JP2021187726A - High-intensity independent foamed tile and method for producing the same - Google Patents

Abstract

To provide a method for producing an independent foamed tile having high intensity, and to provide the high-intensity independent foamed tile.SOLUTION: A method includes: wet-mixing a raw material for an independent foamed tile with a reinforcing material; and press-forming and then heating the raw material, wherein the raw material for the independent foamed tile is obtained by adding, as foaming agents, silicon carbide and zinc powder to at least one or a mixed material of a JIS standard fly ash, and a pulverized rock, coal ash, sand and soil, each having a particle diameter of 500 μm or less and a silicon dioxide content of 45% or more.

Description

The present invention relates to a manufacturing method for increasing the strength of an independent foam tile and an independent foam exterior tile.

Foam tiles are building materials with excellent heat insulation and durability, and because they are lightweight, they have excellent workability and have the advantages of reducing the load applied to the body structure. There are two cases, one is glaze applied to the surface and the other is not applied. When the former glaze is applied, the appearance can be improved and the antifouling property, weather resistance, water resistance, etc. Durability is also improved.

However, since the glaze-coated foam brick and foam tile base material is a continuous foam, if the glaze peels off or cracks for some reason, it absorbs water inside the base material due to the intrusion of rainwater and absorbs water at low temperatures in winter. When the rainwater freezes, the volume expands and the base material is damaged. Therefore, it is important to develop an independently foamed base material that is lightweight and non-absorbent.

On the other hand, independently foamed tiles and bricks have innumerable holes over the entire area and are clearly inferior in strength to ordinary tiles, so they are used as large-area bricks for the outer walls of buildings. , Its use is a concern.

Industrial waste such as coal ash and slag may be used as a method for manufacturing lightweight bricks and tiles, but fly ash, which is a type of coal ash, is composed of crystalline minerals such as mulite and quartz and glassy crystals. Not only is it difficult to control foaming by silicon carbide with fly ash alone because it has intermediate properties between quality materials and vitreous materials, but also the composition of coal ash produced by the type of coal used for combustion is Since they are different, the softening point and melting point are different, and it is difficult to maintain a constant quality. Therefore, fly ash is mostly limited to use as artificial lightweight aggregate, not as bricks or panels for outer walls, and is reused as concrete using artificial aggregate.

W / O2019 / 117435 Patent No. 6370508 Patent No. 5812472 Patent No. 6614537

Patent Document 1 describes a cement in which a resin containing a polyol or an epoxy compound as a constituent component is present inside the fiber bundle, and an acrylic modified epoxy resin or bisphenol is mainly present on the surface of the fiber bundle. Reinforcing fiber materials have been proposed.

In Patent Document 2, precast deck members having a composite cross section in which the lower cross section is formed of fiber-reinforced concrete having a predetermined thickness and the upper cross section is formed of high-strength concrete and integrated are juxtaposed in the direction of the bridge axis. A PC steel material is arranged in the direction perpendicular to the bridge axis and in the direction of the bridge axis in the upper cross section of the deck member, and the PC steel material is tension-fixed in two directions on the entire cross section of the deck member. It has been proposed to precast a bridge in which prestress is applied, the deck members are pressure-bonded and integrated, and the entire cross section of the deck is unreinforced.

Patent Document 3 describes that 100 parts by mass of cement, 5 to 50 parts by mass of fine powder having a BET specific surface area of 3 to 25 m2 / g, and 10 to 50 parts by mass of inorganic powder having a brain specific surface area of 3500 to 10000 cm2 / g. , 50 to 250 parts by mass of fine aggregate, 12 to 30 parts by mass of fiber and water, 0.1 to 2.0 parts by mass of water reducing agent in terms of solid content, 0.1 to 5 parts by mass of shrinkage reducing agent It is a composite beam member that integrates a U-shaped buried mold made of a hardened material containing the compound and ordinary concrete, and a composite beam in which reinforcing bars are arranged on the bottom surface of the U-shaped buried mold. Members have been proposed, the fibers having a diameter of 0.01 to 1.0 mm and a length of 2 to 30 mm, and the blending amount of the fibers is 0.1 to 4 of the volume of the blend in the case of metal fibers. It is 0%, and in the case of carbon fiber, it is 0.1 to 10% of the volume of the compound.

