DE2248304B2 - PROCESS FOR MANUFACTURING NON-COMBUSTIBLE, LIGHTWEIGHT, SHAPED BODY - Google Patents

Description

The invention relates to a method for producing non-flammable, lightweight molded bodies from water glass, inorganic fibers and silicon or silicon alloys by shaping the moldings and then Warming.

In recent times, more and more emphasis is placed on the safety of building elements for buildings against fire placed. The use of non-combustible building materials can cause Fire can be prevented. In addition, for reasons of static load, it is just as off For reasons of heat and sound insulation, it is advisable to use lightweight building materials. These must non-flammable building materials not only be fireproof, but they must also be non-flammable themselves. These Non-flammable building materials must have a number of special properties: They should be do not deform, break or break when exposed to high temperatures, they are not intended to Cracks form through which the flames could penetrate, and the flame should be applied to the fire extinguishing operations Building materials disappear within a short time. They should also be good sound and heat insulating.

The usual non-flammable building elements that are sufficiently fireproof usually have a high Weight and are therefore not suitable for modern lightweight construction methods.

It is known (DT-AS 11 27 270), heat-resistant and to produce porous moldings by optionally using fibers or other reinforcing materials mixed alkali silicate solution evaporated so far to dryness that it still contains 10 to 35% water. That The product obtained is then crushed, brought into a mold and immediately raised to a high Temperature heated. This process gives moldings with low density, but it is in its Implementation relatively cumbersome. In order to avoid such a cumbersome implementation, the known methods for producing such possibly porous molded bodies from alkali silicate are further developed, that the alkali silicate particles are deformed with a corresponding water content when heated, and the molded body produced in this way, optionally another

Heat treatment above 200 "C, expediently between 200 and 600 ° C. Such Moldings, however, tend to grow and are naturally not very water-resistant. They are therefore suitable as No building materials or only to a very limited extent.

It is already known (US-PS 34 46 221) to produce molded bodies from water glass, which are used for reinforcement inorganic fibers and also powder of silicon or silicon-containing alloys is added to so that the water glass is foamed. The sale iu tion is carried out at room temperature or at temperatures up to 90 °, so that the above described known processes very high temperatures are avoided. These known molded bodies However, they are only suitable for use as fireproof components to a limited extent, since the Exposure to heat and flame cracks occur through which flames can penetrate, even if the material itself is not flammable. The moldings produced by this last-mentioned process also have a relatively high weight, since the weight reduction is solely due to the reaction of silicon is achieved with the water glass.

It is the object on which the invention is based to provide a method for the production of moldings, in particular to create components that are much lighter than the known and absolutely fire-proof are, d. H. Not only are they not flammable themselves, but also when exposed to heat or flames, no cracks let occur through which flames could penetrate.

According to the invention, this is achieved in a method of the type mentioned in that the to Shaped bodies to be processed from a mixture of substances

a) 100 parts by weight of a powder made of silicon or a silicon-containing mixture,

b) 100-2000 parts by weight of an inorganic powder with porous or hollow spaces Structure,

c) 100-1200 parts by weight of water glass,

d) up to 80 parts by weight per 100 parts by weight of the total of a), b) and c) of a fibrous Materialund

e) up to 80 parts by weight per 100 parts by weight of the total of a), b) and c) one of the Fire resistance improving material

consists, wherein the mass to be deformed is compressed to a specific density of the shaped body which is 1.5 to 12 times that of the initial mass, and that the resultant Molded body is kept at a temperature between 15 and 120 ° C for foaming and curing.

This method according to the invention surprisingly makes it extremely easy refractory moldings are produced which do not form cracks, especially when exposed to flames, could pass through the flames. This property of avoiding cracking under The expert could not foresee the effects of fire. In the method according to the invention a Reduction in weight, as is known, achieved by the hydrogen gas produced by the reaction between Siiicium and the water glass is released, but the weight reduction is still quite significant increased by the addition of an inorganic porous or voided powder.

The silicon-containing mixture preferably contains ferro-silicon. Calcium silicide. Ferrosilicoaluminum. Silicon manganese aluminum, Calcium silicon manganese, silicon manganese or silicochrome.

