JP2020105037A - Molded article of geopolymer, and method of producing molded article of geopolymer - Google Patents

Abstract

To provide a molded article of a geopolymer showing a massive feeling and a pattern, similar to those of natural stone.SOLUTION: A molded article 1 of a geopolymer comprises a first cured part 2 prepared by curing a first molding material 21 comprising an alkali compound, a silicic acid compound and a first filler at least comprising an aluminum compound, and a plurality of second cured parts 3 prepared by curing a second molding material comprising an alkali compound, a silicic acid compound and a second filler at least comprising an aluminum compound and having a color tone different from that of the first cured part 2. The first cured part 2 is adjacent to each of the second cured parts 3. The first filler does not substantially contain a hardly alkali-soluble material of a refractive index difference of not lower than 0.5 relative to a reaction cured matter of the alkali compound, the silicic acid compound and the aluminum compound.SELECTED DRAWING: Figure 1

Description

The present disclosure relates to a geopolymer molded product and a method for manufacturing the geopolymer molded product.

Conventionally, artificial marble has been given an artificial pattern similar to natural stone.

For example, in Patent Document 1, an artificial marble including applying a main pattern resin after applying the main pattern resin to a mold surface together with a pattern base resin having a viscosity higher than that of the main body molding resin, and molding the resin. Is disclosed.

JP-A-8-174570

However, in the case of Patent Document 1, even if the artificial marble can have a pattern resembling natural stone, the artificial marble contains a resin lighter than the natural stone as a main component, so that the artificial marble has a heavy weight similar to that of the natural stone. It tends to be difficult to give artificial marble a feeling.

An object of the present disclosure is to provide a geopolymer molded product having a profound feeling and a pattern similar to natural stone, and a method for manufacturing a geopolymer molded product.

A geopolymer molded article according to one aspect of the present disclosure includes a first cured portion and a second cured portion. The first hardened part is a hardened first molding material containing an alkali compound, a silicic acid compound, and a first filler containing at least an aluminum compound. The second cured portion has a color tone different from that of the first cured portion and is obtained by curing a second molding material containing an alkali compound, a silicic acid compound, and a second filler containing at least an aluminum compound. The first cured portion and the second cured portion are adjacent to each other. The first filler does not substantially contain a hardly alkali-soluble material having a refractive index difference of 0.5 or more with respect to a reaction cured product of the alkali compound, the silicic acid compound, and the aluminum compound.

A method for producing a geopolymer molded product according to an aspect of the present disclosure is a method for producing a geopolymer molded product. The manufacturing method includes a step of preparing a first molding material containing an alkali compound, a silicic acid compound, and a first filler containing at least an aluminum compound. The manufacturing method further includes a step of preparing a second molding material containing an alkali compound, a silicic acid compound, and a second filler containing at least an aluminum compound and having a color tone different from that of the first molding material. The manufacturing method further includes a step of manufacturing a geopolymer molded article such that a first cured portion where the first molding material is cured and a second cured portion where the second molding material is cured are adjacent to each other. The first filler does not substantially contain a hardly alkali-soluble material having a refractive index difference of 0.5 or more with respect to a reaction cured product of the alkali compound, the silicic acid compound, and the aluminum compound.

According to the above aspect of the present disclosure, it is possible to provide a geopolymer molded product having a profound feeling and pattern similar to natural stone.

FIG. 1 is an explanatory diagram of a geopolymer molded product according to the first embodiment. FIG. 2 is a conceptual diagram showing a mode in which light incident on the first curing unit according to the first embodiment is reflected, refracted, scattered, absorbed, and transmitted in the first curing unit. FIG. 3 is an explanatory diagram of a method for manufacturing a geopolymer molded product according to the first embodiment. FIG. 4A is a photograph showing an example of the geopolymer molded article according to the first embodiment. FIG. 4B is a reference material of FIG. 4A and is a photograph showing a natural stone, Otani stone. FIG. 5: is explanatory drawing of the geopolymer molded article of the 1st example which concerns on 2nd Embodiment. FIG. 6 is an explanatory diagram of a second example geopolymer molded product according to the second embodiment. FIG. 7: is explanatory drawing of the manufacturing method of the geopolymer molded article of the 1st example which concerns on 2nd Embodiment. FIG. 8: is explanatory drawing of the manufacturing method of the geopolymer molded article of the 1st example which concerns on 2nd Embodiment. FIG. 9: is explanatory drawing of the shaping|molding die utilized for the manufacturing method of the geopolymer molded article of the 2nd example which concerns on 2nd Embodiment. FIG. 10: is explanatory drawing of the manufacturing method of the geopolymer molded article of the 2nd example which concerns on 2nd Embodiment. FIG. 11 is an explanatory diagram of a geopolymer molded product according to the third embodiment. FIG. 12: is explanatory drawing of the manufacturing method of the geopolymer molded article of the 2nd example which concerns on 3rd Embodiment. FIG. 13: is explanatory drawing of the manufacturing method of the geopolymer molded article of the 1st example which concerns on 3rd Embodiment. FIG. 14A is a photograph showing an example of a geopolymer molded product according to the third embodiment. FIG. 14B is a reference material of FIG. 14A and is a photograph showing a rhyolite which is a natural stone. FIG. 15 is a photograph showing a reference material of the geopolymer molded article according to the fourth embodiment and showing an example of marble using a resin.

(First embodiment)
First, the first embodiment will be described with reference to FIGS. 1 to 4B.

<Geopolymer molded product>
The geopolymer molded article 1 according to the present embodiment includes a first cured portion 2 and a second cured portion 3, as shown in FIGS. 1 and 4A. The 1st hardening part 2 and the 2nd hardening part 3 adjoin. The 1st hardening part 2 hardens the 1st molding material 21 (refer to Drawing 3). The first molding material 21 contains an alkali compound, a silicic acid compound, and a first filler. The first filler contains at least an aluminum compound. The first filler does not substantially contain a hardly alkali-soluble material having a refractive index difference of 0.5 or more with respect to a reaction cured product of an alkali compound, a silicic acid compound, and an aluminum compound. The second hardened portion 3 is a hardened second molding material and has a different color tone from the first hardened portion 2. The second molding material contains an alkali compound, a silicic acid compound, and a second filler. The second filler contains at least an aluminum compound.

Since each of the first molding material 21 and the second molding material contains an alkali compound, a silicic acid compound, and an aluminum compound, silicic acid is easily obtained from the silicic acid compound in the presence of an aqueous solution of the alkali compound. Aluminum hydroxide can be easily obtained from the compound. Then, a dehydration polycondensation reaction occurs between aluminum hydroxide and the like and silicic acid, whereby a geopolymer having a crosslinked structure is easily produced.

Here, the "geopolymer" is a silicic acid polymer containing aluminum or the like.

In addition, many rocks among natural stones generally contain silicon as a main component.

Therefore, the geopolymer molded product 1 can have a profound feeling and pattern similar to natural stone as shown in FIG. 4B. Moreover, since the first filler does not substantially contain the specific hardly-alkali-soluble material, the first cured portion 2 can have translucency.

The geopolymer molded article 1 is a cured product obtained by molding and curing a molding material (X) containing a first molding material 21 and a second molding material, and a geopolymer generated when the molding material (X) is cured. Contains.

Further, the geopolymer molded article 1 has a pattern in which the first cured portion 2 having a light transmitting property and the second cured portion 3 having a color tone different from that of the first cured portion 2 are adjacent to each other. Specifically, as shown in FIGS. 1 and 4A, the geopolymer molded article 1 has a dispersed structure in which a plurality of second hardened portions 3 are dispersed in the first hardened portions 2 to form a speckled pattern. Since the first cured portion 2 has a light-transmitting property, in the geopolymer molded article 1, the second cured portion 3 can be seen through even in a portion where the second cured portion 3 is not exposed on the surface. Therefore, it has an excellent three-dimensional effect (depth feeling) and can have a profound feeling and a pattern similar to a natural stone (for example, Otani stone) having a spotted pattern. The first cured portion 2 is a portion where the first molding material 21 is cured. The 2nd hardening part 3 is a part where the 2nd molding material hardened.

The first molding material 21 contains an alkali compound, a silicic acid compound, and a first filler. The first filler contains at least an aluminum compound. The first filler is not limited to particles in the first molding material 21 and the first curing part 2, and may be a melted product obtained by dissolving the first filler when the first molding material 21 is manufactured, or It may be a mixture of particles and a melt. When the first molding material 21 contains a melt of the first filler, the melt of the first filler may participate in the production of the geopolymer. As a specific example, the aluminum compound melt is involved in the formation of the geopolymer, as described above.

The first molding material 21 contains the easily alkali-soluble material (M1) and does not substantially contain the hardly-alkali-soluble material (M2) as the first filler. The easily alkali-soluble material (M1) is a material that is easily dissolved in an aqueous solution containing an alkali compound and contains at least an aluminum compound.

