JP2022174741A - Fiber-reinforced inorganic molded body, and method for producing the same - Google Patents

Abstract

To provide a fiber-reinforced inorganic molded body which is lightweight, incombustible, and of good appearance.SOLUTION: A fiber-reinforced inorganic molded body 1 includes: a surface layer 2 containing a cured geopolymer 3; and a reinforced layer 5 that comprises a fiber base material 6 and a geopolymer 7 impregnated and cured in the fiber base material 6. The fiber base material 6 is a glass fiber base material or a basalt fiber base material. The fiber base material 6 is preferably a nonwoven fabric or a mat. The content of the fiber base material 6 in the reinforced layer 5 is preferably from 5 to 25 mass% based on the total mass of the reinforced layer.SELECTED DRAWING: Figure 1

Description

TECHNICAL FIELD The present invention relates to a fiber-reinforced inorganic molded article and a method for producing the same.

Molded bodies such as panels and monuments to be installed on the walls of buildings are sometimes installed in places high above the ground surface, so they are required to be lightweight and strong. By using fiber-reinforced plastic, it is possible to reduce the weight of the molded product while maintaining its strength, but the fire resistance is not good. On the other hand, fiber-reinforced concrete, fiber-reinforced gypsum, and the like are used when flame retardancy and fireproof performance are required, but these are inferior to fiber-reinforced plastics in lightness. In addition, gypsum cannot be used outdoors due to its lack of water resistance, and is also brittle. On the other hand, glass fibers are used in a wide range of applications due to their excellent strength, nonflammability, heat resistance, electrical insulation and chemical resistance.

Patent Document 1 discloses a fiber-reinforced silicate compound composite material in which glass fibers are contained in a matrix of a cured sodium silicate. This composite material uses water glass as a matrix, and the addition of glass fiber or glass fiber powder accelerates the hardening of the matrix and compensates for the brittleness of the matrix, thereby improving the strength of the entire composite material. The composite material is formed into a predetermined shape by injecting a slurry obtained by mixing each component such as an aqueous sodium silicate solution and glass fibers into a mold and subjecting it to curing conditions.

Patent Literature 2 discloses an inorganic curable composition used for producing an inorganic curable body such as a panel. The composition contains metakaolin (inorganic powder), potassium silicate aqueous solution, silica stone powder, wollastonite, vinylon fiber, and metallic silicon powder.

JP-A-05-330889 JP 2007-290316 A

However, when the fiber is highly filled in order to improve the strength of the molded article, there is a problem that fiber traces may occur on the surface of the molded article, impairing the aesthetic appearance of the product. In particular, when the glass fiber is highly filled in order to improve the nonflammability of the molded article, the problem is conspicuous, and when the surface of the molded article is patternless, fiber traces are conspicuous.

Accordingly, in one aspect, the present disclosure provides a fiber-reinforced inorganic molded body that is lightweight, non-flammable, and has good appearance.

In one aspect, the present disclosure includes a surface layer containing a cured geopolymer, a reinforcing layer containing a fibrous base material, and a hardened geopolymer impregnated into the fibrous base material, wherein the fibrous base material comprises: It relates to a fiber-reinforced inorganic molded article, which is a glass fiber base material or a basalt fiber base material.

The present disclosure provides, in one aspect, a mold that is coated with a first geopolymer composition, and a fibrous base impregnated with a second geopolymer composition on top of the first geopolymer composition that has been applied to the mold. At least one sheet of material is arranged to form a laminated structure, the fiber base material is a glass fiber base material or a basalt fiber base material, and the laminated structure is cured and released from the mold. The present invention relates to a method for manufacturing a molded body.

According to one aspect of the present disclosure, it is possible to provide a fiber-reinforced inorganic molded article that is lightweight, nonflammable, and has good appearance.

