JP2005082464A - Freeze damage resistant, lightweight building material - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a freeze damage resistant, lightweight building material, which can be easily fired while securing freeze damage resistance even when the firing temperature is >750 and <850°C. <P>SOLUTION: The freeze damage resistant, lightweight building material is produced by press forming a raw material mixture and firing the formed raw material mixture at a firing temperature of about 800°C so as to foam it. In the raw material mixture, a coarse powder G, a fine powder g, a fine powder g', a weight reducing material K, and a crystallization-preventing agent C, and further, in some cases, a flatting agent r are added, and at least one of the weight reducing material K and the flatting agent r functions as a freeze damage preventing agent. The produced freeze damage resistant, lightweight building material has a bulk specific gravity of 1.0-2.0. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a frost-resistant lightweight building material, and in particular, a raw material mixture obtained by adding a foaming agent to glass powder at a predetermined addition rate under a temperature atmosphere of more than 750 ° C. to less than 850 ° C. The invention relates to a frost-resistant lightweight building material foamed by firing.

  Conventionally, soda-lime glass such as a single plate glass has been finely pulverized and fired and recycled to glass building materials such as foamed glass and sintered glass. This soda-lime-based glass has a devitrification temperature range where the gloss is lost or the transparency is deteriorated due to the crystallization reaction in a liquidus temperature range of about 850 ° C. to 1050 ° C. with a peak at about 930 ° C.

As a method for producing the sintered glass, after blending a baking shrinkage inhibitor composed of 0.05 to 1.5% by weight of antimony trioxide (Sb ₂ O ₃ ) powder into glass powder which is finely pulverized plate glass, A method for producing a sintered glass through dry molding and firing has been proposed (see Patent Document 1). Antimony trioxide exhibits its effect when the firing temperature is around 900 to 1050 ° C.

Further, as a method for producing the above foamed glass, a water glass-based admixture as an anti-crystallization agent and a calcium hydrate hydrate such as mortar as an antifreezing agent, that is, a cement hydrate, is used as an admixture. A method for producing foamed glass at a firing temperature of 700 ° C. to 800 ° C. using glass powder as a raw material has been proposed (see Patent Document 2). Foamed glass produced by this method has a high heat insulating property because it has a bulk specific gravity of 0.20 to 0.80, and has a use as a frost-resistant lightweight heat insulating building material.
Japanese Patent Publication No. 6-88807 JP 2002-179476 A

  However, in the technique described in Patent Document 1, in order to suppress thermal shrinkage of sintered glass, it is necessary to use a special agent that may cause health damage such as antimony trioxide, and the firing temperature is low. Since it is limited to around 900 to 1050 ° C., the firing temperature cannot be lower than that, for example, more than 750 ° C. to less than 850 ° C. Therefore, in this technique, if the firing temperature is low, the moldability deteriorates.

  Moreover, in order to apply the technique of patent document 2 in order to manufacture the lightweight glass building material of bulk specific gravity 1.0-2.0, for example, a calcination temperature is 700 degreeC-800 degreeC to more than 750 degreeC-less than 850 degreeC. It is necessary to make it high. However, when manufacturing a frost-resistant light-weight building material, it does not satisfy the temperature normally required for foaming at the time of firing, that is, a temperature of 770 ° C. or less. Appropriate physical properties for frost-resistant lightweight building materials cannot be secured. In addition, foamed glass is generally poor in moldability because it expands and expands during production.

  Furthermore, in order to recycle soda-lime glass into, for example, a frosted glass building material, it is necessary to devitrify the soda-lime glass, but if the firing temperature is more than 750 ° C. to less than 850 ° C., Soda-lime glass does not devitrify at all, or requires a long time before devitrification. In addition, it is not preferable to add a filler that is unrelated to recycling in order to make the soda-lime glass matt.

  A first object of the present invention is to provide a frost-resistant lightweight building material that can improve moldability while ensuring frost-proof resistance even at a firing temperature of more than 750 ° C. to less than 850 ° C. .

  A second object of the present invention is to provide a frost-resistant lightweight building material that can improve the designability by selecting the gloss of the product without adding an extra filler.

  In order to achieve the first object, the frost-resistant lightweight building material according to claim 1 is obtained by molding a raw material mixture obtained by adding a foaming agent to glass powder at a predetermined addition rate. A frost-resistant lightweight building material in which a body is foamed by firing in a temperature atmosphere above 750 ° C. to less than 850 ° C., and has a bulk specific gravity of 1.0 or more and 2.0 or less.

  The frost-resistant lightweight building material according to claim 2 is the frost-resistant lightweight building material according to claim 1, wherein the foaming agent also serves as an anti-frosting agent.

  The frost-resistant lightweight building material according to claim 3 is the frost-resistant lightweight building material according to claim 2, wherein the foaming agent contains calcium silicate hydrate or cement hydrate.

  The frost-resistant lightweight building material according to claim 4 is the frost-resistant lightweight building material according to claim 2 or 3, wherein the foaming agent includes a cement body having a cement component content of 30% or more. To do.

  The frost-resistant light weight building material according to claim 5 is the frost-resistant light weight building material according to claim 4, wherein the cement body is at least one selected from the group consisting of cement paste, mortar dry powder, and concrete dry powder. It is characterized by including one.

  The frost-resistant lightweight building material according to claim 6 is the frost-resistant lightweight building material according to any one of claims 2 to 5, wherein the foaming agent has a particle size of not more than 150 µm and a content of 50 mass% or more. It is characterized by being.

  The frost-resistant lightweight building material according to claim 7 is the frost-resistant lightweight building material according to any one of claims 2 to 6, wherein the addition rate of the foaming agent is the glass powder having a particle size of 150 µm or less. It is a value that the addition rate with respect to is in the range of 1 to 15% by mass.