However, all of the patent documents are made by wet-kneading fibers into cement or concrete, and since the tiles are not completed by heat-treating the wet-kneaded fibers, resin can also be used as a reinforcing material.

In Patent Document 4, the inventor proposes that zinc powder is mixed with a tile raw material and heat-treated to produce an independent foam tile. It has been found that the tile shape can be maintained even after heat treatment by mixing this zinc powder, but there are innumerable cavities inside the independent foam tile, so there is concern about the strength when using it as an exterior tile. Remain.

The first to third embodiments of the present invention propose a manufacturing method for improving the strength of the independent foam tile manufacturing method according to Patent Document 4.

The first embodiment of the present invention is a JIS standard fly having a silicon dioxide content of 45% or more, a 45 μm sieve residue of 70% or less, a specific surface area of 1500 cm 2 / g or more, and a ignition loss of 5% or less. The raw material for independent foam tiles composed of ash, a foaming agent and zinc powder, and the raw material for independent foam tiles and the reinforcing material are dry-kneaded and then wet-kneaded, and the wet-kneaded material is press-formed and then foamed. It is a method for producing an independent foam tile, which comprises heat-treating the press-formed material at a temperature higher than the foaming temperature of the agent.

In the second embodiment of the present invention, at least one of the raw materials for powdered rock, soil and coal ash having a silicon dioxide content of 45% or more, a foaming agent and a zinc powder passed through a sieve having a 500 μm opening. The raw material for independent foam tiles made of, and the raw material for independent foam tiles and the reinforcing material are dry-kneaded and then wet-kneaded, and the wet-kneaded material is press-formed and then at a temperature higher than the temperature at which the foaming agent foams. It is a method for producing an independent foam tile, which comprises heat-treating the press-formed material.

A third embodiment of the present invention comprises a mixed raw material for independent foam tiles, which is a mixture of a raw material for independent foam tiles according to the first embodiment and a raw material for independent foam tiles according to a second embodiment, and a mixture for the independent foam tiles. The raw material and the reinforcing material are dry-kneaded and then wet-kneaded, the wet-kneaded material is press-formed, and then the press-formed material is heat-treated at a temperature at which the foaming agent foams or higher. This is a method for manufacturing independent foam tiles.

Patent Document 4 describes that without zinc powder, the initial tile shape cannot be maintained after heat treatment and the shape becomes like a bun, so that there is a large yield loss during molding, which is a post-process, and it is not suitable for mass production. However, they have found that the initial tile shape can be maintained even after heat treatment by mixing a reinforcing material, and have reached the present invention.

A fourth embodiment of the present invention is a JIS standard fly having a silicon dioxide content of 45% or more, a 45 μm sieve residue of 70% or less, a specific surface area of 1500 cm 2 / g or more, and an ignition loss of 5% or less. A raw material for independent foam tiles composed of ash and a foaming agent and a reinforcing material are dry-kneaded and then wet-kneaded, and the wet-kneaded material is press-formed and then press-formed at a temperature equal to or higher than the foaming agent. It is a method for manufacturing an independent foam tile, which is characterized by heat-treating the tile.

A fifth embodiment of the present invention comprises at least one material and a foaming agent as raw materials such as powdered rock, soil and coal ash having a silicon dioxide content of 45% or more passed through a sieve having a 500 μm opening. The raw material for foam tiles and the reinforcing material are dry-kneaded and then wet-kneaded, the wet-kneaded material is press-formed, and then the press-formed material is heat-treated at a temperature at which the foaming agent foams or higher. It is a method for manufacturing an independent foam tile, which is a feature.

