhibitor in the form of solid phase powder. The amount of the inhibitor to be added is preferably 1 to 10 parts by weight, more preferably 2 to 8 parts by weight, based on the hydraulic base mortar, It is advantageous to add 3 to 5 parts by weight. If the amount is less than 1 part by weight, the effect as an inhibitor is not obtained. If the amount is more than 10 parts by weight, sufficient foam may not be obtained due to the inhibitor.

Fillers for improving the heat insulation and realizing the weight reduction of the foamed body include inorganic fillers such as dilute perlite, hollow silica, glass bubble, fumed silica, fly ash, diatomaceous earth, hard calcium carbonate, expanded vermiculite, wollastonite, Alumina, aluminum hydroxide, meta kaolin and acidic clay can be selected and mixed.

Further, in order to further enhance the thermal conductivity and realize an ultra-light weight of less than 0.1 g / cm < 2 > and effectively realize the role of the foam absorbing the impact from the outside, a small amount of EPS pole having a diameter of 5 mm or less, It is also a useful method. The addition of EPS contributes to cost reduction by significantly reducing the weight of the slump per unit volume.

The catalyst acts to accelerate the decomposition reaction with the hydrogen peroxide solution used as the blowing agent and to generate a large amount of oxygen. Hydrogen peroxide water is decomposed into water and oxygen by lowering the activation energy by a catalyst such as ferric oxide, manganese dioxide, and potassium iodide. At this time, the mass of the catalyst does not decrease, and the hydrogen peroxide water is decomposed into water and oxygen by the following reaction.

The inventors of the present invention have found that the rate of decomposition reaction due to the direct contact between hydrogen peroxide water and the catalyst ferric oxide, manganese dioxide, and potassium iodide is very rapid, which makes it difficult to control bubbles. However, when the amount of the catalyst is controlled, It was confirmed through experiments that the reaction rate can be controlled sufficiently.

The decomposition reaction is carried out in the final mixing step, and it is preferable that the decomposition reaction is controlled to proceed for about 20 to 30 minutes in consideration of the time of slurry transportation and the time of construction. The catalyst used in the present invention is manganese dioxide, which is selected because it is much cheaper than potassium iodide and relatively easy to control the rate of decomposition reaction than ferric oxide.

The amount of manganese dioxide added for the present invention is advantageously 0.1-1.0 parts by weight, preferably 0.3-0.8 parts by weight, most preferably 0.4-0.6 parts by weight based on 100 parts by weight of the whole slurry. When the addition amount is less than 0.1 part by weight, the decomposition reaction rate is too slow due to the inhibitor and it is difficult to obtain the desired foam. When the addition amount is more than 1.0 part by weight, the decomposition reaction rate becomes too fast, It is preferable to inject it into the reactor.

Among the additives, there may be a reinforcing material for enhancing the strength of the foam, an initial cohesive strength, and a thickening material which is easy to control the viscosity. In the present invention, since the foam is formed at room temperature as a reinforcing material, The initial strength against the expansion after the entire construction is improved, minimizing the rebounding rate and preventing the surface cracking.

As the reinforcing material of the present invention, one kind or more of nylon fiber, glass fiber, carbon fiber, aramid fiber, rock surface fiber, pulp, various kinds of cellulose fibers and the like may be added, and the fiber thickness of the reinforcing material is preferably 20 microns or less And the length is preferably from 2 to 5 mm, and the addition amount is preferably 0.5 to 1 part by weight based on 100 parts by weight of the slurry. Since the reinforcing material enhances the strength of the foamed material, the reinforcing material may be added at a ratio higher than the above-mentioned ratio depending on the application place of the product. However, if the addition amount is less than 0.5 part by weight, it is preferable to add more than 0.5 part by weight because the function as the reinforcing material is insignificant.

On the other hand, one or more additives such as HPMC, CMC, gum arabic, MC, xanthan gum and the like are added to improve initial adhesion and viscosity control, and it is preferable to use powdery additives in the manufacturing process of the product. It is preferable to select an additive having good solubility in water to be applied to the present invention because the mixing time in the process is relatively short such as 3 to 5 minutes.

The initial cohesion and the viscosity control agent are preferably 0.5 to 3.0 parts by weight based on 100 parts by weight of the slurry, and when added in an amount of 0.5 parts by weight or less, the function is not exhibited properly. When 3.0 parts by weight or more is added, the flame retardant performance is lowered, It is preferable to add them in the above ratio.

