JP2002292815A - Cured object and method for manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a cured object capable of efficiently mass-producing the cured object from papermaking sludge, and the cured object having high water resistance. SOLUTION: A raw material solution is filtered using a water filtering member 22A according to a papermaking process and the formed web is transferred to a feed belt 23 and subsequently transmitted to be formed into a multilayered structure while transferred to a making roll 30 and the multilayered web is cut into a predetermined size and the cut unit webs are cured to form cured objects which are, in turn, laminated through an adhesive to obtain the laminate 100 of the cured objects. Since the unit webs are cured, production is easy. Since the laminate of the cured objects is obtained by laminating the cured objects through the adhesive, the laminate is excellent in water resistance and strength.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a cured product obtained by hardening papermaking sludge into a plate and a method for producing the same.

[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,
It has been proposed to reduce the consumption of forest resources. On the other hand, it has been demanded to realize low cost and high functionality of conventionally used inorganic boards such as calcium silicate board, perlite board, slag gypsum board, wood chip cement board and gypsum board.

The present inventors have previously described a technique for producing a cured product that can be effectively used as an architectural panel or the like after papermaking sludge generated after the production of paper is made and then cured by drying. / 36242, WO00 / 362
18, WO00 / 35820, JP-A-2000-30
No. 2415, JP-A-2000-302416, JP-A-20
00-303395, JP-A-2000-303392
JP-A-2000-302414, JP-A-2000-2
No. 82399, JP-A-2000-303394, JP-A-2
000-303396, JP-A-2000-303393
JP-A-2000-296576, JP-A-2000-2
97495, JP-A-2000-301651, JP-A-2
000-297496. Further, the present inventors have developed a technique for efficiently forming a paper from papermaking sludge and producing a cured product from the obtained papermaking body.
No. 9052.

[0004] In the technique of WO 00/79052, a raw material solution containing papermaking sludge is formed into paper using a filter body, and a papermaking sludge paperwork is attached to the surface of the filter body, and the papermaking body is transferred to a conveyor belt. After the transfer, the paper body on the conveyor belt is multilayered while being transferred to a hard roller, and the multilayered paper body is peeled and cut into a predetermined size, and after laminating a plurality of cut paper bodies, A cured papermaking sludge is obtained by pressing the laminated paper, adjusting the water content, and then drying.

[0005]

SUMMARY OF THE INVENTION However, WO
In the technique of 00/79052, since the laminated paper is pressed, it is not possible to efficiently reduce the water content, and it takes a long time to press the paper. Could not be mass-produced. Furthermore, there was a problem that the strength of the produced cured product was low, and in particular, the dimensions were changed due to moisture absorption, and the strength was reduced.

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned problems, and an object of the present invention is to provide a method for producing a cured product capable of efficiently mass-producing a cured product from papermaking sludge, and a highly water-resistant cured product. Is to provide the body.

[0007]

Means for Solving the Problems To solve the above-mentioned problems, a first aspect of the present invention is a method for producing a hardened product comprising papermaking sludge, wherein a raw material solution containing papermaking sludge is formed using a drainage body, and the filtration is performed. A papermaking sludge paperboard is attached to the surface of the water body, and the paperboard is transferred after being transferred to a conveyor belt, and the paperboard on the conveyor belt is multilayered while being transferred to a hard roller. Peeled and cut to a predetermined size, the cut veneer sheet is cured, and the vulcanized product obtained by curing the veneer veneer is laminated with an adhesive interposed, and the cured product is laminated. The technical feature is to get the body.

In the method for producing a cured product according to the first aspect, the veneer is hardened, and the veneer can be produced in a short time, so that the production is easy. Further, since the cured product is laminated with an adhesive interposed therebetween to obtain a laminated product of the cured product, it is excellent in water resistance and strength as compared with the case where the veneer sheet is laminated and then cured.

The cured product of the present invention is used to form papermaking sludge.
And cured, the respective acids of Si, Al and Ca
Fiber composed of polysaccharide in inorganic amorphous body composed of fluoride
A cured product containing fibers and calcium carbonate
Thus, the amounts of Ca, Al, and Si in the cured product are respectively
CaO, Al_TwoO_Three, SiO_TwoCaO / Si
O_TwoRatio of 0.2 to 7.9, CaO / Al_TwoO_ThreeRatio
Is a cured product adjusted to 0.2 to 12.5. this
The brightness of the cured product is a value based on JIS Z 8721
And N5 or more. In addition, these Ca, Al, Si
Amount (CaO, Al _TwoO_Three, SiO_Two Conversion amount)
Is the total amount of Ca, Al, Si in the
If any, calcium carbonate and all
Means the amount of Ca. In addition, CaO / SiO_TwoRatio
CaO / Al exceeding 0.2 and 7.9 or less_TwoO_ThreeIs the ratio
Be a cured product adjusted to more than 0.2 and less than 12.5
Is optimal. .