FIG. 1 is a schematic perspective view of a fiber-reinforced inorganic molded article according to one aspect of the present disclosure. FIG. 2 is a schematic perspective view of a fiber-reinforced inorganic molded article according to one aspect of the present disclosure. 3A to 3E are process diagrams illustrating a method for manufacturing a fiber-reinforced inorganic molded article according to one embodiment of the present disclosure. 4A to 4E are process diagrams illustrating a method for manufacturing a fiber-reinforced inorganic molded article according to one embodiment of the present disclosure. 5 is a photograph of the surface of the molded article of Example 1. FIG. 6 is a photograph of the surface of the molded article of Comparative Example 1. FIG. 7 is a photograph of the surface of the molded article of Example 2. FIG. 8 is a photograph of the surface of the molded article of Comparative Example 2. FIG. 9 is a photograph of the surface of the molded article of Example 3. FIG.

In one aspect, the present disclosure is a fiber-reinforced inorganic molded article (hereinafter sometimes abbreviated as "molded article") including a surface layer and a reinforcing layer. Since the matrix materials of the surface layer and the reinforcing layer are both hardened geopolymers (hereinafter sometimes abbreviated as "GP"), and the reinforcing fibers contained in the reinforcing layer are glass fibers or basalt fibers, The compact is lightweight and nonflammable. Since the molded product has a structure in which a surface layer is provided on a reinforcing layer containing glass fibers or basalt fibers, even if the reinforcing layer is highly filled with glass fibers or basalt fibers, there are no fiber marks on the surface of the molded product. is prevented from occurring. Therefore, in one aspect, the present disclosure can provide a fiber-reinforced inorganic molded article that is lightweight, nonflammable, and has both good appearance and high strength. The term "surface of the molded article" refers to the front surface of the molded article, and means the contact surface formed in contact with the inner surface of the mold during in-mold molding.

Hereinafter, embodiments of the present disclosure will be described in more detail with reference to the drawings. However, the invention is not limited to what is shown in the following drawings.

[Fiber-reinforced inorganic molded product]
FIG. 1 is a schematic perspective view illustrating a fiber-reinforced inorganic molded article of one aspect of the present disclosure, and FIG. 2 is a schematic perspective view illustrating a fiber-reinforced inorganic molded article of another aspect of the present disclosure. be. As shown in FIGS. 1 and 2, molded body 1 includes surface layer 2 and reinforcing layer 5 bonded to surface layer 2 .

[Surface layer]
The surface layer 2 contains a cured body 3 of GP as a main component. GP is at least one of a raw material mainly composed of amorphous aluminum silicate (hereinafter also referred to as "active filler") and an aqueous solution (alkaline solution) of alkali metal silicates, carbonates and hydroxides. It is a general term for amorphous polycondensation polymers formed by reaction with Unlike cement, GP is not a hydrate formed by reacting with water, so the bonds do not break even at high temperatures, and because it has a strong inorganic polymer structure, it is susceptible to deterioration factors such as wind and rain, solar radiation, acid, and temperature changes. strong against

Active fillers (not shown) include amorphous aluminum silicate, and typical examples include metakaolin, fly ash, sewage sludge slag, and granulated blast furnace slag. Metakaolin is preferred because it reacts quickly and has little variation in quality.

The alkali metal silicate is preferably at least one selected from the group consisting of sodium silicate, potassium silicate, and lithium silicate, more preferably potassium silicate, and still more preferably potassium silicate. An aqueous solution of alkali metal silicate can also be prepared by mixing alkali metal hydroxide, amorphous silica and water.

The surface layer 2 may optionally contain reinforcing fibers (not shown) dispersed in the GP to reinforce the surface layer 2 . Any reinforcing fiber can be used depending on the application of the molded article 1 . As the reinforcing fiber, from the viewpoint of good appearance of the surface of the molded body 1 and high reproducibility of the design when forming the design on the surface of the molded body 1, for example, vinylon, acrylic, PE, PP, cellulose, Reinforcing fibers such as aramid, carbon fibers, alumina fibers, and glass fibers can be preferably used. From the viewpoint of durability, it is preferable that the surface layer 2 does not contain glass fibers such as E-glass that are vulnerable to alkali. It may be The content of these reinforcing fibers in the surface layer 2 is preferable from the viewpoint of strength improvement, good appearance of the surface of the molded body 1, and high reproducibility of the design when forming the design on the surface of the molded body 1. is preferably 0.3 to 1.0 mass % of the total mass of the surface layer 2 . From the viewpoint of strength improvement and dispersibility of the reinforcing fibers, the fiber diameter of the reinforcing fibers is preferably 10 to 50 μm, and the fiber length is preferably 1 to 10 mm.