The hardly alkali-soluble material (M2) is a material that is difficult to dissolve in an aqueous solution containing an alkali compound, and is a reaction cured product of an alkali compound, a silicic acid compound, and an aluminum compound (hereinafter, simply referred to as a reaction cured product There is a refractive index of 0.5 or more. For example, when the refractive index of the reaction cured product is 1.50, the first filler does not substantially contain the hardly alkaline soluble material (M2) having a refractive index of 2.00 or more. The hardly alkali-soluble material (M2) easily exists as a particulate filler in the cured product. The poor solubility of an alkali compound in an aqueous solution, which the poorly alkali-soluble material (M2) has, can be obtained, for example, by the following method. For example, to the aqueous alkaline compound solution used for the first molding material 21 having a pH of 14, 1% by weight of the hardly alkaline soluble material (M2) is added to the weight of the aqueous alkaline compound solution. 24 hours after this addition, the hardly-alkali-soluble material (M2) remains as a solid content of 10% by weight or more of the hardly-alkali-soluble material (M2) in the aqueous alkali compound solution. Further, the solubility of the alkali compound contained in the easily alkali-soluble material (M1) in an aqueous solution can be obtained, for example, by the following method. For example, to the alkaline compound aqueous solution used for the first molding material 21 having a pH of 14, 1% by weight of the easily soluble alkali-soluble material (M1) is added to the weight of the alkaline compound aqueous solution. In the alkaline compound aqueous solution, less than 10% by weight of the easily alkali-soluble material (M1) remains as a solid content in the alkaline compound aqueous solution 24 hours after this addition. Alternatively, the easily alkali-soluble material (M1) is completely dissolved.

Since the first filler contains the easily alkali-soluble material (M1) and does not substantially contain the hardly-alkali-soluble material (M2), the hardly-alkali-soluble material (M2) is formed into particles in the first cured portion 2. It becomes difficult to exist as a filler. That is, the amount of the particulate filler contained in the first cured portion 2 can be reduced. Thereby, the refracted light is less likely to be affected by the particulate filler (for example, refracted, scattered, and reflected), and is less likely to be absorbed in the first curing section 2. For this reason, the 1st hardening part 2 becomes easy to obtain translucency.

When the first molding material 21 is hardened, the first hardened part 2 is considered to have the translucency as shown in FIG. Since the first cured portion 2 has a light-transmitting property, the light (incident light) incident on the light receiving surface of the first cured portion 2 is divided into reflected light and refracted light on the light receiving surface. The refracted light is light that is inside the first curing portion 2 when the light is incident on the first curing portion 2, and is bent on the light receiving surface due to the refractive index of the reaction cured product. Then, the refracted light is emitted as regular transmitted light (thick arrow in FIG. 2) from the emission surface on the side opposite to the light receiving surface in the optical axis of the incident light. In the example of FIG. 1, diffuse transmitted light (thin arrow in FIG. 2) is emitted from the emission surface so as to surround the regular transmitted light. Diffuse transmitted light is light that is a part of refracted light scattered by the first filler 22 and the like in the first curing portion 2 to become scattered light, and this scattered light is emitted from the emission surface. The reflected light includes regular reflected light (thick arrow in FIG. 2) and diffuse reflected light (thin arrow in FIG. 2). The specular reflection light is light in which a part of the incident light is specularly reflected on the light receiving surface, and is also called specular reflection light. A part of the refracted light is scattered light in the first curing portion 2 to become scattered light, and the diffuse reflected light is light emitted from the light receiving surface. The diffusely reflected light surrounds the specularly reflected light.

The translucency of the first cured portion 2 is indicated by the visible light transmittance obtained from the cured product (C1) of the first molding material 21. The visible light transmittance of the cured product (C1) is measured according to JIS R 3106. The visible light transmittance of the cured product (C1) is preferably 3% or more when the thickness of the cured product (C1) is 4 mm. In this case, the 1st hardening part 2 becomes easy to obtain translucency. The visible light transmittance of the cured product (C1) is more preferably 10% or more, still more preferably 20% or more. The upper limit of the visible light transmittance of the cured product (C1) is not particularly limited, but is 80%, for example.

Here, "the first filler does not substantially contain the hardly alkaline soluble material (M2)" means that the amount of the hardly alkaline soluble material (M2) is the solid content of the alkali compound, the silicic acid compound and the aluminum compound. It means little to the whole. That is, it means that the first filler preferably does not contain the hardly alkali-soluble material (M2), but allows the content such that the hardly alkali-soluble material (M2) is mixed as an impurity. The amount of the hardly alkali-soluble material (M2) is, for example, less than 2% by weight based on the total solid content of the alkali compound, the silicic acid compound and the aluminum compound. The lower limit amount of the hardly alkali-soluble material (M2) is 0% by weight.

Examples of the hardly alkali-soluble material (M2) include lead stannate, titanium oxide, and iron oxide.

Further, the first filler may further contain a hardly alkali-soluble material (M3) different from the hardly alkali-soluble material (M2). The hardly alkaline soluble material (M3) is a material having a refractive index smaller than 0.5 with respect to the refractive index of a reaction cured product (reaction cured product of an alkali compound, a silicic acid compound and an aluminum compound). In this case, the difference in refractive index between the hardly alkali-soluble material (M3) and the reaction cured product is small. Therefore, even if the particulate first filler 22 made of the hardly alkali-soluble material (M3) is dispersed in the first hardened portion 2, the refracted light remains in the particulate form in the first hardened portion 2. The first filler 22 makes it more difficult to refract, and it becomes difficult to be scattered and absorbed. Since the refracted light is less likely to be absorbed in the first cured portion 2, the first cured portion 2 easily obtains translucency.

The amount of the hardly alkali-soluble material (M3) is preferably less than 8% by weight based on the total solid content of the alkali compound, the silicic acid compound and the aluminum compound. In this case, the 1st hardening part 2 becomes easy to obtain translucency. The amount of the hardly alkali-soluble material (M3) is more preferably 5% by weight or less, and even more preferably 2% by weight or less. The lower limit amount of the hardly alkaline soluble material (M3) is 0% by weight.

The hardly-alkali-soluble material (M3) is a material that hardly dissolves in an alkaline compound aqueous solution, like the hardly-alkali-soluble material (M2). The hardly alkaline soluble material (M3) is, for example, magnesium oxide, barium sulfate or the like.

As described above, the easily alkali-soluble material (M1) is a material that is easily dissolved in an aqueous solution of an alkali compound. Therefore, it becomes difficult for the first cured portion 2 to contain the particulate filler 22 made of the easily alkali-soluble material (M1). Thereby, the refracted light is less likely to be affected by the particulate filler 22 and is less likely to be absorbed in the first curing section 2. For this reason, the 1st hardening part 2 becomes easy to obtain translucency.

The first molding material 21 contains 5% by weight or more and 50% by weight or less of the alkali-soluble material (M1) with respect to the entire solid content. When the first molding material 21 contains 5% by weight or more of the easily alkali-soluble material (M1), the first molding material 21 is easily cured. When the first molding material 21 contains 50% by weight or less of the easily alkali-soluble material (M1), the translucency of the first cured portion 2 is likely to be improved, and the design of the geopolymer molded article 1 may be improved. it can.

The easily alkali-soluble material (M1) contains at least an aluminum compound. The aluminum compound is a compound serving as an aluminum source of the geopolymer when the first molding material 21 is cured.

The first molding material 21 may contain more silicic acid compound than the aluminum compound in terms of solid content. In this case, when the first molding material 21 is cured, a geopolymer is likely to be generated, and the first molding material 21 can be easily cured. The first molding material 21 preferably contains the silicic acid compound at least twice as much as the aluminum compound.

Examples of the aluminum compound include aluminum silicate, aluminum hydroxide, sodium aluminate, and aluminum isopropoxide. The aluminum compound can contain at least one compound selected from the above group.

When the aluminum compound contains aluminum silicate, the amount of aluminum silicate is preferably 10% by weight or more and 40% by weight or less based on the entire solid content of the first molding material 21.

When the aluminum compound contains aluminum hydroxide, the amount of aluminum hydroxide is preferably 10% by weight or more and 35% by weight or less based on the entire solid content of the first molding material 21.

The easily alkali-soluble material (M1) may contain only an aluminum compound or may further contain a metal compound other than the aluminum compound. Examples of metal compounds include calcium compounds and zinc compounds. The metal compound can contain at least one compound selected from the above group. The calcium compound is, for example, calcium hydroxide. The zinc compound is, for example, zinc oxide.

