JP3074921B2 - Vitreous sintered body - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a vitreous sintered body,
In particular, the present invention relates to a large-sized, lightweight, high-strength, refractory ceramic material useful as a building material, which is provided with good shape, dimensional accuracy, high productivity, and low cost.

[0002]

2. Description of the Related Art Conventionally, the following are known as ceramic sintered bodies using a vitreous raw material. Add a small amount of carbon material and organic material to glass powder such as sheet glass, put in a heat-resistant container, heat, melt and foam the material, gradually cool it to a product material, and cut it to make a foam glass product. material. Fill glassy coarse particles and fine powder in a heat-resistant container, heat and sinter to melt and fuse, make a plate-shaped material, gradually cool to a glassy material, cut and process, etc. for building, interior and exterior materials And what. Widely used as the brand name "Neoparrier".

[0003] That is, although many kinds of engineers have attempted to manufacture this kind of product in various countries around the world, the following fate of the vitreous material as described in (i) and (ii) below. Therefore, those commercialized and supplied in large quantities at the industrial production level are limited to the above.

(I) When molding and sintering a vitreous powder, a large volume of shrinkage of about 20% occurs and deforms. Further, a large amount of air is enclosed and the distribution is uneven during melting. Become an organization. In order to remove air bubbles, a long-time treatment at a high temperature is required. Further, the shape and dimensions of the fired material are extremely unstable, and it is not a commercial product unless it is cut and processed. (Ii) Inhomogeneous glass has many built-in potential strains and is broken by even a slight thermal shock. Therefore, it is necessary to take a long time to cool it during firing. "Hotness" may occur.

[0005]

In the above-mentioned conventional vitreous sintered body, the above-mentioned (i) and (ii) also apply.
Due to the fatal disadvantages of the vitreous sintered bodies described above, none of them can exhibit sufficiently satisfactory characteristics, and furthermore, their productivity is extremely poor and their product cost is high.

That is, among the above conventional vitreous sintered bodies,
Because it is extremely difficult to control the balance between the high-temperature viscosity of molten glass and the decomposition of volatile components, the size of bubbles becomes uneven, and the distribution of bubbles differs between the center and the periphery of the container. It is necessary to remove the non-uniform part by cutting in order to obtain a product of uniform quality, resulting in a large amount of material loss.

In particular, the cooling step requires an extremely long time, and if the cooling time is insufficient, cracks are generated, and when the product is manufactured, latent distortion is left, and the product is damaged by a slight thermal shock. There is also.

In addition, the glass powder shrinks by about 20% or more when the glass powder is melted, and is melted in a state where air between the powders is sealed, so that much time is required for “fining” during firing. It is necessary to remove air bubbles and then cool through a long slow cooling step. Also, this material
As it is not possible to satisfy the dimensional accuracy as a building material as it is, it is necessary to cut and process it into a product of a predetermined size, but due to extremely low productivity and cutting and processing loss, low cost and efficient Difficult to produce.

The present invention solves the above-mentioned conventional problems and is a large-sized, lightweight, high-strength refractory ceramic material useful as a building material, having good shape and dimensional accuracy, low productivity and low productivity. It is an object of the present invention to provide a vitreous sintered body that can be manufactured at low cost.

[0010]

According to a first aspect of the present invention, there is provided a vitreous sintered body comprising an artificial or natural vitreous material within a skeleton of a skeleton structure formed of natural wollastonite having a needle-like or plate-like crystal structure. A vitreous sintered body filled with a cured product of a composition containing a raw material as a main component, wherein the content of wollastonite in the sintered body is 10 to 80% by weight.

A second aspect of the present invention is the vitreous sintered body according to the first aspect, wherein the composition mainly composed of a vitreous raw material contains hydraulic cement.

[0013] A third aspect of the present invention is the vitreous sintered body according to the first or second aspect, wherein the composition mainly composed of the vitreous raw material contains a foamed material, and the cured product is porous. It is characterized by the following.

[0013] The vitreous sintered body of claim 4 is claim 1 to claim 3.
Is characterized in that the composition mainly composed of a vitreous raw material contains slag, coal ash or incinerated ash, and its cured product is porous.

Hereinafter, the present invention will be described in detail according to the method for producing a vitreous sintered body of the present invention.

