JP2002088696A - Hardened body - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a hardened body capable of being readily treated. SOLUTION: This hardened body 1 can be readily treated and easily fitted when being used as a flooring material in a panel shape because the edge parts of the plate-shaped hardened body 1 obtained by drying a papermaking sludge are chamfered. The hardened body is hardly chipped or broken at the corner part.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a cured product of papermaking sludge.

[0002]

2. Description of the Related Art Effective utilization of various industrial wastes has been studied in recent years from the viewpoint of protecting the global environment. For example, in the construction industry, which has consumed a large amount of forest resources until now, new construction materials are required for industrial waste,
There is a need to reduce the consumption of forest resources.

[0003] The present inventors have made a papermaking sludge generated after the production of paper, and then hardened by drying the papermaking sludge, to provide a hardened body manufacturing technology that can be effectively used as a building panel or the like. No. 352586.

[0004]

The inventor of the present invention has an idea of using the above-mentioned cured product as a panel-like floor material. However, the cured body has a relatively heavy specific gravity of 1.2 to 1.3, and in order to obtain the required strength as a flooring material,
A weight that requires a thickness of 20 mm or more increases. For this reason, it was anticipated that handling would be difficult when the floor material was inserted in a panel shape.

[0005] The present invention has been made to solve the above-mentioned problems, and an object of the present invention is to provide a cured product which is easy to handle.

[0006]

Means for Solving the Problems In order to solve the above-mentioned problems, a first aspect of the present invention is a plate-shaped cured body composed of an inorganic amorphous material and a fibrous material, which has a chamfer formed at a corner. The technical feature is to do.

A second aspect of the present invention is a plate-shaped cured body obtained by curing papermaking sludge, and has a technical feature that the corner is chamfered.

In the present invention, since the corners of the cured body are chamfered, when used as a building material such as a panel-like flooring material, it is easy to handle and insert. Also, the corners are not chipped or broken. Furthermore, there is no squeak noise generated by rubbing the corners. In addition, it has been found that the sound insulation and vibration damping properties are improved.

Since the chamfer is provided with the C surface, chamfering is easy.

Since the chamfer is provided with a rounded surface, it is easy to handle and insert easily when used as a floor material panel.

[0011]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS First, the structure of a composite cured product produced by the method for producing a composite cured product of the present invention, which will be described later, will be described with reference to the schematic diagram of FIG.

[0012] The present invention is a composite cured product obtained by curing papermaking sludge, the corner of which is chamfered.
For this reason, when used as a building material, it is easy to fit in, there is no chipping of the corner, and there is no squeak noise generated by rubbing of the corner. Furthermore, surprisingly, it is possible to improve the sound insulation and vibration damping properties. This is presumed to be due to the fact that the board becomes easy to move due to the elimination of the corners, so that the sound energy is easily absorbed.

The composite cured product 1 includes an inorganic amorphous material 2 composed of two or more kinds of oxides, and an organic fibrous material 3 mixed in the inorganic amorphous material 2. Basic.
Here, the inorganic amorphous body composed of two or more oxides refers to an oxide (1) -oxide (2)... -Oxide (n) (where n is a natural number, Oxide (1), oxide (2),... Oxide (n) are different oxides).

Although it is difficult to accurately define such an amorphous substance, it is an amorphous compound which is formed by a solid solution or hydration reaction of two or more oxides. Conceivable. Such inorganic amorphous compounds are analyzed by fluorescent X-ray analysis to determine the elements (Al, Si,
Ca, Na, Mg, P, S, K, Ti, Mn, Fe, Z
and at least two types selected from n), and a halo is observed in the range of 2θ: 10 ° to 40 ° in the analysis chart by X-ray diffraction. This halo is a gentle undulation of the intensity of the X-ray, and is observed as a broad swell on the X-ray chart. The halo has a half width of 2θ:
2 ° or more.

The above-mentioned composite cured product 1 is firstly made of an inorganic amorphous material 2
Becomes a strength developing material, and the organic fibrous material 3 is dispersed in the inorganic amorphous material 2 to improve the fracture toughness value, so that the bending strength value and impact resistance can be improved. Also,
A homogeneous cured product having no anisotropy in strength can be obtained. Furthermore, since it is an amorphous body, there is an advantage that sufficient strength can be obtained at a low density.

[0016] The reason why the above-mentioned amorphous material becomes a material exhibiting strength is not clear, but it is presumed that it may be because the progress of cracks is inhibited as compared with the crystalline structure. Further, since the fibrous material is more easily dispersed uniformly in the amorphous state than in the crystalline state, it is considered that the fracture toughness value is also improved. As a result, even if a nail is driven or a through hole is provided,
Since cracks do not occur, it is optimal for materials that require processing, such as building materials.

Here, as the oxide, a metal and / or nonmetal oxide can be used, and Al ₂ O ₃ , Si
O ₂ , CaO, Na ₂ O, MgO, P ₂ O ₅ , SO ₃ ,
It is desirable to be selected from K ₂ O, TiO ₂ , MnO, Fe ₂ O ₃ and ZnO. In particular, Al ₂ O ₃ —S
iO ₂ -CaO-based or Al ₂ O ₃ -SiO ₂ -CaO
-An amorphous body composed of an oxide or a composite of these amorphous bodies is optimal. The oxide in the latter amorphous body is at least one kind of metal and / or non-metal oxide except Al ₂ O ₃ , SiO ₂ and CaO.

First, an amorphous body made of Al ₂ O ₃ —SiO ₂ —CaO system is made of Al ₂ O ₃ , SiO ₂ and CaO.
Is a compound having an amorphous structure in which all or a part of each component is formed by solid solution or hydration reaction with each other. That is, Al ₂ O ₃ and SiO ₂ , SiO ₂ and Ca
O, Al ₂ O ₃ and CaO, and Al ₂ O ₃ , SiO ₂
It is considered to include any of the compounds formed by causing a solid solution or a hydration reaction or the like with a combination of CaO and CaO.

Such an inorganic amorphous compound has a fluorescent X
Al, Si, and Ca were confirmed by the line analysis, and the halo was observed in the range of 2θ: 10 ° to 40 ° in the analysis chart by X-ray diffraction.

