JP2903705B2 - Manufacturing method of high-strength sheet-like ceramic compact - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial applications]

The present invention relates to a method of manufacturing a high-strength thin plate-shaped ceramic molded body, and more particularly to a method of manufacturing a high-strength, large-sized thin plate-shaped ceramic molded body by heating at a low temperature without firing.

2. Description of the Related Art

In recent years, the construction of factories, public buildings, and private houses has been steadily increasing, and the number of renovations has been increasing rapidly.Natural stone, artificial tile, cement・ Concrete, wood, and plywood have been used. However, today, due to labor shortages and changes in architectural styles, the shape of each surface material has become large, and the labor shortage has been eliminated and the construction time has been reduced, the aesthetic appearance and the total construction cost have been reduced. Recently, the size of natural stone is up to 1,800 x 9
0 × 3~4.5mm, although flat artificial tile 900 × 600 × 6 mm is in the context in which it is sold, it is very expensive and more 25,000 yen per 1 m ^2. In addition, natural stones require more time for slicing than imported, resulting in more cutting powder and waste. In addition to the rapid depletion of domestic clay resources,
Large amount of energy consumption due to high temperature firing around 250 ° C,
Environmental pollution due to combustion gas emission also increases, and transportation costs due to higher specific gravity increase. And there is a problem that a lot of labor and time are required for the manufacturing process and the adhesive bonding. Therefore, the present invention is to solve the following problem. 1) Since the shape of the single material of the building interior and exterior is small, thick and heavy, the construction period is long and the construction cost is increased. Solving these bottlenecks by reducing the weight as a single piece of ceramic with a building standard dimension, for example, 1 m ² or 2 m ² unit size and a thin thickness, for example, 6 mm ± 2 mm inside and outside I do. 2) Conventionally, when the basement is made of cement or concrete as the surface material of the inner and outer walls, the adhesion between the groundwork and the wall material is often insufficient, and the base material has fallen, causing an accident. Cracking has also occurred.
In order to solve these problems, the surface material is made large to reduce the number of joints, has a similar composition to the cement / concrete base material, and has a property of having a constant water absorption. Therefore, the adhesion of the substrate can be further improved, and the use of the initial liquid material for forming the ceramic molded body can provide better adhesion. Therefore, a surface material that can be easily formed into a thin plate shape and has high performance against acids, alkalis and high temperatures is provided by an easy manufacturing means.

[Means for Solving the Problems]