[0010] In the present invention, the cured product is manufactured by making a paper using a rotating drum of a net-like body. Since impurities fall off from the mesh, the impurities can be reduced and the brightness can be increased. is there. Further, a cured product containing calcium carbonate, wherein Ca, Al, S in the cured product
When the amount of i is converted into CaO, Al ₂ O ₃ , and SiO ₂ , respectively, the ratio of CaO / SiO ₂ is 0.2 to 7.9,
Since the ratio of / Al ₂ O ₃ is adjusted from 0.2 to 12.5, the Ca component increases and the brightness improves. Also,
This is because strength and nailing performance are also high.

[0011] For this reason, the brightness of the cured product is determined according to JIS
It can be N5 or more with a value based on the definition of Z 8721.
Note that JIS Z 8721 sets the ideal black lightness to 0.
The ideal white lightness is assumed to be 10, and each color is divided into 10 so that the perception of the brightness is equal between the black lightness and the white lightness, and is indicated by symbols N0 to N10. It was done. The actual lightness measurement is compared with the color charts corresponding to N0 to N10. In this case, the first place of the decimal point is 0 or 5. The brightness of the cured product is JIS Z 8
Since the value based on the rule 721 can be N5 or more, coloring and decoration can be performed.

The calcium carbonate crystal habit is desirably at least one type selected from the group consisting of a spindle, a square, a table, a cube and a column. This is because the whiteness is high, and since it has corners, it hardly gets caught in the fiber and falls off, so that it can be incorporated into the cured product even in papermaking.

In the method for producing a cured product according to the second aspect, the veneer sheet is dehydrated by pressing and then dried, so that the veneer sheet is laminated and then cured. Is easy.

In the method for producing a cured product according to claim 3, the moisture content of the veneer sheet is adjusted to be less than 0.5 in terms of the weight ratio with respect to the sludge, so that it is compared with the laminate of veneer sheets. Water content can be easily adjusted.

In the method for producing a cured product according to claim 4, since the pressing is performed at 40 to 100 kg / cm ² , the water content of the veneer sheet can be adjusted to a weight ratio of less than 0.5 to sludge. .

In the method for producing a cured product according to the fifth aspect, the moisture content of the cured product is reduced to less than 0.05 by weight with respect to sludge by drying, so that a cured product having excellent strength can be produced.

The cured product according to the sixth aspect of the present invention is characterized in that a raw material solution containing papermaking sludge is formed into a paper using a drainage body, and the cured veneer cured product is laminated with an adhesive interposed therebetween. Features.

The cured product according to the sixth aspect is obtained by forming a raw material solution containing papermaking sludge by paper filtration using a drainage body, and laminating the cured single-plate cured product with an adhesive interposed therebetween. And excellent strength.

[0019]

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. The composite cured body 1 is composed of an inorganic amorphous body 2 composed of two or more oxides.
And that the organic fibrous material 3 is mixed in the inorganic amorphous body 2. 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 difficult to define an amorphous compound by forming a solid solution or a 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.

The reason why the above-mentioned amorphous material becomes a strength-expressing substance is not clear, but is presumed to 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, the amorphous body composed of the Al ₂ O ₃ —SiO ₂ —CaO system includes 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 oxide 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 of 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. P
₂ O ₅ is particularly advantageous when used for biomaterials (artificial roots, artificial bones) to aid adhesion with bone. SO ₃
Has a bactericidal action and is suitable for antibacterial building materials. TiO
₂ is a white colorant and also acts as a photo-oxidation catalyst, so it can forcibly oxidize attached organic pollutants and can be cleaned only by irradiating light. Has a unique effect that it can be used as 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 body 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 : 6 to 53% by weight based on the total weight of the composite cured product and CaO: 6 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 6% 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 6% 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 Ca content is 3% by weight or more and less than 6% by weight in terms of CaO, the strength is low but the fracture toughness is excellent. The amounts of the Si, Al, and Ca components refer to the total amount in the composite cured product, regardless of whether it is in a crystal or non-crystal. When an inorganic additive is present, the total amount of the components in the additive is also included.

Further, in terms of oxide, CaO / SiO
Adjusting the ratio of ₂ to 0.2 to 7.9 and the ratio of CaO / Al ₂ O ₃ to 0.2 to 12.5 is advantageous for obtaining a cured product having high 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.

It should be noted that whether the structure is 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.

[0037] These crystals are not considered to be strength-generating substances themselves. However, 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 desirably 0.1 to 50% 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 Al ₂ O ₃ —SiO ₂ type crystalline compound is selected from the group consisting of 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, a halogen may be added to an amorphous material composed of at least two 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, the organic fibrous material mixed with the inorganic amorphous material is an organic fibrous material composed of polysaccharides. 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.

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 artificial materials for artificial limbs, artificial bones, artificial dental roots, core substrates of printed wiring boards, interlayer resin insulation layers, as well as new building materials to replace perlite boards, plywood, gypsum boards, etc. it can.

Next, a first embodiment of a method for producing a cured product and a device for producing a cured product according to the present invention will be described with reference to FIGS.
This will be described with reference to FIG. 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. Examples of the papermaking sludge used in the production method of the present invention include printing / information paper, kraft paper, titanium paper, tissue paper, dust paper, toilet paper, sanitary products, towel paper, industrial hybrid paper or household hybrid paper. The papermaking sludge discharged in the pulp manufacturing process, the raw material processing process of used paper, the papermaking process, and the like at the time of the pulp production is desirable. Paper sludge is handled by Maruto Kiln.