The silicic acid compound is a compound that becomes a silicon source of the geopolymer when the first molding material 21 is cured. Examples of the silicic acid compound include silicates such as sodium silicate, potassium silicate, aluminum silicate and sodium metasilicate; water glass; and fumed silica. The silicic acid compound can include at least one compound selected from the above group. The silicic acid compound preferably contains water glass and fumed silica.

Water glass is an aqueous solution in which a silicate is completely dissolved in water or an aqueous solution of an alkaline compound. Fumed silica is a particulate component containing amorphous silicon dioxide as a main component, and has a property of being easily dissolved in an aqueous solution of an alkali compound. Therefore, fumed silica is dissolved in the presence of an aqueous solution of an alkaline compound and becomes a silicon source of the geopolymer.

The alkaline compound is a compound that dissolves in water to make the first molding material 21 alkaline when the geopolymer is produced. Examples of the alkaline compound include sodium hydroxide and potassium hydroxide. The alkaline compound may contain at least one compound selected from the above group, but is preferably potassium hydroxide. In addition, in the present embodiment, the first molding material 21 preferably contains an aqueous solution of an alkaline compound, and more preferably contains an aqueous solution of potassium hydroxide.

In addition, the first molding material 21 can contain various additives such as a thickener and a colorant as long as the effect thereof is not affected.

Examples of the thickener include methyl cellulose, hydroxymethyl cellulose, and carboxymethyl cellulose.

The colorant is a component that can obtain translucency in the first cured portion 2 and that colors the first cured portion 2. As the colorant, for example, a small amount of a hardly alkali-soluble material (M2) such as red iron oxide, iron black, and titanium oxide, or an organic dye can be used.

Further, the geopolymer molded article 1 includes the second cured portion 3 having a color tone different from that of the first cured portion 2 as described above. The 2nd hardening part 3 is a part where the 2nd molding material hardened. In the present embodiment, the second curing section 3 is composed of a granular handle material 3a which is a cured product of the second molding material. Then, a plurality of pattern materials 3a are dispersed in the first cured portion 2 to form a speckled pattern (see FIG. 1).

The second molding material contains an alkali compound, a silicic acid compound, and a second filler. The second filler contains at least an aluminum compound.

The second filler is not limited to a particulate form in the second molding material and the second curing section 3, and may be a mixture of a melted material and particles in which the second filler is dissolved when the second molding material is produced. Good. If the second molding material contains a melt of the second filler, the melt of the second filler may participate in the production of the geopolymer. As a specific example, the aluminum compound melt is involved in the formation of the geopolymer, as described above.

The second molding material contains an easily alkali-soluble material (M1). The easily alkali-soluble material (M1) is a material that is easily dissolved in an aqueous solution containing an alkali compound and contains at least an aluminum compound. Further, the second molding material may contain the hardly alkali-soluble material (M2) as the second filler, or may not substantially contain the hardly-alkali soluble material (M2).

When the second filler contains the hardly alkali-soluble material (M2), the translucency of the second cured portion 3 tends to be low. Even if the translucency of the second cured portion 3 is likely to be low, the geopolymer molded product 1 can have a profound feeling and pattern similar to natural stone because the first cured portion 2 has translucency. The amount of the hardly alkali-soluble material (M2) is preferably 2% by weight or more based on the total solid content of the alkali compound, the silicic acid compound and the aluminum compound. The upper limit of the amount of the hardly alkali-soluble material (M2) is not particularly limited, but is, for example, 20% by weight or less.

When the second filler does not substantially contain the hardly alkali-soluble material (M2), the second hardened part 3 can have translucency like the first hardened part 2, and the geopolymer molded article 1 has The first hardened portion 2 and the second hardened portion 3 are both transparent, and can have a solid feeling and a pattern similar to natural stone such as fluorite.

The hardly alkali-soluble material (M2) is a material that is difficult to dissolve in an aqueous solution containing an alkali compound, and is a reaction cured product of an alkali compound, a silicic acid compound, and an aluminum compound (hereinafter, simply referred to as a reaction cured product. There is more than 0.5). For example, when the reaction cured product has a refractive index of 1.50, the second filler is a material having a refractive index of 2.00 or more.

The poor solubility of the hardly alkaline soluble material (M2) can be obtained by the same method as the first molding material 21.

When the second filler contains the easily-alkali-soluble material (M1) and contains the hardly-alkali-soluble material (M2), the translucency of the second cured portion 3 is lower than that of the first cured portion 2, The color tone of the second cured portion 3 tends to be different from that of the first cured portion 2. When the hardly alkaline-soluble material (M2) is a material that imparts a color to the second molding material, the color tone of the second cured portion 3 is likely to be different from that of the first cured portion 2.

Further, when the second filler does not substantially contain the hardly alkali-soluble material (M2), the hardly-alkali soluble material (M2) is less likely to be present as a particulate filler in the second cured portion 3, Similar to the description of the 1st hardening part 2, the 2nd hardening part 3 will also have translucency. In this case, it is preferable that the second hardened part 3 contains a colorant having a color tone different from that of the first hardened part 2. That is, the second molding material preferably contains a colorant having a color tone different from that of the first molding material 21. Examples of such a colorant include a small amount of a hardly alkali-soluble material (M2) such as red iron oxide, iron black, and titanium oxide, and an organic dye.

Here, "the second filler does not substantially contain the hardly alkaline soluble material (M2)" means that the amount of the hardly alkaline soluble material (M2) is a solid of an alkali compound, a silicic acid compound and an aluminum compound. Means little for the whole minute. That is, it means that the second filler preferably does not contain the hardly alkali-soluble material (M2), but allows the content to the extent that the hardly alkali-soluble material (M2) is mixed as an impurity. The amount of the hardly alkali-soluble material (M2) is, for example, less than 2% by weight based on the total solid content of the alkali compound, the silicic acid compound and the aluminum compound. The lower limit amount of the hardly alkali-soluble material (M2) is 0% by weight.

Examples of the hardly alkali-soluble material (M2) include lead stannate, titanium oxide, and iron oxide.

The translucency of the second cured portion 3 is indicated by the visible light transmittance obtained with the cured product (C2) of the second molding material. The visible light transmittance of the cured product (C2) is measured according to JIS R3106. The visible light transmittance of the cured product (C2) is 0% or more and 80% or less when the thickness of the cured product (C2) is 4 mm. The visible light transmittance of the cured product (C2) may be less than 10%.

Further, the second filler may further contain a hardly alkali-soluble material (M3) different from the hardly alkali-soluble material (M2). As such a hardly alkali-soluble material (M3), the same material as the first curing part 2 can be used.

As described above, the easily alkali-soluble material (M1) is a material that is easily dissolved in an aqueous solution of an alkali compound. Therefore, the easily-alkali-soluble material (M1) is in the form of particles and is less likely to exist, like the first cured portion 2.

The second molding material contains 5% by weight or more of the alkali-soluble material (M1) with respect to the entire solid content. When the second molding material contains 5% by weight or more of the easily alkali-soluble material (M1), the second molding material is easily cured. The upper limit of the amount of the alkali-soluble material (M1) in the second molding material is not particularly limited, but is, for example, 50% by weight or less. In this case, it is possible to suppress a decrease in the light-transmitting property of the second cured portion 3 due to an increase in the easily alkali-soluble material (M1).

The easily alkali-soluble material (M1) contains at least an aluminum compound. The aluminum compound is a compound that becomes an aluminum source of the geopolymer when the second molding material is cured.

The second molding material may contain more silicic acid compound than the aluminum compound in terms of solid content. In this case, when the second molding material is cured, a geopolymer is likely to be generated, and the second molding material can be easily cured. The second molding material preferably contains the silicic acid compound at least twice as much as the aluminum compound.

Examples of the aluminum compound include aluminum silicate, aluminum hydroxide, sodium aluminate, and aluminum isopropoxide. The aluminum compound can contain at least one compound selected from the above group.

When the aluminum compound contains aluminum silicate, the amount of aluminum silicate is preferably 10% by weight or more and 40% by weight or less based on the entire solid content of the second molding material.

When the aluminum compound contains aluminum hydroxide, the amount of aluminum hydroxide is preferably 10% by weight or more and 35% by weight or less based on the entire solid content of the second molding material.

The easily alkali-soluble material (M1) may contain only an aluminum compound or may further contain a metal compound other than the aluminum compound. Examples of metal compounds include calcium compounds and zinc compounds. The metal compound can contain at least one compound selected from the above group. The calcium compound is, for example, calcium hydroxide. The zinc compound is, for example, zinc oxide.

The silicic acid compound is a compound that becomes a silicon source of the geopolymer when the second molding material is cured. Examples of silicic acid compounds include silicates such as sodium silicate, potassium silicate, aluminum silicate and sodium metasilicate; water glass; and fumed silica. The silicic acid compound can include at least one compound selected from the above group. The silicic acid compound preferably contains water glass and fumed silica.