The present invention, as a result of intensive research to solve the above-mentioned problems, as a result, overcoming all of them, has a high strength and a thin plate shape, for example, a width of 1 m, a thickness of 6 mm ± 2 mm range and a flat plate as a substrate,
We have developed a method for manufacturing a ceramic molded body with a specific gravity of around 1.5, which can be easily formed into a thin plate shape, is solidified by heat treatment at 500 ° C or lower, and exhibits high bending strength of 80 to 150 kgf / cm ² . That is, the present invention provides 20 to 30 parts by weight of alkali aluminate, calcium silicate
10 to 20 parts by weight, a mixture of aluminum hydroxide 10 to 20 parts by weight and zinc oxide 10 to 20 parts by weight, water or hot water 500
To 800 parts by weight and sufficiently mixed to form a suspension.10 to 20 parts by weight of boric acid is added to and mixed with the suspension, and then 800 to 1,000 parts by weight of sodium silicate is added and mixed. A first step of preparing a liquid, and 10% of the binder liquid obtained in the first step.
A second step of mixing 300 to 500 parts by weight of an amorphous-based ceramic fine powder having a specific surface area of 3,000 cm ² / g or more with 0 parts by weight and further sufficiently stirring and kneading to obtain a paste-like material After the paste-like material obtained in the second step is formed into a thin plate, it is quickly dried, and then heated and solidified at 200 to 500 ° C to form a thin plate-shaped ceramic having a bending strength of 80 to 150 kgf / cm ^2. And a third step of obtaining a body. In the above invention of the present application, in order to enhance the bending strength of the product, it is preferable that in the second step, a paste-like material is obtained by mixing 0.5 to 5% by weight of the inorganic fine ceramic powder in the second step. . Examples of the inorganic fibers include glass fibers, carbon fibers, ceramic fibers, and metal fibers. In order to impart various colors to the product, a coloring raw material may be added. In the second step, titanium oxide or iron oxide as a coloring agent is added to the paste-like material in an amount of 150 to 700% by weight. %, Preferably 0.5 to 5% by weight of the ceramic fine powder to obtain a paste-like material. Further, in the above, as the alkali aluminate,
Sodium aluminate or its hydrate or potassium aluminate or its hydrate can be used. As the zinc oxide, zinc hydroxide may be used instead, and zinc borate may be used instead of zinc oxide and boric acid. As the sodium silicate, potassium silicate may be used instead. Further, examples of the ceramic fine powder mainly composed of amorphous include pearlite fine powder, obsidian fine powder, volcanic products, granulated slag, and the like. And it is preferable that its specific surface area is a fine substance of about 3,000 cm ² / g or more. According to the above-mentioned method, a high-strength thin plate-shaped ceramic molded body whose dimensions are within 1,000 mm in width, about 6 mm ± 2 mm in thickness, and within 2,000 mm in length can be obtained. Here, the operation of each compounding raw material in the configuration of the present invention will be described. First, alkali aluminate, calcium silicate, aluminum hydroxide, zinc oxide, sodium borate and sodium silicate constitute a binder for producing a high-strength thin plate-shaped ceramic molded body. This binder has the effect of greatly melting and amorphizing the ceramic fine powder mainly composed of amorphous material by heating, further wrapping the colorant and inorganic fibers evenly, and strengthening the adhesion between solid components. As a result of the heat treatment at 500 ° C. or less, it serves as a strong adhesive component for producing an amorphous high-strength product. In the action of the compounding raw material according to the present invention, the alkali aluminate is sodium aluminate, potassium aluminate, etc., which are water-soluble, but the solid has a melting point.