FIG. 3 shows the entire configuration of the apparatus for producing a cured body. The apparatus for producing a hardened body includes a raw material adjusting mechanism 10 for adjusting papermaking sludge to generate a slurry 14, a papermaking mechanism 20 for forming a paperboard 26 from the slurry 14, and a dewatering press 40 for pressurizing and dewatering the paperboard 26. And a dryer 50 for drying the pressed paper to form a cured product 1
Press machine 6 for pressing a plurality of single-plate cured bodies 1
It consists of 0.

First, a raw material adjusting mechanism 10 for adjusting the raw materials.
Will be described with reference to FIG. Raw material 1 above
1 and water 12 were weighed by suction dehydration described later so that the solid content became 3.5 to 25% by weight, and the mixture was mixed with a mixer 13.
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.
The concentration is adjusted to 3.5 to 25% by weight of solid content by suction dehydration. 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, 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 making roll 30 for winding and laminating the paper body 26 conveyed by the conveyor belt 23 to a predetermined thickness; A peeling cutter 31 for cutting and peeling the paper 26 on 30; a cutting cutter 36 for cutting the peeled paper 26 to a length of 2.1 m; and a belt conveyor 38 for transporting the paper 26.
And

The wire cylinders 22A, 22B, 22C
Has a diameter of 70 cm and a width of 1.2 m. In the present embodiment, since the drainage body for draining (papermaking) is formed 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,
It is possible to efficiently mass-produce a cured product from papermaking sludge. The water that has passed through the wire cylinders 22A, 22B, 22C is returned to the mixer 13 shown in FIG. 4A via the pipe 17a and the vacuum pump 17.

In this embodiment, three wire cylinders 22A, 22B, and 22C are provided along the conveyor belt 23, and the papermaking body 26 is transferred onto the conveyor belt 23 while being multi-layered. Therefore, the papermaking product 2
6 can be made with high efficiency, and the cured product can be efficiently mass-produced 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. From the raw material solution 14, a paper 26 can be formed with high efficiency,
This is because it is possible to efficiently mass-produce the cured product from the 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, the wire cylinders 22A, 22A
Although three B and 22C are provided, any number of one or more can be used.

The wire cylinders 22A, 22B,
The mesh of 22C is $ 70 (the number of meshes per inch is 70)
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, if the mesh is coarser than # 40, only the inorganic non-crystalline 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 3.5 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 3.5%, it is not possible to efficiently make a paper from a raw material solution using a wire cylinder (filtration body), and if it exceeds 25%, the uniformity of the product is reduced.

Wire cylinders 22A, 22B, 22C
Conveyor belt 2 that transfers and conveys the paper made by
3 is made of felt having a width of 1.2 m,
A suction boxes 24, 24 and a suction box 27 are provided on the back surface, and dehydration is performed while suction is performed by the vacuum pump 17 and the vacuum pump 28. 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 adsorbed to the vacuum pump 17 side through the suction box 24, and the mixer shown in FIG. Returned to 13. 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, For example, a porous metal, a belt in which a block of a porous metal is fixed with a flexible binder such as rubber, or the like can be used. In the present embodiment, the transport belt 23 is formed of a porous body having continuous pores.
The water is dehydrated in the suction boxes 24 and 24 while being conveyed, so that the water content in the papermaking body 26 can be efficiently reduced. Thereby, the cured body can be constituted homogeneously.

In the present embodiment, the papermaking product 2 is placed in the suction box 27 placed just before the making roll 30.
6 is adjusted to a final weight ratio of 0.9 or less, more preferably 0.8 or less, with respect to the sludge, so that the moisture of the paper-moulded product transferred to the making roll 30 is appropriately adjusted. Can be done. That is, if the water content of the papermaking product 26 exceeds 0.9, it is difficult to transfer the papermaking material from the belt 23 to the making roll 30, and the transferred papermaking product is separated by the centrifugal force generated with the rotation of the making roll 30. However, by reducing the specific gravity by setting the water content to 0.9 or less, the papermaking body does not peel off from the making roll 30, and a cured body can be efficiently produced.

In this embodiment, the transport speed of the transport belt 23 is set to 48 m / min, and the wire cylinders 22A, 22B, 22C are driven by a motor (not shown) so as to synchronize with the transport speed. The making roll 30 and the belt conveyor 38 are driven by a motor (not shown) via a driving roller 34A. 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 exceeds 80 m / min, the papermaking article becomes thinner, making it difficult to obtain a uniform thickness and cutting off the papermaking article.

The making roll 30 that winds and cuts the papermaking body conveyed by the conveyor belt 23 to a predetermined thickness includes:
It is formed so as to have a diameter of 67 cm (outer circumference 2.1 m) and to make one rotation in 7.5 seconds in a counterclockwise direction in the figure.
The making roll 30 has a storage groove 32 for retaining water on its surface, and an elastic member 35 located in the vicinity of the groove 32 and accommodated in an accommodation groove 33 formed parallel to the axis of the roller.
And The elastic member 35 is made of rubber. The making roll 30 winds the papermaking body 26 conveyed from the conveyor belt 23 on the surface thereof while making it into a multilayer.