Further, Al ₂ O ₃ , SiO ₂ and CaO
Other than at least one oxide, ie, Al
_The amorphous body composed of ₂ O ₃ —SiO ₂ —CaO—oxide system includes, in addition to the combination of the above Al ₂ O ₃ —SiO ₂ —CaO system, Al ₂ O ₃ and oxide, and SiO ₂ and oxide , C
aO and oxide, Al ₂ O ₃ and SiO ₂ and oxide, SiO
₂ and CaO and an oxide, Al ₂ O ₃ and CaO and an oxide, or a compound formed by performing a solid solution or hydration reaction with a combination of Al ₂ O ₃ and SiO ₂ and CaO and an oxide. It is considered to include.

It should be noted that the number of the oxides is two or more, that is, Al
_{If it is a 2} O ₃ —SiO ₂ —CaO—oxide (n) -based (n is a natural number of 2 or more) amorphous material, these oxides, for example, oxide (1), oxide (2). ..Oxide (n)
(N is a natural number of 2 or more, and the oxide (n) means a different oxide if the value of n is different, and
₂ O ₃ , SiO ₂ , and CaO), and a compound formed by performing a solid solution or hydration reaction with at least two combinations selected from the group consisting of Al ₂ and Al _2.
Compounds formed by performing a solid solution or hydration reaction with at least two kinds of combinations selected from O ₃ , SiO ₂ , and CaO, and oxides (1), oxides (2),.
At least one selected from oxides (n) (n is a natural number of 2 or more) and Al ₂ O ₃ , SiO ₂ , Ca
It is considered to include any of the compounds formed by solid solution or hydration reaction in combination with at least one selected from O.

Such an inorganic amorphous compound has a fluorescent X
According to the line analysis, in addition to Al, Si and Ca, the elements (Na, Mg, P, S, K, Ti, Mn, F
e, Zn at least two types), and in the analysis chart by X-ray diffraction, 2θ: 10 ° to
The halo is seen in the range of 40 °.

Here, Al ₂ O ₃ , SiO ₂ and Ca
Oxides to be combined with O are one kind or two or more kinds, and are metals other than Al ₂ O ₃ , SiO ₂ and CaO and / or
Alternatively, non-metal oxides can be used, such as Na ₂ O, M
gO, P ₂ O ₅ , SO ₃ , K ₂ O, TiO ₂ , MnO,
It can be selected from Fe ₂ O ₃ and ZnO. This selection can be made based on the characteristics expected of the composite cured product.

For example, since Na ₂ O or K ₂ O can be removed with an alkali or the like, if the removal treatment is performed prior to the plating treatment, the surface to be plated on the surface of the composite hardened body is roughened and acts as an anchor for plating. be able to. Mg
O forms a solid solution with Al ₂ O ₃ , SiO ₂ , and CaO to contribute to strength development, and greatly improves bending strength and impact resistance. S
O ₃ has a bactericidal action and is suitable for antibacterial building materials. T
Since iO ₂ is a white colorant and also acts as a photo-oxidation catalyst, it can forcibly oxidize attached organic pollutants and can be cleaned only by irradiating light. It has a unique effect that it can be used as a filter or a reaction catalyst. MnO is useful as a dark colorant, Fe ₂ O ₃ is useful as a light colorant, and ZnO is useful as a white colorant. These oxides may be present alone in the amorphous body.

The composition of the above-mentioned amorphous material was Al ₂
Al ₂ O ₃ in terms of O ₃ , SiO ₂ and CaO:
3 to 51% by weight based on the total weight of the composite cured body, Si
O ₂ : 5 to 53% by weight based on the total weight of the composite cured product and CaO: 3 to 63% by weight based on the total weight of the composite cured product
And the total content thereof does not exceed 100% by weight.

The reason is that the content of Al ₂ O ₃ is 3% by weight.
If the content is less than 50% or more than 51% by weight, the strength of the composite cured product will be reduced, and if the content of SiO ₂ is less than 5% by weight or more than 53% by weight, the strength of the composite cured product will be reduced. Further, the content of CaO is less than 8% by weight or 63% by weight.
Even when the amount exceeds the weight percentage, the strength of the composite cured product is reduced. When the content of CaO is 3 to 6% by weight, a material having particularly high fracture toughness can be obtained.

Further, in terms of oxide, CaO / SiO
₂ weight ratio from 0.2 to 7.9, the weight ratio of CaO / Al ₂ O ₃ to be adjusted to 12.5 over 0.2 or less, it is advantageous for obtaining a large hardened body strength .

Further, Al ₂ O ₃ , SiO ₂ and CaO
Oxides other than Na ₂ O, MgO, P ₂ O ₅ , S
O ₃ , K ₂ O, TiO ₂ , MnO, Fe ₂ O ₃ and Z
When one or more kinds of nO are contained, the preferred contents of each component are as follows. It goes without saying that the total amount of these oxides does not exceed 100% by weight. Na ₂ O: 0.1-1.
2% by weight MgO: 0.3 to 1 based on the total weight of the composite cured product
1.0 wt% P ₂ O _5: 0.1~7 on the total weight of the composite hardened product.
3% by weight SO ₃ : 0.1 to 3 based on the total weight of the composite cured product.
5 wt% K ₂ O: 0.1~1 on the total weight of the composite hardened product.
2 wt% TiO _2: 0.1 to 8 relative to the total weight of the composite hardened product.
7% by weight MnO: 0.1-1.
5% by weight Fe ₂ O ₃ : 0.2 to 1 with respect to the total weight of the composite cured product
7.8% by weight ZnO: 0.1-1.
8% by weight The reason for limiting the content of these oxides to the above range is that if the content is outside the above range, the strength of the composite cured product is reduced. Note that the composition of Si, Al, and Ca referred to in the present invention is:
This is the composition in the composite cured product, and is the total composition in the Ca-based crystal and the inorganic amorphous material. Therefore, when an inorganic substance is added, the composition includes the added inorganic substance.

In the present invention, the composition is adjusted by a method of selecting a papermaking sludge having a desired Ca component amount, a method of mixing and adjusting a composition by mixing a plurality of papermaking sludges, and adjusting the composition by adding calcium carbonate or silica sand. The method has been adopted. Papermaking sludge has various compositions, but generally has little Ca component. This is because the pH is made acidic in order to agglomerate the papermaking sludge, so that the Ca component does not remain on the precipitation side. If the desired composition is not available, other papermaking sludge of different composition may be appropriately mixed or
It is necessary to add an inorganic component such as calcium carbonate.