The inorganic powder with a porous structure or structure having voids is preferably a powder made of perlite stone, pumice stone microspheres, carbon microspheres, Glass microspheres, foamed pumice stone, foamed clay or vermiculite.

The fibrous material is preferably chrisotile asbost, hard serpentine asbestos, anthophyllite asbestos, amosite asbestos, tremolite asbestos, actinolite asbestos, crocidolite asbestos, Rock wool, slag wool, glass fibers or metal fibers.

The fire resistance improving material is preferably an inorganic powder which is crystal water in the form of water vapor at high temperature, or an inorganic powder that releases consumed in an endothermic process at high temperature, or a mixture of these powders. The inorganic powder, which releases water vapor at high temperatures, can be aluminum hydroxide, Calcium hydroxide, clays, alum, hydrogenated gypsum, sodium sulfate hydrate or disodium phosphate hydrate and the inorganic which is consumed at high temperature in an endothermic process Powder, a powder made from calcium carbonate, magnesium carbonate, zinc carbonate, cadmium carbonate, sodium nitrate, Be lead nitrate, aluminum sulfate, ammonium phosphate, ammonium carbonate or ammonium sulfate.

A method for continuously producing a non-flammable lightweight molded article from a Mixture of substances of the above-explained materials according to the invention is preferably that the mixture is fed into a pressure space between an endless belt and a conveyor plate is formed, wherein the pressure space opposite, inner surface of the endless belt in Contact with pressure rollers is, and the conveyor plate at about the same speed and in the the same direction as the endless belt is moved, whereby the compression deformation is continued so far, until the apparent density of the compressed molding is 1.5 to 12 times that of the starting mixture has, whereupon the shaped body is held in reaction chambers at a temperature of 15 to 120 ° C in such a way becomes that foaming and hardening of the molded body occurs.

Thus, according to the invention, one can obtain a non-flammable, lightweight, molded article which has high mechanical strength, e.g. B. a flexural strength or a compressive strength, and the is heat-resistant and water-resistant, whereby it does not disintegrate in the event of impact, and the pores or cavities of the inorganic powder are not noticeably destroyed.

Not only is this article light and non-flammable, it also has one excellent fire resistance. When the article is used to test its fire resistance by a flame If a high temperature is heated, its fire resistance or structure will not be detrimental influenced, for example, there is no deformation, no disintegration, no peeling or the like. It is also no cracking is to be expected through which the passage of flames would be possible. The temperature on the the surface opposite the heated surface does not rise sharply, although the temperature rise of depends on the thickness of the molded article, and thus the article retains its fire resistance. One Flames or smoke develop during the

Not heating, and after heating the fire extinguishes very quickly.

The article has a good appearance and can be easily and continuously manufactured will.

The item can be sawed and nailed, so it can be used as well become like wood. The article is therefore as a component that should not burn, for example as a material for Roofs, ceilings, floors, interior and exterior walls, and as a material for decorative purposes and furniture are very good usable.

The invention is explained in more detail below with reference to the drawings of exemplary embodiments.

The drawings show an apparatus for the continuous production of a non-combustible very light molded body, namely

F i g. 1 shows a longitudinal section through such a device and

Fig. 2 is a section along the line 11-11 in Fi g. 1.

The material to be deformed 2 is stored in a funnel 1. Pressure rollers 3 to 10 are with the Inner surface of the endless belt 11 in contact. The rollers are spaced from each other and are with increasing distance from the funnel 1 stored deeper and deeper. 12 and 13 are drive rollers and 14 and 16 are guide rollers. The pressure rollers 3 to 10, the drive rollers 12 and 13 and the tape guide rollers 14 to 16 all touch the inner surface of the endless belt 11. This endless belt 11 moves in Direction of the arrow in Fig. 1 by rotating the drive rollers 12 and 13. In the section in which the Rolls 3 to 10 are provided, the surface of the endless belt 11 gradually presses more and more the material 2, this material being conveyed. The tension of the endless belt 11 is through the Guide rollers 14 to 16 maintained, while at the same time a zigzag movement of the endless Band 11 is prevented. Under the endless belt 11 is a conveyor plate 17, which is roughly the same 4 (1 Speed and moves in the same direction as the endless belt. The conveyor plate rests on several support rollers 18 and can be moved by drive roller 19.