A water-soluble organic compound can be added as another strength-enhancing agent in order to enhance the tensile strength of the foam to prevent cracks or cracks from external impacts. One or more of the water-soluble powder type melamine resin, the emulsifying type EVA powder resin, the emulsifying type acrylic powder resin, and the gum arabic can be selected as the strength enhancing agent, and as well as the viscosity adjusting agent, an additive having good solubility in water It is preferable to select it.

The strength improving agent is preferably added in an amount of 3 to 10 parts by weight based on 100 parts by weight of the slurry, and when added in an amount of 3 parts by weight or less, the strength improver is difficult to exhibit its function properly. When added in an amount of 10 parts by weight or more, It becomes difficult to work. Therefore, it is preferable to add them in the above ratio.

When 35% hydrogen peroxide was added as a foaming agent to the mortar slurry produced under the above conditions and remarried for 30 seconds, it was gradually expanded by catalytic reaction for about 20 minutes. The amount of hydrogen peroxide was adjusted by considering the target thickness Work is possible. The amount of the hydrogen peroxide solution to be added is advantageously 2 to 10 parts by weight, preferably 3 to 8 parts by weight, and most preferably 4 to 6 parts by weight based on 100 parts by weight of the slurry. When the addition amount is less than 2 parts by weight, the amount of bubbles to be generated is insufficient due to the effect of the inhibitor, so that expansion can not be obtained and thermal conductivity may be lowered. When the addition amount is 10 parts by weight or more, the effect of the inhibitor becomes insignificant, However, since the mechanical strength is lowered and it can not serve as a heat insulating material, it is preferable to add it in the above ratio.

Hereinafter, the present invention will be described in more detail with reference to the following examples. However, the present invention is not limited by the following examples.

10 g of expanded perlite having a particle size of 0.1 to 1.0 mm produced by the Company, a volume density of 0.15 g / cm 3, 30 g of 3M glass bubble (soda lime borosilicate), 10 g of fused silica of OCI, 10 g of the emulsifiable EVA resin, 2 g of manganese dioxide, 7 g of aluminum monophosphate, 10 g of pulp of 3 g of HPMC, 100 g of active magnesium oxide and 100 g of micro-pulverized magnesium sulfate were added and pre-mixed for about 15 minutes. 250 g of water was added to the premixed mixture, and the mixture was first mixed using a paddle mixer for about 3 to 4 minutes. Then, 15 g of hydrogen peroxide was added and the mixture was finally mixed for 0.5 to 1.0 minute to prepare a slurry.

After that, it was poured into a transparent acrylic jig having a size of 300 × 300 × 30 mm and then left for 30 to 60 minutes. After confirming that swelling and expansion due to sufficient foaming had been made, demoulding was carried out for complete thermal conductivity measurement And dried to a temperature of about 70 to 80 DEG C so that there is no further weight loss. Fig. 1 shows the shape of the embodiment 1. Fig.

(Figure 1)

Same as in Example 1 but 10 g of aluminum monophosphate was added. Figure 2 shows the shape of the second embodiment.

(Figure 2)

Same as Example 1 but 15 g of aluminum monophosphate was added. Figure 3 shows the shape of the third embodiment.

(Figure 3)

(Comparative Example 1)

A sample was prepared in the same manner as in Example 1 except for aluminum monophosphate.

(Comparative Example 2)

Was carried out in the same manner as in Example 1, except that magnesium sulfate was added without grinding to prepare a sample.

Three samples of each of Examples 1 to 3 and Comparative Examples 1 and 2 were produced and measured for the following experimental items and their average values were obtained and are shown in Table 1.

Item
division density
(g / cm3) Thermal conductivity
(W / mK) Expansion ratio
(After expansion / before) Compressive strength
(kg / cm2) Bubble size (mm) Foaming start time (minutes) Initial curing time (minutes) Min. Max. Example 1 0.007 0.031 2.3 8.7 0.5 1.2 22.5 35 Example 2 0.010 0.035 1.8 12.1 0.3 0.7 28.5 38 Example 3 0.016 0.046 1.3 15.4 0.1 0.3 33.5 36 Comparative Example 1 0.055 0.035 2.6 3.2 1.5 5.0 7.5 33 Comparative Example 2 0.090 0.050 1.3
(Contraction after expansion) 6.5 1.0 3.5 7.0 55

The results of Table 1 show that as the amount of aluminum monophosphate added increases, the start time of the foaming is delayed, and the amount of foaming decreases.