  The frost-resistant light-weight building material according to claim 8 is the frost-resistant light-weight building material according to claim 2, wherein the foaming agent is foamed glass powder and silicic acid having an addition rate to the foamed glass powder of 1 to 15% by mass. Calcium hydrate or cement hydrate, an anti-crystallization agent, and another foaming agent made of carbonate having a rate of addition to the foamed glass powder of 1 to 10% by mass.

  A frost-resistant lightweight building material according to claim 9 is the frost-resistant lightweight building material according to claim 8, wherein the crystallization inhibitor is composed of sodium silicate powder or an aqueous solution thereof.

  The frost-resistant lightweight building material according to claim 10 is the frost-resistant lightweight building material according to claim 8 or 9, wherein the carbonate is composed of dolomite or calcium carbonate.

  The frost-resistant lightweight building material according to claim 11 is the frost-resistant lightweight building material according to any one of claims 8 to 10, wherein the foaming agent has a particle size of 500 μm or less.

  The frost damage resistant lightweight building material according to claim 12 is the frost resistant light weight building material according to any one of claims 8 to 11, wherein the blending ratio of the foaming agent in the raw material mixture is 1 to 15% by mass. It is in the range.

  The frost-resistant lightweight building material according to claim 13 is the frost-resistant lightweight building material according to any one of claims 2 to 12, wherein a matting agent is added to the raw material mixture at a predetermined addition rate, The matting agent also serves as the foaming agent.

  The frost-resistant lightweight building material according to claim 14 is the frost-resistant lightweight building material according to any one of claims 1 to 12, wherein a matting agent is added to the raw material mixture at a predetermined addition rate. It is characterized by.

  The frost-resistant lightweight building material according to claim 15 is the frost-resistant lightweight building material according to claim 14, wherein the glass powder is made of soda-lime glass, and the matting agent is reactive with the soda-lime glass. It is characterized by containing a high calcium compound or a hydrate thereof or a dehydrated decomposition product thereof.

  The frost-resistant light-weight building material according to claim 16 is the frost-resistant light-weight building material according to claim 15, wherein the hydrate of the calcium compound comprises calcium silicate hydrate or cement hydrate. .

  The frost-resistant lightweight building material according to claim 17 is the frost-resistant lightweight building material according to any one of claims 14 to 16, wherein the matting agent is a cement having a cement component content of 30% by mass or more. It includes the body.

  The frost-resistant light-weight building material according to claim 18 is the frost-resistant light-weight building material according to claim 17, wherein the cement body is at least one selected from the group consisting of cement paste, mortar dry powder, and concrete dry powder. It is characterized by including one.

  The frost-resistant light-weight building material according to claim 19 is the frost-resistant light-weight building material according to any one of claims 14 to 18, wherein the matting agent is wollastlite, slaked lime, quick lime, calcium carbonate, gypsum. And a hydrate thereof, and a content of at least one substance selected from the group of calcium phosphate, containing a calcium compound containing 50% by mass or more.

  The frost-resistant lightweight building material according to claim 20 is the frost-resistant lightweight building material according to any one of claims 14 to 18, characterized in that the matting agent contains waste fired glass powder.

  The frost-resistant light-weight building material according to claim 21 is the frost-resistant light-weight building material according to any one of claims 15 to 19, wherein the matting agent is a waste fired glass powder and the waste fired glass powder. Compound containing 1 to 20% of calcium compound, hydrate or dehydrated decomposition product thereof, cement body containing 30 mass% or more of cement component, or calcium compound-containing body containing 50 mass% or more And another foaming agent made of carbonate.

  The frost-resistant lightweight building material according to claim 22 is the frost-resistant lightweight building material according to claim 21, wherein the carbonate is composed of dolomite or calcium carbonate.

  The frost-resistant lightweight building material according to claim 23 is the frost-resistant lightweight building material according to any one of claims 13 to 22, wherein the matting agent has a particle size of 50 µm or less in a content of 50 mass%. It is the above.

  25. The frost-resistant lightweight construction material according to claim 24, wherein the frost-resistant lightweight construction material according to any one of claims 13 to 23 is the raw material having a particle size of 500 μm or less. It is a value that makes the addition rate with respect to a mixture become the range of 0.5-20 mass%.

  The frost-resistant lightweight building material according to claim 25 is the frost-resistant lightweight building material according to any one of claims 13 to 24, wherein the addition rate of the matting agent is 0.005 to 20 mass% or less. It is characterized by that.

  The frost-resistant light-weight building material according to claim 26 is the frost-resistant light-weight building material according to any one of claims 1 to 25, wherein the glass powder has a particle size of 3 to 20 mass with a particle size of 10 µm or less. % Range.

  The frost damage resistant lightweight building material according to claim 27 is the frost damage resistant lightweight building material according to any one of claims 1 to 26, wherein a mixing ratio of the glass powder in the raw material mixture is 30% by mass or more. It is characterized by that.

  The frost-resistant lightweight building material according to claim 28 is the frost-resistant lightweight building material according to any one of claims 1 to 27, wherein the glass powder is waste glass building material.

  According to the frost damage resistant lightweight building material according to claim 1, since the bulk specific gravity is 1.0 or more and 2.0 or less, the frost damage resistance is ensured even at a firing temperature of more than 750 ° C. to less than 850 ° C. It is possible to improve the moldability.

  According to the frost damage resistant lightweight building material according to claim 2, since the foaming agent also serves as the frost damage preventing agent, the manufacturing cost can be reduced.