[0015] The vitreous sintered body of the present invention may be, for example,
It is manufactured by mixing glass powder of about 100 mesh, wollastonite of about 60 to 100 mesh and a binder in a predetermined formulation, shaping this into a predetermined shape, and firing at about 1000 to 1200 ° C. for about 1 to 5 hours. be able to.

Here, the glass powder used may be any of plate glass, bottle glass, other artificial glass powder or natural vitreous raw material powder.

Water glass or the like can be used as the binder. Note that a binder is not necessarily required,
It is not necessary if it is not necessary.

In the present invention, among the compounding amounts of the glass powder, wollastonite powder and the binder, the compounding amount of wollastonite is such that the wollastonite content in the obtained vitreous sintered body is 10 to 10.
It is necessary to set so as to be in the range of 80% by weight. When the wollastonite content in the obtained vitreous sintered body is less than 10% by weight, a sufficient skeleton structure cannot be formed by wollastonite, and therefore the strength of the vitreous sintered body is insufficient.

In the present invention, together with the glass powder, a hydraulic cement and a foaming agent capable of forming a foamed structure in the course of the hardening reaction of the cement are blended, and the inside of the skeleton structure made of wollastonite is foamed by foaming. It can be quality.

In this case, the mixing of the glass powder, the hydraulic cement and the foaming agent is such that 10 to 30 parts by weight of the hydraulic cement, 0 to 2.0 parts by weight of the foaming agent, and 100 parts by weight of the glass powder.
In particular, it is preferably 0.2 to 2.0 parts by weight.

As the hydraulic cement, blast furnace cement, ordinary Portland cement, alumina cement or the like can be used, and as the foaming agent, aluminum powder or the like can be used.

Further, in the vitreous sintered body of the present invention, slags, coal ash, incinerated ash, etc. generated during metal refining are blended together with the glass powder, and the carbon contained in these is mixed.
It may be a porous material in which bubbles are generated by decomposition of so-called impurities such as sulfur and a metal oxide in an unoxidized state, and the inside of a skeleton structure made of wollastonite may be filled.

In this case, the mixing ratio of the slag and the like is preferably about 10 to 30 parts by weight with respect to 100 parts by weight of the glass powder.

In particular, in the present invention, metal aluminum powder is added to the raw material composition such as glass powder in an amount of 0.2 to 2.
By using a mixture obtained by adding about 0% by weight and, if necessary, adding about 5 to 10% by weight of quicklime and mixing with water, an extremely lightweight vitreous sintered body can be produced by generation of hydrogen.

[0025]

The vitreous sintered body of the present invention thus produced maintains a needle-like and plate-like crystal structure, and contains a vitreous raw material inside the skeleton of the skeleton structure formed of the natural wollastonite. It is filled with a cured product of a composition mainly composed of, and adds a new idea of assembling a physical structure to the concept of chemical bonding reaction, which is a conventional sintering theory of ceramics in general, The use of the skeletal structure eliminates the fatal disadvantages of the conventional vitreous sintered body.

That is, in the vitreous sintered body of the present invention,
The vitreous material filling the inside of the skeletal structure, during sintering,
Shrinkage, foaming and deformation occur, but the sintered body as a whole hardly shrinks or deforms.

That is, since the filler composition is sintered in a state of being uniformly dispersed in the skeleton structure of wollastonite, internal stress due to rapid heating and cooling in the manufacturing process is absorbed inside the skeleton and shrinks. There is almost no cracking or breakage due to deformation. Therefore, it can be manufactured with higher productivity than conventional general ceramic materials, and an extremely stable vitreous sintered body with small thermal expansion is provided.

According to the second aspect of the present invention, the crystallization water of the hydraulic cement is released at the time of firing, whereby the glass is melted and the viscosity is reduced.
Even at this temperature, several percent of water of crystallization remains in the tissue. Since this volatile water generates a large number of fine bubbles in the molten glass phase, a lightweight vitreous sintered body in which the inside of the skeleton is filled with a porous material is provided.

According to the third aspect of the present invention, foaming is further promoted, and lightness is enhanced.

According to the vitreous sintered body of the fourth aspect, the inside of the skeleton is formed by utilizing the formation of bubbles by so-called impurities such as carbon such as slag, coal ash and incinerated ash, and metal oxides in an unoxidized state. A porous and lightweight, high-strength, vitreous sintered body is provided. It should be noted that a vitreous raw material that generates a liquid phase at a relatively low temperature is very convenient for generating impurities as bubbles.