Then, the making roll 30 is rotated a predetermined number (20 to 30), and the papermaking body 26 has a predetermined thickness (6
〜8 mm), the peeling cutter 31 is pushed out so as to contact the elastic member 35 in synchronization with the rotation of the making roll 30. At the position along the storage groove 32,
Has a high moisture content, and when the peeling cutter 31 is extruded,
It is cut along the storage groove 32, and the cut end falls down to the belt conveyor 38 side as shown in FIG. Then, the rotation of the making roll 30 and the belt conveyor 3
Along with the conveyance of 8, the papermaking body 26 having a predetermined thickness is conveyed onto the belt conveyor 38 (see FIG. 6B). In addition,
The storage groove 32 can be eliminated.

In the first embodiment, the making roll 30
Since the upper paper body is peeled off by pressing against the peeling cutter 31 from the outside, the multilayered paper body 26 can be peeled off cleanly while being transferred to the making roll 30, and efficiently from papermaking sludge. It becomes possible to mass-produce the cured body. In addition, since the cutting of the papermaking body 26 on the making roll 30 is performed when the number of rotations of the making roll 30 reaches a predetermined number, a papermaking body having a uniform thickness can be efficiently generated. In addition, since the peeling cutter 31 is brought into contact with the elastic member 35 to cut the paper body on the making roll 30, the surface of the iron making roll 30 is not damaged by the stainless steel peeling cutter 31.

Here, as shown in FIG. 6C, when the other cut end is conveyed to a position corresponding to the cutting cutter 36,
The cutting cutter 36 is lowered to the belt conveyor 38 side, and the cut end of the papermaking body 26 is separated from the unlaminated paperboard conveyed on the conveyor belt 23.

In the present embodiment, the papermaking material on the conveyor belt 23 is multi-layered while being transferred to the making roll 30, and is cut into a predetermined size when the multilayered papermaking material 26 reaches a predetermined thickness. . The uniform thickness (6 to 8 mm) and size (1.2 m ×
Since the papermaking body 26 of 2.1 m) can be continuously formed, the cured product can be efficiently mass-produced.

Further, in this embodiment, a cutting cutter 36 for cutting the papermaking body 26 having one end cut by the making roll 30 at a constant interval is provided. Therefore, the papermaking body 26 having a predetermined length (2.1 m) can be efficiently formed.
In addition, in this embodiment, although the thickness of the papermaking body 26 was set to 6 to 8 mm, 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 dewatering press 40 for pressurizing and dewatering the papermaking product will be described with reference to FIG. As shown in FIG. 7A, the dewatering press 40 includes a flat plate lower die 42 and an upper die 44, and a felt 46 is provided on the surfaces of the lower die 42 and the upper die 44. Here, a felt is used, but instead, various flexible porous bodies such as a filter cloth and a sponge can be used.

The pressurized dewatering in the dewatering press 40 will be described. First, as shown in FIG. 7B, the cut papermaking body 26 is carried onto the felt 46 of the lower mold 42 by a transport device (not shown). Next, as shown in FIG. 7C, the upper mold 44 is pushed down, and pressure dehydration is performed for 40 to 100 minutes.
The treatment is performed at Kg / cm ² for 10 seconds to 5 minutes, and the water content of the papermaking body 26 is adjusted to less than 0.5 in terms of the weight ratio with respect to the sludge. Thereby, as shown in FIG. 7D, the thickness of the papermaking body 26 is reduced to about half (3 to 5 mm).

In the first embodiment, since the papermaking body 26 is pressed and dewatered with a felt (flexible porous body) 46 interposed therebetween, the moisture in the cured body is efficiently squeezed out and the moisture inside the cured body is removed. To prevent nests from forming. Further, it is possible to prevent a paper containing a large amount of water from being deformed by extending in the lateral direction during pressing. Further, since the surface of the papermaking body 26 can be roughened by felt,
As will be described later, the adhesion through the adhesive can be improved.

Further, in the manufacturing method of the first embodiment, since the veneer sheet is dehydrated, the production is easy as compared with the case where the veneer sheets are laminated and then dewatered.

The pressure press is 40 to 100 kg / cm ²
It is desirable to perform in. If the pressing is performed at less than 5 kg / cm ² , the water content cannot be reduced to 0.5 or less. On the other hand, the water content cannot be reduced efficiently even if the pressing is performed at a pressure exceeding 40 kg / cm ² , resulting in an increase in size and cost of the press.

After dehydration under pressure by the press machine 40 to reduce the water content, it is subsequently substantially completely dehydrated by a drier 50 shown in FIG. .
(Less than 05) The curing reaction proceeds. As a result, a cured product having excellent strength can be produced. The dryer 50 includes the transport roller 5
1 and an outlet 54 for blowing out hot air, and hot air at 120 to 200 ° C. is blown from the upper and lower outlets 54 to the papermaking body 26 supported by the rollers 52 of the transport roller 51 at a wind speed of 10 to 30 m / Then, the papermaking body 26 undergoes a curing reaction to form a cured body 1. Since the dryer 50 blows hot air onto the papermaking body 26 from above and below to dry it, the cured body 1 can be formed without causing warpage. The dryer 50 has a hot air outlet 54, but an infrared heater, steam, a solar dryer, or the like can be used instead.