In the sixth embodiment of the present invention, the mixed raw material for independent foam tile and the reinforcing material, which are a mixture of the raw material for independent foam tile according to the fourth embodiment and the raw material for independent foam tile according to the fifth embodiment, are dry-typed. A method for producing an independent foam tile, which comprises kneading and then wet kneading, press-forming the wet-kneaded product, and then heat-treating the press-formed product at a temperature at which the foaming agent foams or higher. be.

A part of the reinforcing material is exposed on the surface by dry kneading the raw material for independent foam tiles or the mixed raw material for independent foam tiles and the reinforcing material and then wet kneading. It was also found that the expansion of the tile is suppressed in the exposed region and its vicinity, the surface step becomes apparent, and the expansion rate of the tile after the heat treatment is suppressed.

A seventh embodiment of the present invention is obtained by dry-kneading a reinforcing material with either a raw material for independent foam tiles or a mixed raw material for independent foam tiles according to the first to sixth embodiments and then wet-kneading the reinforcing material. In addition, either the raw material for independent foam tiles or the mixed raw material for independent foam tiles of the first to sixth embodiments is dry-kneaded and then wet-kneaded, and the laminated product is press-formed. This is a method for producing an independent foam tile, which comprises heat-treating the press-formed tile at a temperature at which the mixed foaming agent foams or higher.

The thickness of the raw material for independent foam tiles or the mixed raw material for independent foam tiles and the reinforcing material of the seventh embodiment of the present invention is dry-kneaded and then wet-kneaded with respect to the thickness of the raw material for independent foam tiles or the independent foam. The thickness of the upper layer raw material obtained by wet kneading after dry kneading the tile mixed raw material shall be 3% or more and 10% or less. As for the reinforcing material exposed on the surface of the lower layer raw material, it is possible to make the reinforcing material exposed on the surface invisible by laminating at least 3% of the upper layer raw material, and in order to suppress the deterioration of the reinforcing effect. It shall be 10% or less.

The foaming agent is silicon carbide according to Patent Document 4, and the weight% thereof is 0.25% or more and 10% or less, and the heat treatment temperature is 1210 ° C. or more and 1300 ° C. or less. When a foaming agent other than silicon carbide is used, the temperature may be higher than the sublimation temperature of the foaming agent.

As for the reinforcing material, the melting point is higher than the heat treatment temperature of the independent foam tile, and it is essential to increase the strength of the independent foam tile. Alumina and glass are applicable as inorganic materials, and graphite, carbon fiber reinforced plastic and carbon composite materials are applicable as carbon materials. Further, the reinforcing material used may be not only a fiber but also a rod or a mesh structure.

When fibers are used as a reinforcing material, the length of the fibers is set in order to prevent the fibers from becoming entangled with each other and forming pills when kneading the raw materials for independent foam tiles or the mixed raw materials for independent foam tiles. The minimum is 3 mm, the maximum is 3 times the thickness of the press-formed independent foam tile, and the diameter is in the range of 0.007 mm to 5.0 mm.

The reinforcing material is dispersed in the independent foam tile raw material or the mixed raw material for the independent foam tile and is fixed to the tile after the heat treatment to increase the strength, but does not show a sufficient reinforcing effect in the bubble portion. In the production of the independent foam tile of the present invention, since high-density bubbles having a diameter of 0.3 mm to 1 mm are formed, the length of the fiber is 3 mm or more to compensate for the case where three bubbles of 1 mm are connected. And said.

The blending ratio of the reinforcing material is in the range of 0.1% to 20% with respect to the volume of the independent foam tile after press formation. At least 0.1% or more is required to improve the strength of the independent foam tile after heat treatment, and 20% or less so as not to impair the lightness.

