JP3235169B2 - Manufacturing method of high strength thin plate ceramic / metal mesh sheet composite plate - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a high-strength thin plate-shaped ceramic / metal mesh sheet composite plate, and more particularly to a high-strength metal mesh sheet embedded in a ceramic material to provide high fire resistance and destruction. The present invention relates to a method for manufacturing a large, thin, ceramic-metal mesh sheet composite plate that has a residual strength even at times and does not cause the separation of ceramic and metal.

[0002]

[Problems to be solved by the prior art and the invention] Problems of Conventional Structural Materials In recent years, the number of factories, public buildings, and private residence buildings has been increasing, and the number of renovations has been increasing dramatically.
Conventionally, natural stone, artificial tile, cement, concrete / steel plate, wood, plywood, and the like have been used as surface materials for interior and exterior components of these buildings. However, today, due to labor shortages and changes in architectural styles, the shape of the materials has increased, and it has been necessary to eliminate the labor shortages and reduce the construction time and aesthetics, as well as the total construction cost. Recent natural stone become (marble and granite) is the maximum 1,800 × 900 × 4,5mm, ceramic tile is located in the context in which it is marketed is 900 × 900 × 6mm of flat, 1m ² per 25,000 It is very expensive, more than a yen. In addition, since almost all natural stones are imported, slicing takes a long time and generates a large amount of cutting powder and waste stones.

On the other hand, as a raw material for ceramic tiles, a clay product mainly composed of wollastonite has a firing temperature of 1,
Due to the high temperature firing around 200 ° C., the product often warps and cracks. Moreover, transportation costs are increased due to the large consumption of energy and the high specific gravity of the materials. Furthermore, there are many unsolved problems including a large amount of labor and time required for processing, bonding and joining of these materials, and a problem of low yield of the product accompanying a risk in molding. Today, many people are killed or injured in car accidents, which is said to be a traffic war.In this accident, cement, cement composites, organic materials, and metals were used for the median strip, outer curbs, and the outer walls of tunnels. The damage caused by the impact of the impact on the car caused by the destruction, scattering, and burning of the material is large. This is because
Examples include the destructibility and flammability of the material. Recently, SO
Environmental pollution due to x, NOx, and other compounds has become a problem, and corrosion of structures and outdoor monuments has occurred. Therefore, ceramics are becoming indispensable in selecting raw materials constituting materials. In view of such a situation, it is necessary to provide a new material for a structure with high weather resistance, and to supply a large, thin, and fracture-resistant new material for a structure at low cost and in large quantities.

Accordingly, the present invention is to solve the following problem. . Viewpoint for solving the problem The single material of the structural interior / exterior member is a building standard dimension, for example, 1
m ² or 2 m ² is a ceramic composite with a unit size of ² units, and the thickness is as thin as 6 mm inside and outside to reduce the weight by drastically reducing the construction period and construction costs. Solve bottlenecks. 2. Description of the Related Art Conventionally, when a base material is a cement / concrete as a surface material of an inner / outer wall, adhesion between the base material and the wall material is often insufficient, and the material falls and causes an accident. In addition, the damage to the cracks in the media has also occurred. In order to solve these problems, for a large-sized ceramic-metal composite molded body as a surface material, a variety of lightweight ceramic objects into which a frame, a sliding joint, and an anchor bolt etc. to a cement / concrete base can be firmly inserted are manufactured. The method can be implemented to prevent these risks. We will also develop molded articles that have many advantages such as having strong adhesion to the base material.

When used for curbs, side walls, soundproof fire walls, and the like of roads, tunnels, and highways, etc., the strength is increased, the residual application works strongly, and the ceramic is not scattered due to collisions. Provided is a structural molded article having many advantages such as no harmful gas generation and no flammability at a safe use temperature of not less than ° C. A molded body that can cope with environmental pollutants such as acid rain, and has a high temperature resistant property as a ceramic material. And a method for producing the same.
Therefore, in order to solve these problems, there is provided a means by which a ceramic / metal mesh sheet composite plate can be easily formed and the above-mentioned physical properties can be produced by heating at a low temperature.

[0006]

Means for Solving the Problems The inventors of the present invention have conducted intensive studies to solve the above-mentioned problems, and as a result, have overcome all of them, and have a high strength and a thin plate shape. Messi sheet is buried in a large size, for example, width 900 mm, thickness around 6 mm, length 900 mm,
It has a plate shape of about 1,800 mm or 2,400 mm, which is sufficiently cured by a low-temperature heat treatment at a temperature of 600 ° C. or less, and has a large “flexing force” by embedding a metal mesh sheet having a product bending strength of about 200 to 300 kgf / cm ^2. A method for manufacturing a high-strength thin ceramic / metal mesh sheet composite plate having a specific gravity of about 1.8 was developed.

