JP2001342055A - Water-pervious ceramic block and its production method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a water-pervious ceramic block having excellent bending strength and superior in water permeability, and a method of producing the same. SOLUTION: This water-pervious ceramic block is obtained by adding water to a porcelainous aggregate having a maximum particle diameter of 5 mm or less and a mean particle diameter within the range of 1 to 3 mm, mixing them so as to cover the surface of the aggregate with water, gradually adding and mixing a non-plastic binder, further gradually adding and mixing a plastic binder to form a molding having the void ratio of 20% or more, and then firing the molding at a temperature within the range of 850 to 1,300 deg.C.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a water-permeable ceramic block having high water permeability and high strength, and a method for producing the same.

[0002]

2. Description of the Related Art A water-permeable ceramic block is widely used as a pavement material for pedestrian roads because rainwater quickly moves in the block during rainfall and hardly causes puddles on the block surface. .

[0003] However, these blocks have a more porous structure in order to improve the water permeability, and there are problems such as insufficient strength. Since the structure has to be densified, water permeability tends to decrease, and it has been difficult to obtain a block having both water permeability and strength.
More specifically, if the strength is to be kept higher than a certain level, only a block having a water permeability of about 0.01 cm / sec can be obtained, or conversely, if the water permeability is to be ensured, Only a block having a bending strength of about 3 MPa was obtained.

[0004]

SUMMARY OF THE INVENTION An object of the present invention is to solve the above-mentioned conventional problems and to provide a ceramic block having high water permeability and high strength, and a method for producing the same.

[0005]

In order to achieve the above object, the present invention provides a sintered binder and an aggregate having a maximum particle size of 5 mm or less and an average particle size in a range of 1 to 3 mm. Wherein the content of the sintered binder is in the range of 5 to 30% by weight, the content of the aggregate is in the range of 65 to 93% by weight, and the bending determined in accordance with JASS7 M-101. The strength is in the range of 6 to 14 MPa and JIS A12
Water permeability determined in accordance with No. 18 is 0.02 to 0.08 c
It is characterized by a water-permeable ceramic block in the range of m / sec. Here, the sintered binder is at least one kind of plastic binder selected from the group consisting of bentonite, clay, kaolin, pottery stone, wax, clay, mica, and starch, and a non-plastic binder having the following composition. It is also preferred to include.

The content of the compound represented by R ₂ O (where R is a monovalent element): within the range of 10 to 20% by weight The content of the compound represented by RO (where R is a divalent element) : Within the range of 5 to 20% by weight Content of the compound represented by R ₂ O ₃ (where R is a trivalent element): within the range of 1 to 35% by weight Content of the compound represented by RO ₂ ( However, R is a tetravalent element): within the range of 30 to 80% by weight. The aggregate is made of porcelain tile, porcelain tableware, porcelain block, insulator, steel slag, sewage sludge melting slag, dust melting slag, glass And at least one material selected from the group consisting of water sludge and molten slag.

[0007] Further, as the aggregate, at least two materials selected from the following groups A, B, and C having different fire resistances, and at least one material selected from each of the at least two groups: Preferably, it contains a material.

A group: porcelain tile, porcelain tableware, porcelain block, insulator B group: sewage sludge melting slag, trash melting slag, iron and steel slag, tap water sludge melting slag C group: glass Also having a thickness of 20 to 80 mm It is also preferable that a surface layer containing an aggregate is formed on the above-described water-permeable ceramic block in the range of (1).

Further, the thickness of the surface layer is preferably in the range of 2 to 10 mm, and the Mohs hardness of the surface layer is preferably 6 or more.

It is also preferable that the surface layer has a slip resistance of 60 BPN or more when wet according to ASTM E303.

Further, the above-described water-permeable ceramic block, in which a joint width regulating projection is provided on the side surface, is also preferable.

Further, the present invention provides a method of adding water to an aggregate having a maximum particle size of 5 mm or less and an average particle size in a range of 1 to 3 mm so that the surface of the aggregate is covered with water. After mixing, slowly add the non-plastic binder and mix, then
20% porosity by gradually adding and mixing plastic binder
After forming the above-mentioned molded body, this molded body was
The method is characterized by a method for producing a water-permeable ceramic block which is fired at a temperature of 1300 ° C.

[0013]

BEST MODE FOR CARRYING OUT THE INVENTION The permeable ceramic block of the present invention has a sintered binder and a maximum particle size of 5 mm or less,
And an aggregate having an average particle size in the range of 1 to 3 mm, a sintered binder content in the range of 5 to 30 wt%, and an aggregate content of 65 to 93 wt%. It is characterized by being within the range. When the particle size and the content of the sintered binder and the aggregate are within such ranges, a block having excellent bending strength and water permeability can be obtained.