It should be noted that the presence or absence of an amorphous structure can be confirmed by X-ray diffraction. That is, 2θ: 10 ° by X-ray diffraction
If a halo is observed in the region of ４０40 °, it can be confirmed that it has an amorphous structure. In the present invention, in addition to those having a completely amorphous structure, Hydrogen Aluminum Silicate, Kaolinite, Zeolit
e, Gehlenite, syn, Anorthite, Melitite, Gehlenit
e-synthetic, tobermorite, xonotlite, ettringite
Or SiO ₂ , Al ₂ O ₃ , CaO, Na ₂ O, Mg
O, P ₂ O ₅ , SO ₃ , K ₂ O, TiO ₂ , MnO, F
oxides such as e ₂ O ₃ and ZnO, and CaCO ₃
Crystals such as (Calcite) may be mixed.

Although it is not considered that these crystals themselves become a strength-expressing substance, if they have effects such as increasing the hardness and density to improve the compressive strength and suppressing the progress of cracks. Conceivable. The content of the crystal is preferably 0.1 to 50% by weight, particularly preferably 3 to 48% by weight based on the total weight of the composite cured product. This is because if the crystal content is less than 0.1% by weight, effects such as increasing the hardness and density to improve the compressive strength and suppressing the progress of cracks cannot be sufficiently obtained. This is because bending strength is reduced.

Incidentally, the above Al ₂ O ₃ —SiO ₂ type crystalline compound is selected from Hydrogen Aluminum Silicate and Kaolini.
te, Zeolite, Al ₂ O ₃ —CaO based crystalline compounds are Calcium Aluminate, CaO—SiO ₂ based crystalline compounds are Calcium Silicate, Al ₂ O ₃ —SiO ₂ —Ca
O-type crystalline compounds are Gehlenite, syn and Anorthite, and Al ₂ O ₃ —SiO ₂ —CaO—MgO-type crystalline compounds are Melitite and Gehlenite-synthetic.
Further, it is desirable that the above-mentioned crystal contains Ca, and Gehlenite, syn (Ca ₂ Al ₂ O ₇ ), Melitite-s
_{ynthetic (Ca 2 (Mg 0.5 Al} 0.5) (Si 1. 5 Al
_0.5 O ₇ )), Gehlenite-synthetic (Ca ₂ (Mg
_0.25 Al _0.75 ) (Si _1.25 Al _0.75 O ₇ )), Anorthit
e, ordered (Ca ₂ Al ₂ Si ₂ O ₈ ) and calcium carbonate (Calcite) may be contained.

In the composite cured product produced by the production method of the present invention, halogen may be added to an amorphous material composed of at least two or more kinds of oxides. The halogen serves as a catalyst for a solid solution or hydrate formation reaction and also acts as a combustion suppressing substance. Its content is 0.1-1.
2% by weight is desirable. This is because if it is less than 0.1% by weight, the strength is low, and if it exceeds 1.2% by weight, harmful substances are generated by combustion. As the halogen, chlorine, bromine and fluorine are desirable.

Similarly, calcium carbonate (Calcite) may be added. Calcium carbonate itself is not a strength-expressing substance, but it is thought that by surrounding the calcium carbonate with an amorphous body, it contributes to strength improvement by actions such as inhibiting the progress of cracks. The content of the calcium carbonate is 48 to the total weight of the composite cured product.
% By weight or less is desirable. The reason for this is that if it exceeds 48% by weight, the bending strength is reduced. Further, the content is desirably 0.1% by weight or more. If the content is less than 0.1% by weight, it does not contribute to the improvement in strength.

Further, the addition of a binder is advantageous for further improving the strength and for improving the water resistance, chemical resistance and fire resistance. The binder desirably comprises one or both of a thermosetting resin and an inorganic binder. As thermosetting resins, phenolic resins,
At least one resin selected from melamine resin, epoxy resin and urea resin is desirable. The inorganic binder is preferably at least one selected from the group consisting of sodium silicate, silica gel and alumina sol.

Next, in the method for producing a composite cured product of the present invention, as the organic fibrous material mixed in the inorganic amorphous material, an organic fibrous material comprising a polysaccharide is used. This is because polysaccharides have an OH group, and Al ₂ O ₃ ,
This is because they are easily bonded to various compounds of SiO ₂ or CaO.

The polysaccharide is desirably at least one compound selected from amino sugars, uronic acids, starch, glycogen, inulin, lichenin, cellulose, chitin, chitosan, hemicellulose and pectin. As the organic fibrous material comprising these polysaccharides, in general, pulp, pulp grounds, and crushed waste paper such as newspapers and magazines are advantageously suited.

The content of the fibrous material is 2 to 75.
% By weight. The reason for this is that if the content is less than 2% by weight, the strength of the composite cured product is reduced, while if it exceeds 75% by weight, the fire protection performance, water resistance, dimensional stability and the like may be reduced. Further, the average length of the fibrous material is desirably 10 to 1000 μm. If the average length is too short, no entanglement occurs, and if the average length is too long, voids are formed and the strength of the composite cured product is likely to decrease.

The above-mentioned composite cured product 1 is optimally obtained by drying and coagulating and curing paper sludge (scum). That is, the papermaking sludge is a pulp residue containing an inorganic substance, contains an organic fibrous substance, is low in cost because industrial waste is used as a raw material, and contributes to solving environmental problems. Moreover, this papermaking sludge itself has a function as a binder, and is kneaded with itself or with other industrial waste.
It has the advantage that it can be formed into a desired shape.

Further, in the papermaking sludge, in addition to pulp, Al ₂ O ₃ , SiO ₂ , CaO, Na ₂ O, Mg
O, P ₂ O ₅ , SO ₃ , K ₂ O, TiO ₂ , MnO, F
It generally contains a crystal of e ₂ O ₃ and ZnO or a sol that is a precursor of these oxides, or a composite thereof, at least one selected from halogen and calcium carbonate, and water.

Here, as shown in FIG.
It is advantageous to mix the inorganic particles 4 therein to improve the fire resistance or to form a strength-expressing substance by reacting with the amorphous material to improve the strength. By doing so, the specific gravity of the composite cured product can also be adjusted.

