Low density thermoreactive material and method for production thereof

FIELD: inorganic chemistry, in particular low density materials useful in form of molding article as sealing or insulating materials.

SUBSTANCE: claimed method includes blending of aluminum silicate hole beads with powder of epoxy or polyester resin in ratio of (2/3-1/3) pts vol. of aluminum silicate to (1/3-2/3) pts vol. of resin. Mixture is formed and heat treated at 200°C for 0.5-1.5 h. Powder of epoxy or polyester resin represents waste from powder coating or hot-drying varnishing and has particle size of 30 mum or less. Aluminum silicate hole beads have diameter of 10-100 mum. Obtained articles have bulk mass of 0.4-0.5 kg/dm3 and compression strength of 10-20 N/cm2.

EFFECT: thermoreactive material with low bulk mass and good compression strength.

7 cl, 6 dwg

 

The invention relates to a method for manufacturing a low-density material with thermosetting properties that can be applied in the form of molded products for sealing and insulation. In addition, the invention relates to a material of low density, consisting of a main material and a binder, which together are suitable for use as a sealing or insulating material.

This low-density material consists either of easily inflammable plastic, such as Styrofoam, or it can be produced only with relevant costs, due to the significant investment costs and high running costs. This low-density material is typically of a material that has a relatively large hollow spaces, so that the static parameters, as a rule, are poor, particularly poor is the compressive strength made out of molded products. The disadvantage of the other materials is that they absorb and retain water, thereby increasing the weight and dramatically reduces the effectiveness of insulation.

Publication DATABASE WPI Section Ch, Week 199204 Derwent Publications Ltd., London contains the technical solution consists in the fact that the silicate in the form of hollow spheres in a minimum amount of from 0.5 to 3% may be mixed with the resin, dyes, transformer and a large number of quartz sand for the manufacture of this mixture similarity of building block. The proportion of resin to about 30% is very high, and the proportion of quartz sand is over 50%, so therefore, the low-density material can not be obtained in the sense of the word. In addition, as the resin used raw materials, which as such when you purchase and use creates problems.

In the published Patent Abstracts of Japan vol.005, no.114 (C-064), 23.07.81 & JP 56053147 A (Onomichi Kumika Kogyo KK), 12.05.81 disclosed a technique in which process the similarity of the clay, and occurring during the processing of the foam produced from 15-25 wt.%., coating powder", i.e. the similarity of the covering powder. There is a lot that needs to be calcinate at high temperatures of 800 to 1200°C. This drying temperature is very high. Thus obtained material is mixed then with epoxy or similar material to obtain the mixture of the granulate. Finally it should be stated that are not waste, but on the contrary, the new material, which requires not only high cost but also makes it necessary for other applications.

In the published Patent Abstracts of Japan vol.008, no.138 (C-231), 27.06.84 & JP 59047219 A (Toshiba Chemical K.K.), 16.05.84 disclosed the use of a new material in the form of, respectively, the normalized resin and hollow Shari is s, moreover, the mixture ratio is not specified. They say that only applies to very fine-grained material from 5 to 300 μm. In this publication, however, there is no indication that it is possible to apply the material from the powder coating/varnishing thermal drying, which is produced in large quantities and utilized up to now only by the construction of the dumps.

The basis of the invention lies therefore the task of creating a low-density material, which can be used for molded and used for insulating purposes, and method of manufacture, which ensures the application of the waste receiving material, which is easy to manufacture, is easily processed and is primarily water-resistant.

This problem is solved by means of signs, respectively, paragraphs 1 and 9 of the claims.

With this method after heat treatment at a temperature of 200°formed molded product, differing primarily only a small or even absent shrinkage. Formed from the remnants of the epoxy and/or polyester resin is at a temperature of from 60 to 80°soft, then liquid, and, despite a small proportion of the resin is from 20 to 30% of powder residue, it suddenly securely envelops small hollow balls of aluminosilicate and specal them. Formed on the freely steady frame, moreover, due to the relatively small amount of powder resin can be provided with a small weight. The corresponding material, i.e. a material of low density, can be used for a variety of purposes, and before heat treatment is placed in proper form, and then respectively bake or burn. The corresponding low-density material has extremely low specific weight and preferably easily, for example sawn, abrasives, etc. is Preferable further that the binder used in the form formed from the remnants of the powder coating/varnishing hot drying powder epoxy or polyester resin with preliminary sufficient mixing ensures the capture of all components of the aluminosilicate in the form of hollow spheres and their fixation with uniform distribution in the molded product. All the material is hydrophobic, so that it repels water, and it has no effect on the molded product. In addition, as the silicates, and the components of the resin substantially resistant to aging, so that the material differs in this sense.