Among the above, aggregates include porcelain tiles, porcelain tableware, porcelain blocks, insulators, steel slag,
Sewage sludge melting slag, refuse melting slag, glass, tap water sludge melting slag, and the like can be used. These may be used as they are, or may be used after being subjected to treatment such as crushing or pulverization so as to obtain a desired particle size distribution. In addition, they may be used alone or in combination. It is also preferable to use an aggregate whose water absorption is reduced to 1% or less by once applying heat of 1200 ° C. or more, preferably 1,250 ° C. or more.

The sewage sludge molten slag is obtained by separating sewage into sewage and sludge, then condensing and dewatering the sludge, and further melting and cooling the solid (cake).
Depending on the cooling method, it is classified into granulated slag, air-cooled slag, slowly cooled slag, and the like. In the present invention, any of them can be suitably used.

The refuse-melting slag is obtained by melting and cooling incineration ash of refuse, and is classified into granulated slag and air-cooled slag depending on the cooling method.

Further, the sewage sludge melting slag and the refuse melting slag are cooled by controlling the temperature, and the heat treatment is performed on the gradually cooled slag, the granulated slag, and the air-cooled slag which have been crystallized in the process. There are also crystallized slags that have undergone crystallization. Specifically, for example, it can be obtained by melting incinerated ash such as municipal waste at a high temperature of about 1,300 to 1,500 ° C. and then cooling it.

[0018] The tap water sludge molten slag is obtained by converting tap water sludge, which is a solid waste generated in the process of purifying water at a water purification plant, by the above-mentioned method.

The steel slag is a coarse or fine aggregate obtained by quenching or gradually cooling by-product slag generated in a steelmaking process using a blast furnace or an electric furnace, such as a blast furnace slag or an electric furnace slag. There is.

Many of the above-mentioned aggregates used in the present invention have been treated as wastes. Defective products generated from factories and those damaged during use are collected and reused. Alternatively, by recycling what has previously been landfilled, it contributes to the reduction of waste and lowers the cost of raw materials. Therefore, it is suitable as a civil engineering and building material that uses a lot of various materials. In particular, when crystallized slag or porcelain tiles are used, they are excellent in strength and thermally stable, so that they do not easily expand or foam in the firing process, and have excellent strength and dimensional accuracy. You can get blocks.

In the present invention, the maximum particle size of the aggregate used is 5 mm or less, and the average particle size is in the range of 1 to 3 mm. This means that if the maximum particle size exceeds 5 mm or the average particle size exceeds 3 mm, the water permeability improves,
This is because uneven density occurs due to the occurrence of eccentric stones, and the strength is reduced, and blocks of stable quality cannot be obtained. When the average particle size is less than 1 mm, the bending strength is improved, but the water permeability is reduced, and furthermore, it is greatly shrunk in the firing step, and the shape of the obtained block becomes unstable.

In the present invention, the maximum particle size of the aggregate is
Using a sieve specified in JIS Z8801, 100
Expressed as the smallest sieve opening of the sieve through which ~ 95% by weight of aggregate passes. The amount of aggregate used is preferably about 500 g. Similarly, the particle size distribution is determined in accordance with JIS Z8.
Approximately 2 kg of aggregate is sieved with a sieve specified in 801 and expressed as a weight ratio. Further, the average particle size is represented by a particle size corresponding to 50% integration from the integrated distribution of the weight ratio.
Also called 0% particle size or median size.

In the present invention, by setting the particle size of the aggregate in the above range, it becomes easy to mix with the sintered binder, so that the density of the molded body is stabilized, and the water permeability and strength of the block are both high. In addition, a block whose quality is stable can be obtained.

The water-permeable ceramic block of the present invention contains the above-mentioned aggregate in the range of 65 to 93% by weight. When the content is less than 65% by weight, the gap between the aggregates is filled with a large amount of a component such as a binder, the gap is reduced, and the water permeability is reduced. On the other hand, if the content exceeds 93% by weight, the bonding strength between the aggregates is weakened, and the shape retention of the molded body during block molding is reduced, and the strength of the block is also reduced.

In the water-permeable ceramic block of the present invention, it is preferable to divide the aggregate into groups A, B, and C having different degrees of fire resistance, and to use materials selected from at least two of them.

Group A: porcelain tile, porcelain tableware, porcelain block, insulator B group: sewage sludge melting slag, trash melting slag, steel slag, tap water sludge melting slag C group: glass When a heat history is given to the aggregate, it is a temperature at which the aggregates fuse together, and the fire resistance of the aggregate of Group A is the highest and is in the range of 1150 to 1300 ° C. The fire resistance of group B is in the range of 1000 to 1150 ° C, and the fire resistance of group C is in the range of 850 to 1000 ° C. Aggregates with high fire resistance are thermally stable and easily maintain the original shape of the particles,
It serves as a skeleton of the water-permeable ceramic block, and has an effect of preventing shape collapse during firing and an effect of securing water permeability by preventing a decrease in porosity during firing. Aggregates with low fire resistance are more thermally active than high-fire aggregates, are easily bonded to sintered binders, and easily fuse with aggregates adjacent to them, thus improving block strength. Having. By mixing at least two types of aggregates with different fire resistances in a well-balanced manner, mixing an optimal binder, and adjusting firing conditions, it is possible to obtain a block that is stable in shape and has both water permeability and strength. Can be. The calcination is preferably performed just below the melting temperature of the aggregate having the lower fire resistance.