  According to the light-resistant building material resistant to frost damage according to claim 3, since the foaming agent contains calcium silicate silicate or cement hydrate, it is easy to make a light building material resistant to frost damage especially containing soda-lime glass in the raw material mixture. Can be manufactured.

  According to the frost damage resistant lightweight building material according to claim 4, since the foaming agent includes a cement body having a cement component content of 30% or more, the freeze-thaw resistance can be improved.

  According to the frost-resistant lightweight building material according to claim 5, the cement body includes at least one selected from the group of cement paste, mortar dry powder, and concrete dry powder, so that the waste building material is used. This can improve the recycling efficiency.

  According to the frost-resistant light-weight building material according to claim 6, since the addition rate of the foaming agent is a value such that the addition rate with respect to the glass powder having a particle size of 150 μm or less is in the range of 1 to 15% by mass. The blending amount can be reduced.

  According to the frost damage resistant lightweight building material according to claim 8, the foaming agent is foamed glass powder, calcium silicate hydrate or cement hydrate having an addition rate to the foamed glass powder of 1 to 15% by mass, Since it contains an anti-crystallization agent and another foaming agent composed of a carbonate having an addition rate to the foamed glass powder of 1 to 10% by mass, conventional foamed glass, particularly waste foamed glass, can be recycled.

  According to the frost-resistant lightweight building material of claim 9, since the crystallization inhibitor is composed of sodium silicate powder or an aqueous solution thereof, it can be easily granulated.

  According to the frost damage resistant lightweight building material of claim 10, since the carbonate is composed of dolomite or calcium carbonate, it can be easily foamed.

  According to the frost damage resistant lightweight building material of claim 11, since the foaming agent has a particle size of 500 μm or less, frost damage damage can be reliably prevented.

  According to the frost damage resistant lightweight building material according to claim 12, since the blending ratio in the raw material mixture of the foaming agent is in the range of 1 to 15% by mass, the light weight, the molded body shape retention, and the frost damage resistance are improved. Can do.

  According to the frost damage resistant lightweight building material according to claim 13, since the matting agent that also serves as a foaming agent is added to the raw material mixture at a predetermined addition rate, the manufacturing cost can be reduced, and the addition rate depends on the addition rate. The gloss of the product can be selected to improve the design.

  According to the frost-resistant lightweight building material according to claim 14, the matting agent is added to the raw material mixture at a predetermined addition rate, so that the gloss of the product can be selected according to the addition rate and the design is improved. Can do.

  According to the frost-resistant lightweight building material of claim 15, the matting agent contains a calcium compound having high reactivity with the glass powder made of the soda-lime-based glass, or a hydrate or dehydrated decomposition product thereof. Many devitrified substances can be crystallized.

  According to the frost-resistant light-weight building material of claim 16, since the hydrate of the calcium compound is composed of silicate calcium hydrate or cement hydrate, the frost-resistant lightweight building material can be easily produced.

  According to the frost damage resistant lightweight building material according to claim 17, since the matting agent includes a cement body containing a cement component in an amount of 30% by mass or more, the freeze / thaw resistance can be improved.

  According to the frost-resistant lightweight building material according to claim 18, the cement body includes at least one selected from the group consisting of cement paste, mortar dry powder, and concrete dry powder, so that the waste building material is used. This can improve the recycling efficiency.

  According to the frost-resistant lightweight building material of claim 20, since the matting agent contains the waste fired glass powder, the recycling efficiency of the fired glass can be improved.

  According to the frost-resistant lightweight building material according to claim 21, the matting agent is a waste calcined glass powder, a calcium compound having a rate of addition to the waste calcined glass powder of 1 to 20%, or a hydrate thereof, or a dehydration thereof. Recycled fired glass because it contains a decomposed material, or a cement body with a cement component content of 30% by mass or more, or a calcium compound-containing body with a content of 50% by mass or more and another foaming agent made of carbonate. Efficiency can be improved.

  According to the frost-resistant lightweight building material of claim 22, since the carbonate is composed of dolomite or calcium carbonate, it can be easily foamed.

  According to the frost-resistant lightweight building material according to claim 23, the addition rate of the matting agent is such that the addition rate with respect to the raw material mixture having a particle size of 500 μm or less is in the range of 0.5 to 20% by mass. Since there exists, the compounding quantity can be reduced.

  According to the frost damage-resistant lightweight building material according to claim 24, since the addition rate of the matting agent is 0.005 to 20% by mass or less, the gloss of the product can be selected more reliably according to the addition rate, and the design Can be improved.

  According to the frost-resistant light-weight building material of claim 26, since the glass powder has a particle size of 10 μm or less in the range of 3 to 20% by mass, the molded body shape retainability can be improved, Generation of impact cracks and shrinkage cracks can be suppressed.

  According to the frost damage resistant lightweight building material according to claim 27, since the compounding ratio in the raw material mixture of glass powder is 30% by mass or more, the building material property can be improved.

  According to the frost-resistant lightweight building material according to claim 28, since the glass powder is a waste glass building material, the recycling efficiency of the glass building material can be improved.

  Embodiments of the present invention will be described below with reference to the drawings.

  FIG. 1 is a process diagram showing a method for producing a frost-resistant lightweight building material according to an embodiment of the present invention.

  In FIG. 1, first, in process P1, waste glass building materials are collected. This waste glass building material may be obtained by separating a sash from a window glass building material with a waste sash that has been transported from a building demolition site or the like. Next, the waste glass building material is crushed by using a horizontal roll crusher (process P2), and the crushed waste glass material (glass powder) from which impurities are removed is used as raw material powder (process P3). Is prepared (process P4).