Also, as the amount of aluminum monophosphate was increased, the specific gravity of the foam increased, resulting in a decrease in the adiabatic property but an increase in the mechanical strength.

The addition of magnesium sulfate, which is used as a hardening agent for hydraulic mortar, without shredding, markedly retarded the initial curing time and caused a shrinking phenomenon after the expansion of the foam. The mechanical strength after complete curing was lower than that of the powder added have.

Therefore, it is possible to flexibly cope with the amount of aluminum monophosphate added by controlling the addition amount of aluminum monophosphate based on the result of the addition amount.

The repair method according to the present invention will be described with reference to the foamed mortar having fire resistance, fire resistance and excellent heat insulating performance.

FIG. 1 is a schematic view showing a process according to the present invention, and FIG. 2 is a process diagram according to FIG.

1, a paddle mixer 10 into which the raw materials and the raw materials are introduced, a hopper 20 connected to the paddle mixer 10 to feed materials therein, a pump for sucking and mixing the agitated materials, A compressor 30 and a nozzle 40 connected to the compressor 30 by a hose to blow foamed mortar to construct the equipment.

The maintenance method using the inorganic foamed mortar according to the present invention comprises a basic mortar powder production step (S10); (S20) a raw material and a raw material mixture having a thermal insulation performance and capable of improving the mechanical properties of a foamed material with a basic mortar; A mortar pre-mixing step (S30) in which a catalyst, an inhibitor, a reinforcement, and an initial adhesion promoting agent are added and mixed; A step (S40) of preparing a primary slurry by mixing the mortar pre-mixing with water; A step (S50) of preparing a foamed mortar in which a foaming agent for forming bubbles is added to the primary slurry, followed by final mixing; Casting or spraying (S60) a mortar pouring or spraying step in which a final mixed slurry is sprayed on a base surface or poured into a mold to form a uniform bubble; A step (S70) of expansion and expansion of mortar after a lapse of time; And a natural curing and drying step (S80).

After the raw material of the paddle mixer 10 into which the raw material and the auxiliary material A has been added is first stirred with water and then the foaming agent B is added to the hopper 20 to complete the second stirring, (S40-1) of injecting and spraying the mixture, so that the maximum construction thickness is 50mm / round.

FIG. 3 is a process block diagram showing another working process of the inorganic foamed mortar according to the present invention, and FIG. 4 is a process drawing of FIG.

(S50) of injecting the raw material into the hopper 20 which is a spraying equipment and then injecting the foaming agent (B) from the spraying nozzle end nozzle 40 after the step of stirring the raw material and the auxiliary material (A) -1), and it is possible to make the maximum construction thickness 100 mm / times.

While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it is clearly understood that the same is by way of illustration and example only and is not to be taken by way of limitation, It will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the present invention as defined by the appended claims and their equivalents.

10: paddle mixer
20: Hopper
30: Pumps and compressors
40: Nozzles

Claims (14)