As the inorganic particles 4, at least one selected from calcium carbonate, calcium hydroxide, shirasu, shirasu balloon, perlite, aluminum hydroxide, silica, alumina, talc, calcium carbonate, and industrial waste powder is used. it can. In particular, as the industrial waste powder, it is desirable to use at least one or more types of industrial waste powder selected from calcined powder of papermaking sludge, grinding dust of glass, and crushed silica sand. This is because by using these industrial waste powders, cost reduction can be realized and furthermore, it can contribute to solving environmental problems.

The inorganic particles obtained by calcining papermaking sludge can be obtained by subjecting papermaking sludge to heat treatment at 300 to 1500 ° C. The inorganic particles thus obtained are:
Since it is amorphous, has excellent strength and toughness, and has a low density, it can be reduced in weight by being dispersed in a composite cured product. In addition, the papermaking sludge is kept at 300 ° C or more and 800 ° C or more.
The inorganic particles obtained by quenching at less than or less than 300 ° C. and then heat-treating at 300 to 1500 ° C. are advantageous because they surely contain an amorphous body. It is desirable that the inorganic particles 4 have a specific surface area of 0.8 to 100 m ² / g. If it is less than 0.8 m ² / g, the contact area between the amorphous material and the inorganic particles becomes small and the strength is reduced.
If it exceeds m ² / g, effects such as crack development and improvement in hardness are reduced, and as a result, strength is reduced.

Further, the inorganic particles 4 may contain at least one inorganic material selected from silica, alumina, iron oxide, calcium oxide, magnesium oxide, potassium oxide, sodium oxide and phosphorus pentoxide. desirable. This is because they are chemically stable and have excellent weather resistance, and have desirable characteristics as industrial materials such as building materials.

If the average particle diameter of the inorganic particles 4 is too small or too large, sufficient strength cannot be obtained.
It is desirably in the range of 〜100 μm. The content of the inorganic particles is desirably 10 to 90% by weight. That is, if the amount of the inorganic particles is too large, the strength is lowered, and if the amount of the inorganic particles is too large, the strength becomes brittle, and in any case, the strength is lowered.

Composite cured product 1 produced by the method of the present invention
Is used in various industries, calcium silicate plate,
It can be used for electronic materials such as core substrates of printed wiring boards, as well as new building materials that can replace perlite boards, plywood, gypsum boards, etc.

Composite cured product 1 produced by the method of the present invention
Is manufactured to have an equilibrium water content of 3% or less by a manufacturing method described later. Therefore, it has high dimensional stability and can be suitably used for the various industrial applications described above.

Next, an embodiment of a method for producing a cured product and an apparatus for producing a cured product according to the present invention will be described with reference to FIGS. In the production method of the present invention, papermaking sludge is used as a raw material of the composite cured body without kneading with other industrial waste. The papermaking sludge used in the production method of the present invention includes printing / information paper, kraft paper, titanium paper,
Papermaking sludge discharged in the pulp manufacturing process when manufacturing tissue paper, dust paper, toilet paper, sanitary products, towel paper, industrial hybrid paper or household hybrid paper, raw material processing such as waste paper, and papermaking processes, etc. desirable. Paper sludge is handled by Maruto Kiln.

FIG. 3 shows the entire structure of the apparatus for producing a cured body. The apparatus for producing a cured product includes a raw material adjustment mechanism 10 that adjusts papermaking sludge to generate a slurry 14, a papermaking mechanism 20 that papers a paper 26 from the slurry 14, and an inverting device 40 that inverts the paper 26. A press 50 for dehydrating by pressing after laminating the papers 26, and a drier 60 for drying the pressed papers to form the cured body 1.
Consists of

First, a raw material adjusting mechanism 10 for adjusting the raw material.
Will be described with reference to FIG. Raw material 1 above
1 and water 12 were weighed by suction dehydration described below so that the concentration became 0.5 to 25% by weight of solid content, and
And a coagulant (a flocculant: added amount of 0.01 to 4) of aluminum sulfate, ferric chloride, polyaluminum chloride, sodium polyacrylate, polymethacrylate, polyacrylate, or polyacrylamide. 5%) and organic fibers such as vinylon fibers (binder: added amount: 0.1 to 10% by weight).
The mixture is mixed at 3 to prepare a slurry 14. Organic fibers (binders) include synthetic fibers such as polyethylene, polypropylene, and vinylon, pipes, pulp recovered from waste paper,
Besides, fibrous industrial waste can be used. As a raw material, various inorganic powders and resins can be further added to papermaking sludge.

The slurry 14 was placed on the bottom of the filter 1
Suction dehydration is performed using the dehydration container 15 provided with 6.
By suction dehydration, the concentration is adjusted to 0.5 to 25% by weight of solid content. In the suction dehydration, since the fibers of the papermaking sludge are not oriented, the resulting composite cured product is less likely to warp or crack.

The bottom of the dewatering vessel 15 is provided with a vacuum pump 17
And suction of water by the operation of the vacuum pump 17. The filter 16 is not particularly limited, but includes a sintered metal, a perforated metal plate (a metal plate having a hole having a diameter of 1 to 5 mm),
A porous ceramic filter, a porous resin, a glass fiber plate or the like can be used. The raw material 14 whose water content has been adjusted in the dehydration container 15 is temporarily stored in a chest tank 18.
The chest tank 18 is provided with a stirring propeller so that solids in the raw material do not settle.

In the present embodiment, the water content is adjusted by the dehydration vessel 15, but as shown in FIG. 4B, only the amount of water added to the mixer 13 is reduced without using the dehydration vessel 15. It is also possible to adjust the water content with.

Subsequently, the papermaking unit 2 was prepared from the slurry 14 containing the papermaking sludge whose water content had been adjusted by the papermaking mechanism 20.
6 is generated. An inorganic binder such as cement or an organic binder such as a resin may be added to the slurry (raw material solution). The papermaking mechanism 20 will be described with reference to FIG. The papermaking mechanism 20 includes three bats 21A, 21B, and 21C that store the slurry 14, and a wire cylinder 2 that is provided in the bat and that papers the slurry 14.
2A, 22B, 22C and wire cylinders 22A, 2C
A conveyor belt 23 for transferring and conveying the paper body 26 formed by 2B and 22C, a cutting drum 30 for winding and cutting the paper body 26 conveyed by the conveyor belt 23 to a predetermined thickness, Cutter 36 for cutting the body 26
And a belt conveyor 38 for conveying the papermaking body 26.