According to the present invention, coal ash (fly ash, bottom ash) discharged from a thermal power plant, which is mainly reused as an artificial lightweight aggregate, powdered rock and clay having a silicon dioxide content of 45% or more ( High-value-added independent foam tiles can be manufactured from materials that have passed through a sieve with a 500 μm opening against fine sand, silt, clay, etc., and the strength that was a problem because of the addition of reinforcing material is also an issue. It will be possible to increase.

Hereinafter, embodiments according to the present invention will be described.

As the raw material used, fly ash II for concrete obtained from Matsuura Power Station was used. From the results of external analysis, the silicon dioxide content was 62.3%, the moisture content was 0.1%, the remaining amount of intense heat was 2.2%, the density was 2.27 g / cm2, and the powderiness (45 μm sieve residue). ) Was 2%. In addition, coal ash discharged from the same place through a sieve with a 200 μm opening and coal ash passed through a sieve with a 500 μm opening were used. On the other hand, as for the soil, decomposed granite soil collected in the Kotomi area of Nagasaki City, sand collected from the Gobi Desert, and serpentinite powder obtained by crushing warm rock were passed through a sieve with a 500 μm opening. .. As a result of analyzing the silicon dioxide content of the soil, it was confirmed that the decomposed granite soil was 46% and the others were 60% or more.

As the zinc powder, HakusuiTech Co., Ltd.'s F powder (metal zinc content of 94% or more, particle size of 3 to 5 μm) was used.

In Example 1, 0.75% silicon carbide, 10% CMC concentration 0.5% aqueous solution as a binder, and no addition as zinc powder, 0.5% addition to 80 g of the fly ash type II, 1 Approximately 100,000 (0.1% per volume) alumina fibers with a length of 1 cm and a diameter of 0.007 mm were added to the 0% and 10% additions as a reinforcing material, and the CMC aqueous solution was sprayed by spraying after dry kneading. After kneading while kneading, a pressure press of 120 kg weight / cm2 was performed with a 50 mm square mold to prepare a sample having a thickness of 26 mm. After taking out the samples from the mold and leaving them for 1 day, each sample is placed in a small electric furnace, the temperature is raised from room temperature to 1000 ° C in 12 hours, the temperature is raised to 1230 ° C over about 10 hours, and the temperature is maintained for 15 minutes. After that, cooling was performed for 12 hours using a fan and a heater. The product without zinc addition was designated as sample 0, the product with 0.5% zinc added as sample 1, the product with 5.0% zinc added as sample 2, and the product with 10% zinc added as sample 3.

In Example 2, 80 g of commercially available JIS standard fly ash type IV was used, and 0.5% of silicon carbide, 10% of an aqueous solution having a CMC concentration of 0.5% as a binder, and 1.0% of zinc powder were added. Approximately 50,000 carbon fibers (0.16% per volume) with a length of 3 cm and a diameter of 0.007 mm were added as a reinforcing material, and after kneading by dry kneading, the CMC aqueous solution was sprayed and kneaded, and then 50 mm square. A pressure press of 120 kg weight / cm2 was performed in a die to prepare a sample having a thickness of 26 mm, which was taken out from the die and left to stand for 1 day. After taking out the samples from the mold and leaving them for 1 day, each sample is placed in a small electric furnace, the temperature is raised from room temperature to 1000 ° C in 12 hours, the temperature is raised to 1230 ° C over about 10 hours, and the temperature is maintained for 15 minutes. After that, cooling was performed for 12 hours using a fan and a heater. The obtained product was used as sample 4.