In the block of the present invention, the sintered binder is 5 to 5.
Contains 30% by weight. By setting the content of the sintered binder within this range, a block having both improved water permeability and strength can be obtained.

It is preferable that the sintered binder contains both a plastic binder and a non-plastic binder.
Further, it is preferable that each of these binders is contained in the range of 5 to 15% by weight. By including both a plastic and a non-plastic binder, the shape retention of the formed body is improved, and the strength of the fired block can be increased. This is because, in general, the plastic binder has a high melting point, and the non-plastic binder has a low melting point.
This is an effect that the melting behavior of the binder at the time of firing is optimized, and the binder is quickly melted and sintering proceeds while maintaining the shape of the block. It also has the effect of absorbing the expansion of the aggregate and ensuring the dimensional stability of the block,
It also contributes to improving the quality of the blocks. However, when the crushed glass particles are used as the aggregate, the fine particles act as a non-plastic binder, so that the fine particles can be omitted.

Here, the plastic binder is preferably at least one selected from the group consisting of bentonite, clay, kaolin, pottery stone, wax, clay, mica, and starches such as starch and methylcellulose.
By interposing these binders together with the non-plastic binder between the aggregates, the moldability and the shape retention are improved. In addition, it is preferable that these binders have a fine particle shape, and it is preferable that these binders exhibit adhesive strength.

As the non-plastic binder, it is preferable to use glass, frit, feldspar, silica stone, silica sand, dolomite, talc, carbonated lime, magnesite, wollastonite, and the like. By using these materials, it is possible to greatly contribute to resource saving and recycling, particularly by using materials that have been conventionally treated as industrial wastes, such as glass chips and frit. Furthermore, it is preferable to use a non-plastic binder containing a large amount of alkalis, limes, and boric acids.

The non-plastic binder is preferably made of a material having the following composition.

The content of the compound represented by R ₂ O (R is a monovalent element): within the range of 10 to 20% by weight The content of the compound represented by RO (R is a divalent element) : Within the range of 5 to 20% by weight Content of the compound represented by R ₂ O ₃ (where R is a trivalent element): within the range of 1 to 35% by weight Content of the compound represented by RO ₂ ( However, R is a tetravalent element): in the range of 30 to 80% by weight In the above, for example, Na ₂ O or K ₂ O can be used as the compound represented by R ₂ O.
FeO, MgO, CaO, Ba as a compound represented by
O or the like can be used. Similarly, Al ₂ O ₃ or Fe ₂ O ₃ can be used as a compound represented by R ₂ O ₃ , and SiO ₂ or TiO ₂ can be used as a compound represented by RO ₂ .

The above non-plastic binder is 0.1%
It is preferred that the composition contains 90% by weight or more of particles having a particle size of not more than mm. By using a non-plastic binder in this range, the contact area with the aggregate is appropriately maintained, the molten state at the time of firing tends to be uniform, the reaction efficiency is increased, and the strength of the block can be improved. .

Here, the composition of the binder used will be described. If only an organic binder such as starch or starch is used as the binder, it contributes to the shape retention of the molded product during production, but has little role as a sintering material and tends to lead to a decrease in the strength of the block. Also, depending on the amount used, aggregates of the binder may stick to the side wall of the mixer during mixing of the raw materials, or to the side wall or chamfered part of the mold during molding, resulting in poor workability, or aggregation into the block. And it is easy to cause quality deterioration. On the other hand, if only a so-called ceramic raw material binder such as clay or feldspar is used, the function as a sintering material is sufficiently exhibited and the strength of the block is improved. Costs are likely to rise. Also, when small aggregates or slags are used for the aggregate, the melting temperature of these aggregates is low. Appearance defects are likely to occur. Therefore, when glass powder, frit, or the like is used as the binder, it can be fired at a lower temperature and can be a sintered binder suitable for the aggregate to be used.

The block of the present invention has the above-described structure, and also has a JA method in combination with a manufacturing method described later.
Flexural strength measured according to SS7 M-101 is 6-1
The water permeability is within a range of 4 MPa and measured according to JIS A1218, which is 0.02 to 0.08 cm / s.
It can be a block within the range of ec.

In the above description, a block having a one-layer structure has been described.
It is also preferable to form a two-layered block in which a surface layer containing an aggregate is formed on the above-mentioned ceramic block within the range of 0 to 80 mm. As a result, it is possible to freely design the surface layer portion of a block requiring various functions.