The cured product 1 obtained by drying and curing
Has been subjected to pressure dehydration via the felt 46 as described above, so that the surface roughness becomes Rmax 0.01 to 2 mm.

After the cured body 1 is formed by the dryer 50, the cured body 1 is successively laminated by a pressure press 60 shown in FIG. First, as shown in FIG. 9A, after the cured body 1 is placed on the lower mold 62 of the flat plate, the adhesive 66 is evenly applied to the surface of the cured body 1 from the nozzle 65. Here, as the adhesive, for example, vinyl acetate, aqueous vinyl urethane, or the like can be used. Then, as shown in FIG. 9B, four cured bodies 1 are laminated with an adhesive 66 interposed therebetween. Thereafter, the upper mold 64 is pressed down and pressurized at 5 to 40 kg / cm ² for 10 minutes to obtain a cured product laminate 100. Here, the thickness of the adhesive 66 is adjusted to about 0.1 mm. In addition, it is also possible to heat simultaneously with pressurization.

The cured product laminate 100 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. The cut composite cured body 1 is finally inspected for warpage or the like by an inspection machine (not shown). As an inspection machine, X
Line sensors, infrared sensors, etc. can be used. Further, the presence or absence of chipping or cracking may be inspected by an image processing device or the like.

In the method for producing a cured product according to the first embodiment, the veneer sheet 26 is dehydrated by pressing, and then dried. , Easy to manufacture. In addition, since the cured product 1 is laminated with the adhesive 66 interposed therebetween to obtain a cured product laminate 100, the laminate obtained by laminating a single-sheet paper body and then curing is excellent in water resistance and strength. .

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. As a result, the cured product is efficiently mass-produced from the papermaking sludge.

Further, in the present embodiment, since a coagulant is added to the raw material solution containing papermaking sludge to cause coagulation, the cured product 1 having a uniform specific gravity (1.2 to 1.3) is mass-produced from papermaking sludge. can do.

In the manufacturing method of the present embodiment, the cured product 1 obtained by curing the veneer sheet 26 is laminated with the adhesive 66 interposed therebetween to obtain a cured product laminate 100. here,
By setting the surface roughness of the cured product 1 to Rmax 0.01 to 2 mm, the adhesion between the cured product 1 and the adhesive 66 can be increased, and the strength of the cured product laminate 100 can be increased.

The test result of the strength change due to the surface roughness of the laminate 100 of the cured product will be described with reference to FIG. First, as shown in FIG. 10 (A), when a bending load is applied to the laminated cured body 100, the surface roughness Rmax 0.0
If it is less than 1 mm, the strength decreases. That is, the surface roughness Rmax
If the thickness is less than 0.01 mm, it is considered that the adhesion between the cured product 1 and the adhesive 66 is reduced, and the strength of the cured product laminate 100 is reduced.

Next, as shown in FIG. 10 (B), a laminated body 100 of the cured body is formed from the central adhesive 66 by projecting the ends of the cured body half by half, and the laminate is broken by applying a shearing force. Was caused. Here, when the surface roughness Rmax was less than 2 mm, cracks occurred in the cured product 1 and fracture occurred. On the other hand, when the surface roughness Rmax was more than 2 mm, the cured body 1 was separated from the center of the adhesive 66 to the left and right before the cured body 1 was cracked. That is, if the surface roughness exceeds Rmax 2 mm, the amount of the adhesive 66 increases and the adhesiveness decreases,
It is presumed that the surface becomes brittle and the cured body is easily peeled off, and the shear strength of the laminated cured body is reduced.

In addition, the laminated body 100 of the cured product obtained by the production method of the first embodiment and the WO 00/7905 described above
The strength with the cured product by the production method of No. 2 was compared.

Example 1 Unsintered papermaking sludge (trade name of “raw sludge” manufactured by Maruto Kiln Co., Ltd .: solid content 34%, water content 66%) was formed as described above, and was passed through a felt. It was pressed and dried with warm air of 130 ° C. for 3 hours to produce a veneer having a thickness of 4 mm. The surface roughness measured by a stylus type surface roughness meter was Rmax of 1.8 mm. Five such veneers were laminated, and an adhesive made of an aqueous vinyl urethane resin was applied and adhered to form a laminate having a thickness of 28 mm.

Example 2 Unsintered papermaking sludge (trade name: "raw sludge" manufactured by Maruto Kiln Co., Ltd .: solid content 34%, water content 66%) is formed as described above, and is passed through a felt. It was pressed, dried with 130 ° warm air for 3 hours, and polished with a belt sander to produce a 4 mm-thick veneer. The surface roughness measured by a stylus type surface roughness meter was Rmax of 0.03 mm. Five single plates were laminated, and a vinyl acetate adhesive was applied and bonded to form a laminate having a thickness of 21 mm.