  By adjusting the particle size, the raw material powder is coarse powder G pulverized with a hammer crusher so that the particle size is, for example, in the range of more than 150 μm to 1650 μm or less, and the fine powder g described later is separately in the range of 150 μm or less. Using a ball mill so that the ratio to the mass (hereinafter referred to as “content ratio”) is 50% and the content ratio of the fine powder g ′ having a particle size of 10 μm or less is, for example, 23%. A finely divided powder g is obtained. Next, the obtained coarse powder G and fine powder g are fine powder so that the ratio of the coarse powder g to the total mass of the raw material mixture described later (hereinafter referred to as “mixing ratio”) is, for example, 30% by mass. Mixing is performed so that the blending ratio of g ′ is, for example, 7% by mass.

  The raw material mixture is obtained by adding coarse powder G, fine powder g and fine powder g ′ to a lightening material K and a crystallization inhibitor C, which will be described later, and in some cases, a matting agent r. At least one of the lightening material K and the matting agent r, which are agents, functions as a frost damage prevention agent.

  And it is determined whether the matting agent r mentioned later is added to the particle size adjusted glass powder (process P5). In the process P5, when it is determined that the matting material r is not added to the particle size adjusted glass powder, the weight reducing material K as a foaming agent in which the crystallization inhibitor C is added to the particle size adjusted glass powder. Is added (process P6, 7), and finally these are mixed lightly using a mixer to obtain a powder obtained as a raw material mixture (process P8). In processes P6 and P7, crystallization inhibitor C may be added to glass powder separately from lightening agent K.

  In the processes P6 and 7, the weight reducing material K to which the crystallization inhibitor C is added is prepared, for example, as follows.

First, dolomite which is a carbonate of a foaming agent is finely pulverized using a ball mill, and then a dolomite dry fine powder is obtained. Next, ethyl alcohol was added as a grinding aid to a glass cullet containing 5% by mass of dolomite dry fine powder and 6% by mass of waste mortar fine powder, and this was added using a ball mill for 72 hours. Finely pulverize. The fine powder thus obtained is granulated using a pan type granulator with a diameter of 500 mm. In this granulation, the water glass aqueous solution prepared to a concentration of 34% of the water glass solution as the foamed glass crystallization inhibitor C has an addition rate of 17% by weight of the water glass powder to the fine powder in the bread granulator. It is sprayed to become. Here, the water glass aqueous solution also serves as a granulation aid. Moreover, as water glass, the thing of No. 3 based on Japanese Industrial Standard (JIS) K1408 can be used. The obtained granulated body is dried, pulverized using a vertical roll crusher, passed through a sieve, and the thus obtained fine powder having a particle size of 250 μm or less is used as a weight reducing material K.

  Next, the raw material mixture is filled by being sprayed into a molding die set on a shelf board made of mullite and cordierite. The shelf board is previously coated with a release agent such as fine powdery alumina. The mold is partitioned by, for example, an iron plate having a thickness of 1.5 mm so that one section is a 203 mm square. The raw material mixture filled in the mold is press-molded by a relatively low pressure of leveling (process P9). By press molding, it is possible to prevent the material mixture from losing its shape when it is demolded.

  The formed raw material mixture (molded body) is conveyed into a roller hearth furnace (firing furnace) using a roller, and is foamed by firing at a firing temperature of about 800 ° C. or 830 ° C. for about 30 minutes (process P10). Thereby, the frost-resistant lightweight building material whose bulk specific gravity is 1.0-2.0 is manufactured. In addition, the temperature rising rate at the time of heating in this baking is, for example, 16 ° C. per minute, and the temperature decreasing rate at the time of slow cooling is 8 ° C. per minute. Thus, this process is completed.

  In the process P5, when it is determined that the matting agent r is added, a predetermined amount of the matting agent r is added to the glass powder whose particle size has been adjusted, as will be described later. When the matting agent also serves as a foaming agent (process P11), the processes after process P7 are executed.

  Next, the addition of the matting agent r in the process P11 of FIG. 1 will be described.

  The matting agent r is prepared by using a roll crusher and a wet ball mill. For example, the average particle size of the matting agent r is 5 to 6 μm, and the particle size of 10 μm or less is 73% by mass or less.

  The matting agent r prepared in this manner changes its matting effect, that is, its glossiness, according to the addition rate (mass%) of the glass powder whose particle size has been adjusted. The addition ratio of the matting agent r to the raw material mixture is 0.005 to 20% by mass or less. The effect of matting of each frost-resistant lightweight building material when a frost-resistant lightweight building material is manufactured every time the addition rate of the matting agent r is increased is shown as a measurement result of reflectance (%) in Table 1.

なお、表１における反射率は、反射率計（株式会社村上色彩技術研究所製「ＧＭＸ−１０１」）を用いて測定されたものである。

In addition, the reflectance in Table 1 is measured using a reflectance meter (“MMX-101” manufactured by Murakami Color Research Laboratory Co., Ltd.).

  From Table 1, it can be seen that by changing the blending ratio of the matting agent r, it is possible to change the produced frost-resistant light weight building material from a fully matted state to a glossy state. Therefore, the gloss of the product can be selected without adding an extra filler such as alumina fine powder, and the design of the frost-resistant lightweight building material can be improved. Moreover, when a raw material mixture contains waste glass building materials, the recycling efficiency of glass building materials can be improved.

  As described above, according to FIG. 1, the lightening material K and the crystallization inhibitor C, which will be described later, are added to the coarse powder G, the fine powder g, and the fine powder g ′. A raw material mixture, in which at least one of the lightening material K and the matting agent r functions as a frost damage inhibitor, is press-molded (process P9), and the molded raw material mixture is calcined at about 800 ° C. or 830 ° C. Since it is foamed by being at ℃ (process P10) and a frost-resistant lightweight building material having a bulk specific gravity of 1.0 to 2.0 is produced, the frost-resistant resistance is obtained even at a firing temperature of about 800 ° C or 830 ° C. The moldability can be improved while securing the above.