The aggregate used for the surface layer can be made of the same aggregate as the aggregate used for the base layer. However, in order to enhance the design, it is preferable to use a natural material such as marble together with the aggregate. 5-40% by weight of natural material
Is preferably within the range. If the amount used is less than 5% by weight, the design properties will not be sufficiently reflected, and if it exceeds 40% by weight, the strength of the surface layer will decrease, and the color developability when a pigment is added tends to deteriorate.

It is preferable that the colors of the aggregate and the sintered binder are also selected in consideration of the design. If this color is white or close to this, it can be developed beautifully by adding a pigment or the like. As the pigment, powders of iron oxide, titanium oxide, cobalt oxide, chromium oxide, and the like can be used. Although the amount of the pigment depends on the degree of coloring, the amount of the pigment is 0.1 to the aggregate.
It is preferable to add in the range of 2 to 6% by weight. In addition, it is possible to form a variety of patterns such as natural shades by including a spot material having a size equal to or smaller than that of the aggregate, thereby improving the design. As the speckled material, colored artificial inorganic particles, and particles that darkly develop color after firing, such as mica, manganese, iron, garnet, slag particles, and natural particles, are preferable.

It is preferable that the thickness of the surface layer be in the range of 2 to 10 mm, since the surface layer can be formed with a smaller amount of material. When the Mohs hardness of the surface layer is 6 or more,
Wear and the like can be suppressed over a long period of time, and the service life after block laying can be extended. Furthermore, A of the surface layer
If the sliding resistance value in a wet state obtained in accordance with STM E303 is 60 BPN or more, it becomes difficult to slip even during rainfall, and can be suitably used as a block laid on a sidewalk or the like.

It is also preferable that a protrusion for regulating the joint width is provided on the side surface of the ceramic block. By providing the projections, the joint width can be kept constant, and the workability is improved even when many blocks are laid. The thickness of the projection (corresponding to the width of the joint) is 1
Preferably, the length (height) of the projection as viewed from the side surface of the block is within a range of 10 to 80 mm. The position where the projection is provided is
It is preferable that the protrusions of the adjacent blocks do not interfere with each other when the blocks are spread, for example, provided so as to avoid the center or the center of the side surface of the block.

Next, a method of manufacturing the water-permeable ceramic block of the present invention will be described for each step. (1) Base layer material preparation step: In this step, a non-plastic binder and a plastic binder are added to the aggregate and mixed.

First, water is added to the above-mentioned aggregate while mixing using a stirrer equipped with a stirrer or the like so that the surface of the aggregate is covered with water. Next, after adding and mixing a non-plastic binder, a plastic binder is added and mixed.
More preferably, the aggregate is previously divided into coarse aggregate having a large particle size and fine aggregate having a smaller particle size,
Water is added to and mixed with the coarse aggregate, and after sufficiently covering the surface with water, fine aggregate is added and mixed. By performing the mixing in this way, the phenomenon that the aggregate of the small particle size adheres closely to the aggregate of the large particle size and the phenomenon of generating an agglomerate is suppressed,
In addition, it is possible to suppress the occurrence of uneven stone due to vibration or the like, to obtain a molded body with less unevenness in density, and to obtain a high-quality block.

The amount of water to be added is in the range of 2 to 8 parts by weight, more preferably 3 to 6 parts by weight, when the total of the aggregate and the binder is 100 parts by weight. It is good to do so. The addition method at this time is preferably performed such that the water stream has a shower shape. If the amount of water is less than 2 parts by weight, the above-mentioned aggregates are less likely to occur,
The shape retention of the molded body is likely to decrease. If the amount of water exceeds 8 parts by weight, agglomerates are likely to be generated,
Fine powder or the like adheres to the inner wall or the stirring shaft of the mixer, and the mixing efficiency is likely to be deteriorated. Further, it takes time to clean the mixer, and the raw material sticks to the mold, so that lamination occurs in the molded body. In some cases, a drying step may be required separately, which makes the operation complicated.

It is preferable that the binder is charged so that the binder is added little by little to the entire inside of the mixer. In order to supply the binder as uniformly as possible into the mixer, it is advisable to disperse the charging site such as a charging port in several places instead of one place, or to provide a sieve and supply the binder while dispersing the binder at the time of charging. (2) Preparation of surface layer material: Although a block can be composed of only the above-described base layer, a surface layer of another specification can be formed on the base layer to enhance the design property and to impart various functions to the block. . Adjustment of the surface layer material is performed by mixing various materials such as the aggregate, the natural material, the pigment, and the speckle material as in the adjustment of the base layer material. (3) Molding step: Molding is performed by using a mold and filling so as to have a desired thickness after firing, taking into consideration the filling thickness. The molded body may be formed only with the above-mentioned base layer. However, in the case of a two-layer structure with the surface layer, first, the base layer material is put into a mold, and then subjected to primary molding using a hydraulic press or the like,
It is better to put the surface material on top of it and press again to mold.