In particular, as described above, in the case of adding about 0.2 to 2.0% of aluminum powder and about 5 to 10% of quick lime and mixing them with water, bubbles are generated due to generation of hydrogen, and burning occurs. The cellular structure at the time of sintering is dispersed by the skeleton, and the glass material reinforced by the skeleton has extremely high strength, extremely light weight, and extremely high specific strength, with almost no volume shrinkage which is a drawback during firing of this kind of material. A sintered body is obtained.

[0032]

EXAMPLES The present invention will be specifically described below with reference to examples.

Example 1 A mixture obtained by mixing plate glass powder of 150 mesh or less, wollastonite of about 60 mesh and a 30% by weight aqueous solution of sodium silicate No. 3 as a binder in the composition shown in Table 1 was molded. The sintered body was fired at a temperature and the firing shrinkage, bulk specific gravity and bending strength of the obtained sintered body were examined. The results are shown in Table 1.

[0034]

[Table 1]

Example 2 In Example 1, blast furnace cement (B) was used in place of the sodium silicate aqueous solution, and at the blending and firing temperatures shown in Table 2,
Similarly, mixing, molding and firing were performed. Table 2 shows the shrinkage rate (foaming rate), bulk specific gravity, and bending strength of the obtained sintered body due to firing.
Shown in

The obtained sintered body is a foam which largely foams while substantially maintaining the shape of the molded body, and in which bubbles having a diameter of 0.5 to 1.0 mm are uniformly dispersed, and has a specific strength (bending strength / bulk strength). Specific gravity) was extremely high.

[0037]

[Table 2]

Example 3 In Example 2, coal ash (fly ash having a carbon content of 6%) was further added, and mixed, molded and fired in the same manner at the blending and firing temperatures shown in Table 3. Was. Table 3 shows the shrinkage, bulk specific gravity, and bending strength of the obtained sintered body due to firing.
Shown in

[0039]

[Table 3]

Example 4 In Example 1, Portland cement, quicklime and aluminum powder were used instead of the aqueous sodium silicate solution.
The mixing, molding, and firing were performed in the same manner at the blending and firing temperatures shown in Table 1. Table 4 shows the shrinkage, bulk specific gravity, and flexural strength of the obtained sintered body due to firing. The obtained sintered body is an extremely lightweight foamed sintered body, and has a bending strength of, for example, ALC.
(Artificial lightweight concrete) was about 10 times higher in strength.

[0041]

[Table 4]

[0042]

As described in detail above, according to the vitreous sintered body of the present invention, the strength is remarkably increased due to the reinforcing effect of the wollastonite needle-like or plate-like crystal structure, and the shrinkage due to the structure. A vitreous sintered body having significantly improved thermal shock strength as well as toughness due to the stress absorbing effect is provided.
The vitreous sintered body of the present invention is a new material having the same weather resistance as ceramics, and having strength characteristics exceeding that of ceramics, and has a high shape, dimensional stability, and low manufacturing cost. It can be manufactured stably and efficiently and is extremely useful as a building interior / exterior, flooring material and the like.

According to the vitreous sintered body of claims 2 to 4,
By virtue of the porous material having bubbles introduced into the inside of the skeleton, a vitreous sintered body having high strength and light weight and imparted with a sound absorbing property, a heat insulating property and the like by the porous material is provided.

Claims (4)

(57) [Claims] 1. A cured product of a composition mainly composed of an artificial or natural vitreous raw material is filled in a skeleton of a skeletal structure formed of natural wollastonite having a needle-like or plate-like crystal structure. A vitreous sintered body, wherein the content of wollastonite in the sintered body is 10 to 80% by weight. 2. A composition comprising a vitreous raw material as a main component,
The vitreous sintered body according to claim 1, comprising a hydraulic cement. 3. The vitreous sintered body according to claim 1, wherein the composition mainly composed of a vitreous raw material contains a foamed material, and a cured product thereof is porous. 4. The composition according to claim 1, wherein the composition mainly composed of a vitreous raw material contains slag, coal ash or incinerated ash, and a cured product thereof is porous. 4. A vitreous sintered body according to claim 1.