Example 3 As described above, unfired papermaking sludge (trade name "raw sludge" manufactured by Maruto Kiln Co., Ltd .: solid content: 34%, moisture content: 66%) was formed through a felt. Press, dry with 130 ° C warm air for 3 hours, and grind with belt sander.
Sand blasting was performed with zirconia having an average particle diameter of 300 microns to produce a veneer having a thickness of 4 mm. The surface roughness measured by a stylus type surface roughness meter was Rmax of 0.03 mm. Five single plates were laminated, and a vinyl acetate adhesive was applied and bonded to form a laminate having a thickness of 21 mm.

Comparative Example 1 Unsintered papermaking sludge (trade name of “raw sludge” of Maruto Kiln Co., Ltd .: solid content: 34%, moisture content: 66%) was formed as described above to obtain a glass wool mat. Press through and
It was dried with 130 ° warm air for 3 hours to produce a 4 mm-thick veneer. The surface roughness was measured with a stylus type surface roughness meter.
Rmax was 2.2 mm. Five such veneers were laminated, and an adhesive made of an aqueous vinyl urethane resin was applied and adhered to form a laminate having a thickness of 28 mm.

Comparative Example 2 (WO 00/79052) Unsintered papermaking sludge (trade name "raw sludge" of Maruto Kiln Co., Ltd .: solid content 34%, water content 66%) was prepared as described above. Press through a stainless steel plate
After drying for 3 hours with warm air of ゜, further polishing with a belt sander, and further buffing the surface, to produce a 4 mm-thick veneer. The surface roughness was measured with a stylus type surface roughness meter,
The maximum was 0.008 mm. Five single plates were laminated, and a vinyl acetate adhesive was applied and bonded to form a laminate having a thickness of 21 mm.

Comparative Example 3 Unsintered papermaking sludge (trade name "raw sludge" of Maruto Kiln Co., Ltd .: solid content 34%, water content 66%) was paper-formed as described above and passed through a stainless steel plate. Press 130
Then, the plate was dried with warm air for 3 hours, polished with a belt sander, and further buff-polished to produce a plate having a thickness of 20 mm. The surface roughness was measured with a stylus type surface roughness meter,
The maximum was 0.008 mm.

The laminated body 100 of the cured products of Examples 1, 2, and 3
And the cured product laminates of Comparative Examples 1, 2, and 3
When the test was performed with a piece of 0 cm, Examples 1, 2, 3
The cured product laminate 100 showed a higher value. That is, the laminated body 1 of the cured body is formed by interposing the adhesive 66.
00 was found to increase in strength. This is shown in Table 1.

Next, Examples 1, 2, and 3 and Comparative Examples 1, 2,
The result of comparing the water resistance of No. 3 will be described. Water Absorption Swelling Test The cured products of Examples and Comparative Examples were immersed in water at room temperature for 24 hours at a water surface of 3 cm, and the change in thickness after immersion was measured. As a result, it was found that the dimensional change of the cured product of the example was smaller than that of the cured product of the comparative example. It is considered that this is because the adhesive 66 exerts a waterproof effect, and the amount of water absorbed from the front surface and the back surface is relatively small.

Water Absorption Bending Test The cured products of the examples and comparative examples were immersed in water at 70 ° C. for 2 hours, and further immersed in water at room temperature for 24 hours.
The bending test shown in (A) was performed. . As a result, it was found that the cured product of the example had higher strength than that of the comparative example.

With respect to the composite cured products obtained in the above Examples and Comparative Examples, the flexural strength, the coefficient of swelling of water, the flexural strength of water absorption,
A test was conducted for heat cycle characteristics. Table 1 shows the results. In addition, bending strength as a test method is JIS
A Measured according to the method specified in 6901. The heat cycle characteristics are 100 ° C at -55 ° C to -125 ° C.
The presence or absence of peeling in 0 tests was examined.

[0099]

[Table 1]

As described above, the surface roughness of the surface of each veneer affects the bending strength, the coefficient of water absorption expansion, and the bending strength of water absorption. Also,
Lamination via an adhesive is superior in strength and dimensional stability to a thick veneer plate.

Next, an apparatus for manufacturing a cured body according to a second embodiment of the present invention will be described with reference to FIG. The manufacturing apparatus according to the second embodiment includes the first apparatus described above with reference to FIG.
It is almost the same as the manufacturing apparatus of the embodiment. However, in the manufacturing apparatus of the first embodiment, the storage groove 32 for storing water provided on the making roll 30 and the elastic member 3
5 has been abolished. Also, if the peeling cutter is a wire 13
Consists of one. In the first embodiment, when the making roll 30 reaches a predetermined rotation, the papermaking machine is peeled off by the peeling cutter 31, but in the second embodiment, the thickness of the papermaking body 26 on the making roll 30 is not shown. When a predetermined thickness is detected by the sensor, the wire 131 penetrates through the papermaking body 26 and is pressed against the surface of the making roll 30, and in this state, the making roll 30 continues to rotate, so that the papermaking body is surely formed. Peeled off. In the second embodiment, since the wire 131 is used, the papermaking body can be peeled off without damaging the surface of the making roll 30 without interposing an elastic member. Further, there is no need to drive the wire 131 in synchronization with the rotation of the making roll 30.