1,700 ° C or higher. Calcium silicate produces various hydrates and is useful for the hardening action of ceramic materials, and disperses and mixes in a colloidal state to develop its properties when heated. Aluminum hydroxide is useful for its properties as an amphoteric compound and its adsorptivity as a gel by hydration. Zinc oxide is activated by the cocatalytic action and the heating temperature even though the exact chemical formula is not clear, such as a slight excess of zinc relative to oxygen. In addition, it has a property that it is stable to heating, and is also characterized by forming zinc hydrochloride with an acid or alkali. It is considered that the gel-like substance of the binder liquid induces a cross-linking-like action by the promoter action of the zinc oxide and exerts an effective action on the film formation. Heating further strengthens the film. On the other hand, boric acid or zinc borate is an alkali aluminate,
By pouring the boric acid or zinc borate solution into a gel aqueous solution containing a suspension of calcium silicate, aluminum hydroxide, zinc oxide or zinc hydroxide, a part of the suspension is formed into a gel. The solution is made into a gel state containing an aqueous solution and a small amount of a suspension. Even though the state of all these reactions is not sufficiently clear, the mutual reaction of the raw materials producing the gel-like substance became apparent from X-ray diffraction. It is also clear that the suspended substances present in these gel-like substances also exist in a crystalline state. Therefore, the conclusion as to whether the ingredients blended to form the binder liquid react with each other and exist as amorphous or crystalline can be verified by X-ray diffraction. The gel-like substance produced by the mutual reaction of the raw materials thus added exhibits high adhesive strength. This is the base binder solution. Perlite, obsidian, granulated slag, etc. are added to the binder liquid as amorphous fine ceramic powder to form a ceramic molded body (green molded body). The specific surface area of these ceramics at this time is about 3,000 cm ² / g
It is desirable that the material be fine as described above. And of these fine ceramic powders, pearlite,
Visible materials such as obsidian and granulated slag melt when the gel-like substance of the binder liquid reacts with the surface of the fine powder particles.
During heat treatment at a temperature of not more than 0 ° C. (preferably 200 to 500 ° C.), the material is solidified and turned into a ceramic to exhibit fire resistance. Here, an embodiment of the above-mentioned raw material of the present invention and a reaction mode by the blending will be described with reference to an X-ray diffraction diagram. (1) With respect to alkali aluminate, for example, sodium aluminate has a crystalline state as shown in FIG.
When this is brought into contact with an alkaline aqueous solution, it is stably present in the gel of the binder solution. In addition, sodium aluminate itself has a high melting point of 1700 ° C. when heated. (2) Calcium silicate is a compound having a crystalline state as shown in FIG. This effectively affects the hardening action. It also has a high melting point of 1540-2100 ° C. (3) Aluminum hydroxide is hydrated as shown in FIG. It is soluble in both alkalis and acids and becomes a hydrated gel, but when heated to about 450 ° C. or less, it becomes an acid- and alkali-resistant solid. (4) Zinc oxide shows crystals as shown in FIG. The amphoteric oxide dissolves in acids and alkalis, but part of zinc oxide promotes the cross-linking reaction of the gel-like substance in the binder liquid by a co-catalytic action, and furthermore, the activity appears by heating and the heat of the gel-like substance It is considered that the curing of the molded body proceeds in synergy with the curing. Although this effect has not been fully elucidated, it was used based on the idea that zinc oxide was slightly excessive with respect to oxygen, and the excess was due to defects of oxygen atoms on the crystal lattice. , With good results. (5) As shown in FIG. 5, boric acid used a reagent containing some contaminants. Since the aqueous solution is a weak acid, gelation is promoted by the weak acid of the amphoteric oxide. Since the glassy boron oxide is formed at 300 ° C., the heating temperature of the ceramic molded body is set to 500 ° C. or less due to the properties of each compounding raw material and the gel material. (6) Sodium silicate is a reaction product with alumina, silica, and zinc at high temperatures when sodium silicate reacts with each raw material, particularly amphoteric oxide, and surface-modifies and gels amorphous ceramic fine powder. Was used for low temperature sintering. (7) FIG. 6 shows that sodium aluminate: calcium silicate: aluminum hydroxide: zinc oxide: boric acid: sodium silicate is 30: 20: 10: 1 as described above.