The surface layer 2 may optionally contain aggregates 4 that are insoluble in water and do not react with alkali metal silicates to reinforce the surface layer 2 . In particular, when a design is formed on the surface of the molded body 1, it is preferable that the aggregate 4 is contained from the viewpoint of preventing strength reduction and crack generation in fine irregularities. Examples of the aggregate 4 include wollastonite, zircon sand, silica sand, crystalline alumina, mica, copper entanglement, limestone, municipal waste slag, and the like. These may be used alone or in combination of two or more. Among them, wollastonite is preferable because it is needle-shaped and has an effect of preventing shrinkage.

The particle size of the aggregate 4 is preferably 50 to 1000 μm, more preferably 50 to 200 μm, from the viewpoint of good appearance and high design reproducibility. The content of the aggregate 4 in the surface layer 2 is preferably 10 to 50% of the total mass of the surface layer 2 from the viewpoints of strength improvement, good appearance of the surface of the molded body 1, and high design reproducibility. % by weight is preferred. In this specification, the "particle size" refers to a 50% (weight) cumulative particle size, that is, when accumulating from a small particle size, the particles when reaching 50% by weight of the total aggregate Say the diameter.

The preferred thickness of the surface layer 2 varies depending on the use of the molded article 1 and whether or not a design is formed, but from the viewpoint of the strength and appearance of the entire molded article, it is preferably 0.3 to 2.0 mm, more preferably 0.3 to 2.0 mm. is 0.5 to 1.0 mm.

The surface of the surface layer 2, that is, the surface of the molded body 1 may be a smooth surface without a pattern as shown in FIG. 1, or may have a design formed thereon as shown in FIG. Designs include traditional Japanese patterns such as tortoise shells, checkered patterns, and cloisonné ties, geometric patterns, leather grain patterns, rock surface, wood grain, bark (bark), combing, scraping, and chipping.

[Reinforcing layer]
The reinforcing layer 5 is joined to the surface layer 2 and includes a fiber base material 6 such as a glass fiber base material and a geopolymer 7 impregnated in the fiber base material 6 such as a glass fiber base material and cured. If a fiber base material 6 such as a glass fiber base material is used as the reinforcing material, the reinforcing layer 5 can be highly filled with a reinforcing material such as glass fiber. The hardened GP 7 is a matrix material in the reinforcing layer 5, and, like the hardened GP 3 contained in the surface layer, is an amorphous material formed by a reaction between an aqueous solution of an alkali metal silicate or the like and an active filler. It is a polycondensate of quality. The fiber base material constituting the reinforcing layer 5 may be a basalt fiber base material in addition to the glass fiber base material. Basalt fibers are also called basalt fibers because they are fibers obtained by melting and spinning basalt. Basalt fibers are known to have higher heat resistance and higher strength than glass fibers.