In the manufacturing apparatus of the second embodiment, the lower die 142 and the upper die 144 of the dewatering press 140 are provided with through holes 148 for draining water. For this reason, during dehydration,
Moisture can be efficiently removed from the papermaking body 26.

Subsequently, an example in which the composite cured product obtained in the above-mentioned steps was analyzed using an X-ray fluorescence analyzer (RIX2100 manufactured by Rigaku) is shown below. 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%,

Example 4 3020 parts by weight of unsintered papermaking sludge (trade name of “raw sludge” of Maruto Kiln Co., Ltd .: solid content 34%, water content 66%) was prepared. Next, acid washing is performed using a 2N hydrochloric acid aqueous solution,
The component a was almost completely removed, and this was designated as A.

[0105] A pulp: 51.2 wt% MgO: 1.6 wt% SiO _2: 18.6 wt% SO _3: 3.5 wt% Al ₂ O _3: 22.3 wt% P ₂ O _5: 0 0.3% by weight CaO: 0.0% by weight Cl: 0.1% by weight ZnO: 0.2% by weight Other trace

Further, papermaking 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.

Also, papermaking sludge of Maki Paper Co., Ltd.'s inkjet printer paper handled by Maruto Kiln Co., Ltd .: added 51% by weight of solid content, 49% by weight of water and 10% by weight of calcium carbonate (cubic shape) and added C And C Pulp: 15.0 wt% SiO _2: 2.6 wt% Al ₂ O _3: 5.5 wt% P ₂ O _5: 0.1 wt% CaO: 75.0 wt% Na ₂ O: 0.2 % 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 paper was made in the same manner as in Example 1 to produce a cured product, and the flexural strength, compressive strength, and nailability were measured. The results are shown in the graphs of FIGS. Here, FIG.
The relationship between O / SiO ₂ and compressive strength is shown, with the vertical axis representing compressive strength (Kg / cm ² ) and the horizontal axis representing the ratio of CaO / SiO ₂ . FIG. 16 shows the relationship between CaO / Al ₂ O ₃ and compressive strength, with the vertical axis representing compressive strength (Kg / cm ² ) and the horizontal axis representing CaO /
The ratio of Al ₂ O ₃ is shown. FIG. 17 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. 18 shows the relationship between the CaO content and the nail pull-out strength, with the vertical axis representing the nail pull-out strength (Kg).
/ Cm ² ) is the CaO content (%) on the horizontal axis.
As shown in FIG. 15, the cured product has Ca, Al, and Si contents of CaO, Al ₂ O ₃ , and SiO ₂ , respectively.
When the O / SiO ₂ ratio is 0.2 to 7.9, high compressive strength is exhibited. On the other hand, as shown in FIG. 16, the cured body exhibits high compressive strength when the ratio of CaO / Al ₂ O ₃ is from 0.2 to 12.5.

Further, the crystal structure of the composite cured product was confirmed by X-ray diffraction. Charts of the X-ray diffraction are shown in FIGS. 12 and 13, respectively. In addition, X-ray diffraction
Rigaku MiniFlex was used and Cu was targeted. 2θ: A gentle undulation (halo) is observed around 22 °, and a peak indicating a crystal structure is also observed.
It can be seen that the crystal structure is mixed in the amorphous structure. From the peak of the chart shown in FIG. 5, Gehlenite, sy
n, Melilite-synthetic, Gehlenite-synthetic, Anor
thite, ordered was identified.

A composite building material will be described below as an application example of the composite cured body 1. That is, as shown in FIG. 14, in a composite building material in which a reinforcing layer 6 is formed on at least one surface of the core material 5 and on both surfaces in the illustrated example, the composite cured material manufactured by the method of the present invention is applied to the core material 5. Apply 1. That is, by forming the core material 5 into the composite cured body 1 manufactured by the method of the present invention, even when a tensile force is applied to the core material, the core material itself has excellent bending strength, and furthermore, In combination with the provision of the reinforcing layer on the surface, the structure is not easily broken.
Further, even when pressure is locally applied to the surface, no dent or dent occurs.

Further, when the composite building material is used, a decorative layer such as a coating, a decorative panel, and a decorative veneer is provided on the reinforcing layer 6, so that the impact resistance is improved, and Is less likely to occur, and the decorative surface is not distorted by the scratches and the design is not deteriorated.

Further, the reinforcing layer 6 has a structure in which the fiber base material 6b is embedded in the resin 6a. It is particularly desirable to use a thermosetting resin for the resin 6a. That is, unlike a thermoplastic resin, a thermosetting resin has excellent fire resistance and does not soften even at a high temperature, so that the function as a reinforcing layer is not lost. As the thermosetting resin, a phenol resin, a memelamine resin, an epoxy resin, a polyimide resin, a urea resin and the like are suitable. In order to impart sufficient rigidity, impact resistance, and even higher fire resistance to the reinforcing layer, the content of the thermosetting resin in the reinforcing layer is desirably in the range of 10% by weight to 65% by weight.