A relatively high weight ratio of 5: 20: 1,000 parts by weight, further added 500 parts by weight of water, mixed well with gelation and partial suspension (Binder solution) Is dried and then heated and cured at 500 ° C., and is shown by X-ray diffraction. As is apparent from FIG. 6, the zinc oxide is almost in an amorphous state except that zinc oxide remains in a slightly crystalline state. This means that when the raw materials are blended, the gelation is sufficiently performed, and a part of the zinc oxide undergoes a bridging reaction by a cocatalyst action from the gelled state to 500 ° C heating and a curing action of the molded body by activation by heating. It is presumed that it is proceeding. This result is based on the fact that the tendency of the bending strength to increase with the increase in the temperature of the heat treatment rapidly increases during the heating process from room temperature to 200 ° C. In the process, mainly the crosslinking reaction and the curing effect by heating are synergistically caused to increase the product strength. If only the increase in strength due to the curing effect of heating alone is considered, the rate of increase in product strength due to increase in bulk specific gravity due to heating from 200 ° C to 500 ° C is presumed to be too small, so tiles made of general clay materials Unlike the tendency of the strength of ceramics and ceramics to develop, it is not desired to greatly increase the strength by heating at 500 ° C. or more. Therefore, the maximum heating temperature is around 500 ° C. under the optimal heating temperature condition, and a heating temperature of 200 to 500 ° C. is a suitable range. (8) On the other hand, a case where titanium oxide is added as a coloring agent will be described. The above-mentioned example in which a certain amount of the above-mentioned sodium aluminate and the other five raw materials was added is as described above.
FIG. 7 shows an X-ray diffraction pattern of the cured product obtained by heating at a temperature of ° C. Considering the results, the sample containing titanium oxide has a lower X-ray intensity than that in FIG. 6, and therefore has a higher density than the sample obtained by drying and curing the binder liquid because of the denseness. It turns out that specific gravity becomes large. In addition, the titanium oxide of the coloring agent is an anatase type without a change in the crystal state at the initial stage of blending, and has high hardness and high heat resistance due to chemical resistance.
It is stable within 1,500 ° C. Iron oxides can also be used as colorants from black or red to purple, are weather-resistant, have a melting point of 1,300 ° C. or higher, and have heat resistance. (9) A case where a ceramic compact is produced by adding various fine powders as examples of ceramic fine powder mainly composed of amorphous to the binder liquid adjusted as described above will be described. First, as a result of examining the crystal state by X-ray diffraction of a sample prepared by adjusting the specific surface area of pearlite fine powder to 3,000 cm ² / g or more, as shown in FIG. 12, a crystalline component is an amorphous mineral with almost no crystalline component found. However, this was mixed thoroughly with a binder solution and a titanium oxide mixed solution in an amount of 4 times, dried, and cured by heating at 500 ° C., and subjected to X-ray diffraction. As a result, as apparent from FIG. 14, the peak of titanium oxide (anatase type) is remarkable, but most of the peaks are amorphized, and very good results are obtained in the reaction and hardening effects. Was. Next, as a result of examining the crystal state by X-ray diffraction of a sample in which the fine powder of volcanic ash was adjusted to a specific surface area of 3,000 cm ² / g or more,
As shown in FIG. 8, it is mainly a sodium salt mineral of aluminum silicate. This volcanic ash is thoroughly mixed with a binder solution and a titanium oxide mixed solution in a four-fold amount and then dried.
X-ray diffraction was performed on the sample cured by heating at 500 ° C. As a result, as is apparent from FIG. 9, the peak of titanium oxide (anatase type) is remarkable, and although some binder minerals and unreacted volcanic ash crystal minerals are present, most of them are amorphous. It became clear that very good results were also obtained for the reaction and curing action. However, if the adjustment of the binder liquid is insufficient, as shown in FIG. 10, crystal compounds such as zinc oxide and boric acid and sodium silicate and boric acid are generated, and it is difficult to expect good results. Therefore, great care must be taken in adjusting the binder solution. Here, the reason for limiting each valence range in the above configuration of the present invention will be described. Regarding the relative ratios of the raw materials to be used as binder liquids, they are generally. If the amount of alkali aluminate is less than 10 parts by weight, the product will be weak at high temperatures, especially 700 ° C or higher.