1 to 10 parts by weight of a foaming inhibitor comprising at least one of aluminum monophosphate, magnesium phosphate and calcium phosphate per 100 parts by weight of a slurry mixed with a filler in a hydraulic mordant powder as a main raw material; 0.1 to 1.0 part by weight of a foaming catalyst comprising at least one of manganese dioxide, ferric oxide, and potassium iodide; 0.5 to 1.0 part by weight of a reinforcing material comprising at least one of nylon fiber, glass fiber, carbon fiber, aramid fiber, rock surface fiber and pulp; 0.5 to 3.0 parts by weight of an additive comprising at least one of HPMC, CMC, gum arabic, MC, xanthan gum; 3 to 10 parts by weight of a strength-increasing agent comprising at least one of melamine resin, emulsifying type EVA powder resin, emulsifying type acrylic powder resin and gum arabic; And 2 to 10 parts by weight of a foaming agent containing hydrogen peroxide, wherein the foamed mortar is fire-
The amount of the hydraulic mortar powder is 50 to 350 parts by weight based on 100 parts by weight of the filler,
The hydraulic masonry powder,
40 to 60 parts by weight of active magnesium oxide having an average particle size of 3 탆 or less and 40 to 60 parts by weight of magnesium sulfate pulverized to a size of 325 mesh or less by using a pulverizer are mixed in the raw material preparation before preparing the mortar
Nonflammable inorganic foam mortar with fire resistance and insulation performance.
delete The method according to claim 1,
The hydraulic masonry powder,
40 to 60 parts by weight of active magnesium oxide;
And 40 to 60 parts by weight of magnesium sulfate.
Nonflammable inorganic foam mortar with fire resistance and insulation performance.
The method according to claim 1,
Wherein the magnesium sulfate is any one of anhydride, pentahydrate, heptahydrate and octahydrate.
Nonflammable inorganic foam mortar with fire resistance and insulation performance.
(S10) of producing a hydraulic mortar powder as a main raw material; (S20) of mixing a raw material and a raw material for mixing a filler having an adiabatic performance and improving mechanical properties of the foam with a basic mortar; A mortar pre-mixing step (S30) in which a catalyst, an inhibitor, a reinforcement, and an initial adhesion promoting agent are added and mixed; A step (S40) of preparing a slurry to be mixed with water in the mortar pre-mixing; A step (S50) of preparing a foamed mortar in which a foaming agent for forming bubbles is added to the slurry, followed by final mixing; A method for producing a nonflammable inorganic foamed mortar having fire resistance and thermal insulation performance, comprising a mortar casting or spraying step (S60) in which a final mixed slurry is sprayed on a base surface or cast into a mold to form uniform bubbles,
As a process for producing the hydraulic masonry powder,
40 to 60 parts by weight of active magnesium oxide having an average particle size of 3 占 퐉 or less and 40 to 60 parts by weight of magnesium sulfate pulverized to a size of 325 mesh or less by using a pulverizer are mixed in the raw material preparing step before the production of the mortar
A method for producing a nonflammable inorganic foamed mortar having fire resistance and heat insulation performance.
delete 6. The method of claim 5,
As a process for improving the heat insulation and fire resistance, preventing the cracks and deformation of the foam, and improving the mechanical strength,
Foam silica, Carbonate lime borosilicate, Aerogel, Fly ash, Aluminum hydroxide, Magnesium oxide, Expanded vermiculite, Diatomaceous earth, Wollastonite, Sericite, Stalactite , And talc. ≪ RTI ID = 0.0 >
A method for producing a nonflammable inorganic foamed mortar having fire resistance and heat insulation performance.
6. The method of claim 5,
To improve the heat insulation and fire resistance, to prevent cracks and deformation of the foam, and to improve the mechanical strength,
It is preferable to add one or more of 5 mm diameter or shredded foam (EPS), nylon fiber, glass fiber, carbon fiber, aramid fiber, rock wool, pulp and various kinds of cellulose- And one or more of HPMC, CMC, MC, xanthan gum, and modified starch to control the viscosity of the slurry
A method for producing a nonflammable inorganic foamed mortar having fire resistance and heat insulation performance.
delete delete delete Basic mortar powder manufacturing step; A raw material and a sub-material mixing step of mixing a filler having an adiabatic performance and improving the mechanical properties of the foam with a basic mortar; A mortar pre-mixing step of adding a catalyst, an inhibitor and a reinforcing agent, and an initial adhesion promoting agent to the mixture; Mixing the mortar pre-mixing with water to produce a slurry; Adding a foaming agent to the slurry to form bubbles, and finally mixing the foamed mortar; A mortar casting or spraying step in which a final mixed slurry is sprayed on a base surface or cast into a mold to form a uniform bubble; Expanding the mortar foaming after the lapse of time; A maintenance method using a nonflammable inorganic foamed mortar having fire resistance and heat insulation performance including a natural hardening and drying step,
In the mortar powder production step,
40 to 60 parts by weight of active magnesium oxide having an average particle size of 3 μm or less and 40 to 60 parts by weight of magnesium sulfate pulverized to a size of 325 mesh or less by using a pulverizer are mixed in the raw material preparation before preparing the mortar,
And a step of injecting the raw material into a hopper as a spraying equipment after the step of first stirring the raw material and the raw material with stirring and then injecting the foaming agent at a spray nozzle end nozzle so as to be able to perform a maximum construction thickness of 100 mm / Characterized by
Repair method using nonflammable inorganic foamed mortar with fire resistance and insulation performance. delete delete

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