KR100491730B1 - Light brick using polystyrene foam and Process for the preparation thereof - Google Patents

Abstract

The present invention is a clay; Busan lime; By providing a light-weight brick and a method of manufacturing the same, comprising a foamed polystyrene, it is easy to control the porosity and strength of the light brick, has a uniform pore therein, and can be used as a structural material.

Description

Light brick using polystyrene foam and Process for the preparation

The present invention relates to a lightweight brick using foamed polystyrene and a method of manufacturing the same, and more particularly, to a lightweight brick using foamed polystyrene and by-product lime as an additive to clay to form internal pores, and a method of manufacturing the same.

Lightweight brick, also known as insulating firebrick, is a generic term for bricks with a porous structure. The bulk specific gravity is 0.10 ~ 1.25 and the thermal conductivity is 0.13 ~ 0.45 kcal / mh ℃, so the thermal insulation or heat insulation is very good at 900 ~ 1500 ℃. Therefore, when used as a wall material in the heat treatment apparatus can significantly reduce the fuel or electricity, it is possible to obtain the effect of maintaining the internal temperature uniformly or to reach a predetermined temperature quickly.

In general, the thermal insulation brick generates bubbles in the firing process to include pores therein. For this, diatomaceous earth, expanded vermiculite, asbestos, and pearlite are used as raw materials, or organic powder such as powdered coal, sawdust, etc. It is made by molding, drying and firing by mixing about 50%.

However, the above method is difficult to form pores uniformly inside the brick, and in particular, it is impossible to control the size of the pores, and there has been a demand for research on a suitable lightweight brick according to the use purpose. In addition, porous bricks are not used as structural materials because of their weak strength, and most of them were used as heat dissipation, sound insulation, and partition wall decoration.

On the other hand, Busan lime is a residue of sodium carbonate (Na ₂ CO ₃ ) in the process of producing sodium carbonate (Na ₂ CO ₃ ) by reacting sodium chloride (NaCl) and limestone (CaCO ₃ ) is a material to be discarded, and the reaction process in the production of sodium carbonate Looking at it as in Scheme 1 below.

As shown in Scheme 1, sodium carbonate is prepared using sodium chloride and limestone as main raw materials, and calcium chloride (CaCl ₂ ) is formed together with sodium carbonate. The general chemical composition of the lime is shown in Table 1 below.

Item % CaCO ₃ 30.1 CaO 20.9 CaSO ₄ 4.3 CaCl ₂ 11.8 MgO 8.4 NaCl 6.2 FeCO ₃ , Al ₂ O ₃ 10.0 SiO ₂ 7.2 Etc 1.1 system 100.0

Limestone contained in the mixture generates carbon dioxide gas in accordance with the following Reaction Formula 2 in the calcination process, and thus serves to form pores in the calcined body.

Korean Patent Publication No. 10-0358926 discloses a method for producing lightweight aggregate using the above reaction. However, the lightweight aggregate produced by the above method does not have sufficient porosity for thermal insulation, and in particular, its strength is weak so that it cannot be used as a structural material.

In order to solve the above problems, an object of the present invention is to provide a lightweight brick that can be used as a structural material by using a porous polystyrene foam and by-product lime, and having a uniform porosity and easy pore size adjustment.

Lightweight brick of the present invention for this purpose is clay; Busan lime; It is characterized by including a polystyrene foam.

In addition, the lightweight brick of the present invention is characterized in that the ratio of clay, by-lime, and expanded polystyrene in a ratio of 20 to 50 parts by weight of by-product lime, and 20 to 30 parts by volume of expanded polystyrene when 100 parts by weight of clay.

In addition, the manufacturing method of the lightweight brick using the expanded polystyrene foam of the present invention is 20 to 50 parts by weight of by-product lime, 20 to 30 parts by volume of polystyrene foam when the ratio of clay, Busan lime, and expanded polystyrene is 100 parts by weight of clay. Producing a mixture blended with;

Shaping and drying the mixture;

It characterized in that it comprises the step of firing the dried product at 900 ℃ to 1100 ℃.