Wire cylinders 22A, 22B, 22C
Has a diameter of 70 cm and a width of 1 mm. In this embodiment, since the drainage body for draining (papermaking) is composed of a rotating drum (wire cylinder) composed of a net-like body, the papermaking body 26 can be continuously formed from the raw material solution 14, and the papermaking sludge can be efficiently produced. The mass can be mass-produced.
The water that has passed through the wire cylinders 22A, 22B, and 22C passes through a pipe 17a and a vacuum pump 17 as shown in FIG.
It is returned to the mixer 13 shown in FIG.

In this embodiment, the wire cylinder 2
2A, 22B, and 22C are provided side by side along the transport belt 23, and the paper
Transfer 6 For this reason, the papermaking product 26
Paper with high efficiency, and it is possible to efficiently mass-produce cured products from papermaking sludge. In this embodiment, the rotation speed of the wire cylinder is set to 60 rotations / minute. This rotation speed is desirably 1 to 100 times / minute. This is because the papermaking body 26 can be formed from the raw material solution 14 with high efficiency, and the hardened body can be efficiently mass-produced from papermaking sludge. Here, if the rotating drum is lower than 1 rotation / minute, the papermaking efficiency is low. On the other hand, if the number of rotations exceeds 100 rotations / minute, it becomes difficult to form a sheet with a uniform thickness. In the present embodiment, three wire cylinders 22A, 22B, and 22C are provided in parallel, but one or more wire cylinders can be used.

The wire cylinders 22A, 22B,
The mesh of 22C is $ 60 (the number of meshes per inch is 60)
Is formed. Wire cylinders 22A, 22B,
The mesh size of 22C is preferably $ 40 to 150. From the raw material solution (slurry) 14, a papermaking body 26 can be produced with high efficiency,
This is because it is possible to efficiently mass-produce a high-density cured product from papermaking sludge. Here, when the mesh is coarser than # 40, only the inorganic amorphous material comes off from the raw material solution, and the density and strength of the cured product decrease. On the other hand, if the mesh is finer than # 150, the removal of water becomes worse, and it becomes impossible to make a papermaking product from the raw material solution with high efficiency. Since floc is formed in the papermaking sludge (raw material solution) by the coagulant, the papermaking can be performed efficiently.

The concentration of the raw material solution containing papermaking sludge is desirably 0.5 to 25% by weight of solid content. This is because the papermaking property from papermaking sludge can be improved and the cured product can be efficiently mass-produced. That is, if the concentration is less than 0.5%, it cannot be efficiently made from a raw material solution using a wire cylinder (filtration body), and if it exceeds 25%, the uniformity of the product is reduced.

The wire cylinders 22A, 22B, 22C
Conveyor belt 2 that transfers and conveys the paper made by
Numeral 3 is made of felt having a width of 1 m, suspended by rollers 34, provided with a suction box 24 on the back surface, and performing dehydration while suctioning by a vacuum pump 17. That is, the belt 23 adsorbs the moisture of the raw material 14 including the papermaking sludge into the pores of the felt, and the adsorbed moisture is absorbed by the suction box 2.
4 and is adsorbed to the vacuum pump 17 side and returned to the mixer 13 shown in FIG. In the first embodiment, the belt 23 is made of felt, but instead of this, a porous resin having continuous pores, a porous rubber, a material obtained by solidifying inorganic fibers with a binder, a sintered metal, A porous metal, a belt made of a porous metal block fixed with a flexible binder such as rubber, or the like can be used. In this embodiment, since the transport belt 23 is formed of a porous body having continuous pores and is dehydrated while being transported by the transport belt 23, the moisture in the papermaking body 26 can be efficiently reduced.

In the present embodiment, the transport speed of the transport belt 23 is set to 48 m / min, and the wire cylinders 22A, 22B, 22C, the cutting rotary drum 30, and the belt conveyor 38 are synchronized with the transport speed. Are driven by a motor (not shown). The transport speed of the transport belt 23 is desirably 5 to 80 m / min. This is because a paper having an appropriate thickness can be formed from the raw material solution with high efficiency, and the cured body can be efficiently mass-produced. Here, if the conveying speed is lower than 5 m / min, the papermaking body can be made thicker, but the papermaking efficiency is low. On the other hand, if the transport speed is 80
When the rate exceeds m / min, the sheet becomes thin, it is difficult to obtain a uniform thickness, and the sheet may be cut.

The cutting rotary drum 30, which winds and cuts the paper conveyed by the conveyor belt 23 to a predetermined thickness,
It has a diameter of 64 cm (outer circumference 2 m), and has a storage groove 32 for retaining water on the surface and a piano wire 31 housed in a housing groove 33 located near the groove 32. The cutting rotary drum 30 winds the papermaking body 26 conveyed from the conveyor belt 23 on the surface thereof while forming a multilayered structure.

Then, the sheet 26 has a predetermined thickness (1.5
cm), and when this is detected by a sensor (not shown),
The piano wire 31 in the accommodation groove 33 is pushed out. Storage groove 3
At the position along 2, the paper body 26 has a high water content, and when the piano wire 31 is extruded, the paper body 26 is cut along the storage groove 32, and as shown in FIG. Fall. Then, with the rotation of the cutting rotary drum 30 and the transport of the belt conveyor 38, the papermaking body 26 having a predetermined thickness is transported onto the belt conveyor 38 (see FIG. 6B). Here, as shown in FIG. 6C, when the other cut end is conveyed to a position corresponding to the cutter 36, the cutter 36 is lowered to the belt conveyor 38 side, and
The cut end of the paper body 26 and the unstacked paper body conveyed on the conveyor belt 23 are separated.

In the present embodiment, the papermaking material on the conveyor belt 23 is multi-layered while being transferred to the rotary drum 30 for cutting.
When the multilayered paper body 26 reaches a predetermined thickness, it is cut into a predetermined size. The papermaking body 26 having a uniform thickness (1.5 cm) and a size (1 mx 2 m) is obtained by the rotary drum for cutting.
Can be continuously molded, so that the cured body can be efficiently mass-produced.