Here, the porosity of the obtained molded product was set to 20%.
By doing so, the water permeability of the block is improved. In order to increase the porosity of the molded body to 20% or more, the molding pressure should be 4 to 1%.
It is good to set within the range of 5 MPa. Molding pressure is 4MP
If it is less than a, the porosity will increase, but lamination will occur in the molded body, and the molded body will be weakly tightened, and chipping and breakage will tend to occur. When the molding pressure is 15
If it exceeds MPa, the porosity becomes too small and the water permeability of the block tends to decrease. Note that it is preferable to prevent the molded product from being damaged by mechanical handling when transporting or transferring the molded product. It is also preferable to apply various designs such as flattening or embossing the surface during pressing. (4) Firing step: In this step, the molded body obtained in the above-mentioned molding step is fired to obtain a water-permeable ceramic block. For firing, a tunnel kiln, a roller hearth kiln, or the like can be used. The sintering temperature may be determined in consideration of the melting temperature of the aggregate, the melting behavior of the binder, and the like, and is preferably set in the range of 850 to 1300 ° C. The firing time may also be appropriately determined depending on the size of the molded product, the type of the base layer and the type of aggregate of the surface layer, but usually,
It is preferable to set it within the range of 3 to 48 hours. In addition, at the time of baking, if alumina powder, silica sand, or the like is arranged on the surface of the setter serving as the base of the block, setter contamination due to binder sintering can be prevented. It is also preferable to reduce the number of contact points between the setter and the block.For example, if fine projections are provided on the setter surface, in addition to preventing setter contamination, the cooling efficiency of the block is also increased.
This is preferable because it hardly causes cold cracks and the like.

[0046]

EXAMPLES (Example 1) The following materials were mixed to obtain a base layer material.

Aggregate: Tile Cerven, which is obtained by crushing defective tiles, is used.

The maximum particle size is 5 mm or less. Average particle size is 2.2
mm.

Coarse aggregate: particle size of 1.4 mm or more: 56% by weight Fine aggregate: particle size of less than 1.4 mm 26% by weight Non-plastic binder: glass powder is used .

[0050] 90 wt% or more of those having a particle size of 0.1 mm or less are contained.

... 12% by weight Plastic binder: Uses bentonite. ... 6% by weight mixing was performed by first adding water to the coarse aggregate. The amount of water is
The total amount of the raw materials was adjusted to be 3 parts by weight when the total was 100 parts by weight. Next, fine-grained aggregate was added and mixed well, and then mixed while adding a non-plastic binder little by little. Further, a plastic binder was added little by little and mixed.
By this mixing procedure, a base material having no aggregate was visually obtained.

Further, after mixing the following raw materials, an iron oxide-based inorganic pigment was mixed so as to be 1 part by weight when the total amount of the surface aggregate was 100 parts by weight to obtain a surface layer material. Was.

Aggregate: Tile Cerven obtained by crushing defective tiles is used.

The maximum particle size is 5 mm or less. Average particle size is 1.9
mm.

Coarse aggregate: those having a particle size of 1.4 mm or more: 39% by weight Fine aggregates: those having a particle size of less than 1.4 mm ... 39% by weight Non-plastic binder: glass powder is used .

[0056] 90% by weight or more of particles having a particle size of 0.1 mm or less are contained.

... 14% by weight Plastic binder: Uses bentonite. ... 8% by weight was first mixed with water while the aggregate was in the mixer. The amount of water was adjusted so as to be 4% by weight when the total of the raw materials was 100 parts by weight. Next, the non-plastic binder was mixed while being added little by little, and then the plastic binder and the inorganic pigment were added little by little and mixed. Thus, a surface material having no agglomerates was obtained visually.

Next, the above-mentioned base layer material was put into a mold and subjected to primary molding at 6.5 MPa using a hydraulic press, and then a surface layer material was placed thereon and molded again at 6.5 MPa. The porosity of the molded body was about 26%. Next, the molded body was baked for 48 hours at a maximum temperature of 1,115 ° C. using a tunnel kiln, the size was 197 × 97 mm, the thickness of the surface layer was 6 mm, and the thickness of the base layer was 54 mm. A water-permeable ceramic block having a thickness of 60 mm was obtained.

The characteristics of the block thus obtained were evaluated as follows. The bending strength is JASS7 M-101, and the permeability is JIS.
A1218, sliding resistance value is ASTM E303-66
T and Mohs' hardness were determined based on Mr. Mohs's scratch hardness with minerals, respectively.

Flexural strength: 8 MPa Hydraulic permeability: 0.03 cm / sec Sliding resistance value when wet: 70 BPN Mohs hardness of surface layer: 6.5 This ceramic block has a flexural strength and a water permeability.
It can be seen that it is improved as compared with the conventional water-permeable interlocking block. (Example 2) The following raw materials were mixed in the same manner as in Example 1,
A base layer material was obtained.

Aggregate: Tile seruben and molten slag obtained by pulverizing defective tiles are used.

The maximum particle size is 5 mm or less. Average particle size is 2.0
mm.