The conveyor plate 17 can consist of a hard, flat 4 "> Plate exist, but you can also use an endless belt that rests on several rollers. In in this case, the endless belt used in place of the conveyor plate 17 can be used in the same Direction in which the endless belt 11 is moved in the printing roller section. The conveyor plate 17 can also can be made from several plates, and in this case the long plates are moved on support rollers.

From Fig. 2 it can be seen that side walls 20 provided upright and facing each other vi are, which cover the two side ends of the endless belt in the part where the pressure rollers 3 to 10, the Drive rollers 12 and 13 and the lateral ends of the lower part of the endless belt 11 and the two Ends of the stripe part 1 lie, whereby a pressure space mi 21 between the endless belt 11, the guide plate 17 and the funnel 1 is formed.

The pressure chamber 21 gradually narrows from the funnel 1, since the rollers 3 to 10 are increasingly disordered. The cross-sectional area of the pressure roughness μ slot 21 thus gradually decreases from the point of the pressure roller 3 to the pressure roller 10. The preferred ratio of the cross-sectional area of the pressure space 21 at the location of the pressure roller 10 to that at the location of the pressure roller 3 is in the range from 1/20 to 1/3, preferably in the range from 1/10 to 1/4. When the ratio of the cross-sectional areas becomes smaller than about 1/20, the compressive forces become too large and the pores of the inorganic powder in the molding material collapse, and it is sometimes impossible to obtain a light object. If the ratio is more than 1/3, the compressive force is too small and the molded article may be destroyed if the impact occurs. The thus produced non-flammable molded article is low in strength and open pores occur, thereby lowering fire resistance.

If the aspect ratio is between 1/20 and 1/3, the molding material can be deformed so much be that the compromised material has a density 1.5 to 12 times higher than the density before Compression lies.

It is necessary that the first pressure rollers at the funnel 1 in the direction of movement of the belt 11 are stored increasingly deeper. The last pressure roller 10 and the adjacent pressure roller 9 or other pressure rollers, which are immediately adjacent, can also be arranged at the same height, so that the material is deformed into a flat plate. In Fig. 1 is the material to be deformed by the pressure rollers 3 to 8 are pressed together, and the shaping into a plate is carried out by the Print rollers 9 and 10.

In Fig. 2, reference numerals 22 and 23 denote Screws to fix the wall panels 20, and the vertical position of the pressure roller 4 is through a Adjusting device 24 set by which the cover roller 4 can be moved up and down. the Power supplied by a motor is transmitted via a sprocket 27 attached to a shaft 28 is attached, which in turn delivers the power to sprockets 25 and 26 to drive the endless belt.

The object which has been produced by compression and molding between the conveyor plate 17 and the pressure rollers 3 to 10 in the pressure space 21 is then introduced into reaction chambers 29, 30 and 31. A plurality of conveyor rollers 32 are provided in each of these reaction chambers. As the conveyor plate 17 passes through the reaction chambers 29, 30 and 31 by means of the conveyor rollers 32, the shaped article, which is delivered from the pressure chamber 21, is guided one after the other through the reaction chambers. The reaction chambers 29 and 30 contain a tube 33 through which a medium serving for heating or cooling is supplied, e.g. B. hot or cold air to adjust the temperature of the chambers to a value of about 15 to 120 ⁰ C.

The alkali hydroxide reacts in these reaction chambers, which forms in the shaped body as a result of the hydrolysis of the water glass, with silicon or in the This alloy contains silicon, which releases hydrogen, which causes foaming of the molded article causes. The molded body is formed by the foaming process and the evaporation of water hardened to form the desired, non-flammable, shaped object.

The reaction chambers 29, 30 and 31 also contain outlets 35, 36 and 37 so that there is a risk of failure Explosion by hydrogen is avoided. The molded body, which is foamed and hardened, is before

the reaction chamber 31 is delivered to the conveyor roller 34. The resulting, non-flammable, molded article is then cut to the desired dimensions and forms the final product. In the following examples, the proportions given are parts by weight, unless otherwise specified be made. The properties given in the examples were illustrated by those shown below Procedure determined.

