JP2013227188A - Method for manufacturing building material using recyclable material and building material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To manufacture a lightweight tough building material from recyclable waste materials.SOLUTION: A method for manufacturing a building material using recyclable materials is characterized in that: a ceramic waste material, an organic combustible material, a ceramic hardening agent, a glass binder and water are mixed and stirred to prepare a homogeneous viscous material; the viscous material is put in a building material mold and molded into a rough building material; the rough building material is dried and heated to 600-1,000°C to burn the organic combustible material; and the resulting material is allowed to cool naturally.

Description

  The present invention relates to a manufacturing method and building materials for various building materials such as tiles, tiles, outer wall materials or road pavement materials, water retaining bricks or greening materials, which are mainly made of recycled materials and have non-combustible, lightweight, heat-insulating and non-degrading characteristics. Is.

  Conventionally, there have been many proposals for building materials such as the use of recycled materials or the manufacture of lightweight roof tiles, each of which has been specifically adopted for use. However, few materials are used for various building materials using the same material, and few building materials are industrially mass-produced.

JP 2000-507660 Gazette JP-A-7-109183 JP 2011-256523 A

  Conventionally, for the reuse of waste, waste tires are crushed, glass fiber and steel belt fragments are mixed with an epoxy mixture consisting of an oxirane-containing resin and an amine-containing hardener to produce other products (eg sleepers) There is known a technique for forming a film (Patent Document 1).

  There is also a proposal of a ceramic composite in which fibers are mixed and reinforced in a plate-like foam formed by sintering glass powder (Patent Document 2).

  Moreover, the technique which manufactures a foam glass particle using a glass waste material and manufactures a lightweight tile or a lightweight tile using this foamed glass particle is also proposed (patent document 3).

  Each of the building materials is a building material using waste, but there is a problem that the product becomes heavy when the waste does not contain synthetic resin.

  In the above, waste molten glass forming foam cools molten slag obtained by melting waste such as municipal waste, sewage sludge, fly ash, mine demolition, river deposits, and sludge in lakes. Solidified, crushed to an appropriate particle size and molded into a sintered material.

  Accordingly, since foaming occurs due to the release of a gas such as nitrogen, carbon monoxide or sulfur oxide contained in the waste molten glass, or water vapor, it has been difficult to obtain a uniform foamed product by normal heating foaming.

  On the other hand, the present invention relates to a combustible material (for example, dried plant waste or resin powder), a glassy binder (for example, a powder of 300 mesh or less and melted at 700 ° C. to 1000 ° C.), sodium oxalate ( Water glass) and water-kneaded material are used as raw materials to form a building material (a tile if a roof mold is used), and after drying this building material, it is fired at 700 to 800 ° C. Of lightweight building materials.

  In the above, the plant waste disappears upon firing, and only the cavity remains in the part. By this treatment, a porcelain film is formed on the surface of the cavity to reinforce the entire surface.

The materials used in the present invention are as follows.
1. Ceramic waste material (clays of water tank residue of dredged sand, other clays)
2. Organic combustible materials (plants and resins)
3. Ceramic hardener (water glass, sodium oxalate)
4). Glass binder (flax, CRT, liquid crystal glass, etc.)
5. water

  The present invention uses the waste materials described in the above 1, 2, and 4 to recycle resources that have been discarded in the past to generate new building materials (for example, tiles, tiles, other exterior building materials, etc.). .

  In the above, the clay of the ceramic waste material is a main raw material and constitutes the whole material, and the main raw material is integrated with a glass-based binder to constitute a desired building material. The other clays mentioned above include clays generated during work with different purposes (for example, during civil engineering work).

  In the above, the following functions are achieved by integrating the materials.

  When the ceramic waste material clay is formed and fired as a main raw material, it becomes a main raw material having a pressure strength. Moreover, as an organic combustible material, for example, a plant chip (a thinned wood of a forest and a pulverized product of 5 to 10 mm or less) is used. In addition to the above, the noble flammable materials include sawdust, leaf waste, wood chips (woodworking waste) and the like. The sawdust, leaf waste, wood chips, etc. are mixed in a litter such as a poultry house, a pig house or a cow house, or used alone, and thereafter used as a fertilizer for farmland. Or it can also be mixed with chemical fertilizers or used alone for fertilizers such as farmland forests. Further, it can be used as a material for unfired building materials together with gypsum board or foamed cement.

  When the various organic waste materials are mixed with clay and molded, and then fired, the waste materials are burned to form cavities, so that the molded product is lightened, and the weight is reduced to 1/2 to 1/1 depending on the mixing ratio of organic materials. Can be 3.

  The ceramic curing agent is used as a clay curing agent during molding. This has the role of hardening the clay during the course from molding to firing.

  Further, since the glass-based binder is obtained by pulverizing general waste glass, cathode ray tube, liquid crystal glass or the like to 300 mesh or less and mixing with clay, if the flammable material in the clay is burned out at around 600 ° C., the burned-out There is a cavity in the part. When the temperature is 800 ° C. or higher, the binder melts and adheres to the cavity wall to form a film, so that the strength of the cavity is improved.

  As described above, the formation of cavities and the strengthening of the cavity walls due to the combustion of organic substances have not been known or predicted.

  The water in the above will adjust the plasticity in either dry or wet molding.