The lightweight brick of the present invention is first put into clay and pulp and foamed polystyrene for mixing in a refining machine uniformly and then cut into a wire or knife to form a uniform shape, and manufactured through a drying and firing process. Drying may be effected by air drying in room and daylight or in a drying room, but drying sufficiently. The firing process is carried out at a temperature of 900-1100 ℃. At this time, the expanded polystyrene in the mixture contains carbon dioxide in the synthesis of polystyrene and exists in the form of small beads. When it is heated in the form of bricks, the hydrocarbon inside is pyrolyzed and gasified into CO ₂ to form pores therein. This will form pores in the fired body. These pores give sufficient porosity inside the lightweight brick of the present invention, which is insufficient only in the pores generated during the calcining process of limestone.

In addition, the expanded polystyrene can adjust the size of the bead according to the amount of carbon dioxide contained in the synthesis process. By controlling this, it is possible to control the size and strength of pores generated in the fired body.

In addition, by using a polystyrene foam having a uniform size, it is possible to uniformly control the size of the pores generated in the fired body.

As the clay used in the present invention, it is preferable to use clay containing much iron oxide.

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

Experimental Example 1

Changes in Specific Gravity and Strength According to the Ratio of Busan Lime in the Mixture

<Example 1>

A mixture was prepared in which 100 parts by weight of clay, 10 parts by weight of by-lime lime, and 30 parts by weight of expanded polystyrene were prepared. At this time, the secondary clay (Fe ₂ O ₃ content of more than 3.5%) containing a large amount of organic matter and iron was used as the clay. Busan lime having the composition shown in Table 1 was used. The mixture and the predetermined water were put in a refining machine and uniformly mixed, and then made into a size of 210 mm long, 100 mm wide and 60 mm thick. It was dried in room daylight. Then, by firing at a temperature of 1000 ℃ in a tunnel kiln to prepare a lightweight brick using a polystyrene foam. The measured values of specific gravity and strength of the prepared bricks are recorded in Table 2.

<Example 2>

A light weight brick using foam polystyrene was prepared in the same manner as in Example 1 except for preparing a mixture in which 100 parts by weight of clay, 20 parts by weight of by-lime lime, and 30 parts by volume of expanded polystyrene were prepared. The measured values of specific gravity and strength of the prepared bricks are recorded in Table 2.

<Example 3>

A light weight brick using foam polystyrene was prepared in the same manner as in Example 1 except that a mixture including 100 parts by weight of clay, 50 parts by weight of by-product lime, and 30 parts by weight of expanded polystyrene was prepared. The measured values of specific gravity and strength of the prepared bricks are recorded in Table 2.

<Example 4>

A light weight brick using foam polystyrene was prepared in the same manner as in Example 1 except for preparing a mixture containing 100 parts by weight of clay, 70 parts by weight of Busan lime, and 30 parts by weight of expanded polystyrene. The measured values of specific gravity and strength of the prepared bricks are recorded in Table 2.

division Ratio of Busan lime (clay: Busan lime) importance Strength (kg / cm ² ) Example 1 100: 10 1.3 56 Example 2 100: 20 0.9 50 Example 3 100: 50 0.7 47 Example 4 100: 70 0.2 25

As shown in the table, as the ratio of Busan lime increased, the specific gravity of the light brick decreased, but the strength also decreased. Lightweight bricks have a specific gravity of 1.25 or less, and since the strength of 45 kg / cm ² or more is required to be used as a structural material, a preferable ratio of by-product lime in light bricks is 20 to 50 parts by volume with respect to 100 parts by volume of clay.

Experimental Example 2

Changes in Specific Gravity and Strength According to the Ratio of Expandable Polystyrene in the Mixture

<Example 1>

A light weight brick using foamed polystyrene was prepared in the same manner as in Example 1 of Experimental Example 1 except for preparing a mixture of 100 parts by weight of clay, 30 parts by weight of Busan lime, and 10 parts by volume of expanded polystyrene. The measured values of specific gravity and strength of the prepared bricks are recorded in Table 3.

<Example 2>

A light weight brick using foam polystyrene was prepared in the same manner as in Example 1 except that 100 parts by volume of clay, 30 parts by weight of by-product lime, and foamed polystyrene were prepared. The measured values of specific gravity and strength of the prepared bricks are recorded in Table 3.