In this embodiment, the rotary drum 3 for cutting is used.
A cutter 36 is provided for cutting the papermaking body 26, one end of which is cut at 0, at regular intervals. Therefore, the predetermined length (2
m) of the papermaking body 26 can be formed. In the present embodiment, the thickness of the papermaking body 26 is 1.5 cm, but the thickness is desirably 2 cm or less. If the thickness is 2 cm or less, papermaking is easy, and handling is easy in transportation and the like.

The reversing device 40 for reversing the papermaking product will be described with reference to FIG. In the manufacturing apparatus of the present embodiment, as described later, since the papermaking bodies are alternately inverted and laminated, the papermaking bodies 26 are inverted every other sheet. The reversing device 40 includes a transport device 42 for sucking and transporting the papermaking body, a table 44, and a reversing plate 46.

As shown in FIG. 7A, the papermaking body 26 on the belt conveyor 38 is
6. The reversing plate 46 is driven, and the
Is inverted (see FIG. 7B). And FIG. 7 (C)
3 is transported by the transport device 42 to the press 50 shown in FIG. In addition,
As described above, in the present embodiment, the binder is added to the slurry 14 so that the papermaking body 26 has flexibility, and handling after cutting is easy.

Pressing machine 50 for pressurizing and dewatering the papermaking body
Will be described with reference to FIGS. 8 and 9. FIG.
As shown in (A), a press machine 50 includes a female mold 54 having a concave portion 54A and a male mold 52 fitted into the concave portion 54A.
The female mold 54 and the male mold 52 are formed with fine through holes 54a and 52a, respectively, for extracting water generated when the paper is pressed. In addition, the press 50 is provided with a curtain coater 56 for applying the raw material solution 14 to the papermaking body 26 (FIG. 8).
(B)).

The lamination and pressurization in the press machine 50 will be described. First, as shown in FIG. 8A, the cutting rotary drum 30 is inverted as a lowermost layer in the concave portion 54 </ b> A of the female mold 54 by the inverting device 40 described above with reference to FIG. Papermaking body 26 with the contact surface side of the
It is carried in by the transport device 42. Next, as shown in FIG. 8 (B), the raw material solution 14 is applied to the upper surface of the papermaking body 26, that is, the bonding surface with the upper layer papermaking body, by the curtain coater 56. The amount of this raw material solution is
50g / m ² ~500g / m ² are preferred in solids. In addition, although the curtain coater 56 is used here,
Various coating devices such as a roll coater can be used.

As shown in FIG. 8C, as the second layer of the papermaking product, the papermaking product 26 on the belt conveyor 38 is carried into the concave portion 54A of the female mold 54 by the transfer device 42 without being inverted. Thereafter, as shown in FIG. 9A, the raw material solution 14 is applied, and then the inverted papermaking product 26 of the third layer is applied.
Is placed, and after applying the raw material solution 14, the fourth layer (top layer) of the non-inverted papermaking product 26 is placed, and the lamination is completed. Here, four layers are laminated, but any number of two or more sheets may be used, and even one sheet may be used when a thin cured product is manufactured.

Thereafter, the male mold 52 is pushed down, and a pressure press is performed at 60 kg / cm ² (see FIG. 9B). At this time, the water seeping out of the papermaking body 26 is led out through the holes 54a and 52a. Thereafter, the male mold 52 is raised (see FIG. 9C), and the composite cured body 1 formed by pressurization is taken out of the female mold and transported to the dryer 60.

In this embodiment, the pressure is applied to the mold (recess 54A).
Since it is performed inside, the papermaking body 26 does not break even when pressurized at a high pressure, and it is possible to produce a high-strength cured body 1 from papermaking sludge at a high yield. In addition, since the male mold 52 and the female side 54 are provided with through holes 52a and 54a for removing water seeping out of the papermaking body 26, dehydration is performed at the time of pressurization, and the curing step by subsequent drying is completed in a short time. Let me do. Further, since a plurality of papermaking sludge papermaking bodies are laminated with the raw material solution 14 interposed therebetween, a multilayer cured body without peeling can be produced.

The pressure press is desirably performed at 10 to 250 kg / cm ² . If the pressing is performed at less than 10 kg / cm ² , the required strength cannot be obtained. Meanwhile, 2
This is because even if the pressure exceeds 50 kg / cm ² , the strength cannot be increased, and the press becomes larger and more expensive.

In this embodiment, a plurality of papermaking sludge papermaking products obtained by making a raw material solution using a wire cylinder (filtration body) are laminated. Since it is inefficient to obtain a thick paper by papermaking, a thin paper is efficiently formed from papermaking sludge and a cured product having the required strength and thickness is produced by stacking. This allows
Efficient mass production of cured products from papermaking sludge.

Further, in the production method of this embodiment, the papermaking sludge is formed into a thickness of 20 mm or less, and the papermaking sludge is efficiently produced and laminated to produce a cured product having the required strength and thickness. I do. For this reason, it is possible to efficiently mass-produce the cured body from the papermaking sludge.

In this embodiment, the papermaking bodies 26 are laminated while alternately reversing the laminating surface. That is, since the papermaking body 26 is laminated while reversing the direction in which the warpage occurs, the papermaking body 2
6 does not warp and cause delamination. In addition, the uppermost and lowermost papermaking products are laminated so that the exposed surface is the surface that was in contact with the rotating drum and the uneven surface that was in contact with the conveyor belt 32 made of felt is inside. The surface of the cured product can be smoothed.

Further, in this embodiment, since a flocculant is added to the raw material solution containing papermaking sludge to cause coagulation, the cured product 1 having a uniform specific gravity (in the range of 1.2 to 1.3) is mass-produced from papermaking sludge. can do. Further, in this embodiment, since the lamination is performed in the female mold 54, it is not necessary to transfer the laminated papermaking body, which is suitable for mass production. In the present embodiment, the layers are stacked in the mold 54, but it is also possible to transfer them into the mold after the stacking.