Used aluminium silicate in the form of hollow balls can come from various sources (power plants). To provide the necessary binding silicate preferably of alomisyl the kata in the form of hollow beads with a grain size of > 10 μm to <100 μm to mix with powder epoxy and/or polyester residual resin, and then subjected to further processing. Given the size of the grains is preferably uniform distribution and formation of uniform layers, so that this material can be securely bonded powder epoxy and/or polyester resin. These prescribed limits does not necessarily follow exactly as the original material, as it already has a high fine grain. It is important, however, that has not been used for grain size below the lower limit, i.e. less than 10 μm, however, we are talking about the appropriate improvement. The same applies to the temperature and the duration of exposure during the heat treatment.

Above it was mentioned that the epoxy and/or polyester resin at a temperature of about 60-80°starts to move in the liquid phase. To ensure reliable bonding of all silicate invention provides that "the process of roasting a firing temperature of about 200°With support for 0.5-1.5 hours. Thus always ensures the uniform execution of the produced molded products. In particular ensures that the respectively processed resin really is applied on the hollow balls and binds them.

Methods of coating powder, lakirovanie the hot drying is used for a variety of purposes. This forms a more or less residual material, sometimes with a significant amount of recyclable. This material, i.e., the powder of the resin, can with advantage be used in the method according to the invention for the manufacture of him and silicate in the form of hollow balls of the respective molded products or use this material for insulating purposes. Depending on the hardness of the produced molded product, its resistance to the destruction or depending on the application, it may be desirable that the mixture consisted of 2/3 parts by volume of silicate and 1/3 parts by volume of the powder of the resin up to 1/3 of silicate and 2/3 of the resin. Universally applicable method allows you to adapt to the conditions of use and manufacturing of the final product, which optimally match the specified conditions of use. It is enough to change the mix ratio, and found that the mixture consists of only two components, namely from the resin and silicate.

For manufacturing molded products of the invention provides that the mixture fills the form and then subjected to the "firing". The appropriate forms can be completed so that they get molded product, which can then be processed further; on the other hand, there is, e is Testino, the ability to immediately execute the form, to obtain the final molded product, does not require further processing. To prevent burning of the mixture, i.e. in particular, the resin powder, forms can be prepared so that the burnt material easily they were separated.

Another preferred modification of the invention is that the mixture fills the corresponding hollow body and then subjected to the "firing". Maybe it's add, finally, that the firing process is combined with a coating of hot drying or other processes, if desirable or necessary processing of the outer surface of the hollow body. The firing process at 200°With no effect on the outer surfaces, respectively, there is a possibility of filling the pores in the surface layer when the firing process is already finished, i.e. when cooling the outer layer, respectively, of the walls of the hollow body.

From such forms that must be filled, can preferably be abandoned, if the mixture is mixed with water and/or oil as a temporary binder, tformat her and be "firing". These temporary binders or fading during prolonged storage, or at the latest during the firing process without influencing the rest of the process. Temporary with Azania water or oil ends at a temperature of about 80° With, and then linking is becoming liquid resin, so that in this implementation of the method can be operated without any form. A separate molded products perform in the wet state and then in this form is subjected to the firing process, is achieved where appropriate hardening, respectively, the final binding.

If you want to achieve further weight reduction of such molded products and may lower the strength, mixture it is preferable to add, with partial replacement of share silicate, plastic in the form of beads or fibers, which pass into the gaseous state at a temperature of about 100°C. it is Clear that the use of such plastics obtain a molded product with hollow spaces, which has a lower weight in the first place due to the hollow spaces formed by the plastic transition into a gaseous state.

It is also possible to add in a mixture of silicate and resin as a filling material, sand or other material with partial substitution of silicate. The appropriate filler, as well as hollow balls aluminosilicate, are enclosed in the resin and bound, of course, have to come to terms with the highest weight.

The firing process can preferably be optimized to improve the heat is and by adding to the mixture of inorganic binders in the form of phosphates, silicate, boric acid, etc., preferably as a partial replacement of the proportion of the resin. This ensures a high thermal resistance corresponding to the received material or relevant manufactured molded product.

Furthermore, the method according to the invention provides the possibility of incorporating a stabilizing parts, for example, for the manufacture of freely structural parts, which, however, should have a low weight. In accordance with this invention provides for the inclusion of a molded product before the "firing" of the valve, preferably of steel reinforcement. This steel reinforcement is also associated as a powder resin is deposited on it and provides a strong connection moulded products and fittings.