Water glass is an aqueous solution in which a silicate is completely dissolved in water or an aqueous solution of an alkaline compound. Fumed silica is a particulate component containing amorphous silicon dioxide as a main component, and has a property of being easily dissolved in an aqueous solution of an alkali compound. Therefore, fumed silica is dissolved in the presence of an aqueous solution of an alkaline compound and becomes a silicon source of the geopolymer.

The alkaline compound is a compound that dissolves in water to make the second molding material alkaline when the geopolymer is produced. Examples of the alkaline compound include sodium hydroxide and potassium hydroxide. The alkaline compound may contain at least one compound selected from the above group, but is preferably potassium hydroxide. Moreover, in this embodiment, the second molding material preferably contains an aqueous solution of an alkaline compound, and more preferably contains an aqueous solution of potassium hydroxide.

In addition, the first molding material 21 can contain various additives such as a thickener as long as its effect is not affected.

Examples of the thickener include methyl cellulose, hydroxymethyl cellulose, and carboxymethyl cellulose.

Further, it is preferable that each of the first molding material 21 and the second molding material contains 5% by weight or more and 50% by weight or less of the alkali-soluble material (M1) with respect to the entire solid content. When the molding material (X) contains 5% by weight or more of the easily alkali-soluble material (M1), the molding material (X) is easily cured. When the molding material (X) contains 50% by weight or less of the easily alkali-soluble material (M1), the translucency of the first cured portion 2 is likely to be improved, and the design of the geopolymer molded article 1 may be improved. it can.

The geopolymer molded article 1 may contain more silicic acid compound than the aluminum compound in terms of solid content. That is, the molding material (X) may contain more silicic acid compound than the aluminum compound in terms of solid content. In this case, when the molding material (X) is cured, a geopolymer is likely to be generated, and the molding material (X) can be easily cured. The molding material (X) preferably contains the silicic acid compound at least twice as much as the aluminum compound.

<Method for manufacturing geopolymer molded product>
Next, a method for producing the geopolymer molded article 1 according to the present embodiment (hereinafter sometimes simply referred to as a production method) will be described with reference to FIG. The manufacturing method is a method for manufacturing the geopolymer molded article 1. Therefore, for the manufacturing method, the specific description of the geopolymer molded article 1 can be referred to.

The manufacturing method includes a preparation step and a molding and curing step.

The preparation step is a step of preparing the first molding material 21 and the second molding material. Therefore, the preparation step includes a step of preparing the first molding material 21 (first preparation step) and a step of preparing the second molding material (second preparation step).

The first preparation step includes a first mixing step, an adding step, and a second mixing step.

The first mixing step is a step of mixing an alkali compound and a first filler containing at least an aluminum compound to obtain a mixture. When the first filler further comprises a metal compound other than an aluminum compound and at least one compound selected from the group of sparingly alkali-soluble materials (M3), these compounds are pre-mixed before the first mixing step. Or may be mixed with the alkaline compound during the first mixing step. Before the first mixing step, an alkaline compound aqueous solution in which an alkaline compound is dissolved in water may be prepared in advance, and when the silicic acid compound is a solid silicate, the silicate is It may be dissolved in water or an aqueous alkaline compound solution in advance. After the first mixing step, the adding step and the second mixing step are performed.

The adding step is a step of adding a silicic acid compound to the mixture obtained in the first mixing step. During the addition step, the total amount of silicic acid compound may be added to the mixture. Alternatively, the silicic acid compound may be added to the mixture in a plurality of times by simultaneously performing the adding step and the second mixing step. The first filler contained in both the aluminum compound and the silicic acid compound, such as aluminum silicate, is usually mixed with the alkali compound in the first mixing step, but in the addition step as well, the first filler is added in the second mixing step. You may make it mix.

The second mixing step is a step of mixing the mixture containing the silicic acid compound to obtain the first molding material 21. When the first molding material 21 obtained in the second mixing step does not contain water, after the second mixing step, water is added to the first molding material 21 and further mixed, whereby the first molding material 21 The compound in can be dissolved in water.

In the second preparation step, the second molding material can be obtained in the same manner as the first molding material 21 by using the second filler instead of the first filler. It should be noted that the second filler contained in both the aluminum compound and the silicic acid compound, such as aluminum silicate, is usually mixed with the alkali compound in the first mixing step. You may make it mix.

In this embodiment, the mold 5 is also prepared during the preparation step.

After the preparation step, the molding and curing step is performed.

The molding and curing step is a step of manufacturing the geopolymer molded article 1 such that the first cured portion 2 in which the first molding material 21 is cured and the second cured portion 3 in which the second molding material is cured are adjacent to each other. .. In such a molding and curing step, the first molding material 21 and the second molding material are molded and cured.

In the molding and curing step of this embodiment, the second molding material is molded into a block shape, and this molded product is once cured. Then, by crushing the cured product of the second molding material, the particulate handle material 3a is manufactured. The pattern material 3a becomes the second cured portion 3 in the geopolymer molded product 1. Next, the pattern material 3 a and the first molding material 21 are mixed to disperse the pattern material 3 a in the first molding material 21 in spots, and the mixture is stored in the storage tank 41.

As shown in FIG. 3, the mixture in the storage tank 41 is supplied into the molding die 5 through the nozzle 41 a connected to the storage tank 41. Then, the mixture is cured in the molding die 5. Then, the cured product is removed from the molding die 5, so that the geopolymer molded article 1 having an outer shape corresponding to the inner surface of the molding die 5 is obtained. The geopolymer molded product 1 thus obtained can have a pattern resembling natural stone. Moreover, since the geopolymer molded article 1 contains the geopolymer generated during curing, it can have a solid feeling similar to natural stone.

The temperature for curing the first molding material 21 and the second molding material (curing temperature) is not particularly limited, but is, for example, 20° C. or higher and 100° C. or lower.

In the present embodiment, the upper end of the molding die 5 is open, but the molding space may be secured and the upper end of the molding die 5 may be closed.

(Second embodiment)
Next, a second embodiment will be described with reference to FIGS. In this embodiment, the same components as those in the first embodiment are designated by the same reference numerals in the drawings and the description thereof is omitted.

The geopolymer molded article 1 according to the present embodiment has a layered structure in which layered first cured portions 2 and layered second cured portions 3 are alternately laminated, as shown in FIGS. 5 and 6.

Such a geopolymer molded article 1 can have a profound feeling and a pattern similar to natural stone having a layered structure.

In the geopolymer molded article 1, the first cured portion 2 may be laminated on the second cured portion 3 as shown in FIG. 5, and the first cured portion 2 and the second cured portion 3 as shown in FIG. May be laminated multiple times in this order along the laminating direction. In the present embodiment, the layer structure of the geopolymer molded article 1 is not limited to the aspect shown in FIGS. 5 and 6, and even if the stacking order of the first cured portion 2 and the second cured portion 3 is changed. Good. Specifically, in the aspect as shown in FIG. 5, the second curing section 3 may be laminated on the first curing section 2. Further, in the embodiment as shown in FIG. 6, the second cured portion 3 and the first cured portion 2 may be laminated in this order a plurality of times along the laminating direction. The thickness of each layer may be the same or different.

The first curing portion 2 is a portion where the first molding material 21 as shown in FIGS. 7 and 10 is cured. Moreover, the 2nd hardening part 3 is a part which the 2nd molding material 31 like FIG. 7 and FIG. 10 hardened. As the first molding material 21 and the second molding material 31, the same materials as the first molding material 21 and the second molding material of the first embodiment can be used, respectively.

In manufacturing the geopolymer molded article 1, for example, first, the first molding material 21 is stored in the first storage tank 42 and the second molding material 31 is stored in the second storage tank 43 during the molding and curing step.

Next, the second molding material 31 is supplied into the molding die 5 through the second nozzle 43a connected to the second storage tank 43 and is formed into a layer. Further, the first molding material 21 is supplied in the molding die 5 and on the second molding material 31 through the first nozzle 42a connected to the first storage tank 42 to form a layer (FIG. 7). reference). As a result, the first molding material 21 and the second molding material 31 are alternately stacked in the molding die 5. In the present embodiment, the order of supplying the first molding material 21 and the second molding material 31 is not limited to the mode shown in FIG. 7, and the second molding material 31 is supplied on the first molding material 21. They may be laminated together.

Further, when the first molding material 21 and the second molding material 31 are supplied into the molding die 5, each of the first molding material 21 and the second molding material 31 may be supplied once, and a plurality of them may be supplied. May be supplied twice. By supplying each of the first molding material 21 and the second molding material 31 once, the geopolymer molded article 1 as shown in FIG. 5 can be obtained. By supplying each of the first molding material 21 and the second molding material 31 a plurality of times, the geopolymer molded product 1 as shown in FIG. 6 can be obtained.