[0093] The dehydration drying under pressure is performed by the press machine 50,
After lowering the water content, it will be stored in a warehouse (not shown) for 1 day.
Store for about 90 days and allow to dry naturally until the water content becomes 4-6%. After that, the curing reaction is advanced by a dryer 60 shown in FIG. 4 and completely dried to an equilibrium water content (3% or less). The dryer 60 includes an electric heater 62 and a fan 64, and performs drying at a temperature of 80 to 200 ° C. Dryer 60
Is equipped with an electric heater 62, but instead, an infrared heater, steam, a solar dryer, or the like can be used. Because the cured product shrinks greatly due to changes in moisture,
It is desirable that drying is carried out over a certain period of time by natural drying over a long period of time, followed by drying in a drier for the sake of shape stability.

The cured body 1 having undergone the drying step is further conveyed and cut into a predetermined size by a cutter (not shown).
The cutting is performed by a cutter or a saw provided on the conveyor.

Thereafter, as shown in FIG. 10A, a corner is chamfered by a grinder to provide a C plane. Cured body 1
Is formed as a panel-like flooring that provides a hollow portion for arranging computer wiring. Therefore, the cured body 1 is formed to have a thickness (h) of 25 mm and a width (w) of 50 cm. The C plane is preferably formed to have a length of 0.1 to 2 mm. As a result, when used as a panel-like floor material,
Easy to handle and fill. Also, the corners are missing,
It will not break. As shown in FIG.
When forming a surface, there is an advantage that processing is easy.

On the other hand, as shown in FIG. 10 (B), it is also possible to form an R surface at the time of chamfering. The R surface is preferably formed with a radius of 0.1 to 5 mm. Thereby, when used as a panel-like flooring material, it is easy to handle and insert. Also, the corners are not chipped and broken. Note that chamfering may be performed after curing or during molding before curing.

Finally, the composite cured body 1 is inspected for warpage or the like by an inspection machine (not shown). As the inspection machine, an X-ray sensor, an infrared sensor, or the like can be used. Further, the presence or absence of chipping or cracking may be inspected by an image processing device or the like.

The following is an example in which the composite cured product obtained in the above-mentioned steps is analyzed using a fluorescent X-ray analyzer (Rigaku RIX2100). It was found that the composition was as follows in terms of oxide. The pulp was calcined at 1100 ° C. and measured from the weight loss. Serial Pulp: 51.4 wt%, SO _3: 0.5 wt% SiO _2: 24.2 wt%, P ₂ O _5: 0.2 wt% Al ₂ O _3: 14.0 wt%, Cl: 0 .2 wt% CaO: 8.0 wt%, ZnO: 0.1 wt% MgO: 1.4 wt%, others: traces TiO _2: 1.0 wt%,

FIG. 11 shows a cured body 1 arranged as a panel-like flooring material providing a hollow portion for arranging computer wiring. The figure shows a state in which one cured body 1 has been removed, and the wiring 102 arranged under the cured body 1 can be inspected. In this embodiment, since the hardened body 1 is chamfered, it is easy to remove and insert the hardened body after construction, and also to minimize injuries even if an operator accidentally drops the foot. Can be suppressed. In addition, there is no squeak noise generated when the corners are rubbed.

In the paper making method of the present embodiment, a rotating
The cured body is manufactured by making a paper using a
Since pure substances fall off, impurities can be reduced,
It is possible to increase the brightness. Also, calcium carbonate
A cured product containing a rubber, wherein C in the cured product is
The amounts of a, Al and Si are CaO and Al, respectively._TwoO_Three, S
iO _TwoCaO / SiO_TwoFrom the weight ratio of 0.2
7.9, CaO / Al_TwoO_ThreeWeight ratio of 0.2 to 1
Since it was adjusted to 2.5, the Ca component increased,
The degree improves. Also, strength and nailing performance are high.
You. For this reason, the brightness of the cured product is JIS Z 8
721 can be set to N4 or more.

According to JIS Z 8721, the ideal black lightness is 0, the ideal white lightness is 10, and the perception of the brightness is equal between the black lightness and the white lightness. Each color is divided into ten parts so as to obtain the rate, and displayed by symbols N0 to N10. The actual measurement of lightness is N0
To N10. In this case, the first place of the decimal point is 0 or 5. The lightness of the cured product is J
Since the value based on IS Z 8721 can be N4 or more, coloring and decoration can be performed.

Example Unfired papermaking sludge (papermaking sludge of Mino Paper Co., Ltd. handled by Maruto Kiln Co., Ltd .: solid content 3)
(4% by weight, water content: 66% by weight) was prepared. Next, acid washing was performed using a 2N aqueous hydrochloric acid solution to remove the Ca component almost completely.

A Pulp: 51.2% by weight MgO: 1.6% by weight SiO ₂ : 18.6% by weight SO ₃ : 3.5% by weight Al ₂ O ₃ : 22.3% by weight P ₂ O ₅ : 0 .3 wt% CaO: 0.0 wt% Cl: 0.1% by weight SO _3: 1.2 wt% ZnO: 0.1 wt% Others traces

In addition, paper making sludge of ink jet printer paper of Maki Paper Co., Ltd. handled by Maruto Kiln Co., Ltd .: B was 51% by weight of solid content and 49% by weight of water. B Pulp: 21.8 wt% SiO _2: 4.6 wt% Al ₂ O _3: 7.5 wt% P ₂ O _5: 0.1 wt% CaO: 65.0 wt% Na ₂ O: 0.2 % By weight SO ₃ : 0.2% by weight Other trace amount The amount of calcium carbonate was 55% by weight.

In addition, papermaking sludge of Maki Paper Co., Ltd.'s inkjet printer paper, which is handled by Maruto Kiln Co., Ltd .: 51% by weight of solid content, 49% by weight of water, and 10% by weight of calcium carbonate (cubic shape) And

C pulp: 16.4% by weight SiO ₂ : 2.6% by weight Al ₂ O ₃ : 5.5% by weight P ₂ O ₅ : 0.1% by weight CaO: 75.0% by weight Na ₂ O: 0.1% by weight SO ₃ : 0.2% by weight Other trace amount The amount of calcium carbonate was 65% by weight.

Samples were prepared by appropriately mixing A, B, and C as described above, and were prepared by the apparatus shown in FIG. Wire cylinder
60, diameter 70cm, width 1m, rotation speed 60 rotations / min, belt conveyance speed 48m / min, making roll 64cm in diameter
It is. The solid content of the raw material is 5%. The size of the press mold was 1800 mm × 1000 mm.
Further, 45 push bars of 190 mm square were used.