  The firing temperature is more than 750 ° C. to less than 850 ° C., preferably more than 760 ° C. to less than 820 ° C. This temperature range is much lower than the firing temperature of about 1000 ° C. in the manufacture of Wall Star (trade name). Thereby, the heating cost can be reduced when commercializing a frost-resistant lightweight building material. The reason for the above numerical limitation is as follows. When the firing temperature is lower than the lower limit, the lightening agent K is insufficient and the softening of the glass powder is insufficient, and the produced frost-resistant lightweight building material is insufficiently colored, so that the color tone looks dull. Not only will the surface be smooth. On the other hand, if the firing temperature is higher than the upper limit, excessive foaming will occur, frost damage resistance will deteriorate, deviation in firing dimensions and shape will occur, heat resistance of metals will deteriorate, shelf boards, frames and meshes The metal jig in the firing furnace such as a belt cannot be used.

  Hereinafter, the frost-resistant lightweight building material according to the present embodiment will be described.

  The frost damage resistant lightweight building material according to the present embodiment is required to suppress the generation of impact cracks during transportation and the generation of shrinkage cracks during sintering during manufacture. It is required that the shape retainability is excellent.

  The impact crack is a crack generated in a frost-resistant light-weight building material produced by an impact applied to the molded body before the molded body is loaded on a shelf board or a mesh belt and conveyed in the firing furnace. In order to suppress the occurrence of the impact crack, there are a method of press molding the raw material mixture as finely as possible with high pressure or a method of wet molding with the adhesive force of a compound such as clay or water glass. Therefore, the raw material mixture is preferably as coarse powder.

  In addition, the shrinkage cracks are more likely to occur during the manufacture of building materials made from ceramics such as clay, and the more the finer the raw material, the more likely the shrinkage cracks. Therefore, the raw material mixture is preferably as coarse powder. The above-mentioned molded body shape retainability refers to resistance to deformation (brittleness) at the time of press molding and release in the process P9 and at the time of conveyance, and in order to make this excellent, between the raw materials of the raw material mixture Cohesive force is required. Therefore, the raw material mixture is preferably finer.

  In other words, the raw material mixture for frost-resistant lightweight building materials is required to be a coarse powder in order to reduce the occurrence of shrinkage cracks, while it must be a fine powder in order to have excellent molded body shape retention. Desired.

  On the other hand, in this Embodiment, a raw material mixture is made into coarse powder, and impacts, such as play and a bending, are absorbed with the loose coupling force between the raw materials in a molding body. Thereby, even if a raw material mixture is coarse powder, generation | occurrence | production of a shrinkage crack can be reduced.

  Hereinafter, the raw material mixture of a frost-resistant lightweight building material is demonstrated.

  Waste glass building materials used as a raw material for glass powder include plate glass such as float plate glass, mold plate glass, meshed plate glass, Low-E plate glass, and mirror plate glass, and bottle glass containing colored glass. Moreover, although glass powder was used as the waste glass building material, it may contain some impurities such as waste glass distributed in the city and factory circulation glass cullet. The glass powder is preferably made of soda-lime glass.

  Although the compounding rate of glass powder is not specifically limited, Preferably it is 30 mass% or more, More preferably, it is 50 mass% or more. As a result, the manufactured frost-resistant lightweight building materials are excellent in basic performances required for use in, for example, inner wall materials, outer wall materials, and floor materials, such as strength, hardness, contamination resistance, and contamination cleaning properties. can do. Contamination resistance refers to the property that contaminants such as dust are difficult to adhere to the surface of lightweight construction materials that are resistant to frost damage, or the contaminants attached to the surface are easily detached from the surface. The term “freezing damage resistant lightweight building material” means that even if a contaminant adheres to the surface of the building material, it is easy to remove (clean) due to its poor adhesion.

  The glass powder has a particle size of 10 μm or less in the range of 3 to 20% by mass, preferably 5 to 10% by mass. The reason for this numerical limitation is that if the content of the glass powder having a particle size of 10 μm or less is 3% by mass or more, preferably 5% by mass or more, the molded product shape retention of the produced frost-resistant lightweight building material is excellent. If the content is 20% by mass or less, preferably 10% by mass or less, it is possible to suppress the occurrence of impact cracks during transportation and shrinkage cracks during sintering. It is.

  Further, if the maximum particle size of the coarse powder G of glass powder is 5000 μm, it is possible to eliminate the loss of moldability of the frost-resistant lightweight building material. In addition, in order to ensure designability, you may add glass cullet with a particle size over 5000 micrometers to this coarse powder G. As described above, the glass powder according to the present embodiment contains a relatively low amount of the coarse powder G, and the formed body is formed at a relatively low pressure in the press molding of the process P9. Large equipment required for press molding and wet molding can be eliminated, and the degree of freedom in design and physical properties can be improved to suit the application.

  Further, in the glass powder, the coarse powder G and the fine powder g have a blending ratio of 30% by mass and a blending ratio of the fine powder g ′ of 3-20% by mass, preferably 5-10% by mass. So that they are mixed. The reason for the above numerical limitation is as follows. In order to ensure the shape retainability of the molded body, the blending ratio of the fine powder g ′ is 3 to 10% by mass, preferably 5% to 10% by mass, and prevents an impact crack during transportation and a shrinkage crack during sintering. This is because the blending ratio of the fine powder g ′ is 20% by mass or less, preferably 10% by mass or less. Thereby, while being able to ensure a molded object shape retainability reliably, generation | occurrence | production of an impact crack and a shrinkage crack can be suppressed reliably.