Although the upper end of the molding die 5 shown in FIG. 7 is open, the molding space may be secured and the upper end of the molding die 5 may be closed.

After stacking, as shown in FIG. 8, the pattern forming member 6 is moved by bringing the tip of the pattern forming member 6 into contact with the inner bottom surface of the molding die 5 while simultaneously combing the first and second molding materials 21 and 31. May be. At the time of this movement, the second molding material 31 is pushed away by the pattern forming member 6 to form a recess, and the first molding material 21 flows into this recess to form a pattern. A line-shaped pattern is formed by moving the pattern forming member 6 along one direction. Further, a spiral pattern is formed by moving the pattern forming member 6 while drawing a spiral in the molding die 5.

When forming the pattern, it is preferable to move the pattern forming member 6 at a speed such that the first molding material 21 and the second molding material 31 are not completely mixed. The moving speed of the pattern forming member 6 is not particularly limited, but is, for example, 1 mm/sec or more and 10 cm/sec or less.

The pattern may be formed by the pattern forming member 6 a plurality of times. In this case, since the pattern fluctuates, a pattern more similar to natural stone can be obtained. The geopolymer molded article 1 thus obtained has a streak pattern on the surface and a layered pattern on the cross section intersecting with the surface. This layered pattern is preferably present in at least a part of all the cross sections.

Examples of the pattern forming member 6 include a comb-shaped member and a rod-shaped member.

Further, in another example of the present embodiment, the molding and curing step is performed using the molding die 5 as shown in FIG. Therefore, the geopolymer molded article 1 as shown in FIG. 6 can be obtained. The molding die 5 includes a first die 51, a second die 52, and a gasket 53. The gasket 53 prevents the first molding material 21 and the second molding material 31 supplied into the molding die 5 from leaking out of the molding die 5. The gasket 53 has a thickness (height) facing the thickness of the geopolymer molded product 1 and a rubber hardness, and is fixed to the second mold 52.

The first die 51 has a thickness and includes first to ninth supply holes 5a, 5b, 5c, 5d, 5e, 5f, 5g, 5h, and 5i. Each of the first to ninth supply holes 5a, 5b, 5c, 5d, 5e, 5f, 5g, 5h, 5i is a hole penetrating the first die 51 along the thickness direction of the first die 51. Of these supply holes 5a to 5i, for example, the first, third, fifth, seventh, and ninth supply holes 5a, 5c, 5e, 5g, and 5i are used for supplying the first molding material 21. The second, fourth, sixth, and eighth supply holes 5b, 5d, 5f, and 5h are used to supply the second molding material 31.

In the molding and curing step, when the first molding material 21 and the second molding material 31 are supplied to the molding die 5, the molding die 5 is tilted to provide the first to ninth supply holes 5a, 5b, 5c, 5d, 5e. 5f, 5g, 5h, and 5i are arranged at positions having different heights in the vertical direction. After this arrangement, the first molding material 21 and the second molding material 31 are placed in the molding die 5 in the order of the first to ninth supply holes 5a, 5b, 5c, 5d, 5e, 5f, 5g, 5h, 5i. Supply. As a result, as shown in FIG. 10, the first molding material 21 and the second molding material 31 are laminated in this order a plurality of times in the molding die 5.

When the first molding material 21 and the second molding material 31 are supplied, the second molding material 31 is supplied after the first molding material 21 in the molding die 5 is semi-cured and the fluidity is lowered. The operation of supplying the first molding material 21 may be repeated after the second molding material 31 is semi-cured to lower the fluidity. In this case, it becomes easy to obtain the geopolymer molded product 1 in which at least a part of the interface between the first cured portion 2 and the second cured portion 3 is blurred. This makes it possible to efficiently obtain a geopolymer molded product 1 having a layered structure similar to natural stone and a profound feeling.

When the molding die 5 is tilted, the back surface of the second die 52 (the surface of the second die 52 opposite to the surface on which the gasket 53 is fixed in the direction in which the first die 51 and the second die 52 are aligned). And the angle θ between any horizontal plane parallel to the horizontal direction can be varied for each feed. In this case, it is possible to obtain the geopolymer molded product 1 in which the thickness of each layer is different. The angle θ is not particularly limited, but is, for example, in the range of ±2° to ±90°, that is, 2° or more and 90° or less, or −90° or more and −20° or less.

In addition, in the present embodiment, the first, third, fifth, seventh, and ninth supply holes 5a, 5c, 5e, 5g, and 5i are used to supply the second molding material 31, and the second and fourth supply materials are used. The sixth, eighth, and eighth supply holes 5b, 5d, 5f, and 5h may be used to supply the first molding material 21. In this case, in the molding die 5, the second molding material 31 and the first molding material 21 can be laminated a plurality of times in this order.

(Third Embodiment)
Next, a third embodiment will be described with reference to FIGS. In this embodiment, the same components as those in the first and second embodiments are designated by the same reference numerals in the drawings, and the description thereof will be omitted.

The geopolymer molded article 1 according to this embodiment has a structure in which the second cured portions 3 are present in a streak shape in the first cured portion 2.

Such a geopolymer molded article 1 can have a profound feeling and pattern similar to natural stone having a streak pattern.

The first cured portion 2 is a portion where the first molding material 21 (see, for example, FIG. 13) is cured. Moreover, the 2nd hardening part 3 is the part which the 2nd molding material 31 (for example, refer FIG. 13) hardened|cured.

Further, the geopolymer molded article 1 can have not only the streaky pattern but also the spiral pattern 1a.

In manufacturing the geopolymer molded article 1, during the molding and curing step, first, the first molding material 21 and the second molding material 31 are supplied into the molding die 5, for example, by the method shown in FIG. 12, and The first molding material 21 and the second molding material 31 are brought into contact with each other. After the supply, as in the second embodiment, the first and second molding materials 21 and 31 are simultaneously carded while the tip of the pattern forming member 6 is in contact with the inner bottom surface of the molding die 5 as shown in FIG. The forming member 6 may be moved to form a wavy or spiral pattern.

Further, in the present embodiment, the molding and curing step is performed using the molding die 5 as shown in FIG. 12, the first supply device 71, and the second supply device 72.

As shown in FIG. 12, the first supply device 71 includes a first cylinder 71a, a first screw 71b, a first connecting pipe 71c, and a plurality (for example, three) of first nozzles 71d. The first cylinder 71a has a cylindrical shape that becomes thinner toward a portion closer to the molding die 5, and has an inner shape that accommodates the first screw 71b. The first screw 71b is for rotating and pushing out the first molding material 21 in the first cylinder 71a and supplying it to the molding die 5. The first connecting pipe 71c is a pipe that connects the first cylinder 71a and the first nozzle 71d and has an inner diameter smaller than that of the first cylinder 71a. The first nozzle 71d has a tubular shape connected to the molding die 5.

The second supply device 72 includes a second cylinder 72a, a second screw 72b, a second connecting pipe 72c, and a plurality of (for example, two) second nozzles 72d. The second cylinder 72a has a cylindrical shape that becomes thinner toward a portion closer to the molding die 5, and has an inner shape that accommodates the second screw 72b. The second screw 72b is configured to push out the second molding material 31 in the second cylinder 72a and supply it to the molding die 5 while rotating. The second connecting pipe 72c connects the second cylinder 72a and the second nozzle 72d, and has a tubular shape having an inner diameter smaller than that of the second cylinder 72a. The second nozzle 72d has a tubular shape connected to the molding die 5.

The molding die 5 includes a plurality of (for example, five) supply holes 54. The supply hole 54 is a hole that penetrates the molding die 5. Of the plurality of supply holes 54, some (for example, three) supply holes 54 are connected to the first nozzle 71d, and the remaining (for example, two) supply holes 54 are connected to the second nozzle 72d. .. Therefore, the molding die 5 is connected to the first supply device 71 and the second supply device 72. As a result, the first molding material 21 in the first cylinder 71a is supplied into the forming die 5 through the first nozzle 71d, and the second molding material 31 in the second cylinder 72a moves to the second nozzle 72d. It will be supplied to the forming die 5 through it.

In the molding and curing step, the first and second screws 71b and 72b are simultaneously operated. As a result, the first molding material 21 and the second molding material 31 are simultaneously supplied into the molding die 5. Then, the interface portion is mixed while the first molding material 21 and the second molding material 31 maintain the streak shape. Further, a vortex may be generated in the mixture flowing in the molding die 5 at the time of supply, and the portion where the vortex is formed is hardened to form the vortex-shaped pattern 1a.

In another example of this embodiment, the nozzles 71d and 72d are connected to both the first supply device 71 and the second supply device 72. Then, the first molding material 21 and the second molding material 31 are simultaneously supplied to the molding die 5 from the respective nozzles 71d and 72d. At this time, the first molding material 21 and the second molding material 31 are supplied from the respective nozzles 71d and 72d so as to prevent them from being easily mixed. This makes it possible to obtain a geopolymer molded article 1 having a profound feeling and pattern similar to that of natural stone having a streak pattern.

