Refractory heat insulation material and method for producing the same

Abstract

Based on the total weight of the material, 19-40% by weight of porous glass balls with a diameter of 0.3-1 mm and 1370-1400 kg / m 3 A fire-resistant heat insulating material comprising a curable compound containing 60 to 81 weight percent of an aqueous sodium silicate solution having a density in the range of 100 to 1500 rpm and a molar ratio of SiO2 to Na2O in the range of 3.2 to 3.4, 0.1 to 1 weight percent of a glass binder stabilizer, 2 to 10 weight percent of chopped basalt fiber, and 0.1 to 0.9 weight percent of carbon black, wherein the carbon black is provided on the surface of a porous glass ball. A continuous process for producing a fire-resistant insulating material, comprising the steps of: first, mixing porous glass balls with an aqueous carbon black solution so that the entire surface of the porous glass balls is covered with carbon black; then, mixing the porous balls with the carbon black with chopped basalt fibers, and mixing them to form an insulating compound; second, adding a water glass stabilizer to an aqueous sodium silicate solution, then adding a hardener to the solution, and then stirring the solution for 1 to 10 minutes to form a binder solution; third, pouring the insulating compound into the binder solution with constant stirring, mixing the whole, then pouring the resulting mixture onto an application site; and finally, leaving the resulting mixture to harden.

Description

Technical Field

[0001] The present invention relates to a refractory heat-insulating material, in particular a refractory heat-insulating material composed of a compound containing water glass, and a method for manufacturing the same.

Background Art

[0002] From current technologies, mixtures of all ranges of mortar and concrete are known that are used not only as common building materials but also for fire protection and heat insulation of buildings.

[0003] Among known foamed heat-insulating masonry materials, for example, polystyrene concrete can be mentioned. Its base is foamed polystyrene balls of various sizes with a diameter of 2 to 6 mm. These balls are surface-treated and remain separated to eliminate electrostatic attraction. Polystyrene concrete is constructed on a horizontal surface like concrete or panelized.

[0004] From Czech Patent Document CZ PV 2003-2196, a mortar for the top layer of plaster is known that contains perlite as a filler and bentonite as an insulator and is intended as a sound-absorbing and refractory layer. The disadvantage of this mortar is that bentonite has low fire resistance and heat insulation. A further disadvantage is that bentonite has high absorbency and swells in water, which is why bentonite is not suitable as an exterior plaster.

[0005] Furthermore, from Russian Patent Document RU 2687816, foamed concrete having perlite and kaolin wool, cellulose, and silicate fiber is known. The disadvantages are that this material does not have significant fire-resistant properties, has low mechanical strength, and is brittle.

[0006] From Czech Patent Document CZ PV 2004-536, a masonry material is known whose binder is a lime solution. The fillers are slag, clay, crushed quartz, and limestone. The material is reinforced with steel wire. The disadvantages are that it is not a heat-insulating material and that it is relatively absorbent.

[0007] From another Czech Patent Document CZ PV 1990-6611, masonry and coating materials with a binder and a dispersion in the form of soluble cellulose are known. This material contains water glass, which here does not fulfill the function of a binder but is an additive. In addition to a basic pulverulent filler, granular polystyrene or perlite is added. The disadvantages of this material are that it is not fire-resistant and that it has low heat-insulating and sound-insulating properties.

[0008] From Czech Utility Model CZ 23529, geopolymers based on slag and water glass are known. The water glass is treated with sodium hydroxide. Ceramic balls are added for weight reduction. The disadvantages are that this material is heavy, has no heat resistance, and is relatively absorbent.

[0009] From further Chinese Patent Document CN102964107, panels composed of perlite, glass fiber, clay, and silica gel are known, where the main binder is clay. The disadvantages are that the panels have low heat-insulating properties, are absorbent, and are not fire-resistant.

[0010] From Czech Utility Model CZ 31096, compounds for a glass-based permeable refractory foam insulation system are known, which contain glass balls with heat stability up to 1000°C. The disadvantages are that the compressive strength is lower and the heat resistance is lower.