Addition of 0 parts by weight or more has little effect on improving fire resistance. . Aluminum hydroxide is closely related to the amount of alkali aluminate added.In general, when the amount of alkali aluminate is around 30 parts by weight, the amount of aluminum hydroxide is 10 parts by weight or less, and the amount of alkali aluminate is 30 parts by weight or less. In some cases, it is desirable to add aluminum hydroxide within 20 parts by weight, 10 parts by weight or more, and within the range of the respectively set blending weight. This is related to the fire resistance due to the production of alkali aluminate and aluminum hydroxide at high temperatures and the formation of gels at low temperatures. That is, the strength development at high temperature and the ratio of the product of the reaction of the amorphous substance at low temperature with the alkaline solution affect the physical properties. . The amount of zinc oxide or zinc hydroxide depends on the mixing of the other ingredients. Mixing in a solution is generally extremely inadequate, so that an excess of zinc oxide or the like causes an even catalytic action to take place. However, if mixing is sufficient, 5 parts by weight is sufficient. Therefore, this range is empirically determined from the technical aspect of binder solution adjustment. . When boric acid or zinc borate is used, the gelling of the amphoteric oxide is further performed with a weak acid after the gelling reaction in an alkaline solution, and when the added weight of each raw material is relatively small, 10 parts by weight is sufficient. But 25 for large amounts
Appropriate amount inside and outside parts by weight An addition amount larger than that is not desirable because the viscosity of the gel-like substance is lowered. . The addition amount of sodium silicate or potassium silicate is important for the gelation and development of viscosity of each raw material.
700 parts by weight, with a maximum value of 1,300 parts by weight. If the amount is less than the minimum amount, cracks occur during molding in relation to the amount of the ceramic added. If the amount is more than 1.300 parts, the apparent viscosity becomes high, molding becomes difficult, and the fire resistance decreases. . Although the mixing ratio of the colorant depends on the degree of color, it is considered that a mixing amount of approximately 1,000 parts by weight or less is desirable in a conventionally preferred color tone range. It is preferable to add 150 to 700% by weight of the paste-like material. . When the compounding amount of inorganic fibers such as glass fiber, carbon fiber, ceramic fiber and metal fiber is more than 5% of the amount of ceramic fine powder mainly composed of amorphous, it is difficult to form into a thin plate.
If it is less than 5%, the strength of the ceramic molded body cannot be increased.
Although determined in relation to the amount of the binder liquid and the amount of the ceramic fine powder, the median of the preferable amount is about 2%, and it is desirable to increase or decrease this value as a guide. . The heating temperature after molding is set to about 500 ° C. or less, and even if the heating temperature is increased more than that, it is not desired to greatly increase the strength. Even at a low temperature of 500 ° C. or less, heating at least 200 ° C. or more is desirable. . The amorphous-based ceramic raw material is finely pulverized, and is uniformly adhered to the periphery of the particles due to the wetting of the binder solution and the particles and the particle region are mutually contacted by the binder solution, and dried in this state, When heated, it cures in a state in which homogeneity is maintained in synergy with a cocatalytic action. Moreover, the surface of the cured molded article is extremely smooth. In order to cause this state, the ceramic fine powder mainly composed of amorphous
3,000 cm ² / g or more is desirable. In this way, a good ceramic molded body is manufactured and completed.