The form of the fiber base material (glass fiber base material or basalt fiber base material) 6 includes plain weave, satin weave, non-woven fabric, mat, knit, braid, or a combination thereof, or a combination of these and chop. From the viewpoint of high filling of the reinforcing layer 5 with glass fibers or basalt fibers, a nonwoven fabric or a mat is preferable, and a mat is more preferable. The type of mat is, for example, a chopped strand mat in which glass fiber strands or basalt fiber strands cut to a predetermined length are dispersed in random directions and laminated to a uniform thickness, and made into a mat shape with a binder. A stitch mat in which glass fiber strands or basalt fiber strands cut to a predetermined length are sewn with another continuous fiber and sewn into a sheet, or a mat in which continuous fibers are piled up in a spiral, for example, and bound and continuous strand mats. The preferred basis weight of one nonwoven fabric or mat is the impregnability of GP, the handleability of the mat itself, and the polymer-containing fiber base material (polymer-containing glass fiber base material or polymer base material) impregnated with the second geopolymer composition described later. It is 30 to 600 g/m ² from the viewpoint of compatibility with the handleability of the basalt fiber base material). The number of glass fiber strands constituting the glass fiber substrate is preferably 5 to 500 tex, and the fiber length is preferably 1 to 100 mm, more preferably 20 to 100 mm. The count of the basalt fiber strands constituting the basalt fiber base material is preferably 5 to 500 tex, and the fiber length is preferably 1 to 100 mm, more preferably 20 to 100 mm.

The number of layers of the fiber base material (glass fiber base material or basalt fiber base material) 6 in the reinforcing layer 5 may be appropriately selected according to the application of the molded article, for example, 1 to 10 layers, preferably 3 to 5 layers. In addition, the fiber base material (glass fiber base material or basalt fiber base material) 6 is laminated in the form of a base material by spraying strands obtained by cutting a roving to 1 to 100 mm, preferably 20 to 100 mm, with a spray gun. It may be From the viewpoint of strength improvement, the content of the glass fiber substrate in the reinforcing layer 5 is preferably 5 to 25% by mass, more preferably 5 to 20% by mass of the total mass of the reinforcing layer. The content of the basalt fiber base material in the reinforcing layer 5 is also preferably 5 to 25% by mass, more preferably 5 to 20% by mass of the total mass of the reinforcing layer, from the viewpoint of improving strength.

The reinforcing layer 5 may optionally contain an inorganic filler (not shown), eg for weight adjustment. Examples of inorganic fillers include talc, fine wollastonite, silica powder, zeolite, calcium carbonate, aluminum hydroxide, barium sulfate, and crushed rocks. The particle size of the inorganic filler is not particularly limited as long as it does not interfere with the impregnation of the fiber base material (glass fiber base material or basalt fiber base material) 6 with GP, and is preferably 5 μm or more and less than 50 μm. The content of the inorganic filler in the reinforcing layer 5 is preferably the total weight of the reinforcing layer, from the viewpoint of improving the strength and impregnating the GP into the fiber base material (glass fiber base material or basalt fiber base material) 6. Among them, 50% by mass or less is preferable.

A preferred thickness of the reinforcing layer 5 varies depending on the use of the molded article 1, but from the viewpoint of improving the strength of the molded article, it is preferably 2.0 to 10 mm, more preferably 3.0 to 6.0 mm.

A preferred thickness of the molded article 1 varies depending on the use of the molded article 1, but from the viewpoint of improving the strength of the molded article, it is preferably 2.3 to 12 mm, more preferably 3.5 to 7.0 mm.

[Method for producing fiber-reinforced inorganic molded product]
Next, a method for manufacturing a molded body according to one aspect of the present disclosure will be described with reference to FIGS. 3 and 4. FIG.
In one aspect of the present disclosure, a mold is coated with a first geopolymer composition (hereinafter sometimes abbreviated as "first GP composition"), and the first GP composition applied to the mold is coated with , by arranging one or more glass fiber substrates impregnated with the second geopolymer composition (hereinafter sometimes abbreviated as "second GP composition") to produce a laminated structure, and The present invention relates to a method for producing a fiber-reinforced inorganic molded article, in which the structure is cured and completely hardened, and then released from the mold.
In one aspect of the present disclosure, a mold is coated with a first geopolymer composition (hereinafter sometimes abbreviated as "first GP composition"), and the first GP composition applied to the mold is One or more basalt fiber base materials impregnated with a second geopolymer composition (hereinafter sometimes abbreviated as "second GP composition") are placed thereon to produce a laminated structure, The present invention relates to a method for producing a fiber-reinforced inorganic molded article, in which the laminated structure is cured and completely cured, and then released from the mold.