Above it was mentioned that when filled with a mixture of hollow body respectively to handle this hollow body. According to the invention is provided, which is filled with a mixture of hollow body/profiles then covered with a powder of epoxy and/or polyester resin, and the mixture is simultaneously subjected to heat treatment. This heat treatment is carried out using a powder coating or special units, and due to the low shrinkage ensures almost 100% filled with filling of the hollow space. In addition, the material is the tsya hydrophobic, so that eliminates the penetration of moisture into suitably protected hollow body.

Suitable for various applications the low-density material differs in that the basic material is aluminosilicate in the form of hollow beads and the binder is a powder of epoxy and/or polyester resins, which are joined together by applying heat with the formation of a light, floating, durable molded products that can be processed using conventional tools. When the aluminosilicate in the form of hollow balls and a powder of the polyester resin, respectively, epoxy resins provide generally performed with a uniform fun-molded product, which is suitable for a variety of applications and is well treated and, among other things, different hydrophobic surface.

According to modification of the invention polyester resin can be partially replaced by phosphates, silicates or boric acid, to thereby obtain the "neutral stuff"that on the basis of the added substances is even less flammable and thereby protected. It is stable up to temperatures of 400°C and above.

Depending on quality requirements, respectively, to the strength of the molded product should preferably consist of 2/3 surround the parts of the aluminosilicate in the form of hollow balls and 1/3 parts by volume of powder of epoxy and/or polyester resin to 1/3 parts by volume of silicate in the form of hollow balls and 2/3 parts by volume of powder of epoxy and/or polyester the resin. Between them are any values that provide an easy-molded product, it is manufactured for the intended application.

For changing the amount of strength it is possible to replace the main material aluminium silicate in the form of hollow balls partially with sand or similar filler.

The low-density material can be further facilitated if the basic material of aluminium silicate in the form of hollow balls partially replace plastics, melting or evaporating at temperatures below 200°C, preferably balls of Styrofoam or the like, These plastic evaporate when, respectively, below the 200°With, however, provide education hollow space in the hollow body and thereby a significant reduction in overall weight.

The low-density material differs, in particular, the fact that the obtained molded product has a bulk density of 0.4 to 0.5 g/DM3and the compressive strength of 10-20 N/cm2. As mentioned above, bulk density and compressive strength can be changed, respectively, to align with the specified requirements by introducing in the process of making appropriate additional components.

Especially the low price of these low-density materials is achieved, in particular, when using powder remaining after on the rite/coating thermal drying of the old and the residual powder (27) with a particle size of up to about 30 microns. Such binder of epoxy and/or polyester resin because of the small grain size optimally suited for mixing and further processing with balls of aluminum silicate. The powder particles are about the size of grains is equal to or less than the value used hollow balls of aluminosilicate.

The invention is distinguished in particular in that it is designed the way and a molded article, respectively, the low-density material, which is optimally suitable for the most different applications. For example, from the corresponding low-density material, you can easily make any receptacle for plants with large sizes, up to a simple flower pot, and this material has the advantage that it is on the basis of their hydrophobicity securely holds moisture in the zone of plants, and on the other hand, provides optimal temperature ratio. Thus, made from it vessels for plants provide favorable conditions for plants. In addition, it is possible to use the low-density material for sound insulation and fire-prevention measures, in particular if it is at the expense of an additional binding agents, such as phosphates, has high heat resistance. For thermal insulation, you can apply a low-density material in the form of plates or f is rovannykh products, moreover, it is possible to make also shell for pipes, if you make a single molded product corresponding form. In addition, the advantage is that such materials can also be used to fill hollow spaces, and by appropriate heat treatment provides a firm connection of the filling material with the inner walls of the profiles. Since there is practically no shrinkage, get a very robust item. However, you can stabilize yourself moulded products, if they are to provide a valve that can also tie firmly.

Other details and advantages of the subject invention follow from the subsequent description of the relevant drawing, which shows a preferred exemplary embodiment with the necessary details and individual parts. In the drawings shows:

figure 1 - scheme of the method of manufacturing,

figure 2 is a molded product with a perspective projection

figure 3 - formwork for pipes

figure 4 - fire-resistant door,

5 is a flower pot and

6 is a reinforced arch support.

Figure 1 shows schematically an installation 1 for the manufacture of low-density materials. Raw materials are delivered by trucks 2 or otherwise, and provided a hopper 3 for silicate in the form of hollow W is Rykov, the hopper 4 to the sand hopper 5 for additional binder, and a hopper 6 for epoxy and/or polyester resin.