Further, in still another example of the present embodiment, the first nozzle 71d and the second nozzle 72d may not be provided. In this case, for example, the second molding material 31 is linearly supplied from above to the inner surface of the molding die 5 similar to that shown in FIG. 13, and then the first molding material 21 is supplied into the molding die 5 to form the second molding material. The material 31 is filled with the first molding material 21 while keeping the streak shape. When the first molding material 21 is supplied into the molding die 5, the streaky second molding material 31 is preferably semi-cured. In this case, it becomes difficult for the first molding material 21 and the second molding material 31 to be completely mixed, and it becomes easy to maintain the second molding material 31 in a streaky state.

Further, in still another example of the present embodiment, the second molding material 31 is supplied into the first molding material 21 so that the second molding material 31 exists in a streak shape in the first molding material 21. .. As this method, for example, the second molding material 31 is linearly supplied into the first molding material 21 rotating at a low speed, or a small amount of the second molding material 31 is supplied on the first molding material 21. After that, the pattern forming member 6 is moved, and the second molding material 31 is stretched and formed in a streak shape. Then, the first molding material 21 in which the streak-shaped second molding material 31 exists is supplied from above to the inner surface of the molding die 5 similar to FIG. Such a geopolymer molded article 1 can have a profound feeling and pattern similar to natural stone having a streak-like pattern as shown in FIG. 14B (see FIG. 14A).

(Fourth Embodiment)
As shown in FIG. 15, the geopolymer molded article 1 according to the present embodiment has a structure in which a thin second cured portion 3 exists in a streak pattern between the large-sized first cured portion 2 and the first cured portion 2. Have.

Such a geopolymer molded article 1 can be manufactured using the first molding material 21 in a semi-cured state. That is, by aging the first molding material 21 under a predetermined condition, a semi-cured state is obtained. Then, the semi-cured first molding material 21 is crushed to form semi-cured particles. Next, the second molding material 31 is supplied to the surface of the particles in the semi-cured state to produce the particles of the first molding material 21 in the semi-cured state covered with the second molding material 31. Then, the particles of the first molding material 21 in a semi-cured state coated with the plurality of second molding materials 31 are supplied to the inner surface of the molding die 5 to be deformed by pressurizing to fill the gaps between the particles. This makes it possible to obtain a geopolymer molded article 1 in which a thin second cured portion 3 exists in a streak shape between the large-sized first cured portion 2 and the first cured portion 2.

(Other embodiments)
In the above-described embodiment, the structure in which the second cured portions 3 are present in the first cured portion 2 in the form of spots or streaks is shown, but the first cured portion 2 is in the spots or streaks in the second cured portion 3. It may be a structure that exists in a shape. The geopolymer molded article 1 in this case can also have a profound feeling and pattern similar to natural stone. In manufacturing the geopolymer molded article 1, it can be obtained by using the first molding material 21 and the second molding material 31 of the above embodiment in reverse.

Hereinafter, the present disclosure will be specifically described with reference to examples.

(1) Confirmation of translucency of the first cured portion <Adjustment Examples 1 to 22>
Each adjustment example was performed using the following components.

KOH aqueous solution: potassium hydroxide aqueous solution (solid content: 27.3% by weight)
・Water glass: aqueous solution of potassium silicate (solid content: 49.7% by weight)
Fumed silica: Aerosil 200 (manufactured by Nippon Aerosil Co., Ltd.).

{First molding material and second molding material}
[Adjustment example 1]
A mixture was prepared by mixing 46.0 parts by mass of KOH aqueous solution and 21.7 parts by mass of aluminum silicate. Then, 19.7 parts by weight of water glass and 10.3 parts by weight of fumed silica were added to the mixture and further mixed to prepare a first molding material.

[Adjustment example 2]
A mixture was prepared by mixing 46.0 parts by mass of KOH aqueous solution, 21.7 parts by mass of aluminum silicate, and 0.3 parts by mass of aluminum hydroxide. Then, 19.7 parts by weight of water glass and 10.3 parts by weight of fumed silica were added to the mixture and further mixed to prepare a first molding material.

[Adjustment example 3]
A first molding material was prepared in the same manner as in Preparation Example 2 except that the amount of aluminum hydroxide was changed to 1 part by mass.

[Adjustment example 4]
A first molding material was prepared in the same manner as in Preparation Example 3 except that 1 part by mass of calcium hydroxide was used instead of aluminum hydroxide.

[Adjustment example 5]
A first molding material was prepared in the same manner as in Preparation Example 3 except that 1 part by mass of zinc oxide was used instead of aluminum hydroxide.

[Adjustment example 6]
A first molding material was produced in the same manner as in Preparation Example 3 except that 1 part by mass of magnesium oxide was used instead of aluminum hydroxide.

[Adjustment example 7]
A second molding material was prepared in the same manner as in Preparation Example 3 except that 1 part by mass of lead stannate was used instead of aluminum hydroxide.

[Adjustment example 8]
A second molding material was prepared in the same manner as in Preparation Example 3 except that 1 part by mass of titanium oxide was used instead of aluminum hydroxide.

[Adjustment example 9]
A second molding material was prepared in the same manner as in Preparation Example 3 except that 1 part by mass of iron oxide was used instead of aluminum hydroxide.

[Adjustment example 10]
A first molding material was prepared in the same manner as in Preparation Example 2 except that the amount of aluminum hydroxide was changed to 3 parts by mass.

[Adjustment example 11]
A first molding material was prepared in the same manner as in Preparation Example 3 except that the amount of calcium hydroxide was changed to 3 parts by mass.

[Adjustment example 12]
A geopolymer molding material was produced in the same manner as in Preparation Example 4 except that the amount of zinc oxide was changed to 3 parts by mass.

[Adjustment Example 13]
A first molding material was produced in the same manner as in Preparation Example 5 except that the amount of magnesium oxide was changed to 3 parts by mass.

[Adjustment Example 14]
A second molding material was prepared in the same manner as in Preparation Example 7 except that the amount of lead stannate was changed to 3 parts by mass.

[Adjustment example 15]
A second molding material was produced in the same manner as in Preparation Example 8 except that the amount of titanium oxide was changed to 3 parts by mass.

[Adjustment Example 16]
A first molding material was prepared in the same manner as in Preparation Example 2 except that the amount of aluminum hydroxide was changed to 5 parts by mass.

[Adjustment Example 17]
A first molding material was produced in the same manner as in Preparation Example 3 except that the amount of calcium hydroxide was changed to 5 parts by mass.

[Adjustment Example 18]
A first molding material was produced in the same manner as in Preparation Example 4 except that the amount of zinc oxide was changed to 5 parts by mass.

[Adjustment Example 19]
A second molding material was produced in the same manner as in Preparation Example 5 except that the amount of magnesium oxide was changed to 5 parts by mass.

[Adjustment example 20]
A second molding material was prepared in the same manner as in Preparation Example 7 except that the amount of lead stannate was changed to 5 parts by mass.

[Adjustment example 21]
A second molding material was produced in the same manner as in Preparation Example 8 except that the amount of titanium oxide was changed to 5 parts by mass.

[Adjustment Example 22]
A mixture was prepared by mixing 46.9 parts by mass of KOH aqueous solution and 6.1 parts by mass of aluminum hydroxide. Then, 20.1 parts by weight of water glass and 24.6 parts by weight of fumed silica were added to the mixture and further mixed to prepare a first molding material.

{Cured product}
The molding material of each adjustment example (first molding material or second molding material) was provided to a molding die having a depth of 4 mm, and the thickness of the molding material in the molding die was set to 4 mm. Then, the molding material in the molding die was left to cure at room temperature (25° C.) for 24 hours. As a result, a cured product having a thickness of 4 mm was produced.

{Refractive index of cured product}
The refractive index of the cured product of each adjustment example was measured according to JIS K 7142:2018.

{Translucency of cured product (visible light transmittance of cured product)}
The visible light transmittance of the cured product of each preparation example was measured according to JIS R 3106.

{Alkali solubility}
The alkali solubility of the fumed silica and the filler used in the molding material of each preparation example was evaluated by the following method.

To 10 g of an aqueous potassium hydroxide solution having a pH of 14, 0.1 g of each of fumed silica and filler was added. Then, after visually confirming the dissolved state after 24 hours, the supernatant was taken out and the remaining precipitate was dried. After drying, the weight of the precipitate was measured, and the alkali solubility of each of the fumed silica and the filler was evaluated according to the following items.
1: completely dissolved, solution is clear,
2: There is no precipitate, but the solution is opaque,
3: There was more than 0% by weight and less than 10% by weight of precipitate, based on the weight at the time of addition.
4: There was a precipitate of 10% by weight or more and less than 50% by weight, based on the weight at the time of addition.
5: 50% by weight or more of the weight of the precipitate was added.