Sewage sludge melting slag: ... 32% by weight Waste melting slag: ... 32% by weight Tile selven (thing with a particle size of less than 1.4 mm): ... 16% by weight Non-plastic binder: Glass powder is used .

[0064] 90% by weight or more of particles having a particle diameter of 0.1 mm or less are contained.

... 12% by weight Plastic binder: Bentonite used. ... 8% by weight In addition, after mixing the following raw materials, the iron oxide-based inorganic pigment and mica particles were added in an amount of 1 part by weight and 3 parts by weight, respectively, when the total amount of the aggregate of the surface layer was 100 parts by weight. The mixture was mixed to obtain a surface layer material. Mixing was performed in the same manner as in Example 1.

Aggregate: Tile Cerven, which is obtained by crushing defective tiles, is used.

The maximum particle size is 5 mm or less. The average particle size is 1.8
mm.

Coarse aggregate: a particle diameter of 1.4 mm or more: 41% by weight Fine aggregate: a particle diameter of less than 1.4 mm: 41% by weight Non-plastic binder: glass powder is used .

[0069] 90% by weight or more of particles having a particle diameter of 0.1 mm or less are contained.

... 12% by weight Plastic binder: Kibushi clay ... 2% by weight Bentonite ... 2% by weight Clay ... 2% by weight (However, the weight ratio is clay / porcelain stone / feldspar = 35) / 10/5
5) Next, the above-mentioned base layer material was put into a mold, and 1
After primary molding at 0 MPa, put the surface layer material on it,
It was molded again at 10 MPa. The porosity of the molded body is about 24%
Met. Next, using a tunnel kiln, the molded body was baked for 40 hours so that the maximum temperature was 1,135 ° C., the size was 197 × 97 mm, the surface layer thickness was 6 mm,
A water-permeable ceramic block having a base layer thickness of 54 mm and an overall thickness of 60 mm was obtained.

The characteristics of the block thus obtained were evaluated in the same manner as in Example 1, and the results were as follows.

Flexural strength: 14 MPa Water permeability: 0.06 cm / sec Slip resistance in wet conditions: 65 BPN Mohs hardness on the surface of the surface layer: 7.5 This ceramic block also has the same flexural strength and water permeability as in Example 1. It can be seen that it is improved as compared with the conventional water-permeable interlocking block. (Example 3) The following raw materials were used as aggregates.

Aggregate: Porcelain tile (fire resistance group A) and glass (fire resistance group C) are used.

Porcelain tile The maximum particle size is 4.75 mm or less. The average particle size is 2.2 mm.

Composition: particle size in the range of 4.75 to 1.18 mm: 60% by weight Particle size in the range of 1.18 to 0.5 mm: 20% by weight Less than 0.5mm 20% by weight Glass (crushed bottles) Maximum particle size is 4.75mm or less. The average particle size is 1.8 mm.

Composition: particle size in the range of 4.75 to 1.18 mm ... 66% by weight Particle size in the range of 1.18 to 0.5mm ... 20% by weight Glass having a particle diameter of less than 0.5 mm acts as a non-plastic binder.

The porcelain tile 47% by weight, the glass 47% by weight, and bentonite 6 as a plastic binder
% By weight as the base material.

For mixing, first, the porcelain tile is put into a mortar mixer, and 4.5% by weight based on the total weight of the base material.
Of water was added. Next, the glass was added and mixed well, and then mixed while adding little by little bentonite as a plastic binder. By this mixing procedure, a base material having no aggregate was visually obtained.

After mixing the following raw materials, an iron oxide-based inorganic pigment was mixed so as to be 1 part by weight when the total amount of the aggregate of the surface layer was 100 parts by weight to obtain a surface layer material. Was. Mixing was performed in the same manner as in Example 1.

Aggregate: Tile Cerven obtained by grinding defective tiles is used.

The maximum particle size is 5 mm or less. Average particle size is 1.9
mm.

Coarse aggregate: particle size of 1.4 mm or more: 39% by weight Fine aggregate: particle size of less than 1.4 mm: 39% by weight Non-plastic binder: glass powder is used .

[0083] 90% by weight or more of particles having a particle diameter of 0.1 mm or less are contained.

... 14% by weight Plastic binder: Bentonite used. ... 8% by weight Next, the above-mentioned base layer material is put into a mold, and is put into a
After primary molding at a pressure of 0 MPa, a surface layer material was put thereon, and pressure was again applied at 10 MPa to obtain a molded body. The porosity of the molded body was about 24%. Next, this molded body was fired in an electric furnace at a temperature of 950 ° C. for 10 hours to obtain a water-permeable material having a size of 197 × 97 mm, a surface layer thickness of 6 mm, a base layer thickness of 54 mm, and an overall thickness of 60 mm. A ceramic block was obtained.

The characteristics of the block thus obtained were evaluated in the same manner as in Example 1. The results were as follows.

