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US20010038169A1 - Process for producing a non-combustible moulded article, especially a building panel - Google Patents

Process for producing a non-combustible moulded article, especially a building panel Download PDF

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Publication number
US20010038169A1
US20010038169A1 US09/125,111 US12511198A US2001038169A1 US 20010038169 A1 US20010038169 A1 US 20010038169A1 US 12511198 A US12511198 A US 12511198A US 2001038169 A1 US2001038169 A1 US 2001038169A1
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US
United States
Prior art keywords
fact
process according
binding agent
inorganic binding
granulate
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
US09/125,111
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US6395113B2 (en
Inventor
Erwin Tomandl
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Thermax Brandschutzbauteile GmbH
Original Assignee
Thermax Brandschutzbauteile GmbH
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
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Application filed by Thermax Brandschutzbauteile GmbH filed Critical Thermax Brandschutzbauteile GmbH
Assigned to THERMAX BRANDSCHULTZBAUTEILE GESELLSCHAFT M.B.H. reassignment THERMAX BRANDSCHULTZBAUTEILE GESELLSCHAFT M.B.H. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: TOMANDL, ERWIN
Publication of US20010038169A1 publication Critical patent/US20010038169A1/en
Application granted granted Critical
Publication of US6395113B2 publication Critical patent/US6395113B2/en
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Classifications

    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B14/00Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B14/02Granular materials, e.g. microballoons
    • C04B14/04Silica-rich materials; Silicates
    • C04B14/20Mica; Vermiculite
    • C04B14/204Mica; Vermiculite expanded
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B23/00Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
    • B28B23/0081Embedding aggregates to obtain particular properties
    • B28B23/0087Lightweight aggregates for making lightweight articles
    • CCHEMISTRY; METALLURGY
    • C04CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04BLIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements

Definitions

  • the invention relates to a process for the production of nonflammable molded parts, especially building material panels, in which vermiculite granules are expanded at an elevated temperature and then mixed with a binding agent, following which a bulk material or compressed cake is formed of the granulate, which has been coated with adhesive, and it is pressed into a nonflammable molded part.
  • An advantage of the process according to the invention resides in the fact that the discontinuous hot compression occurs in a press that is heated by the usual heating media, and by means of high-frequency current as well. Furthermore, the discontinuous hot compression occurs, to good advantage, in the presence of a steam sieve for the purpose of removing solvent residues. Similarly, in the case of the continuous precompression, cover sheets arranged on one or both sides of the bulk cake can be compressed with the cake to good effect.
  • a binding agent that contains phosphorous is used to good advantage as an inorganic binding agent, such that those that are based upon acids that contain phosphorous, and/or their salts, are particularly well-suited.
  • silicate compounds can be used to good effect as inorganic binding agents, preferably silicate of potassium or sodium, hydraulic binders, preferably cement, Sorel binders, as well as hemihydratic or hydratic binders, such as gypsum.
  • Other additives preferably agents that render the solution hydrophobic, may be added to the solution of inorganic binding agents as well.
  • the vermiculite granulate is expanded at a temperature of ca. 850° C.
  • the expanded vermiculite granulate is then placed into a mixing unit, in which it is mixed with the binding agent solution, which is added by means of a dosage apparatus.
  • the binding agent solution consists, for example, of aqueous orthophosphoric acid, which contains, in addition, hydrophobizing agents that are based upon organo-silicon compounds.
  • the dosage is controlled in such a manner that the quantity of binding agent in the finished panel amounts to about 10% by weight.
  • This water from the reaction, as well as any solvent residues that may be present, can be removed by means of a steam sieve that is applied within the press. As a result of this measure, irregularities in the surface of the panel can be avoided.
  • the finished pressed panel is now separated from the pressure panel and cooled. Then the panels are cut to the desired format and stacked.
  • nonflammable molded parts that are manufactured according to the invention can be used, for example, in machine building and in the construction industry.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Ceramic Engineering (AREA)
  • Structural Engineering (AREA)
  • Organic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Civil Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Mechanical Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Inorganic Chemistry (AREA)
  • Press-Shaping Or Shaping Using Conveyers (AREA)
  • Building Environments (AREA)
  • Paper (AREA)
  • Porous Artificial Stone Or Porous Ceramic Products (AREA)
  • Compositions Of Oxide Ceramics (AREA)
  • Finishing Walls (AREA)
  • Devices For Post-Treatments, Processing, Supply, Discharge, And Other Processes (AREA)
  • Adhesives Or Adhesive Processes (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)
  • Laminated Bodies (AREA)

Abstract

A process is proposed for producing non-combustible moulded articles from blown vermiculite, the blown vermiculite granules being mixed with an inorganic binder and then pressed. The blown vermiculite granules are mixed with a solution of an inorganic binder, the vermiculite granules once mixed are pre-pressed, cut to the shape required and the cut blanks are pressed non-continuously at at least room temperature and preferably at temperatures of at least 100° C. and pressures of at least 0.3 N/mm2 to ensure that all solvent residues are removed from the finished noncombustible moulded article.