【Example】

Next, the method for producing a ceramic molded body of the present invention will be specifically described with reference to examples. FIG. 11 shows the relationship between the heating temperature and the heating time of the ceramic molded body (green molded body) (ceramic plate) of the first embodiment in an electric furnace. Example 1: 30 parts by weight of sodium aluminate, calcium silicate 20
Parts by weight, 15 parts by weight of aluminum hydroxide, and 20 parts by weight of zinc oxide, 300 parts by weight of water were added and mixed well.
500 parts by weight of an aqueous solution containing 0 parts by weight is added, and 1,100 parts by weight of sodium silicate is added to the gel-like solution which has been further reacted to adjust the binder liquid. To 100 parts by weight of this binder liquid, 500 parts by weight of pearlite fine powder sieved to a specific surface area of 3,000 cm ² / g or more were added and mixed by stirring, and then 500 parts by weight of anatase-type titanium oxide adjusted to 0.5 μm or less was added. Then, 15 parts by weight of 3.0% of the fine pearlite powder is added to the glass fiber, and the mixture is sufficiently mixed and kneaded to complete the preparation of the paste-like material of the ceramic molded body. The paste-like material thus prepared was formed into a flat plate shape by roller molding, dried, and then heated to a predetermined temperature of 200 ° C., 350 ° C., 500 ° C. in an electric furnace along a heating curve shown in FIG.
After heating at ℃, it was allowed to cool to produce a thin plate-shaped ceramic molded body. The various physical properties of the 500 ° C. heat-treated product of the ceramic molded body thus obtained are shown below. Apparent specific gravity: 1.52 Flexural strength: 146fkg / cm ² (room temperature, 50mm x 100mm x 6mm, distance between supports 90mm, JISA5209
Water absorption: 12.3% (However, water absorption of less than 5% by ceramic coating, conforms to JIS A5209) Abrasion resistance: 1.7 times that of epoxy paint Spalling test: No cracking Heat resistance: 980 ° C Chemical resistance ( Immersion): good (no change) 1% solution of caustic soda, hydrochloric acid, sulfuric acid Immersion for 3 days Petroleum ether, petroleum benzine (90v%) Immersion for 7 days Molded form: 200 × 200 × 6mm plate Example 2: Sodium aluminate 40 Parts by weight, calcium silicate 10
Parts by weight, 10 parts by weight of aluminum hydroxide, 10 parts by weight of zinc oxide, and 400 parts by weight of water, and thoroughly mixed.
Aqueous solution containing 5 parts by weight was added to 300 parts by weight, and further mixed and reacted.
The binder solution is prepared by adding parts by weight and stirring. To 100 parts by weight of this binder liquid, 300 parts by weight of pearlite fine powder sieved to a specific surface area of 3,000 cm ² / g or more were added, mixed with stirring, and mixed with 150 parts by weight of anatase-type titanium oxide adjusted to 0.5 microns or less. Then, 6 parts by weight of 2.0% of fine pearlite powder is added to the glass fiber, and mixing and kneading are sufficiently repeated to complete the preparation of the paste material of the ceramic molded body. The raw material thus prepared was flattened by roller molding, and then dried, and thereafter, at a predetermined temperature of 200 ° C., 350 ° C., 50 ° C. in an electric furnace along a heating curve shown in FIG.
After heating at 0 ° C., it was left to cool to produce a thin plate-shaped ceramic molded body. The ceramic molded body thus obtained is
The various physical properties of the heated product at 500 ° C. are shown below. Apparent specific gravity: 1.45 Flexural strength: 130 fkg / cm ² (room temperature, 50 mm x 100 mm x 6 mm, distance between supports 90 mm, conforming to JISA5209) Water absorption: 13.3% (However, water absorption is 5% or less by ceramic coating the surface, Abrasion resistance: 1.7 times that of epoxy paint Spalling test: no cracking Chemical resistance (immersion): good (no change) 1% solution of caustic soda, hydrochloric acid, sulfuric acid 3 days immersion Petroleum ether, petroleum benzine (90v% 7 days immersion Heat resistance: 980 ° C Molded form: 200 × 200 × 6 mm plate Example 3: 15 parts by weight of sodium aluminate, calcium silicate 20
Parts by weight, 20 parts by weight of aluminum hydroxide, 10 parts by weight of zinc oxide, and 400 parts by weight of water.
To a gel-like solution obtained by pouring 250 parts by weight of an aqueous solution containing 0 parts by weight and further mixing and reacting, sodium silicate 800
The binder solution is prepared by adding parts by weight and stirring. To 100 parts by weight of this binder liquid, 250 parts by weight of pearlite fine powder sieved to a specific surface area of 3,000 cm ² / g or more were added and mixed by stirring.
% Of 5 parts by weight, and mixing and kneading are sufficiently repeated to complete the preparation of the paste material of the ceramic molded body. The paste-like material thus prepared was flattened by roller molding, dried, and then heated to a predetermined temperature of 200 ° C., 350 ° C., 500 ° C. in an electric furnace along a heating curve shown in FIG.
And then allowed to cool to produce a ceramic molded body. The various physical property values of the thus-obtained ceramic molded body heated at 500 ° C. are shown below. Apparent specific gravity: 1.42 Flexural strength: 128 fkg / cm ² (room temperature, 50 mm x 100 mm x 6 mm, distance between supports 90 mm in accordance with JISA5209) Water absorption: 14.3% (However, water absorption of 5% or less by ceramic coating the surface, JISA5209 Abrasion resistance: 1.7 times that of epoxy paint Spalling test: no cracking Chemical resistance (immersion): good (no change) 1% solution of caustic soda, hydrochloric acid, sulfuric acid 3 days immersion Petroleum ether, petroleum benzine (90v%) 7 days immersion Heat resistance: 980 ° C Molded form: 200 × 200 × 6mm plate