Source material jointly or separately passed through a double sieve 13, while the separated material with a size below 10 μm and 100 μm. It is also possible instead of the double sieve 13 to use two screens. This area of the screens depicted in a simplified way.

After passing sieve 13 mix together or separately enters the mixer 7, in this case, the mixing auger in which the individual components are intensively mixed with one another. Then the mixture is fed to the conveyor belt 8, respectively, in the forms 9, 10, so then it can be in forms 9, 10 to bring to the furnace 11 and firing through the oven. Detail not shown that after exiting the furnace 11 firing separate molded product 25 is separated from the forms 9, 10, on which the conveyor belt 8 is returned, while a separate molded products are delivered to the warehouse 12 and can it be distributed next.

If the forms 9, 10 are not used, there is also the possibility to apply the mixture after passing through the mixer 7 in dorabatyvalsya mixer 16, which from the tank 15 bring water or oil and mix with the mixture. Then this wet mixture is led to the respective forming roller 17 or similar formula is this instrument to obtain the corresponding molded or formed products 25, which on the conveyor belt 18 is served in the oven 19 firing to complete the formation process. Water or oil evaporate, so after exiting the furnace 19 firing on the stock 20 are accurately completed molded product 25.

Figure 2 shows such a molded product 25 that has passed through the furnace 11 or furnace 19 and has a very stable form. It does not show the individual components that comprise a molded product 25. Shown only the silicates in the form of hollow balls 26 and also schematically powder 27 from the resin. Instead of the molded product 25 that you can handle a saw or similar tool, can be produced consisting of two parts of the casing 29 to the pipe in which the silicates in the form of hollow balls 26 and the powder 27 of resin is connected so as to form a stable half-timbering, which can be installed around pipe (not shown).

Figure 4 shows the door 30, the hollow space which is equipped with a filler 31. The filler door is also a mixture of silicates in the form of hollow balls 26 and powder 27 of resin, which are connected properly with the help of the solidification process, respectively, kiln. Shown in figure 4, the door can be used as fire doors, because it can over time effect the painted high temperatures without its destruction.

Figure 5 shows schematically a flower pot 32, also consisting of a mixture of silicates in the form of hollow balls 26 and powder 27 from the resin. The respective components are mixed together and then flower pot 32 properly annealed in a furnace 19 or 11 firing. This flower pot is, first and foremost good stability and very low birth weight.

Figure 6 illustrates the versatility of such a low-density material. Shown schematically arch support 33 placed in her reinforcing rods 34 to increase the bearing capacity of the supporting arch 33. This arch support 33 can be used for various purposes, since the reinforcing rods 34 are tightly enclosed in a mixture of aluminosilicate in the form of hollow balls 26 and the resin 27, as shown in Fig.6.

All of these symptoms, including only shown in the drawings, separately and in combination should be considered as essential for the invention.

1. A method of producing low-density material with thermosetting properties, which is in the form of molded products can be used for sealing and insulation, by mixing of the aluminosilicate in the form of hollow spheres with size larger than 10 microns to less than 100 microns with a powder epoxy and/or polyester resins with particle sizes up to 30 μm, which is the waste powder coating or lakiro is of thermal drying, on the basis of these resins, at a ratio of 2/3 parts by volume of silicate and 1/3 parts by volume of resin to 1/3 parts by volume of silicate and 2/3 parts by volume of the resin, followed by molding the mixture, and the heat treatment of the molded product at 200°for 0.5 to 1.5 hours

2. The method according to p. 1, wherein the mixture is added water and/or oil as a temporary binder, is then formed and subjected to heat treatment.

3. The method according to one of paragraphs. 1 and 2, characterized in that the mixture as a partial replacement of the aluminosilicate type of plastic in the form of beads or fibers, which are at a temperature of about 100°To pass into the gaseous state.

4. The method according to one of paragraphs. 1-3, characterized in that the mixture of the inorganic binder in the form of phosphate, silicate, boric acid, etc. as a partial replacement of resin.

5. The method according to one of paragraphs. 1-4, characterized in that before the heat treatment in a molded product is placed a valve, preferably of steel.

6. The method according to one of paragraphs. 1-5, characterized in that the molded fill with a mixture of hollow body/profiles, then covered with powder, and simultaneously carry out heat treatment of the mixture.

7. The low-density material with thermosetting properties in the form of a molded product is used as uplotnitel the th or insulating material, obtained by the method according to claims 1 to 6, and having a bulk density of 0.4-0.5 kg/DM3and ultimate compressive strength of 10 to 20 N/cm2.



 

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