Incombustibility

The sample was heated for three minutes with a town gas burner, using 1.5 liters of air per minute were supplied, then there was additional heating with a heating furnace, the nickel-chrome wire as a heating element and had an output of 1.5 kW / h. This additional heating lasted 17 minutes. Smoke, Flaming and burning was observed, and by a synthetic determination of all of these Phenomena, the non-combustibility of the sample was determined.

Water resistance

The sample was immersed in hot water at 80 ^° C. for 48 hours. The flexural strength of the sample before immersion became the same as that after immersion

it was heated for two hours and the temperatui of the molded article was 1010 ° C, then the maximum temperature was the opposite rear surface at 245 ° C. In addition, when heated, neither deformation nor Destruction or degradation was observed, and cracks did not occur either. After the heating it went out Flame instantly. An analysis of the sample after the experiment showed that the aluminum hydroxic converted to alumina by dehydration.

The article had an apparent density of 0.65, a flexural strength of 22 kg / cm ^2, and a compressive strength of 28 kg / cm ² . It was also very waterproof and suitable as a building material for decks or walls.

Example 2

Each of the following mixtures (Sample Nos. 1 to 3] were treated in the same way as in Example 1, except that the Deformation conditions were applied, which are set out in the table. The characteristics of the so obtained articles are summarized in the table.

Sample # 1

compared, making the water resistance example 1 a) Ferrosilicon the sample a) 30th c) 35 a) Ferrosilicoaluminum Ferrosilicon 100 parts was determined. (Grain size smaller than 325 microns) d) (Grain size smaller than 325 microns) b) pearlite rock b) Obsidian pearlite 600 parts (less than 500 microns) e) (Grain size smaller than 500 microns) 500 parts c) water glass Water glass d) asbestos
(Fiber length less than 30 mm) 100 parts asbestos 80 parts e) aluminum hydroxide (Fiber length less than 31 mm) 660 pieces Calcium silicate hydrate 320 parts 540 parts (Grain size smaller than 100 microns) 100 parts Sample # 2 600 parts

A mixture containing the above ingredients (apparent density 0.24) was poured into a mold given their dimensions

900 mm 900 mm χ 47 mm

would have. The mixture was molded at a pressure of 27 kg / cm ^2. The shaped body had an apparent density of 0.79. The molded article was taken out of the mold. The sodium hydroxide formed upon hydrolysis of the water glass reacted with the silicon contained in ferro-silicon, releasing hydrogen gas, curing the molded article at 45 ° C. The molded article had an apparent density of 0.71. The article was excellently non-flammable, no smoke, no flame, and no residual flame formation was observed.

The article has been tested for fire resistance. if

(Grain size less than 325 microns) 100 parts

b) pearlite rock

(Grain size less than 500 microns) 540 parts

c) water glass 430 parts

d) rock wool

(Fiber length less than 30 mm) 70 parts

e) disodium phosphate hydrate

(Grain size less than 100 microns) 290 parts

Sample # 3

a) Calcium silicide

so (grain size less than 325 microns) loo parts

b) pumice stone microspheres

(less than 500 microns) 300 parts

c) 200 parts water glass

d) Amositasbestos

(Fiber length less than 10 mm) loo parts

e) calcium carbonate

(Grain size less than 100 microns) 175 parts

Tabel

Sample no.
1

Deformation conditions

Apparent density of the mixture before

Deform

Shape size (mm)

χ 900 χ 38

0.13

900 χ 900 χ 37

0.19

900 χ 900 x 40

ίο

continuation

Sample no.