The first GP composition includes, for example, the active filler and an aqueous alkaline solution, such as an aqueous solution of an alkali metal silicate. If necessary, the first GP composition may contain the reinforcing fibers (reinforcing fibers) such as organic fibers, aggregates, and the like. Suitable alkaline aqueous solutions, active fillers, reinforcing fibers, and aggregates are as described above. The solid content concentration of the first GP composition is preferably 70 to 85% by mass from the viewpoint of coating properties. In the first GP composition, the preferred content of the alkali metal silicate is 35 to 60 parts by mass with respect to 100 parts by mass of the active filler in terms of solid content, and the preferred content of the aggregate 4 is the shrinkage From the viewpoint of prevention and strength of the molded product, the amount is 20 to 100 parts by mass with respect to 100 parts by mass of the active filler.

The second GP composition includes, for example, an active filler and an alkaline aqueous solution, such as an aqueous solution of an alkali metal silicate. The second GP composition may contain an inorganic filler or the like, if necessary. Details of suitable alkaline aqueous solutions, active fillers, and inorganic fillers are as described above. The solid content concentration of the second GP composition is preferably 70 to 85% by mass from the viewpoint of impregnation into the fiber base material (glass fiber base material or basalt fiber base material) 6. In the second GP composition, the preferred content of the alkali metal silicate is preferably 40 to 60 parts by mass based on 100 parts by mass of the active filler in terms of solid content, and the preferred content of the inorganic filler is From the viewpoint of the strength and workability of the molded product, the amount is preferably 75 parts by mass or less per 100 parts by mass of the active filler.

As a mold used in the method for manufacturing a molded article according to one aspect of the present disclosure, for example, a mold made of materials such as urethane rubber, fiber-reinforced plastic, and silicone rubber can be used. If necessary, a release agent can be used, and for example, a wax-based, silicone-based, fluorine-based, or surfactant-based release agent can be used.

Next, as shown in FIGS. 3A and 4A, the first GP composition 30 containing the aggregate 4 is applied to the mold 8 coated with the release agent. Next, the fiber base material (glass fiber base material or basalt fiber base material) 6 impregnated with the second GP composition 70 is placed on the first GP composition 30 applied to the mold 8 . Details of suitable glass fiber substrates and basalt fiber substrates are provided above. Placement of the fiber base material (glass fiber base material or basalt fiber base material) 6 on top of the first GP composition applied to the mold is performed while the geopolymer in the first GP composition 30 is uncured. Alternatively, the geopolymer in the first GP composition 30 may be cured but not completely cured.

Arrangement of a plurality of fiber substrates (glass fiber substrates or basalt fiber substrates) 6 impregnated with the second GP composition 70 on the first GP composition 30 applied to the mold 8 is performed by the following method ( I) and method (II), or both.
(I) As shown in FIG. 3B, after placing a fiber base material (glass fiber base material or basalt fiber base material) 6 on the first GP composition 30, as shown in FIG. A polymer-containing fiber base material (polymer-containing glass fiber base material or polymer-containing basalt fiber base material) 9 is obtained by impregnating a second GP composition 70 into a glass fiber base material or basalt fiber base material) 6 .
(II) As shown in FIG. 4B, a polymer-containing fiber base (polymer-containing glass fiber base or A polymer-containing basalt fiber substrate) 9 is provided and placed on top of the first GP composition 30 as shown in Figure 4C. That is, the fiber base material (glass fiber base material or basalt fiber base material) 6 is impregnated with the second GP composition 70 and then placed on top of the first GP composition 30 .