In Example 3, for coal ash obtained from Matsuura Power Station, a raw material having a particle size of 200 μm or less passed through a sieve having a 200 μm opening and a particle size size of 500 μm or less passed through a sieve having a 500 μm opening. Approximately 100,000 alumina fibers with a length of 1 cm and a diameter of 0.007 mm were added to 80 g of each of the raw materials to which 1% silicon carbide and 0.5% zinc powder were added (per volume). 0.1%) is added, and after kneading while spraying 10% of CMC in a 0.5% concentration aqueous solution as a binder by spraying, a pressure press of 120 kg weight / cm2 is performed with a 50 mm square mold. A 26 mm thick sample was prepared and left to stand for one day. After taking out the samples from the mold and leaving them for 1 day, each sample is placed in a small electric furnace, the temperature is raised from room temperature to 1000 ° C in 12 hours, the temperature is raised to 1230 ° C over about 10 hours, and the temperature is maintained for 15 minutes. After that, cooling was performed for 12 hours using a fan and a heater. The product obtained from a raw material having a particle size of 200 μm or less was used as sample 5, and the product obtained from a raw material having a particle size of 500 μm or less was used as sample 6.

In Example 4, a raw material having a particle size of 500 μm or less, which was obtained by passing warm rock powder, true sand soil collected in Kotomi, Nagasaki City, and sand from the Gobi Desert through a sieve with a 500 μm opening, was prepared, and for each 80 g of the raw material. Alumina fiber having a length of 2 cm and a diameter of 0.5 mm is added as a reinforcing material to an aqueous solution containing 0.75% silicon carbide, a CMC concentration of 0.5% as a binder, and 5% zinc powder, respectively. After adding 5,000 pieces (13% per volume) and kneading while spraying the CMC aqueous solution by spraying, a pressure press of 120 kg weight / cm2 was performed with a 50 mm square mold to prepare a sample having a thickness of 26 mm. After taking out the samples from the mold and leaving them for 1 day, each sample is placed in a small electric furnace, the temperature is raised from room temperature to 1000 ° C in 12 hours, the temperature is raised to 1230 ° C over about 10 hours, and the temperature is maintained for 15 minutes. After that, cooling was performed for 12 hours using a fan and a heater. The product obtained from warm stone powder was used as sample 7, the product obtained from decomposed granite soil collected in Kinkai, Nagasaki City was used as sample 8, and the product obtained from sand in the Gobi desert was used as sample 9.

From the results of the visual inspection of the samples subjected to the pressure press before the heat treatment, it was confirmed that the reinforcing material was not a little exposed on the surface in all the samples. From the viewpoint of fiber length, in the sample of Example 1 (fiber length 1 cm, diameter 0.01 mm) and the sample of Example 2 (fiber length 3 cm, diameter 0.01 mm), the fibers are increased as the fiber length increases. It was found that the number of entanglements tended to increase. From the viewpoint of the diameter of the fiber, it was confirmed that there was almost no entanglement of the fiber in Example 3 (fiber length 1 cm, diameter 0.5 mm) and Example 4 (fiber length 2 cm, diameter 0.5 mm).

Table 1 shows the product size results for the heat-treated samples obtained in Examples 1 to 4. All the samples expanded substantially uniformly, and it was confirmed from the results of Example 1 that there was no change in the presence or absence of zinc powder and the difference in concentration. According to Patent Document 4, if zinc powder is not mixed, the initial tile shape should be greatly deformed after heat treatment (the thickness of the center swells by about 18 to 25% with respect to the thickness of the edge), but the reinforcing material should be mixed. It was found that there is a shape-maintaining effect (the thickness of the center is about 5 to 7% with respect to the thickness of the end, and the expansion rate is suppressed as compared with the zinc powder alone mixed in Patent Document 4). In addition, when the concentration of the reinforcing material increases, not only the expansion rate decreases, but also in all the samples, a dent of about several mm is generated near the surface where the reinforcing material is exposed, and the ratio of the reinforcing material increases. It was also found that the surface step became apparent.