Flexural strength: 6.2 MPa Water permeability: 0.050 cm / sec Slip resistance when wet: 65 BPN Mohs hardness on the surface of the surface layer: 7.5 This ceramic block also has the same flexural strength and water permeability as in Example 1. It can be seen that the property is improved as compared with the conventional water-permeable interlocking block. (Example 4) The following raw materials were used as aggregates.

Aggregate: Porcelain tile (fire resistance A group) and sewage sludge molten slag (fire resistance B group) are used.

Porcelain tile The maximum particle size is 4.75 mm or less. The average particle size is 2.2 mm.

Composition: particle size in the range of 4.75 to 1.18 mm ... 62% by weight Particle size in the range of 1.18 to 0.5 mm ... 23% by weight Less than 0.5mm ... 15% by weight Sewage sludge melting slag Maximum particle size is 4.75mm or less. The average particle size is 2.4 mm.

Composition: particle size in the range of 4.75 to 1.18 mm ... 75% by weight Particle size in the range of 1.18 to 0.5mm ... 20% by weight Less than 0.5 mm ... 5% by weight 53% by weight of the above porcelain tile, 27% by weight of sewage sludge molten slag, and bentonite 7 as a plastic binder
% By weight and 13% by weight of glass powder as a non-plastic binder
Was used as a base layer material.

The mixing was performed by first putting the porcelain tile and the sewage sludge molten slag into a mortar mixer, and adding 4.5% by weight of water to the total weight of the base material. Next, the glass powder as a non-plastic binder was mixed while being added little by little, and further, the bentonite as a plastic binder was mixed while being added little by little. By this mixing procedure, a base material having no aggregate was visually obtained.

Further, after mixing the following raw materials, an iron oxide-based inorganic pigment was mixed so as to be 1 part by weight when the total amount of the aggregate of the surface layer was 100 parts by weight to obtain a surface layer material. Was. Mixing was performed in the same manner as in Example 1.

Aggregate: Tile Cerven obtained by grinding defective tiles is used.

The maximum particle size is 5 mm or less. Average particle size is 1.9
mm.

Coarse aggregate: particle size of 1.4 mm or more: 39% by weight Fine aggregate: particle size of less than 1.4 mm: 39% by weight Non-plastic binder: glass powder is used .

[0096] 90% by weight or more of particles having a particle size of 0.1 mm or less are contained.

... 14% by weight Plastic binder: Uses bentonite. ... 8% by weight Next, the above-mentioned base layer material is put into a mold, and is put into a
After primary molding at a pressure of 2 MPa, a surface layer material was put thereon, and pressurized again at 12 MPa to obtain a molded body. The porosity of the molded body was about 22%. Next, this molded body is fired at a temperature of 1100 ° C. for 10 hours using an electric furnace, and has a water permeability of 197 × 97 mm, a surface layer thickness of 6 mm, a base layer thickness of 54 mm, and an overall thickness of 60 mm. A ceramic block was obtained.

The characteristics of the block thus obtained were evaluated in the same manner as in Example 1, and the results were as follows.

Flexural strength: 8.5 MPa Water permeability: 0.025 cm / sec Slip resistance when wet: 70 BPN Mohs hardness on the surface of the surface layer: 7.5 This ceramic block also has the same flexural strength and water permeability as in Example 1. It can be seen that the property is improved as compared with the conventional water-permeable interlocking block. (Example 5) The following raw materials were used as aggregates.

Aggregate: Sewage sludge molten slag (fire resistance B group)
And glass (fire resistance class C).

The maximum particle size of sewage sludge molten slag is 4.75.
mm or less. The average particle size is 1.6 mm.

Composition: those having a particle size in the range of 4.75 to 1.18 mm ... 60 wt% those having a particle size in the range of 1.18 to 0.5 mm ... 15 wt% Less than 0.5mm ... 25% by weight Glass (crushed bottles) Maximum particle size is 4.75mm
Less than. The average particle size is 1.8 mm.

Composition: particle size in the range of 4.75 to 1.18 mm ... 66% by weight Particle size in the range of 1.18 to 0.5mm ... 20% by weight Glass having a particle diameter of less than 0.5 mm acts as a non-plastic binder.

The base layer material was 42% by weight of the sewage sludge molten slag, 51% by weight of the glass, and 7% by weight of bentonite as a plastic binder.

For mixing, first, the sewage sludge molten slag was put into a mortar mixer, and 4.5 parts based on the total weight of the base material.
This was done with the addition of water by weight. Next, the glass was added and mixed well, and then mixed while adding little by little bentonite as a plastic binder. By this mixing procedure, a base material having no aggregate was visually obtained.

Further, after mixing the following raw materials, an iron oxide-based inorganic pigment was mixed so as to be 1 part by weight when the total amount of the aggregate of the surface layer was 100 parts by weight to obtain a surface layer material. Was. Mixing was performed in the same manner as in Example 1.

Aggregate: Tile Cerven, which is obtained by crushing defective tiles, is used.