In method (I), impregnation of the second GP composition into the fiber base material (glass fiber base material or basalt fiber base material) 6 is performed manually using, for example, a brush or a roller. Air in the fiber base material (glass fiber base material or basalt fiber base material) 6 is also removed at the same time as the impregnation. In method (II), the impregnation of the second GP composition into the fiber base material (glass fiber base material or basalt fiber base material) 6 is performed, for example, by impregnating the second GP composition with the fiber base material (glass fiber base material or basalt fiber base material). material) is immersed. At the same time as the immersion, the air in the fiber base material (glass fiber base material or basalt fiber base material) 6 is also removed.

In the case of forming a design on the surface of the molded body, in method (I), the fiber base material (glass fiber base material or basalt fiber base material) 6 is pressed against the mold 8 side to shape it, and then the fiber base material ( The glass fiber base material or basalt fiber base material) 6 is impregnated with the second GP composition 70 . Alternatively, the second GP composition 70 is rubbed into the fiber base material (glass fiber base material or basalt fiber base material) 6, and the second GP is applied to the fiber base material (glass fiber base material or basalt fiber base material) 6. The fiber base material (glass fiber base material or basalt fiber base material) 6 is shaped while being impregnated with the composition 70 . Alternatively, the fiber base material (glass fiber base material or basalt fiber base material) 6 is shaped before and during impregnation with the second GP composition 70 . In method (II), the fiber base material (glass fiber base material or basalt fiber base material) 6 is shaped by forming the polymer-containing fiber base material (polymer-containing glass fiber base material or polymer-containing basalt fiber base material) 9 into a second When placing on the 1GP composition 30, it is carried out by pressing against the molding die 8 side.

For example, method (I) and method (II) are performed a predetermined number of times, and as shown in FIGS. 3D and 4D, a polymer-containing fiber substrate (polymer-containing glass A laminated structure 10 is formed by laminating a plurality of fiber base materials or polymer-containing basalt fiber base materials) 9 .

The laminated structure 10 is then cured and demolded after the geopolymer is fully cured. As shown in FIGS. 3E and 4E, the first GP composition 30 becomes the surface layer 2 by curing, and the laminate of the polymer-containing fiber base material (polymer-containing glass fiber base material or polymer-containing basalt fiber base material) 9 is reinforced. Layer 5 is formed. The curing temperature is preferably 10-90° C. and the relative humidity is preferably 50-90%. Curing time is preferably 2 to 24 hours.

One form of the molded body of the present disclosure described with reference to FIGS. 1 to 4 is a flat plate shape, but the molded body of the present disclosure is not limited to a flat plate shape, and may be a curved plate-shaped molded body. . In addition, one form of the molded article of the present disclosure may be a three-dimensional molded object such as a pseudo-rock, a pseudo-tree, a monument, or an image.

EXAMPLES The present invention will be specifically described below using examples. In addition, the present invention is not limited to the following examples.

[raw materials used]
Details of the raw materials used to prepare the geopolymer composition are as follows.
・Metakaolin (manufactured by Sobuecre)
・Potassium silicate aqueous solution (1.4 50° manufactured by Osaka Sanso (molar ratio 1.4, solid content 45.4% by mass))
・ Wollastonite (NYAD-G manufactured by IMERYS)

(Example 1)
Metakaolin and an aqueous potassium silicate solution were mixed at a mass ratio of 100:100 (100:45.4 in terms of solid content) to prepare a geopolymer mortar for a reinforcing layer (second GP composition). Metakaolin, an aqueous potassium silicate solution, and wollastonite (aggregate) were mixed at a mass ratio of 100:90:30 (100:40.9:30 in terms of solid content) to form a geopolymer mortar for the surface layer (1st GP composition) was adjusted. The molded article of Example 1 was produced by a hand layup method as described below.
First, a wax-based release agent was applied to a non-patterned urethane rubber mold. Next, the first GP composition was applied to the urethane rubber mold. A glass chopped strand mat (manufactured by Nittobo, basis weight 450 g/m ² ) was placed on the applied first GP composition. Next, the second GP composition was applied to the mat so as to be rubbed into the mat, and the mat was impregnated while removing air from the mat to obtain a polymer-containing glass fiber substrate. This was repeated 4 times. The obtained laminated structure was cured in an atmosphere of 60° C. for 24 hours to completely harden the GP. Then, the mold was released to obtain a molded article of Example 1.
In the molded article of Example 1, the thickness of the surface layer was 1.0 mm, and the thickness of the reinforcing layer was 4.0 mm. The content of the aggregate contained in the surface layer is 17.6% by mass of the total mass of the surface layer, and the content of the mat contained in the reinforcing layer is 17% by mass of the total mass of the reinforcing layer. %.