Prior Art Documents

Patent Documents

[0011]

Patent Document 1

Patent Document 2

Patent Document 3

Patent Document 4

Patent Document 5

Patent Document 6

Patent Document 7

Summary of the Invention

Problems to be Solved by the Invention

[0012] From the above current technology, it is clear that the main drawbacks of the current technology are that the known materials have low heat resistance and fire resistance, and at the same time, they are often very absorbent.

[0013] The object of the present invention is to construct a refractory heat-insulating material having high fire resistance and excellent heat-insulating properties at the same time.

Means for Solving the Problems

[0014] The above drawbacks are significantly removed, and the object of the present invention is achieved by a compound for a refractory heat-insulating material, particularly a refractory heat-insulating material containing water glass. According to the present invention, this compound contains 19 to 40% by weight of porous glass balls and has a density in the range of 1370 to 1400 kg / m 3 and an SiO in the range of 3.2 to 3.4 2 to Na 2It contains a 60 - 81 wt% aqueous sodium silicate solution having a molar ratio of O, a 0.1 - 1 wt% water glass binder stabilizer, and further contains 2 - 10 wt% chopped basalt fiber. Carbon black is provided on the surface of a porous glass ball having a diameter of 0.3 - 1 mm, and the carbon black constitutes 0.1 - 0.9 wt% of the total weight. The advantages of this heat insulating material are its high fire resistance and excellent insulation properties. This heat insulating material also has an excellent antifungal effect and is environmentally friendly. The advantages of this fire - resistant heat insulating material are its extremely high fire resistance and excellent heat insulation. The advantage of using an aqueous sodium silicate solution is that the resulting material has excellent adhesion and sealing effects. Its heat resistance is above 1000 °C. After curing, since it has the form of glass, it is sufficiently hard, strong, water - resistant, and at the same time it is even vapor - permeable. The molar mass ratio of silica to sodium oxide, and the related density and concentration of the solution have a significant impact on the rheological properties of water glass as a polymer mixture, electrical properties such as in electrolytes, compressibility and adhesion strength, and further hardness, strength, etc. The advantage of the above - mentioned parameters is that the resulting heat insulating material is partially flexible and also flexible after solidification. The advantage of providing carbon black on the surface of the porous glass ball is that the carbon black thus provided does not increase the thermal conductivity, and the carbon black favorably wraps the porous glass ball, thereby increasing the radiation impermeability.

[0015] Advantageously, the basalt fiber has a length of 6 mm and a thickness of 0.014 mm. The fiber is flexible, has high strength and flexibility, low thermal conductivity, high heat resistance, is water - resistant, has chemical resistance to alkalis, acids, and organic solvents, has a high sound absorption coefficient, and is incombustible.

[0016] It is also very advantageous for the porous glass balls to contain 12 to 16% by weight of aluminum oxide. Thanks to this, they have a higher heat resistance, are very hard, and have chemical and mechanical resistance. They are of purely inorganic origin, they are environmentally friendly and do not harm health. In contrast to conventional glass balls, they can withstand temperatures up to 1,400 °C. At the same time, for example, unlike ceramic balls, they are thin-walled and contain a large amount of air, so they are excellent heat insulators.

[0017] It is also advantageous for the water glass stabilizer to be a hydrophilic alkoxyalkyl-ammonium salt.

[0018] A further advantageous refractory heat-insulating material contains a water glass hardener. The advantage is that it is possible to optimize the curing rate.

[0019] The above-mentioned disadvantages are largely eliminated, and the object of the present invention is achieved by a method for manufacturing a refractory heat-insulating material, in particular a method for manufacturing a refractory heat-insulating material containing water glass. The present invention first mixes porous glass balls with an aqueous carbon black solution so that their entire surface is coated, then mixes the porous glass balls with carbon black with chopped basalt fibers, and mixes them to form a heat-insulating compound. Add a water glass stabilizer to an aqueous sodium silicate solution, then add a hardener to this solution, then stir the solution for 1 to 10 minutes to form a binder solution, then pour the heat-insulating compound into the binder solution while constantly stirring, mix everything, then pour the resulting mixture into the application site and let it stand until the resulting mixture hardens.

[0020] It is even more advantageous if the application site is a mold. The advantage is that it is possible to easily manufacture a product with precise parameters.