  The lightening agent K (hereinafter referred to as “foaming agent K”) includes calcium silicate hydrate or cement hydrate. Silicic acid calcium hydrate or cement hydrate gradually dissociates using its crystal water as a gas over a temperature ranging from over 100 ° C. to nearly 1000 ° C. The glass powder starts sintering when the firing temperature exceeds about 600 ° C., captures the gaseous crystal water as the sintering progresses, and the sintered glass starts to soften when the firing temperature reaches about 800 ° C. Then, the crystal water captured as the softening progresses is released again as a gas to foam, thereby reducing the weight of the manufactured frost-resistant lightweight building material.

  As a result, it is possible not only to eliminate the use of a special drug that may cause harm to health such as antimony trioxide as in the technique described in Patent Document 1, but also using antimony trioxide. The improvement in the shape retention of the molded body that could not be achieved can be achieved at a firing temperature of more than 750 ° C. to less than 850 ° C. In addition, because the lightening agent K is added to the raw material mixture, it is possible to perform nailing, drilling, and cutting with a circular saw, which are not possible with glass products, when installing frost-resistant lightweight building materials, improving workability. Can be made.

  The foaming agent K may include a cement body containing cement paste and at least one selected from the group of dry powders of cement hydrate such as mortar and concrete. In addition, mortar means the cement body which contains a cement component about 25% by mass, and concrete means the cement body which contains about 10-14 mass% of cement components. In the present embodiment, the cement body has a cement component content of 30% by mass or more. Thereby, freeze-thaw resistance can be improved. The concrete may be lightweight cellular concrete (ALC). Recycling efficiency can be improved by using waste at the time of building demolition as these cement bodies.

  The content of the foaming agent K having a particle size of 150 μm or less is 50% by mass or more, and preferably the content of one having a particle size of 10 μm or less is 50% by mass or more.

  The addition rate of the blowing agent K is a value such that the addition rate with respect to the glass powder is 1 to 15% by mass, preferably 2 to 10% by mass, although the particle size is 150 μm or less. Although the particle size is 10 μm or less, the addition ratio is in the range of 0.5 to 10% by mass, preferably in the range of 2 to 7% by mass. If it is less than these lower limits, the foaming action (lightening effect) of the foaming agent K cannot be sufficiently achieved. If these upper limits are exceeded, softening of the glass powder is suppressed and foaming in the molded body (lightening) ) Will not occur.

  In addition, since the frost damage light weight building material which concerns on this Embodiment is not attaching importance to heat insulation rather than the frost damage light weight heat insulation building material of patent document 2, the bulk specific gravity exists in the range of 1-2, and calcination temperature. Is higher than ordinary foamed glass, and occupies an intermediate position between heat-insulating foamed glass and sheet glass in terms of strength, designability, hardness, and bulk specific gravity. As a result, the frost damage resistant lightweight heat insulating building material described in Patent Document 2 can be made superior in terms of strength, design properties, hardness, and the like, while the firing temperature is higher than that of ordinary foamed glass. Damage is likely to occur. In order to suppress frost damage, it is conceivable to adjust the particle size of the raw material mixture. As a method of adjusting the particle size, there is a method of making a raw material mixture into a fine powder. The finer the raw material mixture, the more fine bubbles are dispersed in the manufactured frost-resistant lightweight building material. Therefore, it is considered that each bubble is surrounded by a glass component, so that water penetrates into the void called bubbles, that is, the water absorption is reduced and the occurrence of frost damage is suppressed. ing. That is, the freezing damage resistant lightweight building material is given a certain degree of freezing damage due to the formed bubbles.

  The matting agent r contains a calcium compound or a hydrate thereof or a dehydrated decomposition product thereof. The hydrate of the calcium compound consists of silicate calcium hydrate or cement hydrate.

Calcium compounds have high reactivity with soda-lime glass constituting glass powder even when the firing temperature is higher than 750 ° C. to lower than 850 ° C., and these cause devitrification (crystallization) reaction. By the devitrification reaction, devitrification substances (crystals) such as devitrite (Na ₂ O · 3CaO · 6SiO ₂ ), wollastonite (CaO · SiO ₂ ), and quartz (SiO ₂ ) are mainly crystallized. Therefore, the matting agent r changes the degree of devitrification of the frost-resistant lightweight building material in accordance with the blending ratio of the calcium compound, and exhibits its matting action.

  The matting agent r may include a cement body containing at least one selected from the group of cement itself, cement paste, and dry powder of cement hydrate such as mortar and concrete. Of the cement bodies, the cement itself is not a hydrate but stable at a high temperature, and therefore is preferably a hydrate and another cement body that is activated at a high temperature to cause a dehydration reaction. The cement body has a cement component content of 30% by mass or more. Thereby, freeze-thaw resistance can be improved. The concrete may be lightweight cellular concrete (ALC). Recycling efficiency can be improved by using waste at the time of building demolition as these cement bodies.

Matting agents r are wollastlite, slaked lime (Ca (OH) ₂ ), quicklime (CaO), calcium carbonate (CaCO ₃ ), gypsum and hydrates thereof (CaSO ₄ , CaSO ₄ .2H ₂ O, CaSO _4. A calcium compound-containing body in which the content of at least one substance selected from the group of 1 / 2H ₂ O) and calcium phosphate (Ca (PO ₃ ) ₂ ) is 50% by mass or more may be used.

  The matting agent r may contain waste calcined glass powder.