(Example 2)
A molded article of Example 2 having the same configuration as that of Example 1 was produced, except that a urethane rubber mold with a wood grain pattern was used as the mold.

(Example 3)
A first GP composition and a second GP composition were prepared in the same manner as in Example 1, and a molded article of Example 3 was produced as follows.
First, a wax-based release agent was applied to a urethane rubber mold with a grain pattern. Next, the first GP composition was applied to the urethane rubber mold. Four polymer-containing glass fiber substrates obtained by immersing a basalt fiber mat (manufactured by Each DreaM, basis weight 450 g/m ² ) in the second GP composition were prepared and applied to the urethane rubber mold. layered on top of the first GP composition. The obtained laminate structure was cured in an atmosphere of 60° C. for 24 hours to be completely cured. Then, the mold was released to obtain a molded article of Example 3.
In the molded article of Example 3, the thickness of the surface layer was 1.0 mm, and the thickness of the reinforcing layer was 5.0 mm. The content of the aggregate contained in the surface layer is 17.6% by mass of the total mass of the surface layer, and the content of the mat contained in the reinforcing layer is 14% by mass of the total mass of the reinforcing layer. %.

(Comparative example 1)
A molded body having the same configuration as that of Example 1 was produced except that the surface layer was not provided.

(Comparative example 2)
A molded body having the same structure as in Example 2 was produced, except that the surface layer was not provided.

<Appearance of molded body surface>
5 and 6 are photographs of the surfaces of the molded bodies of Example 1 and Comparative Example 1, respectively. As shown in FIG. 6, many fiber traces were observed on the surface of the molded article of Comparative Example 1, but as shown in FIG. 5, no fiber traces were observed on the surface of the molded article of Example 1. .

<Design reproducibility>
7 and 8 are photographs of the surfaces of the molded bodies of Example 2 and Comparative Example 2, respectively. A comparison between FIGS. 7 and 8 shows that the molded article of Example 2 has better pattern reproducibility than the molded article of Comparative Example 2. FIG. As shown in FIG. 8, many traces of fibers were observed in the areas where the glass fibers were coated with the geopolymer on the surface of the molded article of Comparative Example 2. FIG. 9 is a photograph of the surface of the molded article of Example 3, and it can be seen that even when basalt fiber is used as the fiber base material, the reproducibility of the pattern is good and there are few fiber marks.

<Stability promotion test>
1. Water resistance test A water resistance test was performed on the molded bodies of Examples 2 and 3 above.
A molded body and water were placed in a plastic sealed container, and the molded body was immersed in water. The container was sealed with a lid, placed in an oven at 80° C. for 28 days, and the change in flexural strength of the molded product over time was examined. The average initial value (n=5) of the bending strength of the molded article of Example 2 was 45.8 MPa, and the average value (n=5) of the bending strength after the water resistance test was conducted was 37.7 MPa. The average initial value (n=5) of the bending strength of the molded article of Example 3 was 57.9 MPa, and the average value (n=5) of the bending strength after the water resistance test was conducted was 64.7 MPa.
2. Humidity Resistance Test The molded bodies of Examples 2 and 3 were subjected to a humidity resistance test.
A net with legs was placed in a closed plastic container, water was poured under the net, and the molding was placed on the net. The container was sealed with a lid, placed in an oven at 80° C. for 28 days, and the change in bending strength of the molded product over time was examined. The average initial value (n=5) of the bending strength of the molded article of Example 2 was 45.8 MPa, and the average value (n=5) of the bending strength after the moisture resistance test was conducted was 42.5 MPa. The average initial value (n=5) of the bending strength of the molded article of Example 3 was 57.9 MPa, and the average value (n=5) of the bending strength after the moisture resistance test was conducted was 57.2 MPa.