In the evaluation of alkali solubility, 40% by weight of aluminum hydroxide was precipitated with respect to the weight at the time of addition. 15% by weight of calcium hydroxide was precipitated with respect to the weight at the time of addition. As for zinc oxide, 10% by weight was precipitated with respect to the weight at the time of addition. 100% by weight of magnesium oxide was precipitated with respect to the weight at the time of addition. 100% by weight of lead stannate was precipitated with respect to the weight at the time of addition. 100% by weight of titanium oxide was precipitated with respect to the weight at the time of addition. 100% by weight of iron oxide was precipitated with respect to the weight at the time of addition.

Alkali solubility and each evaluation result are shown in Tables 1 to 3. Thereby, with respect to the reaction cured product of the alkali compound, the silicic acid compound, and the aluminum compound, Adjustment Examples 1 to 6 using the filler that does not substantially contain the hardly alkali-soluble material having a refractive index difference of 0.5 or more. In the adjustment examples 10 to 13, the adjustment examples 16 to 19, and the adjustment example 22, the visible light transmittance of the cured product was 3% or more, and it was confirmed that the light transmittance was improved. On the other hand, Adjustment Examples 7 to 9 using a filler substantially containing a hardly alkali-soluble material having a refractive index difference of 0.5 or more with respect to a reaction cured product of an alkali compound, a silicic acid compound, and an aluminum compound, It was confirmed that Adjustment Examples 14 to 15 and Adjustment Examples 20 to 21 have low visible light transmittance.
(2) Geopolymer molded product <Production Example 1>
A geopolymer molded article 1 was produced by using the material of Preparation Example 3 as the first molding material and using the material of Preparation Example 3 mixed with a commercially available black pigment as the second molding material. Specifically, first, the second molding material was allowed to stand at room temperature (25° C.) for 48 hours in the mold for a pattern material to be cured to obtain a block-shaped molded product. This molded product was crushed to produce a particulate handle material. Next, the first molding material and the pattern material were mixed until the pattern material was dispersed in the first molding material, and this mixture was stored in the storage tank 41 (see FIG. 3). Then, the mixture in the storage tank 41 was supplied into the molding die 5 through the nozzle 41a. After the supply, the mixture was left to cure in the molding die 5 at room temperature (25° C.) for 48 hours. After curing, the cured product was removed from the mold 5 to obtain a geopolymer molded product 1 in which the pattern material was dispersed in spots in the first cured portion. The obtained geopolymer molded product 1 is shown in FIG. 4A.

<Production Example 2>
A geopolymer molded article was produced by using the material of Preparation Example 1 as the first molding material and the material of Preparation Example 9 as the second molding material. Specifically, in the molding die 5 shown in FIG. 9, the first molding material is supplied to the first, third, fifth, seventh, and ninth supply holes 5a, 5c, 5e, 5g, and 5i. The second molding material is supplied to the second, fourth, sixth, and eighth supply holes 5b, 5d, 5f, and 5h. Then, the molding die 5 is tilted on the workbench, and the first to ninth supply holes 5a, 5b, 5c, 5d, 5e, 5f, 5g, 5h, and 5i are arranged at positions having mutually different heights in the vertical direction. .. After this arrangement, the first molding material and the second molding material were supplied into the molding die 5 in the order of the first to ninth supply holes 5a, 5b, 5c, 5d, 5e, 5f, 5g, 5h, 5i. .. During this supply, the operation of supplying the second molding material after the first molding material was semi-cured and supplying the first molding material after the second molding material was semi-cured was repeated. After the supply, the first and second molding materials in the molding die 5 were left standing at room temperature (25° C.) for 24 hours to be cured with the molding die 5 tilted. After curing, the cured product was removed from the mold 5 to obtain a geopolymer molded product 1 in which layered first cured portions and layered second cured portions were alternately laminated.

<Production Example 3>
A geopolymer molded article 1 was produced using the material of Preparation Example 3 as the first molding material and the material of Preparation Example 9 as the second molding material. Specifically, after a small amount of the second molding material 31 is supplied onto the first molding material 21, the rod-shaped pattern forming member 6 is rotationally moved and the second molding material 31 is stretched in a streak shape. A molding material in which the second molding material 31 exists in a streak shape in the 1 molding material 21 is prepared. Then, the first molding material 21 in which the streak-shaped second molding material 31 exists was supplied from above to the inner surface of the molding die 5 similar to FIG. After the supply, the first and second molding materials in the molding die 5 were left to cure at room temperature (25° C.) for 24 hours. After curing, the cured product is removed from the molding die 5 to form a laminated geopolymer molded product in which a first cured portion and a second cured portion have a streak portion and a spiral portion. Got 1. The obtained geopolymer molded product 1 is shown in FIG. 14A.

(Summary) As described above, the first aspect is a geopolymer molded article (1), which includes a first cured portion (2) and a second cured portion (3). The 1st hardening part (2) hardens the 1st molding material (21) containing an alkali compound, a silicic acid compound, and the 1st filler. The first filler contains at least an aluminum compound. The second cured portion (3) has a different color tone from the first cured portion (2). The 2nd hardening part (3) hardens the 2nd molding material (31) containing an alkali compound, a silicic acid compound, and the 2nd filler. The second filler contains at least an aluminum compound. The 1st hardening part (2) and the 2nd hardening part (3) adjoin. The first filler does not substantially contain the hardly alkali-soluble material [M2] having a refractive index difference of 0.5 or more with respect to the reaction cured product of the alkali compound, the silicic acid compound, and the aluminum compound.

According to the first aspect, since the first filler does not substantially contain the specific hardly-alkali-soluble material [M2], the first cured portion (2) has a light-transmitting property, so that the geopolymer molded article ( 1) can have a profound feeling and a pattern similar to natural stone.

A second aspect is the geopolymer molded article (1) of the first aspect, which has a dispersed structure in which the spot-shaped second cured portions (3) are dispersed in the first cured portion (2).

According to the second aspect, the geopolymer molded product (1) can have a profound feeling and pattern similar to natural stone having a spotted pattern.

A third aspect is the geopolymer molded article (1) of the first aspect, which has a layered structure in which layered first cured portions (2) and layered second cured portions (3) are alternately laminated. ..

According to the third aspect, it is possible to have a profound feeling and pattern similar to natural stone having a layered structure.

A fourth aspect is the geopolymer molded article (1) of the first aspect, which has a structure in which the second cured portions (3) are present in a streak shape in the first cured portion (2).

According to the fourth aspect, the geopolymer molded product (1) can have a profound feeling and pattern similar to natural stone having a streak pattern.

A fifth aspect is the geopolymer molded article (1) according to any one of the first to fourth aspects, wherein the second filler is a reaction cured product of the alkali compound, the silicic acid compound, and the aluminum compound. On the other hand, it contains 2% by weight or more of the hardly alkaline soluble material [M2] having a refractive index difference of 0.5 or more.

According to the fifth aspect, since the light transmissivity of the second hardened portion (3) is reduced by the hardly alkali-soluble material [M2], it is possible to easily make the color tone different from that of the first hardened portion (2).

A sixth aspect is the geopolymer molded article (1) according to any one of the first to fourth aspects, wherein the second filler is a reaction cured product of the alkali compound, the silicic acid compound, and the aluminum compound. On the other hand, the hardly alkali-soluble material [M2] having a difference in refractive index of 0.5 or more is not substantially contained.

According to the sixth aspect, the second hardened part (3) can have a light-transmitting property, and the geopolymer molded article (1) has the first hardened part (2) and the second hardened part (3). Can have a profound feeling and pattern similar to natural stone, which are both transparent.

A seventh aspect is the geopolymer molded article (1) according to any one of the first to sixth aspects, wherein the easily alkali-soluble material [M1] containing at least the aluminum compound is added to the solid content in an amount of 5%. It is contained in an amount of 50% by weight or more and 50% by weight or less.

According to the seventh aspect, the geopolymer molded product (1) can have a profound feeling and pattern similar to natural stone.

An eighth aspect is the geopolymer molded article (1) according to any one of the first to seventh aspects, which contains the silicic acid compound in an amount larger than that of the aluminum compound.

According to the eighth aspect, the geopolymer molded product (1) can have a profound feeling and a pattern similar to natural stone.

A ninth aspect is the geopolymer molded article (1) according to any one of the first to eighth aspects, wherein the first filler is at least one selected from the group consisting of aluminum silicate and aluminum hydroxide. Containing the compound of.

According to the ninth aspect, the geopolymer molded product (1) can have a profound feeling and pattern similar to natural stone.