The amount of each component in this invention is as follows with respect to 100 (weight) of clay.
Organic combustible materials (wood, leaves, sawdust) 5% to 10%
Ceramic hardener (water glass) 3% to 10%
Glass binder (glass fine powder) 20% to 25%
Water (plasticity) 10% to 20%

  According to the present invention, since the organic matter mixed in the clay is burned out and a cavity is formed, there is an effect that means for generating the cavity is not required. Therefore, no consideration is required for heating and cooling.

  In addition, since a hard film is formed on the cavity wall, there is an effect of increasing the strength. Furthermore, since the cavity is created by burning off the organic combustible material, the specific gravity and strength of the product, the amount of the cavity, and the size of the cavity can be controlled by the size and amount of the organic combustible material. There are also effects such as.

(A) The partial cross-section enlarged view of the tile raw material in the Example of this invention, (b) The partial cross-section enlarged view of a product.

  In this invention, ceramic waste materials such as clay of clay residue of dredged sand, organic combustible materials made of plants and resins, ceramic hardeners such as water glass and sodium oxalate, and glass waste materials such as cathode ray tube and liquid crystal glass Add water to the mixture to make it viscous (similar to adding an appropriate amount of water to the clay), and put it in a mold to form building materials such as tiles and tiles.

  The building material material is dried to a moisture content of 20% or less, and then fired at 700 ° C. to 800 ° C. to produce a predetermined lightweight building material. The bulk specific gravity of the building material can be freely selected between 1 and 2.5. Since building materials with a small specific gravity are likely to be reduced in strength, they are adjusted according to the amount and size of the organic combustible material.

  The shape of the product is equivalent to that of the conventional product if a conventional mold is used, but the size and shape can be freely selected according to the characteristics of the present invention. Although the specific gravity can be freely selected, the strength is generally reduced if the weight is reduced. Therefore, the shape, weight, and strength are selected according to the type of building materials used. In general, when used for the exterior, the shape and strength are determined in consideration of contact or collision with other objects. Moreover, when using for interior, consideration is given to the appearance, color, etc., but it is also possible to freely use appropriate reinforcing materials (for example, fine wires arranged in a reinforcing bar shape) for both the interior and exterior.

  A first embodiment of the present invention will be described. 15% of water is mixed in and mixed with 8% sawdust 3, 8% water glass (ceramics), and 20% waste glass powder, and put into a mold. For example, the tile material 1 is molded in a tile shape. Next, if the tile material 1 is dried by ventilation (25 ° C. to 30 ° C.) and dried to a moisture content of 20%, a product can be obtained by heating and baking at 600 ° C. to 1000 ° C. for 2 hours.

  By the firing at 600 ° C. to 1000 ° C., the organic matter in the tile material 1 is burned away and the part becomes a cavity 4. Moreover, the surface of the cavity 4 is melted by heating at 600 ° C. to 1000 ° C. to form the porcelain film 5. The whole is reinforced by this porcelain coating 5.

  In the tile material 1, the sawdust 3 is mixed in the mixture 2 of clay, water glass and waste glass powder (FIG. 1 (a)). Thus, the tile 6 with the porcelain coating 5 is formed (FIG. 1B).

A second embodiment of the present invention will be described. The materials used in this example are as follows.
Clay 100 (weight)
Sawdust 9%
Ceramic curing agent 9%
Glass binder 20%
15% water

  The material is put in a mixer and mixed uniformly to form a mud, which is then filled into a mold and molded (for example, a tile material). Next, when the roof tile material is dried under ventilation and the water content becomes 20% or less, it is put into a heating furnace and heated to 450 ° C. to 1000 ° C. (for example, temperature rise in 2 hours). Next, the product of the present invention can be obtained by taking out the fired product and allowing it to cool naturally.

  In the heating, the temperature reaches from room temperature to 1000 ° C. within 10 hours, and then is cooled to 100 ° C. within 12 hours. In the above, cooling is based on natural cooling and is returned to room temperature over 24 hours.

DESCRIPTION OF SYMBOLS 1 Tile material 2 Clay, water glass and waste glass powder mixture 3 Sawdust 4 Cavity 5 Porcelain coating 6 Tile

Claims (7)

  Ceramic waste material, organic combustible material, ceramic hardener, glass binder and water are mixed and stirred to form a uniform viscous material. The viscous material is put into a building material mold to mold the building material, and the building material is dried. And after heating this to 600 to 1000 degreeC and baking the said organic combustible material, the manufacturing method of the building material using the recycling material characterized by carrying out natural cooling.   Organic combustible material 5% to 10%, ceramic hardener 3% to 10%, glass-based binder 20% to 25%, and water 10% to 20% with respect to 100% by weight of ceramic waste material A method for producing a building material using the recycled material according to claim 1.   The method for producing a building material using the recycled material according to claim 1, wherein the ceramics waste material is made of clay of a cocoon residue of dredged sand.   The method for producing a building material using the recycled material according to claim 1, wherein the organic combustible material is sawdust, leaf waste, waste wood, and resins.   The method for producing a building material using the recycled material according to claim 1, wherein the ceramic curing agent is water glass and / or sodium oxalate.   The method for producing a building material using the recycled material according to claim 1, wherein the glass-based binder is a flax, a cathode ray tube, or liquid crystal glass.   A building material manufactured using a recycled material manufactured by the manufacturing method according to claim 1.

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