(bending strength)
The flexural strength (MPa) of the moldings of Examples 2 and 3 was measured as follows.
The test pieces before and after the water resistance test and the moisture resistance test were subjected to a bending test according to the three-point bending test of JIS A 1408 to measure the bending strength. The unit MPa that indicates bending strength is sometimes expressed as N/mm ² .

For example, when a molded article containing glass fibers as a reinforcing material is used outdoors or under high humidity conditions, the water that enters the interior of the molded article becomes alkaline, and the alkaline liquid degrades the glass fibers. There is a risk that the strength of the molded body itself will decrease over time. However, for the molded body of Example 2, the general physical properties of glass fiber reinforced cement (for example, direct spray method, bending strength (breaking strength) 20 ~30 N/mm ² (20 to 30 MPa), Source: "Physical Properties and Product Standards of GRC" Japan GRC Industry Association, HYPERLINK "https://www.grc.gr.jp/product/index3.html" https:// www.grc.gr.jp/product/index3.html). Regarding the molded article of Example 3, there was no substantial change in bending strength before and after the water resistance and moisture resistance tests. Therefore, the present disclosure can provide a molded article that is lightweight, nonflammable, has both good appearance and high strength, and has high durability.

Suitable uses of the molded article of the present disclosure are, for example, artificial rocks, artificial trees, monuments, statues, flat, wavy or dome-shaped building materials, panels, etc., which are installed indoors or outdoors.

1 fiber reinforced inorganic molded body 2 surface layer 3 hardened body of geopolymer 30 first geopolymer composition 4 aggregate 5 reinforcing layer 6 fiber base material 7 hardened body of geopolymer 70 second geopolymer composition 8 mold 9 polymer Containing fiber base material

Claims (10)

a surface layer containing a cured geopolymer;
a fibrous substrate and a reinforcing layer comprising a cured geopolymer impregnated into the fibrous substrate;
The fiber-reinforced inorganic molded article, wherein the fiber base material is a glass fiber base material or a basalt fiber base material. The fiber-reinforced inorganic molded article according to claim 1, wherein the fiber base material is a nonwoven fabric or a mat. The fiber-reinforced inorganic molded article according to claim 1 or 2, wherein the content of said fiber base material contained in said reinforcing layer is 5 to 25 mass% of the total mass of said reinforcing layer. The fiber-reinforced inorganic molded article according to claim 1 or 2, wherein the surface layer further includes aggregate dispersed in the geopolymer. 5. The fiber-reinforced inorganic molded article according to claim 4, wherein the content of said aggregate contained in said surface layer is 10 to 50% by mass of the total mass of said surface layer. The fiber-reinforced inorganic molded article according to claim 1 or 2, wherein a design is formed on the surface of said surface layer. applying a first geopolymer composition to the mold;
At least one fibrous base material impregnated with a second geopolymer composition is placed on the first geopolymer composition applied to the mold to form a laminated structure, and the fibrous base material is A glass fiber base material or a basalt fiber base material,
A method for producing a fiber-reinforced inorganic molded article, wherein the laminated structure is cured and released from the mold. The fiber-reinforced inorganic molded article according to claim 7, wherein the first geopolymer composition contains 20 to 100 parts by mass of aggregate with respect to 100 parts by mass of the active filler contained in the first geopolymer composition. Production method. The fiber-reinforced inorganic molded article according to claim 7 or 8, wherein the fiber base material is impregnated with the second geopolymer composition after placing the fiber base material on the first geopolymer composition. Production method. 9. The method for producing a fiber-reinforced inorganic molded article according to claim 7 or 8, wherein the fibrous base material is impregnated with the second geopolymer composition and then placed on top of the first geopolymer composition.

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