  The other matting agent r is a waste calcined glass powder, a calcium compound having a rate of addition to the waste calcined glass powder of 1 to 20% by mass, or a hydrate or dehydrated decomposition product thereof, or the matting agent r A similar cement body, or the above-mentioned calcium compound-containing body, and another foaming agent made of carbonate are included. The carbonate is composed of dolomite or calcium carbonate.

  The matting agent r has a particle size of 50 μm or less, preferably a particle size of 50 μm or less, more preferably 50 μm or less, more preferably a particle size of 10 μm or less. % Or more.

  As the matting agent r is finer, its addition rate can be reduced. The value of the addition ratio of the matting agent r to the glass powder is such that the addition ratio to the glass powder of a particle size of 500 μm or less is in the range of 0.5 to 20% by mass, preferably in the range of 1 to 15% by mass, and the particle size is The addition rate of the glass powder of 150 μm or less is determined to be in the range of 0.1 to 15% by mass, preferably in the range of 0.5 to 8% by mass. Preferably, the addition rate of the matting agent r is in the range of 0.01 to 10% by mass, preferably 0.1 to 5%, with respect to the glass powder having a particle size of 10 μm or less in addition to the above ranges. It is determined to be in the range of mass%. In these numerical limits, the matting effect of the matting agent r can be obtained at the lower limit value, and the frost-resistant lightweight building material can be completely matted at the upper limit value.

  Next, the shape retention of the molded body of the frost-resistant lightweight building material will be described.

  The frost damage resistance, light weight, building material properties of the prepared test piece when the mixing ratio [mass%] of the raw material mixture of the frost damage resistant lightweight building material manufactured according to the manufacturing process of FIG. Table 2 shows the shape retention of the molded body. Table 2 shows that for each test piece, water absorption [mass%] and freeze-thaw resistance cycle are measured as frost damage resistance, bulk specific gravity is measured as light weight, and bending strength [MPa] is measured as building material properties. As the shape retention, an evaluation is made as to whether or not the shape has been lost and whether or not shrinkage cracks have occurred during firing. In Examples 1 to 9 and Comparative Examples 1 to 4, the firing temperature was about 800 ° C., and in Examples 10 and 11, the firing temperature was about 830 ° C.

なお、表２において、型崩れに関する評価は、型崩れしている場合を○、型崩れしていない場合を×とされ、収縮亀裂に関する評価は、収縮亀裂が発生しなかった場合を○、収縮亀裂が発生した場合を×とされており、いずれの評価も○である場合には、試験片の成型体形状保持性が優れていると評価される。

In Table 2, the evaluation regarding the loss of shape is indicated as ◯ when the shape is lost, and the case where the shape is not lost is indicated as ×, and the evaluation regarding the shrinkage crack is indicated as ○ when the shrinkage crack does not occur. The case where a crack is generated is evaluated as x, and in the case where both evaluations are ◯, it is evaluated that the molded product shape retention of the test piece is excellent.

  From Table 2, in the freezing damage resistant lightweight building material, the content of coarse powder g having an average particle size of 150 μm or less is 50% by mass and the content of particles having a particle size of 10 μm or less is 73% by mass is 20% by mass or more. (Examples 1 to 11), it can be seen that the molded product shape retention is excellent.

  In the above embodiment, the foaming agent may be another foaming agent K described later instead of the foaming agent K.

  Another foaming agent K consists of foamed glass powder, calcium silicate hydrate or cement hydrate having an addition rate of 1 to 15% by mass to the foamed glass powder, and crystallization prevention consisting of sodium silicate powder or an aqueous solution thereof. The agent C and the other foaming agent which consists of carbonate with the addition rate to a foamed glass powder of 1-10 mass% are included. The carbonate is composed of dolomite or calcium carbonate.

  Another foaming agent K further contains sodium silicate powder as an anti-crystallization agent C, or contains an aqueous solution of sodium silicate powder (water glass) as an anti-crystallization agent C and a granulating binder (granulation aid). But you can. Thereby, the processes P6 and 7 of FIG. 1 can be performed simultaneously.

  In this case, another blowing agent K has a particle size of 500 μm or less, preferably 300 μm. In order to obtain this particle size, it is preferable that the raw material is granulated or pulverized after granulation. The reason for this is that if another foaming agent K contains foam particles having a high particle size, the produced frost-resistant lightweight building material is damaged due to frost damage centered on the foam particles (hereinafter referred to as "frost damage"). Because it does.

  Moreover, the compounding rate in the raw material mixture of another foaming agent K exists in the range of 1-15 mass%, Preferably it is the range of 3-8 mass%. The reason for this is that if the blending ratio is less than the lower limit value, the produced frost-resistant lightweight building material is excellent in frost resistance, but the lightness deteriorates and the bulk specific gravity increases, The property of maintaining the shape, that is, the fired size retention property is deteriorated. On the other hand, if the blending ratio exceeds the upper limit, the manufactured frost-resistant light weight building material is excellent in light weight, but excessive foaming occurs during firing, so that the frost resistance and light weight deteriorate.

  The frost-resistant lightweight building materials according to the above-described embodiments mainly have uses such as interior / exterior wall materials and floor materials of buildings.

  A frost-resistant lightweight building material may be colored by adding a pigment, for example, an inorganic pigment, to the raw material mixture of the frost-resistant lightweight building material. Moreover, you may make the coloring in a surface layer into a pattern especially by adding in combination of an inorganic pigment. Thereby, the designability of a frost-resistant lightweight building material can be improved.

  Moreover, you may change the physical property of the surface layer of a frost-resistant lightweight building material by adding a coarse grain and another raw material to a raw material mixture.