In Example 5, 0.75% of silicon carbide, 10% of an aqueous solution having a CMC concentration of 0.5% as a binder, and alumina having a length of 1 cm and a diameter of 0.007 mm as a reinforcing material with respect to 80 g of Fly Ash II. Approximately 100,000 fibers (approximately 0.1% per volume), 3 cm in length, approximately 32,000 carbon fibers with a diameter of 0.007 mm (approximately 0.1% per volume), 2 cm in length, 0 in diameter Approximately 5,000 (13% per volume) of 5.5 mm alumina fibers are added, and after kneading while spraying the CMC aqueous solution by spraying, a pressure press of 120 kg weight / cm2 is performed with a 50 mm square mold to obtain a thickness of 26 mm. A sample was prepared. After taking out the samples from the mold and leaving them for 1 day, each sample is placed in a small electric furnace, the temperature is raised from room temperature to 1000 ° C in 12 hours, the temperature is raised to 1230 ° C over about 10 hours, and the temperature is maintained for 15 minutes. After that, cooling was performed for 12 hours using a fan and a heater. Sample 10 of about 100,000 alumina fibers with a diameter of 0.007 mm, sample 11 with a length of 3 cm, and about 32,000 products of carbon fibers with a diameter of 0.007 mm, sample 11, 2 cm in length, 0 in diameter. Approximately 5,000 products of 5.5 mm alumina fibers were sampled.

Table 2 shows the product size results for the heat-treated samples obtained in Example 5. It was confirmed that the expansion was substantially uniform in all the samples by mixing the reinforcing material without mixing the zinc powder, and no change in the expansion rate was observed depending on the type of the reinforcing material. Further, as shown in Table 1, it was confirmed that the expansion coefficient decreased as the concentration of the reinforcing material increased. It was also found that a dent of about several mm was formed in the vicinity of the surface where the reinforcing material was exposed, and the surface step became apparent as the concentration of the reinforcing material increased.

In Example 6, all the samples obtained in Examples 1 to 5 were divided by a cutting machine and cross-sectional observation was performed. From the results of the cross-sectional observation, it was also confirmed that the reinforcing material was dispersed on the cross section in all the samples, but the reinforcing material was unevenly distributed in the sample 4. Further, from the result of the tentacle inspection of the cross section, it was possible to stroke without discomfort when the diameter of the carbon fiber was 0.007 mm, but when the diameter of the SUS316 fiber used in Example 3 was 0.5 mm, it was slightly. I felt stuck. It was found that the larger the diameter of the fiber, the more likely it is that when the independent foam tile is used as the outer wall, it may cause injuries to residents and damage clothing.

From the results of Examples 1 to 6, it was found that there are two major problems for practical use of the reinforcement improvement by the reinforcing material of the independent foam tile. The first problem is that if elongated fibers are used as a reinforcing material, the fibers become entangled with each other and become pills when kneading the raw materials of the independent foam tile, and cannot be dispersed throughout the tile. The second problem is the generation of surface steps after heat treatment due to the reinforcing material exposed on the surface. As a result, the yield is significantly reduced in the molding process.

As a countermeasure for the first problem, it is solved by dividing the reinforcing material into several times when kneading the raw materials of the independent foam tiles in order to suppress the entanglement of the fibers.

In Example 7, when the raw materials of the independent foam tiles of Example 2 were kneaded, the total number of carbon fibers was not added from the initial stage of kneading, but the carbon fibers were divided and added in 5 batches, and then 120 kg weight / cm2 was used in a 50 mm square mold. A sample having a thickness of 26 mm was prepared by performing a pressure press on the above. After taking out the sample from the mold and leaving it for 1 day, each supplement is placed in a small electric furnace, the temperature is raised from room temperature to 1000 ° C in 12 hours, the temperature is raised to 1230 ° C over about 10 hours, and the temperature is maintained for 15 minutes. After that, cooling was performed for 12 hours using a fan and a heater. The obtained product was used as sample 13.

From the results of the visual inspection, it was confirmed that the entanglement of carbon fibers could be suppressed. In addition, the sample was divided by a cutting machine and the cross section was observed, and it was confirmed that the sample was dispersed substantially uniformly on the cross section.