Description

    TECHNICAL AREA
  • The invention relates to a process for the production of nonflammable molded parts, especially building material panels, in which vermiculite granules are expanded at an elevated temperature and then mixed with a binding agent, following which a bulk material or compressed cake is formed of the granulate, which has been coated with adhesive, and it is pressed into a nonflammable molded part. [0001]
  • STATE OF THE ART
  • In the production of nonflammable molded parts, it is known how to coat expanded materials such as vermiculite, perlite, or light expanded clay aggregate with binding agents comprised of inorganic and organic components, and then to compress them so that a connection of the expanded material particles to each other arises. Due to the fact that condensation resins, such as formaldehyde condensation resins, for example, are used as organic components, it has been shown that, due to the processing parameters during the compression procedure, compounds of these resins that have a low molecular weight, such as formaldehyde, are liberated. As a result, these well-known methods have proven to be a relatively large source of environmental pollution. [0002]
  • Now it is the task of the invention to indicate a process of the type mentioned at the outset for the production of nonflammable molded parts that is environmentally friendly and yields satisfactory properties at the end product of the process, such as its mechanical stability and absence of flammability. [0003]
  • PRESENTATION OF THE INVENTION
  • According to the invention, therefore, a process of the type mentioned at the outset is proposed, which is characterized by the fact that the expanded vermiculite granulate is furnished with an application of an adhesive coating comprised of a solution of an inorganic binding agent, and that the coated vermiculite granulate is precompressed, continuously or discontinuously, cut to the shape of the individual piece, and that these custom-cut pieces are compressed discontinuously at room temperature or higher, preferably at temperatures of at least 100° C., and at pressures of at least 0.3 N/mm[0004] 2, so that all solvent residues are removed from the final, finished, nonflammable molded part.
  • An advantage of the process according to the invention resides in the fact that the discontinuous hot compression occurs in a press that is heated by the usual heating media, and by means of high-frequency current as well. Furthermore, the discontinuous hot compression occurs, to good advantage, in the presence of a steam sieve for the purpose of removing solvent residues. Similarly, in the case of the continuous precompression, cover sheets arranged on one or both sides of the bulk cake can be compressed with the cake to good effect. [0005]
  • In the process according to the invention, a binding agent that contains phosphorous is used to good advantage as an inorganic binding agent, such that those that are based upon acids that contain phosphorous, and/or their salts, are particularly well-suited. [0006]
  • Furthermore, silicate compounds can be used to good effect as inorganic binding agents, preferably silicate of potassium or sodium, hydraulic binders, preferably cement, Sorel binders, as well as hemihydratic or hydratic binders, such as gypsum. Other additives, preferably agents that render the solution hydrophobic, may be added to the solution of inorganic binding agents as well.[0007]
  • AN ADVANTAGEOUS WAY OF IMPLEMENTING THE INVENTION
  • The invention will now be illustrated in greater detail by virtue of an embodiment example: [0008]
  • In a rotary kiln, the vermiculite granulate is expanded at a temperature of ca. 850° C. The expanded vermiculite granulate is then placed into a mixing unit, in which it is mixed with the binding agent solution, which is added by means of a dosage apparatus. The binding agent solution consists, for example, of aqueous orthophosphoric acid, which contains, in addition, hydrophobizing agents that are based upon organo-silicon compounds. The dosage is controlled in such a manner that the quantity of binding agent in the finished panel amounts to about 10% by weight. [0009]
  • The mixture that is removed from the mixing unit, which has been given an adhesive coating of binding agent, is now transferred to a dispersion hopper or a dispersion station, in which a bulk load of uniform height is formed. This bulk load is then transported to a preliminary compression unit in which it undergoes precompression to about 50% of the original bulk load's height. Covering sheets, such as decorative sheets, can be applied to both sides of the bulk cake. After the preliminary compression, the blank that has undergone preliminary compression is cut into large panels and transferred discontinuously to a press that can be heated with high-frequency current and heating oil, in which the panels are compressed at a temperature of 200° C. and a compression pressure of 1 N/mm[0010] 2. A cross-linking of the phosphoric acid, with a loss of water, occurs as a result of the elevated temperature. This water from the reaction, as well as any solvent residues that may be present, can be removed by means of a steam sieve that is applied within the press. As a result of this measure, irregularities in the surface of the panel can be avoided. The finished pressed panel is now separated from the pressure panel and cooled. Then the panels are cut to the desired format and stacked.
  • COMMERCIAL APPLICABILITY
  • The nonflammable molded parts that are manufactured according to the invention can be used, for example, in machine building and in the construction industry. [0011]

Claims (11)