Pressure force during deformation (kg / cm ² ) 26

Apparent density of the deformed mixture 0.70

Reaction temperature (0 ⁰ C) 45

Properties of the deformed article Apparent density (g / cm ³ )

Flexural strength (kg / cm ² )

Compressive strength (kg / cm ² )

Incombustibility

Water resistance (kg / cm ² )

Thermal insulation (kcal / m h "C)

Fire resistance

Duration of heating (hours)

Temperature of the heated surface (° C) Maximum temperature of the opposite, rear surface ( ⁰ C)

Deformation, destruction, degradation and cracking results of the analysis

Fire resistance test

From the table above it can be seen that the objects were not flammable and did not develop smoke, flames or residual flames and 20
0.63

45

15 0.68

45

0.64 0.57 0.60 20th 26th 12th 28 31 15th excellent excellent excellent 18th 23 10 0.13 0.10 0.11 1 1 1 925 925 925 255 256 250 no no no Calcium silicate Disatrium Calcium carbonate hydrate was in phate hydrate became to Calcium silicate in disatriumph Calcium oxide converted phat converted decomposed

Article immediately after switching off the flames used for heating.
The articles had good water resistance and

exhibited excellent fire resistance. In the 35 were suitable as building materials such. B. for ceilings and Fire resistance test, the flame on the wall went out.

For this purpose 2 sheets of drawings

Claims (8)

Patent claims: 1. Process for the production of non-flammable, lightweight moldings from water glass, inorganic Fibers and silicon or silicon alloys by shaping the moldings and subsequent heating, characterized in that the mixture of substances to be processed into molded bodies consists of a) 100 parts by weight of a powder made of silicon or a silicon-containing mixture, b) 100-2000 parts by weight of an inorganic powder with porous or cavities Structure, c) 100-1200 parts by weight of water glass, d) to 80 parts by weight per 100 parts by weight of the total of a), b) and c) of a fibrous Materials and e) up to 80 parts by weight per 100 parts by weight of the total of a), b) and c) one of the Fire resistance improving material consists, wherein the mass to be deformed is compressed to a specific density of the molded body, which is 1.5 to 12 times that of the starting material, and that the resulting molded body is kept at a temperature between 15 and 120 ⁰ C for foaming and curing . 2. The method according to claim 1, characterized in that a silicon-containing mixture, the Ferrosilicon, calcium silicide, ferrosilicoaluminium, Silicomanganaluminum, calcium silicomanganese, SiIicomangan or Silicochrom contains used will. 3. The method according to claim 1 or 2, characterized in that as the inorganic powder with porous or voided structure perlite stone, pumice stone microspheres, carbon microspheres, Glass microspheres, foamed pumice stone, foamed clay or vermiculite are used will. 4. The method according to any one of claims 1-3, characterized in that as a fibrous Material chrysotile asbestos, hard serpentine asbestos, anthophyll asbestos, amosite asbestos, tremolite asbestos, Actinolite asbestos, crocidolite asbestos, rock wool, lank wool, glass fibers or metal fibers are used will. 5. The method according to any one of claims 1-4, characterized in that as the fire resistance Improving material an inorganic powder, which is crystal water in the form of water vapor at high temperature releases, or an inorganic powder that is in an endothermic process consumed at high temperature, or a mixture of these powders is used. 6. The method according to claim 5, characterized in that water vapor as at high temperature releasing inorganic powder, aluminum hydroxide, calcium hydroxide, clays, alum, hydrogenated Gypsum, sodium sulfate hydrate, or disodium phosphate hydrate is used. 7. The method according to claim 5, characterized in that as an inorganic powder, which is at high temperature consumed in an endothermic process, calcium carbonate, magnesium carbonate, Zinc carbonate, cadmium carbonate, sodium nitrate, lead nitrate, aluminum sulfate, ammonium phosphate, Ammonium carbonate or ammonium sulfate is used. 8. Process for the continuous production of a non-flammable, lightweight molded body from a mixture of substances according to one or more of claims 1-7, characterized in that the mixture is fed into a pressure space between an endless belt and a conveyor plate is formed, wherein the pressure chamber opposite, inner surface of the endless Belt is in contact with pressure rollers, and the conveyor plate is at about the same speed and is moved in the same direction as the endless belt, the compression deformation so far continues until the apparent density of the compressed molded article is 1.5 to 12 times that of Has starting mixture, whereupon the shaped body in reaction chambers to a temperature of 15 to 120 ° C is maintained in such a way that foam formation and hardening of the molded body occurs.