Regarding the second issue, the suppression of surface steps due to the fibers exposed on the surface, the surface steps of the reinforcing material are suppressed by heat treatment, so that the surface steps become apparent, so at least on the exterior surface side. Surface steps can be suppressed by laminating raw materials for independent foam tiles without reinforcing materials.

Example 8 is for an independent foam tile in which 0.75% of silicon carbide, 10% of an aqueous solution having a CMC concentration of 0.5% as a binder, and 0.5% of zinc powder are added to 80 g of fly ash II. Approximately 1,000 SUS316 fibers (2.6% per volume) with a length of 1.0 cm and a diameter of 0.5 mm were added to the raw material as a reinforcing material, and after dry kneading, the CMC aqueous solution was sprayed and kneaded. The raw material is an independent foam tile base material, while 0.75% silicon carbide is added to 80 g of fly ash II, 10% CMC concentration 0.5% aqueous solution is added as a binder, and 0.5% is added as zinc powder. The independent foam tile raw material obtained by kneading the raw material for the independent foam tile while spraying the CMC aqueous solution by spraying after dry kneading was used as the independent foam tile exterior raw material. 97% (thickness: 25.2 mm) of the independent foam tile base material is poured into a 50 mm square mold, and 3% (thickness: 0.8 mm) of the independent foam tile exterior material is placed on the independent foam tile base material. A pressure press of 120 kg weight / cm2 was performed to prepare a sample having a thickness of 26 mm. After taking out the samples from the mold and leaving them for 1 day, each sample is placed in a small electric furnace, the temperature is raised from room temperature to 1000 ° C in 12 hours, the temperature is raised to 1230 ° C over about 10 hours, and the temperature is maintained for 15 minutes. After that, cooling was performed for 12 hours using a fan and a heater. The obtained product was used as sample 14.

It was confirmed that no exposure of the reinforcing material was observed on the surface of the independent foam tile exterior raw material with respect to the sample 14 before the heat treatment in Example 8, and no surface step was observed even after the heat treatment.

In Example 9, all the samples obtained in Examples 1 to 8 were subjected to a floating and sinking experiment with water. The sample was divided into two equal parts in the vertical direction using a cutting machine, washed with water, and dried for 1 hour. All the samples were weighed, placed in a water tank infused with water and left for 24 hours, then the samples were collected, the surface water was wiped off, dried for 30 minutes, and then weighed again. In addition, the sample was placed in the water-injected water tank, a weight was placed on the sample, and the sample was soaked in water for 1 week.

It was confirmed that all the samples were floating in the water tank, and it was confirmed that there was no change in weight before and after leaving for 24 hours. In addition, it was confirmed that there was no change in weight of the sample submerged for one week. From this, it can be concluded that the bubbles inside the product are not continuously formed but foamed as a single substance for all the samples in which foaming was observed.

Industrial application fields

Since the independent foam tile is lightweight, it improves workability and improves the seismic effect when used for wall materials such as houses. In addition, since the reinforcing material is added, the problem in terms of strength is solved.

Claims (15)