1. A process for the production of a nonflammable molded part, in particular, a building material panel, in which vermiculite granulate is expanded at an elevated temperature and then mixed with a binding agent, following which a bulk load or a compressed cake is formed of the granulate that has been coated with adhesive and pressed into a nonflammable molded part, characterized by the fact that a coating of adhesive solution of an inorganic binding agent is applied to the expanded vermiculite granulate, that the vermiculite granulate that is furnished with the adhesive coating is subjected to preliminary compression, continuously or discontinuously, custom cut to the individual shape of the piece, and that these custom-cut units undergo discontinuous compression at room temperature or higher, preferably at temperatures of at least 100° C., and pressures of at least 0.3 N/mm2, so that all solvent residues are removed from the finished, nonflammable molded part.
2. A process according to
claim 1
, characterized by the fact that the discontinuous hot compression occurs in a press that is heated with the usual heating media, and in addition by means of high-frequency current.
3. A process according to
claim 1
or
2
, characterized by the fact that the discontinuous hot compression occurs in the presence of a steam sieve in order to remove solvent residues.
4. A process according to one of claims 1 through 3, characterized by the fact that in the case of the continuous preliminary compression, covering sheets that are provided on one or both sides of the bulk cake are compressed as well.
5. A process according to one of claims 1 through 4, characterized by the fact that the inorganic binding agent is a binding agent that contains phosphorous.
6. A process according to
claim 5
, characterized by the fact that the inorganic binding agent that contains phosphorous is one that is based upon acids that contain phosphorous and/or their salts.
7. A process according to one of claims 1 through 4, characterized by the fact that the inorganic binding agent is one based upon silicate compounds, preferably silicate of potassium or sodium.
8. A process according to one of claims 1 through 4, characterized by the fact that the inorganic binding agent is a hydraulic binder, preferably cement.
9. A process according to one of claims 1 through 4, characterized by the fact that the inorganic binding agent is a Sorel binder.
10. A process according to one of claims 1 through 4, characterized by the fact that the inorganic binding agent is a hemihydratic or hydratic binder, such as gypsum.
11. A process according to one of claims 1 through 10, characterized by the fact that additives, preferably hydrophobizing agents, are mixed with the solution of inorganic binding agents.
US09/125,111 1996-02-23 1997-02-17 Process for producing a non-combustible moulded article, especially a building panel Expired - Lifetime US6395113B2 (en)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
EP96890026 1996-02-23
EP96890026.6 1996-02-23
EP96890026 1996-02-23
PCT/EP1997/000746 WO1997030951A1 (en) 1996-02-23 1997-02-17 Process for producing a non-combustible moulded article, especially a building panel

Publications (2)

Publication Number Publication Date
US20010038169A1 true US20010038169A1 (en) 2001-11-08
US6395113B2 US6395113B2 (en) 2002-05-28

Family

ID=8226190

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US09/125,111 Expired - Lifetime US6395113B2 (en) 1996-02-23 1997-02-17 Process for producing a non-combustible moulded article, especially a building panel

Country Status (11)

Country Link
US (1) US6395113B2 (en)
EP (1) EP0881997B1 (en)
CN (1) CN1118442C (en)
AT (1) ATE185787T1 (en)
AU (1) AU1873997A (en)
DE (1) DE59700587D1 (en)
DK (1) DK0881997T3 (en)
EA (1) EA000460B1 (en)
UA (1) UA54416C2 (en)
WO (1) WO1997030951A1 (en)
ZA (1) ZA971233B (en)

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KR20030025443A (en) * 2001-09-20 2003-03-29 김환성 Method for manufacturing non-flammable and exterior panels using vermiculite
DE10314977A1 (en) * 2003-04-02 2004-10-14 H.C. Starck Gmbh Process for producing silicate shaped bodies
US20040202687A1 (en) * 2003-04-14 2004-10-14 Babu M.K. Manoj Ciprofloxacin formulations and methods of making and using the same
FR2916439B1 (en) * 2007-05-23 2010-09-10 Commissariat Energie Atomique PROCESS FOR PRODUCING HIGHLY EXFOLIATED VERMICULITE DOES NOT REQUIRE THE USE OF ORGANIC BINDING OR ORGANIC ADDITIVE TO BE SHAPED
CN103011749A (en) * 2012-11-23 2013-04-03 苏州科信遮阳新材料科技有限公司 Plant fiber building composite board
KR101619331B1 (en) * 2015-09-23 2016-05-10 주식회사 버미코리아 Slim Vermiculite Board for Construction Finishing
KR101840275B1 (en) 2016-06-28 2018-03-20 현대자동차주식회사 Vermiculite Core for Vehicle and Method for Manufacturing thereof
CN106674595A (en) * 2016-11-22 2017-05-17 闫博文 Preparation method of environment-friendly compound fire retarding agent used for flame retardant plastic

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Also Published As

Publication number Publication date
WO1997030951A1 (en) 1997-08-28
UA54416C2 (en) 2003-03-17
AU1873997A (en) 1997-09-10
ATE185787T1 (en) 1999-11-15
EP0881997B1 (en) 1999-10-20
CN1118442C (en) 2003-08-20
CN1211965A (en) 1999-03-24
EA199800761A1 (en) 1999-04-29
ZA971233B (en) 1998-09-14
EP0881997A1 (en) 1998-12-09
EA000460B1 (en) 1999-08-26
DK0881997T3 (en) 2000-03-13
DE59700587D1 (en) 1999-11-25
US6395113B2 (en) 2002-05-28

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