On the other hand, it is desirable to use inorganic fibers for the fiber base 6b. This is because the strength of the reinforcing layer 6 can be improved and the coefficient of thermal expansion can be reduced. Low-cost and heat-resistant use of at least one of inorganic fibers, glass fiber, rock wool, ceramic fiber, glass fiber chopped strand mat, glass fiber roving cloth, glass fiber continuous strand mat, and glass fiber paper It is preferable in terms of excellent properties and strength. This fiber base material is a material obtained by molding a discontinuous fiber into a mat shape, or a material obtained by cutting continuous long fibers into a mat shape by cutting into 3 to 7 cm (a so-called chopped strand mat), and dispersing in water to form a sheet. A material obtained by piling up, a continuous long fiber spirally laminated to form a mat, or a continuous long fiber woven is applicable.

Further, the thickness of the reinforcing layer is from 0.1 mm to
It is desirable to be 3.5 mm. This is because, if it is set in this range, sufficient rigidity and impact resistance can be obtained, and high workability can be maintained. The reinforcing layer may contain a flame retardant such as aluminum hydroxide and magnesium hydroxide, and a commonly used inorganic binder such as silica sol, alumina sol, and water glass. Here, the reinforcing layer is provided, but the surface may be coated with a resin or the like so that the cured body does not absorb moisture.

[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 a composite cured product of the present invention.

FIG. 3 is a conceptual diagram of an apparatus for manufacturing a cured body according to the 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 diagrams of the operation of the making roll.

FIGS. 7A, 7B, 7C, and 7D are explanatory diagrams of the operation of the dehydration press.

FIG. 8 is an explanatory diagram of a dryer.

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

FIGS. 10A and 10B are explanatory diagrams of a strength test of the laminate according to the first embodiment.

FIG. 11 is a conceptual diagram of an apparatus for manufacturing a cured body according to a second embodiment of the present invention.

FIG. 12 is an X-ray diffraction chart of the composite cured product according to the embodiment.

FIG. 13 is an X-ray diffraction chart of the composite cured product according to the embodiment.

FIG. 14 is a schematic cross-sectional view of a composite building material using the composite cured body of the present invention.

FIG. 15 is a graph showing the relationship between CaO / SiO ₂ and compressive strength.

FIG. 16 is a graph showing the relationship between CaO / Al ₂ O ₃ and compressive strength.

FIG. 17 is a graph showing the relationship between CaO content and bending strength / compression strength.

FIG. 18 is a graph showing the relationship between the CaO content and nail pull-out strength.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Composite hardened body 2 Amorphous body 3 Fibrous material 4 Inorganic powder 5 Core material 6 Reinforcement layer 10 Raw material adjustment mechanism 14 Raw material solution (slurry) 15 Dehydration container 16 Filter 17 Vacuum pump 18 Chest tank 20 Papermaking mechanism 21A, 21B, 21C Butt 22A, 22B, 22C Wire Cylinder 23 Conveyor Belt 24 Suction Box 26 Papermaking 27 Suction Box 28 Vacuum Pump 30 Making Roll 31 Peeling Cutter 32 Storage Groove 33 Housing Groove 35 Elastic Member 36 Cutting Cutter 38 Belt Conveyor 40 Dehydrating Press Machine 42 Lower mold 44 Upper mold 46 Felt 50 Dryer 52 Transport roller 54 Blow-out port 60 Crimping press 66 Adhesive 100 Laminated body of cured body 131 Wire

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme court ゛ (Reference) E04C 2/04 E04C 2/04 E (72) Inventor Satoshi Takahashi 2-1-1 Kanda-cho, Ogaki-shi, Gifu Ibid F Term (Reference) 2E162 CC06 4F100 AK22 AK51 BA03 BA06 BA10A BA10C CB00B DG10A DG10C EC18 EH41A EH41C EJ17A EJ17C GB07 JB07 JK01 JK12A JK12C 4L055 AG99 AH01 BE14 BF01 EA13 EA0122

Claims (6)

[Claims] 1. A method for producing a cured product comprising papermaking sludge, comprising: forming a raw material solution containing papermaking sludge by using a filter body; attaching a papermaking sludge paperwork to the surface of the filter body; After being transferred to the conveyor belt, the paper is transferred to the paper conveyor. The paper on the conveyor belt is transferred to a hard roller to be multi-layered. The multi-layered paper is peeled off and cut into a predetermined size. A method for producing a cured body, comprising: curing a body; and curing a cured body obtained by curing a veneer sheet, with an adhesive interposed therebetween to obtain a laminate of the cured body. 2. The method according to claim 1, wherein in the step of curing the veneer sheet, the veneer sheet is dehydrated by pressing and then dried. 3. The method for producing a cured product according to claim 2, wherein, when the pressing is performed, the water content of the veneer sheet is adjusted to a weight ratio of less than 0.5 to sludge. 4. The method according to claim 3, wherein the pressing is performed at 40 to 100 kg / cm ² . 5. The method for producing a cured product according to claim 2, wherein the moisture content of the cured product is reduced to less than 0.05 by weight with respect to sludge by the drying. 6. A cured product obtained by forming a raw material solution containing papermaking sludge by paper filtration using a drainage body and laminating a cured product of a veneer with an adhesive interposed therebetween.