<Example 3>

A light weight brick using foamed polystyrene was prepared in the same manner as in Example 1, except that a mixture of 100 parts by weight of clay, 30 parts by weight of by-lime lime, and 30 parts by volume of expanded polystyrene were prepared. The measured values of specific gravity and strength of the prepared bricks are recorded in Table 3.

<Example 4>

A light weight brick using foam polystyrene was prepared in the same manner as in Example 1 except for preparing a mixture containing 100 parts by weight of clay, 30 parts by weight of lime, and 50 parts by weight of expanded polystyrene. The measured values of specific gravity and strength of the prepared bricks are recorded in Table 2.

Example 5

A light weight brick using foam polystyrene was prepared in the same manner as in Example 1 except for preparing a mixture containing 100 parts by weight of clay, 30 parts by weight of lime, and 70 parts by weight of expanded polystyrene. The measured values of specific gravity and strength of the prepared bricks are recorded in Table 2.

division Ratio of polystyrene foam (clay: polystyrene foam) importance Strength (kg / cm ² ) Example 1 100: 10 1.5 57 Example 2 100: 20 1.1 53 Example 3 100: 30 0.9 50 Example 4 100: 50 0.6 42 Example 5 100: 70 0.1 26

As shown in the table, as the proportion of the expanded polystyrene increases, the specific gravity of the light brick decreases but the strength also decreases. The increase in foam polystyrene leads to a drastic change in the specific gravity and strength reduction of lightweight bricks, and the preferred proportion of foam polystyrene is 20 to 30 parts by volume or less based on 100 parts by volume of clay.

Experimental Example 3

Change of Specific Gravity and Strength by Firing Temperature

<Example 1>

A light weight brick using foamed polystyrene was prepared in the same manner as in Example 1 of Experimental Example 1 except that the firing temperature was 800 ° C. The measured values of specific gravity and strength of the prepared bricks are recorded in Table 4.

<Example 2>

A light weight brick using foamed polystyrene was prepared in the same manner as in Example 1 except that the firing temperature was 900 ° C. The measured values of specific gravity and strength of the prepared bricks are recorded in Table 4.

<Example 3>

A light weight brick using foamed polystyrene was prepared in the same manner as in Example 1 except that the firing temperature was set at 1000 ° C. The measured values of specific gravity and strength of the prepared bricks are recorded in Table 4.

<Example 4>

A light weight brick using foamed polystyrene was prepared in the same manner as in Example 1 except that the firing temperature was 1100 ° C. The measured values of specific gravity and strength of the prepared bricks are recorded in Table 4.

Example 5

A light weight brick using foamed polystyrene was prepared in the same manner as in Example 1 except that the firing temperature was set at 1200 ° C. The measured values of specific gravity and strength of the prepared bricks are recorded in Table 4.

division Firing temperature (℃) importance burglar Example 1 800 1.2 43 Example 2 900 1.0 49 Example 3 1000 0.9 54 Example 4 1100 0.6 51 Example 5 1200 0.3 45

As shown in the above table, when the firing temperature is 900 ° C. or less, the desired strength cannot be obtained. When the firing temperature is 1000 ° C., the maximum strength is obtained, but the strength decreases at a high temperature of 1100 ° C. or more. In other words, the preferred firing temperature is 900 ℃ to 1100 ℃.

Lightweight brick of the present invention by using the clay of the material of the normal brick as a base material and using expanded polystyrene and Busan lime as an additive, it is easy to control the porosity and strength and has uniform pores therein, structural material Can be used as

Claims (3)

delete In the lightweight brick comprising clay, Busan lime, and expanded polystyrene, Lightweight brick, characterized in that it comprises a ratio of 20 to 50 parts by weight of Busan lime, 20 to 30 parts by volume of expanded polystyrene when 100 parts by weight of clay. Producing a mixture of clay, by-lime lime, and expanded polystyrene in a ratio of 20 to 50 parts by weight of by-product lime and 20 to 30 parts by weight of expanded polystyrene when the volume is 100 parts by weight of clay; Shaping and drying the mixture; Method for producing a lightweight brick, characterized in that it comprises the step of firing the dried material at 900 ℃ to 1100 ℃.