【The invention's effect】

As described in detail in the above examples and the like, according to the method for manufacturing a ceramic molded body of the present invention, the bending strength is 80 to
It is possible to provide a high-strength thin-plate-shaped ceramic molded body having a sheet-like fire resistance and chemical resistance exhibiting a high strength of 150 kgf / cm ² and which can be manufactured by heating at a low temperature. The ceramic molded body manufactured according to the present invention has a lower specific gravity than general ceramics, and can be formed in any shape such as an arbitrary size, thickness, and accessory. Therefore, the manufactured ceramic molded body is useful as a member of inner and outer wall materials such as a housing building material, a civil engineering building material, a tunnel wall body, a sound-insulating wall of a Shinkansen, and a board material such as cement / concrete, block, wood, etc. It can be used both as a decorative ceramic plate and as a sufficient ceramic new material as an acid rain resistant member. Further, since it can be manufactured by low-temperature heating, it is economical in terms of energy consumption and pollution prevention, and has many advantages such as simple and easy on-site processing as well as factory design.

[Brief description of the drawings]

1 to 5 show the X of the raw material used in the production of the binder liquid.
FIG. 1 is sodium aluminate, FIG. 2 is calcium silicate, FIG. 3 is aluminum hydroxide, FIG. 4 is zinc oxide, and FIG. 5 is boric acid. FIG. 6 is an X-ray diffraction diagram of a binder solution produced from the above raw materials, and shows sodium aluminate-calcium silicate-
It is an aluminum hydroxide-zinc oxide-boric acid-sodium silicate system. FIG. 7 is an X-ray diffraction diagram when titanium oxide is added as a coloring agent to the raw material system of FIG. 6, and shows sodium aluminate-calcium silicate-aluminum hydroxide-zinc oxide-
It is a boric acid-titanium oxide-sodium silicate system. FIG. 8 is an X-ray diffraction diagram of volcanic ash as a fired product of vitreous rock as ceramic in the raw material system of FIG.
The figure is an X-ray diffraction diagram of a system in which the volcanic ash of FIG. 8 is mixed with the system of FIG. That is, sodium aluminate-calcium silicate-aluminum hydroxide-zinc oxide-boric acid-
It is a titanium oxide-sodium silicate-volcanic ash system, and this system is generally used as a paste material which is a raw material of a ceramic molded body. FIG. 10 is an X-ray diffraction pattern in which the gelation was insufficiently promoted due to insufficient treatment in the preparation of the binder solution, and was obtained by using sodium aluminate-calcium silicate-aluminum hydroxide-zinc oxide-borane. Acid-sodium silicate system,
This is for comparison with an X-ray diffraction diagram obtained by mixing the same raw materials as in FIG. FIG. 11 is a diagram showing a relationship between heating temperature and time as heating conditions of the ceramic molded body using the paste-like materials of Example 1 and Examples 4 to 6. FIG. 12 is an X-ray diffraction diagram of the fine pearlite powder. FIG. 13 is an X-ray diffraction diagram of a system in which the pearlite fine powder of FIG. 12 is mixed with the system of FIG. That is, it is a sodium aluminate-calcium silicate-aluminum hydroxide-zinc oxide-boric acid-titanium oxide-sodium silicate-pearlite system, and this system is a paste-like material which is a raw material of the ceramic molded body according to the present invention. It becomes.

──────────────────────────────────────────────────続 き Continued on the front page (58) Field surveyed (Int. Cl. ⁶ , DB name) C04B 35/00-35/22 C04B 35/622-35/636

Claims (6)

(57) [Claims] 1. A mixture of 20 to 30 parts by weight of an alkali aluminate, 10 to 20 parts by weight of calcium silicate, 10 to 20 parts by weight of aluminum hydroxide and 10 to 20 parts by weight of zinc oxide is mixed with 500 to 800 parts of water or hot water. Parts by weight, and mixed well to form a suspension.10 to 20 parts by weight of boric acid is added and mixed to the suspension, and then 800 to 1,000 parts by weight of sodium silicate is added and mixed to form a suspension. A first step of preparing, and an amorphous ceramic fine powder having a specific surface area of 3,000 cm ² / g or more with respect to 100 parts by weight of the binder liquid obtained in the first step
A second step of mixing 300 to 500 parts by weight and further sufficiently stirring and kneading to obtain a paste-like material. After the paste-like material obtained in the second step is formed into a thin plate, it is immediately dried. And a third step of obtaining a thin plate-shaped ceramic molded body having a bending strength of 80 to 150 kgf / cm ² by heating and solidifying at 200 to 500 ° C., thereafter, a method of manufacturing a high-strength thin plate-shaped ceramic molded body. . 2. A high-strength sheet-like material according to claim 1, wherein in the second step, a paste-like material is obtained by mixing 0.5 to 5% by weight of the inorganic fine ceramic powder with inorganic fibers in the second step. Manufacturing method of ceramic molded body. 3. The method according to claim 2, wherein the inorganic fibers are glass fibers, carbon fibers, ceramic fibers or metal fibers. 4. The method according to claim 2, wherein in the second step, titanium oxide or iron oxide as a coloring agent is added in an amount of 150 to 700% by weight of the paste-like material.
The method for producing a high-strength thin plate-shaped ceramic molded body according to any one of claims 1 to 3, wherein a paste-like material is obtained by mixing 0.5 to 5% by weight of the inorganic fine powder with the inorganic fiber. 5. The high-strength thin plate-shaped ceramic according to claim 1, wherein the alkali aluminate is sodium aluminate or a hydrate thereof, or potassium aluminate or a hydrate thereof. Manufacturing method of molded body. 6. The ceramic fine powder mainly composed of amorphous is pearlite, obsidian, volcanic eruption product, or granulated slag, and has a specific surface area of about 3,000 cm ² / g or more. 6. The method for producing a high-strength thin plate-shaped ceramic molded body according to any one of 1 to 5.