[0021] The main advantages of the refractory heat-insulating material and its manufacturing method according to the present invention are that the obtained material has excellent fire resistance and heat-insulating properties, while being permeable and relatively lightweight. There is also the advantage that the water glass used ensures the non-combustibility of the entire compound. A further advantage is that the combination of glass balls, basalt fiber, carbon black and sodium silicate - water glass - creates a material that is simultaneously very hard, strong and resistant to high pressure. It is non-flammable, but has heat resistance comparable to refractory clay or dinas earth (silica). At the same time, it is purely inorganic and thus an environmentally friendly and harmless material. This can be used as a compound for foamed concrete, as well as for floor fillers, etc., or after drying and curing for manufacturing panels and blocks. These can be used as masonry materials, or for the heat insulation or protection of existing masonry.

Embodiments for Carrying Out the Invention

[0022] Example 1

[0023] The refractory heat-insulating material is composed of a curable compound containing 30% by weight of porous glass balls, 64% by weight of an aqueous sodium silicate solution, and 0.5% by weight of a water glass binder stabilizer.

[0024] The refractory heat-insulating material further contains 5% by weight of chopped basalt fiber.

[0025] The porous glass balls have a diameter of 0.5 mm and contain 15% by weight of aluminum oxide.

[0026] On the surface of the porous glass balls, carbon black constituting 0.5% by weight of the total weight is provided.

[0027] The water glass stabilizer is a hydrophilic alkoxyalkyl-ammonium salt in the form of a 98% aqueous solution of N,N,N',N'-tetrakis(2-hydroxypropyl)ethylenediamine.

[0028] The refractory heat-insulating material further contains a water glass hardener, which is a compound of pure glycerol diacetate / triacetate, at a concentration of 2% by weight with respect to pure water glass and in a volume ratio of 7:3.

[0029] The density of the aqueous sodium silicate solution is 1380 kg / m 3 and the molar ratio of SiO 2 to Na 2 O is 3.3.

[0030] According to the method for manufacturing the heat-insulating material, first, porous glass balls are mixed with an aqueous carbon black solution so that the entire surface is coated, then the porous glass balls with carbon black are mixed with chopped basalt fibers, and these are mixed to form a heat-insulating compound. A water glass stabilizer is added to this aqueous sodium silicate solution, then a hardener is added to this solution, then this solution is stirred for 5 minutes to form a binder solution. Then, the heat-insulating compound is poured into the binder solution while continuously stirring, and the whole is further mixed. Then, the obtained mixture is poured into a coating site which is a silicon mold and left to stand until the obtained mixture is cured. Carbon black is added to the compound in the form of an aqueous solution with a concentration of 25% by weight.

[0031] Example 2

[0032] The refractory heat-insulating material is composed of a curable compound containing 37% by weight of porous glass balls, 60% by weight of an aqueous sodium silicate solution, and 0.9% by weight of a water glass binder stabilizer.

[0033] The fireproof material further contains 2% by weight of chopped basalt fibers.

[0034] The porous glass balls have a diameter of 1 mm and contain 12 wt% aluminum oxide.

[0035] On the surface of the porous glass balls, carbon black constituting 0.1 wt% of the total weight is provided.

[0036] The water glass stabilizer is a hydrophilic alkoxyalkyl-ammonium salt in the form of a 98% aqueous solution of N,N,N’,N’-tetrakis(2-hydroxypropyl)ethylenediamine.

[0037] The fireproof material further contains a water glass hardener, which is a compound of pure glycerol diacetate / triacetate at a concentration of 0.5 wt% with respect to pure water glass and in a volume part ratio of 7:3.

[0038] The density of the aqueous sodium silicate solution is 1370 kg / m 3 and the molar ratio of SiO 2 to Na 2 O is 3.2.

[0039] According to the method for manufacturing the heat insulating material, first, the porous glass balls are mixed with an aqueous carbon black solution so that the entire surface is coated, then the porous glass balls with carbon black are mixed with chopped basalt fiber, and these are mixed to form a heat insulating compound. A water glass stabilizer is added to this aqueous sodium silicate solution, then a hardener is added to this solution, then this solution is stirred for 1 minute to form a binder solution. Then, the heat insulating compound is poured into the binder solution while continuously stirring, and further mixed as a whole. Then, the obtained mixture is poured into a silicon mold at the application site and left to stand until the obtained mixture hardens. The carbon black is added to the compound in the form of an aqueous solution with a concentration of 25 wt%.