A tenth aspect is the geopolymer molded article (1) according to any one of the first to ninth aspects, wherein the second filler is at least one selected from the group consisting of aluminum silicate and aluminum hydroxide. Containing the compound of.

According to the tenth aspect, the geopolymer molded product (1) can have a profound feeling and a pattern similar to natural stone.

An eleventh aspect is the geopolymer molded article (1) according to any one of the first to tenth aspects, wherein the silicic acid compound in the first molding material (21) and the second molding material (31) are used. Both of said silicic acid compounds of: include water glass and fumed silica.

According to the eleventh aspect, the geopolymer molded product (1) can have a profound feeling and pattern similar to natural stone.

A twelfth aspect is the geopolymer molded article (1) according to any one of the first to eleventh aspects, wherein the alkaline compound in the first molding material (21) and the second molding material (31) Both the alkaline compound contains potassium hydroxide.

According to the twelfth aspect, the geopolymer molded product (1) can have a profound feeling and pattern similar to natural stone.

A thirteenth aspect is a method for producing a geopolymer molded article (method for producing geopolymer molded article (1)). The manufacturing method includes a step of preparing a first molding material (21) containing an alkali compound, a silicic acid compound, and a first filler containing at least an aluminum compound. The said manufacturing method contains the alkali compound, the silicic acid compound, and the 2nd filler which contains an aluminum compound at least, The step which prepares the 2nd molding material (31) whose color tone differs from a 1st molding material (21). Is further included. In the manufacturing method, the first polymer (21) is cured to a first cured portion (2) and the second molding material (31) is cured to a second cured portion (3) so that they are adjacent to each other. The method further comprises the step of manufacturing the molded article (1). The first filler does not substantially contain the hardly alkali-soluble material [M2] having a refractive index difference of 0.5 or more with respect to the reaction cured product of the alkali compound, the silicic acid compound, and the aluminum compound.

According to the thirteenth aspect, the geopolymer molded article (1) obtained by the above-mentioned manufacturing method can have a profound feeling and a pattern similar to natural stone because the first cured portion (2) has a light-transmitting property. ..

A fourteenth aspect is the method for producing a geopolymer molded article according to the thirteenth aspect, further including the step of molding the second molding material (31) to manufacture the handle material (3a). The manufacturing method further includes a step of dispersing the pattern material (3a) in spots on the first molding material (21) and molding.

According to the fourteenth aspect, the geopolymer molded product (1) obtained by the above-mentioned production method can have a profound feeling and pattern similar to natural stone having a spotted pattern.

A fifteenth aspect is the method for producing a geopolymer molded article according to the thirteenth aspect, wherein the first molding material (21) and the second molding material (31) are alternately supplied, and these are laminated alternately. The method further comprises forming and shaping the layered structure.

According to the fifteenth aspect, the geopolymer molded product (1) obtained by the above manufacturing method can have a profound feeling and a pattern similar to natural stone having a layered structure.

A sixteenth aspect is the method for producing a geopolymer molded article according to the thirteenth aspect, wherein the first molding material (21) and the second molding material (31) are used so that the second molding material (31) has a streak shape. The method further includes the step of supplying and molding.

According to the sixteenth aspect, the geopolymer molded product (1) obtained by the above-mentioned production method can have a profound feeling and pattern similar to natural stone having a streak pattern.

A 17th aspect is the method for producing a geopolymer molded article according to any one of the 13th to 16th aspects, wherein the second filler is a reaction-cured product of the alkali compound, the silicic acid compound, and the aluminum compound. On the other hand, it contains 2% by weight or more of the hardly alkaline soluble material [M2] having a refractive index difference of 0.5 or more.

According to the seventeenth aspect, even when the light transmissivity of the second cured portion (3) is easily reduced by the hardly alkali-soluble material [M2], the geopolymer molded article (1) obtained by the above-mentioned production method is It can have a profound feeling and pattern similar to natural stone.

An eighteenth aspect is the method for producing a geopolymer molded article according to any one of the thirteenth to sixteenth aspects, wherein the second filler is a reaction cured product of the alkali compound, the silicic acid compound, and the aluminum compound. In addition, it does not substantially contain a hardly alkali-soluble material having a refractive index difference of 0.5 or more.

According to the eighteenth aspect, the second cured part (3) can have a light-transmitting property, and the geopolymer molded product (1) obtained by the above-mentioned manufacturing method has a profound feeling and a pattern similar to natural stone. Can have.

1 Geopolymer molded product 2 1st hardening part 21 1st molding material 3 2nd hardening part 31 2nd molding material

Claims (18)

A first cured part obtained by curing a first molding material containing an alkali compound, a silicic acid compound, and a first filler containing at least an aluminum compound;
An alkali compound, a silicic acid compound, and a second cured part having a different color tone from the first cured part obtained by curing the second molding material containing the second filler containing at least an aluminum compound,
The first curing portion and the second curing portion are adjacent to each other,
The first filler does not substantially contain a hardly alkali-soluble material having a refractive index difference of 0.5 or more with respect to a reaction cured product of the alkali compound, the silicic acid compound, and the aluminum compound,
Geopolymer molded product. The geopolymer molded article according to claim 1, which has a dispersed structure in which the spot-shaped second cured portions are dispersed in the first cured portion. The geopolymer molded article according to claim 1, having a layered structure in which the layered first cured portion and the layered second cured portion are alternately laminated. The geopolymer molded article according to claim 1, which has a structure in which the second cured portion exists in a streak shape in the first cured portion. The second filler contains a hardly alkali-soluble material having a refractive index difference of 0.5 or more with respect to a reaction cured product of the alkali compound, the silicic acid compound, and the aluminum compound,
The amount of the hardly alkali-soluble material is 2% by weight or more based on the total solid content of the alkali compound, the silicic acid compound, and the aluminum compound contained in the second molding material. The geopolymer molded article according to any one of 1. The second filler does not substantially contain a hardly alkali-soluble material having a refractive index difference of 0.5 or more with respect to a reaction cured product of the alkali compound, the silicic acid compound, and the aluminum compound. 4. The geopolymer molded article according to any one of 4 to 4. The geopolymer molded article according to any one of claims 1 to 6, wherein the alkali-soluble material containing at least the aluminum compound is contained in an amount of 5% by weight or more and 50% by weight or less based on the entire solid content. The geopolymer molded article according to any one of claims 1 to 7, which contains more of the silicic acid compound than the aluminum compound. The geopolymer molded article according to any one of claims 1 to 8, wherein the first filler contains at least one compound selected from the group consisting of aluminum silicate and aluminum hydroxide. The geopolymer molded article according to any one of claims 1 to 9, wherein the second filler contains at least one compound selected from the group consisting of aluminum silicate and aluminum hydroxide. 11. The silicic acid compound in the first molding material and the silicic acid compound in the second molding material both contain water glass and fumed silica. The geopolymer molded product according to. The geopolymer molding according to any one of claims 1 to 11, wherein both the alkali compound in the first molding material and the alkali compound in the second molding material contain potassium hydroxide. Goods. A method for producing a geopolymer molded article, comprising:
Preparing a first molding material containing an alkali compound, a silicic acid compound, and a first filler containing at least an aluminum compound;
A step of preparing a second molding material containing an alkaline compound, a silicic acid compound, and a second filler containing at least an aluminum compound, and having a color tone different from that of the first molding material;
A step of producing a geopolymer molded article such that a first cured portion where the first molding material is cured and a second cured portion where the second molding material is cured are adjacent to each other;
Including
The first filler does not substantially contain a hardly alkali-soluble material having a refractive index difference of 0.5 or more with respect to a reaction cured product of the alkali compound, the silicic acid compound, and the aluminum compound,
Method for producing geopolymer molded product. Molding the second molding material to produce a handle,
A step of dispersing the pattern material in the first molding material in the form of spots, and molding.
The method for producing a geopolymer molded article according to claim 13, further comprising: The manufacturing of a geopolymer molded article according to claim 13, further comprising a step of alternately supplying the first molding material and the second molding material to form a layered structure in which these layers are alternately laminated and molded. Method. The method for producing a geopolymer molded article according to claim 13, further comprising the step of supplying and molding the first molding material and the second molding material so that the second molding material becomes streaky. The second filler contains a hardly alkali-soluble material having a refractive index difference of 0.5 or more with respect to a reaction cured product of the alkali compound, the silicic acid compound, and the aluminum compound,
The amount of the hardly alkaline soluble material is 2% by weight or more based on the total solid content of the alkali compound, the silicic acid compound, and the aluminum compound contained in the second molding material. A method for producing a geopolymer molded article according to any one of 1. 14. The second filler does not substantially contain a hardly alkali-soluble material having a refractive index difference of 0.5 or more with respect to a reaction cured product of the alkali compound, the silicic acid compound, and the aluminum compound. 17. The method for producing a geopolymer molded article according to any one of items 1 to 16.