The maximum particle size is 5 mm or less. Average particle size is 1.9
mm.

Coarse aggregate: those having a particle diameter of 1.4 mm or more: 39% by weight Fine aggregate: those having a particle diameter of less than 1.4 mm ... 39% by weight Non-plastic binder: glass powder is used .

[0110] 90% by weight or more of particles having a particle diameter of 0.1 mm or less are contained.

... 14% by weight Plastic binder: Uses bentonite. ··· 8% by weight Next, the above-mentioned base layer material is put into a mold, and 1
After primary molding at a pressure of 2 MPa, a surface layer material was put thereon, and pressurized again at 12 MPa to obtain a molded body. The porosity of the molded body was about 22%. Next, this molded body is fired in an electric furnace at a temperature of 950 ° C. for 10 hours, and has a size of 197 × 97 mm, a surface layer thickness of 6 mm, a base layer thickness of 54 mm, and an overall thickness of 60 mm. A ceramic block was obtained.

The characteristics of the block thus obtained were evaluated in the same manner as in Example 1. The results were as follows.

Flexural strength: 6.5 MPa Water permeability: 0.030 cm / sec Slip resistance when wet: 70 BPN Mohs hardness on the surface of the surface layer: 6.5 This ceramic block also has the same flexural strength and water permeability as in Example 1. It can be seen that the property is improved as compared with the conventional water-permeable interlocking block.

[0114]

According to the present invention, there is provided an aggregate having a predetermined particle size, and the contents of the aggregate and the sintered binder are within a predetermined range. Thus, a block having excellent water permeability can be obtained. Therefore, for example, it can be suitably used not only on a sidewalk where walking is required such as when it is raining, but also on a portion where strength is required such as a place where a vehicle or the like enters.

Further, as the sintering binder, it is possible to use inexpensive raw materials usually discarded as industrial wastes, such as various slags and glass chips, thereby contributing to effective use and recycling of resources.

Claims (10)

[Claims] 1. A sintered binder and an aggregate having a maximum particle size of 5 mm or less and an average particle size in a range of 1 to 3 mm, wherein the content of the sintered binder is 5 to 30% by weight. %, The content of the aggregate is in the range of 65 to 93% by weight, the bending strength determined in accordance with JASS7 M-101 is in the range of 6 to 14 MPa, and JIS A1
218 is 0.02 to 0.08
A water-permeable ceramic block, which is in the range of cm / sec. 2. A sintered binder comprising bentonite, clay,
The water-permeability according to claim 1, comprising at least one kind of a plastic binder selected from the group consisting of kaolin, pottery stone, wax stone, clay, mica, and starches, and a non-plastic binder having the following composition. Ceramic block. Content of compound represented by R ₂ O (R is a monovalent element): within the range of 10 to 20% by weight Content of compound represented by RO (R is a divalent element): 5 to 5% by weight Content of the compound represented by R ₂ O ₃ in the range of 20% by weight (R is a trivalent element): Content of the compound represented by RO ₂ in the range of 1 to 35% by weight (where R is (Tetravalent element): within the range of 30 to 80% by weight 3. The aggregate is at least one selected from the group consisting of porcelain tile, porcelain tableware, porcelain block, insulator, steel slag, sewage sludge melting slag, refuse melting slag, glass and tap water sludge melting slag. The permeable ceramic block according to claim 1 or 2, comprising a kind of material. 4. An aggregate comprising the following groups A and B having different fire resistances:
The water-permeable ceramic block according to any one of claims 1 to 3, which is at least two groups of materials selected from a group and a group C, and includes at least one material selected from each of the at least two groups. . Group A: Porcelain tile, porcelain tableware, porcelain block, insulator B group: Sewage sludge melting slag, trash melting slag, steel slag, tap water sludge melting slag C group: glass 5. A water-permeable ceramic block having a surface layer containing an aggregate formed on the water-permeable ceramic block according to any one of claims 1 to 4, having a thickness in the range of 20 to 80 mm. 6. The water-permeable ceramic block according to claim 5, wherein the thickness of the surface layer is in the range of 2 to 10 mm. 7. The water-permeable ceramic block according to claim 5, wherein the Mohs hardness of the surface layer is 6 or more. 8. The water-permeable ceramic block according to claim 5, wherein the sliding resistance value of the surface layer when wet determined in accordance with ASTM E303 is 60 BPN or more. 9. The water-permeable ceramic block according to claim 1, wherein a joint width regulating projection is provided on a side surface. 10. The maximum particle size is 5 mm or less, and
After water is added to the aggregate having an average particle size in the range of 1 to 3 mm and mixed so that the surface of the aggregate is covered with water, a non-plastic binder is gradually added and mixed, and then the plastic binder is mixed. A method for producing a water-permeable ceramic block, which comprises gradually adding and mixing to form a molded body having a porosity of 20% or more, and then firing the molded body in a range of 850 to 1300 ° C.