[0040] Example 3

[0041] The refractory heat-insulating material is composed of a curable compound containing 19% by weight of porous glass balls, 70% by weight of an aqueous sodium silicate solution, and 0.1% by weight of a water glass binder stabilizer.

[0042] The fireproof material further contains 10% by weight of chopped basalt fiber.

[0043] The porous glass balls have a diameter of 0.5 mm and contain 16% by weight of aluminum oxide.

[0044] On the surface of the porous glass balls, carbon black constituting 0.9% by weight of the total weight is provided.

[0045] The water glass stabilizer is a hydrophilic alkoxyalkyl-ammonium salt in the form of a 98% aqueous solution of N,N,N’,N’-tetrakis(2-hydroxypropyl)ethylenediamine.

[0046] The refractory heat-insulating material further contains a water glass hardener, which is a compound of pure glycerol diacetate / triacetate at a concentration of 5% by weight with respect to pure water glass and a volume ratio of 7:3.

[0047] The density of the aqueous sodium silicate solution is 1400 kg / m 3 and the molar ratio of SiO 2 to Na 2 O is 3.4.

[0048] According to the method for manufacturing a heat insulating material, first, porous glass balls are mixed with an aqueous carbon black solution so that the entire surface thereof is coated, then the porous glass balls provided with carbon black are mixed with chopped basalt fibers, and these are mixed to form a heat insulating compound. A water glass stabilizer is added to this aqueous sodium silicate solution, then a curing agent is added to this solution, then this solution is stirred for 10 minutes to form a binder solution, then the heat insulating compound is poured into the binder solution while continuously stirring, and further the whole is mixed. Then, the obtained mixture is poured into a coating site which is a silicon mold, and left to stand until the obtained mixture is cured. Carbon black is added to the compound in the form of an aqueous solution having a concentration of 25% by weight.

Industrial Applicability

[0049] The refractory heat insulating material according to the present invention has a wide range of uses particularly in the construction industry. For example, it can be used as a substitute for foamed concrete for leveling floors and ceilings with low construction loads, and also as a refractory, heat resistant and water resistant heat insulating material. Further, it is possible to manufacture panels or blocks provided as a masonry material having heat insulating properties, fire resistance, permeability and antifungal properties, or as a coating material on an existing masonry.

Claims

1. 19 to 37.8% by weight of porous glass balls, 60 to 81% by weight of an aqueous sodium silicate solution having a density in the range of 1370 to 1400 kg / m3 and a molar ratio of SiO2 to Na2O in the range of 3.2 to 3.4, 0.1 to 1% by weight of a water glass binder stabilizer, and consisting of a curable compound, further comprising 2 to 10% by weight of chopped basalt fibers, carbon black is provided on the entire surface of the porous glass balls having a diameter of 0.3 to 1 mm, and the carbon black constitutes 0.1 to 0.9% by weight of the total weight, The water glass binder stabilizer is a hydrophilic alkoxyalkylammonium salt, and is a refractory heat insulating material.

2. The refractory heat insulating material according to claim 1, wherein the porous glass balls contain 12 to 16% by weight of aluminum oxide.

3. The refractory heat insulating material according to any one of claims 1 or 2, further comprising a water glass curing agent.

4. A method for manufacturing the refractory heat insulating material according to any one of claims 1 to 3, First, the porous glass balls are mixed with an aqueous carbon black solution so that the entire surface thereof is coated with carbon black, Next, the porous glass balls provided with carbon black are mixed with chopped basalt fibers to form a heat insulating compound, Then, after adding a water glass binder stabilizer to the aqueous sodium silicate solution, a curing agent is added to this solution and stirred for 1 to 10 minutes to form a binder solution, Next, the heat insulating compound is poured into the binder solution while continuously stirring, and the whole is mixed, Next, the obtained mixture is poured into the application site, Finally, the obtained mixture is allowed to stand until it cures, and is a method for manufacturing a refractory heat insulating material.

5. The method for manufacturing a refractory heat insulating material according to claim 4, wherein the application site is a mold.