  By making the blending ratio of the foaming agent K in the raw material mixture to 0% by mass or a small value, the hardness of the surface layer of the freezing damage resistant lightweight building material and the contamination cleaning property may be improved. Thereby, the frost-resistant lightweight building material with improved hardness and contamination cleaning property can be applied to kitchen wall materials, floor materials, and the like.

  Further, the manufactured frost-resistant lightweight building material may be partially press-molded with a mold, and the surface may be embossed (relief). Thereby, the designability of a frost-resistant lightweight building material can be improved.

  The frost-resistant lightweight building material according to the present embodiment has uses such as interior and exterior wall materials such as kitchen wall materials and floor materials in buildings.

It is process drawing which shows the manufacturing process of the frost damage resistant lightweight building material which concerns on embodiment of this invention.

Claims (28)

  Freezing damage resistance obtained by molding a raw material mixture obtained by adding a foaming agent to glass powder at a predetermined addition rate, and foaming the obtained molded body by firing in a temperature atmosphere of more than 750 ° C. to less than 850 ° C. A light-weight building material having a bulk specific gravity of not less than 1.0 and not more than 2.0.   2. The frost damage resistant lightweight building material according to claim 1, wherein the foaming agent also serves as an anti-frost damage agent.   The frost-resistant lightweight building material according to claim 2, wherein the foaming agent contains calcium silicate hydrate or cement hydrate.   The frost-resistant lightweight building material according to claim 2 or 3, wherein the foaming agent includes a cement body having a cement component content of 30% or more.   The frost-resistant lightweight building material according to claim 4, wherein the cement body includes at least one selected from the group consisting of a cement paste, a dry powder of mortar, and a dry powder of concrete.   The frost-resistant light-weight building material according to any one of claims 2 to 5, wherein the foaming agent has a particle size of 50% by mass or more with a particle size of 150 µm or less.   The addition rate of the foaming agent is a value such that the addition rate with respect to the glass powder having a particle size of 150 µm or less is in a range of 1 to 15 mass%. Lightweight building material resistant to frost damage as described in the item.   The foaming agent includes foamed glass powder, calcium silicate hydrate or cement hydrate having an addition rate of 1 to 15% by mass to the foamed glass powder, an anti-crystallization agent, and addition to the foamed glass powder. The frost-resistant lightweight building material according to claim 2, further comprising another foaming agent comprising a carbonate having a rate of 1 to 10% by mass.   9. The frost-resistant lightweight building material according to claim 8, wherein the crystallization inhibitor comprises sodium silicate powder or an aqueous solution thereof.   The lightweight frost-resistant building material according to claim 8 or 9, wherein the carbonate is composed of dolomite or calcium carbonate.   The frost-resistant lightweight building material according to any one of claims 8 to 10, wherein the foaming agent has a particle size of 500 µm or less.   12. The frost damage resistant lightweight building material according to claim 8, wherein a blending ratio of the foaming agent in the raw material mixture is in a range of 1 to 15 mass%.   The matting agent is added to the raw material mixture at a predetermined addition rate, and the matting agent also serves as the foaming agent. Building materials.   A frost-resistant lightweight building material according to any one of claims 1 to 12, wherein a matting agent is added to the raw material mixture at a predetermined addition rate.   The glass powder is made of soda-lime glass, and the matting agent contains a calcium compound having high reactivity with the soda-lime glass, a hydrate thereof, or a dehydrated decomposition product thereof. The frost-resistant lightweight building material described.   The frost-resistant lightweight building material according to claim 15, wherein the hydrate of the calcium compound comprises silicate calcium hydrate or cement hydrate.   The frost-resistant lightweight building material according to any one of claims 14 to 16, wherein the matting agent includes a cement body having a cement component content of 30% by mass or more.   The lightweight construction material according to claim 17, wherein the cement body includes at least one selected from the group consisting of a cement paste, a dry powder of mortar, and a dry powder of concrete.   The matting agent contains a calcium compound in which the content of at least one substance selected from the group of wollastlite, slaked lime, quicklime, calcium carbonate, gypsum and its hydrate, and calcium phosphate is 50% by mass or more. The frost-resistant lightweight building material according to any one of claims 14 to 18, further comprising a body.   The frost-resistant light-weight building material according to any one of claims 14 to 18, wherein the matting agent contains waste fired glass powder.   The matting agent has a waste calcined glass powder, a calcium compound whose addition ratio to the waste calcined glass powder is 1 to 20%, a hydrate or dehydrated decomposition product thereof, or a cement component content of 30% by mass The cement body containing above, or a calcium compound-containing body having a content of 50% by mass or more, and another foaming agent made of carbonate, are included in any one of claims 15 to 19, Lightweight building material resistant to frost damage.   The frost-resistant lightweight building material according to claim 21, wherein the carbonate is composed of dolomite or calcium carbonate.   The frost-resistant lightweight building material according to any one of claims 13 to 22, wherein the matting agent has a particle size of not more than 500 µm and a content of 50 mass% or more.   24. The addition rate of the matting agent is a value such that the addition rate with respect to the raw material mixture having a particle size of 500 μm or less is in a range of 0.5 to 20% by mass. The frost-resistant light-weight building material according to any one of the items.   25. The frost-resistant lightweight building material according to any one of claims 13 to 24, wherein an addition rate of the matting agent is 0.005 to 20% by mass or less.   26. The frost damage resistant lightweight building material according to any one of claims 1 to 25, wherein the glass powder has a particle size of 3 to 20% by mass with a particle size of 10 [mu] m or less.   27. The frost damage resistant lightweight building material according to any one of claims 1 to 26, wherein a mixing ratio of the glass powder in the raw material mixture is 30% by mass or more.   The frost-resistant light-weight building material according to any one of claims 1 to 27, wherein the glass powder is waste glass building material.

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