Independent consisting of JIS standard fly ash, foaming agent and zinc powder having a silicon dioxide content of 45% or more, a 45 μm sieve residue of 70% or less, a specific surface area of 1500 cm 2 / g or more, and a ignition loss of 5% or less. After the raw material for foam tile and the reinforcing material are dry-kneaded and then wet-kneaded, the wet-kneaded material is press-formed, and then the press-formed material is heat-treated at a temperature at which the foaming agent foams or higher. A characteristic method for manufacturing independent foam tiles. Raw materials and reinforcing materials for independent foam tiles consisting of at least one of the raw materials for powdered rock, soil and coal ash having a silicon dioxide content of 45% or more and a foaming agent and zinc powder passed through a 500 μm opening sieve. The independent foam tile is characterized by dry-kneading and then wet-kneading, press-forming the wet-kneaded product, and then heat-treating the press-formed product at a temperature at which the foaming agent foams or higher. Production method. A mixed raw material for independent foam tiles, which is a mixture of the raw material for independent foam tiles according to claim 1 and the raw material for independent foam tiles according to claim 2, and a reinforcing material are dry-kneaded and then wet-kneaded. A method for producing an independent foam tile, which comprises heat-treating the press-formed material at a temperature equal to or higher than the temperature at which the foaming agent foams after press-forming. For independent foam tiles consisting of JIS standard fly ash and foaming agent with silicon dioxide content of 45% or more, 45 μm sieve residue of 70% or less, specific surface area of 1500 cm 2 / g or more, and ignition loss of 5% or less. Independently characterized in that the raw material and the reinforcing material are dry-kneaded and then wet-kneaded, the wet-kneaded material is press-formed, and then the press-formed material is heat-treated at a temperature at which the foaming agent foams or higher. How to make foam tiles. Dry type of at least one of the raw materials for powdered rock, soil and coal ash having a silicon dioxide content of 45% or more passed through a 500 μm open sieve, and a raw material for independent foam tiles and a reinforcing material composed of a foaming agent. A method for producing an independent foamed tile, which comprises kneading and then wet-kneading, press-forming the wet-kneaded product, and then heat-treating the press-formed material at a temperature at which the foaming agent foams or higher. A mixed raw material for independent foam tiles obtained by mixing the raw material for independent foam tiles according to claim 4 and the raw material for independent foam tiles according to claim 5 and a reinforcing material are dry-kneaded and then wet-kneaded, and the wet-kneaded product is used. A method for producing an independent foam tile, which comprises heat-treating the press-formed material at a temperature equal to or higher than the temperature at which the foaming agent foams after press-forming. The independent foaming according to claims 1 to 6 is obtained by dry-kneading the reinforcing material with either the raw material for independent foam tiles according to claims 1 to 6 or the mixed raw material for independent foam tiles and then wet-kneading the reinforcing material. Either the raw material for tiles or the mixed raw material for independent foam tiles was dry-kneaded and then wet-kneaded, and the laminated material was press-formed and then press-formed at a temperature equal to or higher than the foaming agent. A method for manufacturing an independent foam tile, which comprises heat-treating an object. The raw material for independent foam tiles or the mixed raw material for independent foam tiles and the mixed raw material for independent foam tiles were dry-kneaded with respect to the thickness of the material obtained by dry-kneading the raw material for independent foam tiles or the mixed raw material for independent foam tiles and then wet-kneading. The method for producing an independent foam tile according to claim 7, wherein the thickness of the tile that has been wet-kneaded later is 3% or more and 20% or less. The independent foaming according to any one of claims 1 to 7, wherein the reinforcing material is at least one of a metal fiber, an inorganic fiber, a carbon fiber and a carbon composite fiber having a melting point higher than the foaming temperature of the foaming agent. How to make tiles. The minimum length of the reinforcing material is 3 mm or more, the maximum length is 3 times or less the thickness of the press-formed material, and the diameter of the reinforcing material is in the range of 0.007 mm to 5.0 mm. The method for manufacturing an independent foam tile according to any one of claims 1 to 7. The method for producing an independent foam tile according to claim 1, wherein the blending ratio of the reinforcing material is in the range of 0.1% to 20% with respect to the volume of the press-formed material. The method for producing an independent foam tile according to claim 1 to 7, wherein the foaming agent is silicon carbide. The method for producing an independent foam tile according to claim 1 to 7, wherein the weight% of the foaming agent is 0.25% or more and 10% or less. The method for producing an independent foam tile according to claim 1 to 3, wherein the weight% of the zinc powder is 0.5% or more and 10% or less. The method for producing an independent foam tile according to claim 1 to 7, wherein the heat treatment temperature is 1210 ° C. or higher and 1300 ° C. or lower.