[0092] The results of measuring the bending strength, compressive strength, nailing properties, lightness, and fracture toughness of the cured product were shown in Figs.
The results are shown in the graph of FIG. FIG. 12 shows the relationship between CaO / SiO ₂ and the compressive strength and lightness, with the vertical axis representing the compressive strength (Kg / cm ² ).
In addition, the ratio of CaO / SiO ₂ is plotted on the horizontal axis with the brightness (N). FIG. 13 shows the relationship between CaO / Al ₂ O ₃ and the compressive strength and lightness. The vertical axis shows the compressive strength (Kg / cm ² ) and the lightness (N), and the horizontal axis shows the ratio of CaO / Al ₂ O _3. It is.
FIG. 14 shows the relationship between the CaO content and the bending strength / compression strength, with the ordinate representing the bending strength / compression strength (Kg / cm ² ) and the abscissa representing the CaO content (%). FIG.
The relationship between the O content and the nail pull-out strength and fracture toughness is shown. The vertical axis represents the nail pull-out strength (Kg / cm ² ) and the fracture toughness (MPa · m ^1/2 ), and the horizontal axis represents the CaO content (%). ) Has been taken.

The fracture toughness peaks at 3 to 6% by weight in terms of CaO. In addition, the pull-out strength of the nail is based on 20 kg / cm ^2, but it is 4 to 6 in terms of CaO.
It will be in the range of 3% by weight. The same tendency also appears in bending strength and compressive strength. Further, the ratio of CaO / SiO ₂ is 0.2 to 7.9, and the ratio of CaO / Al ₂ O ₃ is 0.4.
By adjusting from 2 to 12.5, the compressive strength and the brightness N4.0 or more can be achieved.

In this example, a composite cured product obtained by curing a papermaking sludge in which A, B and C were mixed at a ratio of 1: 3: 1 was 1 mm.
A board A having a size of × 1 mm and a thickness of 2 mm was cut out, and a board A provided with a C surface having a length of 1 mm on the outer periphery, a board B provided with an R surface having the same size of 1 mm, and a board C without chamfer were manufactured.

When the boards A, B, and C were laid as shown in FIG. 11 and walked on each other, no squeak sound was confirmed on the boards A and B, but a squeak sound was generated on the board C. The squeak sound is considered to be caused by the rubbing of the corners between the boards, but in the present invention, there is no such squeak sound because there is no corner.

Further, the sound transmission loss and the loss coefficient (thickness: 2 mm) were measured at a frequency of 125 to 4000 Hz. The transmission loss indicates sound insulation, and the loss coefficient indicates vibration suppression. FIG.
6, by providing a chamfered shape as shown in FIG.
Surprising results have been obtained in which the passage loss and the loss coefficient increase. We estimate that chamfering makes it easier for the board to vibrate and absorb sound energy. Therefore, it is particularly effective in building material applications such as soundproofing materials, vibration damping materials, flooring materials, ceiling materials and wall materials.

[0097]

As described above, the present invention is particularly effective for use in building materials such as soundproofing materials, vibration damping materials, flooring materials, ceiling materials, wall materials, etc. There is no chipped corner and no squeaking noise generated by rubbing of the corner. Furthermore, surprisingly, it is possible to improve the sound insulation and vibration damping properties.

[Brief description of the drawings]

FIG. 1 is a schematic cross-sectional view of a composite cured product of the present invention.

FIG. 2 is a schematic cross-sectional view of the composite cured product of the present invention.

FIG. 3 is a conceptual diagram of an apparatus for manufacturing a cured body according to a first embodiment of the present invention.

FIGS. 4A and 4B are conceptual diagrams of a raw material adjustment mechanism.

FIG. 5 is a conceptual diagram of a papermaking mechanism.

FIGS. 6A, 6B, and 6C are explanatory views of the operation of the cutting rotary drum.

FIGS. 7A, 7B, and 7C are explanatory diagrams of the operation of the reversing device.

FIGS. 8A, 8B, and 8C are explanatory diagrams of the operation of the press machine.

FIGS. 9A, 9B, and 9C are explanatory diagrams of the operation of the press machine.

FIGS. 10A and 10B are cross-sectional views of a cured body used as a flooring material.

FIG. 11 is a plan view of a cured body used as a floor material.

FIG. 12 is a graph showing the relationship between CaO / SiO ₂ and compressive strength and brightness.

FIG. 13 is a graph showing the relationship between CaO / Al ₂ O ₃ , compressive strength, and brightness.

FIG. 14 is a graph showing the relationship between CaO content and bending strength / compression strength.

FIG. 15 is a graph showing the relationship between the CaO content, nail pull-out strength, and fracture toughness.

FIG. 16 is a graph showing transmission loss of a cured product.

FIG. 17 is a graph showing a loss coefficient of a cured product.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Composite hardened body 2 Amorphous body 3 Fibrous material 4 Inorganic powder 6 Coating layer 10 Raw material adjustment mechanism 14 Raw material solution (slurry) 15 Dehydration container 16 Filter 17 Vacuum pump 18 Chest tank 20 Paper making mechanism 21A, 21B, 21C Butt 22A , 22B, 22C Wire cylinder 23 Conveyor belt 24 Suction box 26 Papermaking machine 30 Rotating drum for cutting 31 Piano wire 32 Storage groove 33 Storage groove 36 Cutter 38 Belt conveyor 40 Reversing device 42 Transport device 44 Table 46 Reversing plate 50 Press machine 52 Male Mold 52a Through hole 54 Female type 54A Concave portion 54a Through hole 56 Curtain coater 60 Dryer

 ──────────────────────────────────────────────────続 き Continued on the front page F term (reference) 2E162 CC00 FB00 FD00 4D059 AA30 BB02 BD18 BD32 BE14 BE15 BE25 BK08 CB04 CC04 DA03 DA15 DA19 DA54 DA70 DB34 4L055 AF50 AG04 AG12 AH01 BF05 FA20 FA30 GA21 GA24 GA38

Claims (4)

[Claims] 1. A cured product comprising an inorganic amorphous material and a fibrous material, wherein the cured product has a chamfered corner. 2. A cured product obtained by curing papermaking sludge, wherein the cured product has chamfered corners. 3. The cured product according to claim 1, wherein the chamfer is provided with a C surface. 4. The cured product according to claim 1, wherein the chamfer is provided with an R surface.