That is, the present invention relates to (a). A first step of adding 3 to 10 parts by weight of wollastonite, 5 to 10 parts by weight of blast furnace slag fine powder and 5 to 15 parts by weight of silica fine particles to 70 to 90 parts by weight of fly ash, and mixing uniformly; For 100 parts by weight of the mixture obtained in the first step, 10 to 30 parts by weight of aluminum hydroxide, 20 to 50 parts by weight of zinc oxide and 30 to 60 parts by weight of sodium aluminate, and a boric acid saturated solution 500 to Add 1,000 parts by weight, and then add 800 to 1,500 parts by weight of sodium silicate and mix well to obtain a muddy binder.
A second step of adding 20 to 35 parts by weight and sufficiently kneading to obtain a paste-like material; (c). A third step of embedding a metal mesh sheet in the paste-like material obtained in the second step to form a thin plate, and then humidifying and drying to obtain a dry composite plate;
(D). The dried composite plate obtained in the third step is prepared for 350 to 60
A fourth step of heating at 0 ° C. to obtain a ceramic / metal mesh sheet composite plate having a high strength and excellent refractory strength with a high residual strength. This is a method for manufacturing a composite plate.
In the present invention, in the above-mentioned third step, the paste-like material obtained in the second step is used in the form of udon, chip or plate.
Extruded under reduced pressure as one of the shapes selected from above, set the extruded material on the top and bottom of a stainless steel or iron metal mesh sheet, and rolled the top and bottom with rollers to form a plate with a thickness of several millimeters After that, it is also preferable to cut it into a certain length and humidify and dry to obtain a dry composite plate.

In the invention of the present application, the first step is carried out in order to increase not only the bending strength of the obtained product but also the impact resistance and the bending property due to the increase in the so-called residual strength due to the "flexure" property. And adding 0.5 to 3.0 parts by weight of carbon fibers to the mixture to obtain a paste-like material, and burying a metal mesh sheet at substantially the center of the paste-like material in the third step. Is preferred. As the shape of the carbon fiber, a general-purpose product having a diameter of about 7 microns and a length of about 3 to 6 mm is sufficient, but processing of the fiber surface with an organic substance is not desirable in view of adhesive strength, and a single fiber which is not a bundle is preferable. In addition, after adding 800 to 1,500 parts by weight of sodium silicate in the second step, adding 10 to 50 parts by weight of kaolin fine powder can appropriately adjust the viscosity of the paste-like material and improve the strength of the final product. Preferred.

Further, the shape of the metal mesh sheet depends on the thickness of the composite plate material according to the present invention, but when the thickness is around 6 mm, the thickness of the metal wire is preferably about 0.3 to 0.5 mm in diameter. The mesh opening is desirably about 5 to 15 mm. Further, the particle size range of the ceramic powder such as fly ash as a raw material component in the first step is generally about 10 to 30 μm for fly ash, 40 to 70 μm for wollastonite, and fine powder of blast furnace slag: specific surface area of 6,000. ~ 8,
000 cm ² / g and a fine silica powder of 1 micron or less. In addition, the zinc oxide in the second step is preferably 0.5 μm or less, and the kaolin fine powder is preferably 2 μm or less.
Preferably it is less than 5 microns. As described above, the particle size of each material needs to be configured in a range in which the particle size composition is good together with the amount added in order to exhibit high strength as a structural material. Further, it is experimentally verified as a sufficient and satisfactory particle size range to adhere to the periphery of the metal mesh sheet together with the slurry-like binder in the second step and serve as a granule for increasing the adhesive strength.

[0010] The particle size composition of each of the above materials and a binder as a slurry-like binder are mixed to form a paste-like material in the third step, and a metal mesh sheet is interposed in the center of the paste-like material. The thin plate is formed as a composite formed plate having a width of 900 mm, a length of 2,400 mm and a thickness of about 6 mm. As a preferable forming method of this composite plate,
The paste-like material is extruded into a udon shape, a chip shape or a flat plate shape by vacuum extrusion molding, and the extruded product is supplied to the lower surface portion and the upper surface portion of the metal mesh sheet, and is sent out in a sandwich shape, for example, to a width of about 1,000 mm. . At this time, the extruded material in the shape of a udon, a chip, or a flat plate has a thickness that can be extended to about 3 mm on the upper and lower surfaces of the metal mesh sheet after rolling by a roller. 0.5 mm or less.

Further, when the extruded material is rolled by the upper and lower rollers, the material may stick to the surface of the roller. Therefore, before the extruded material is rolled, a film-like material such as polypropylene film or polyethylene may be formed. It is preferable that the sheet is sandwiched between the upper and lower portions of the same material, and then the upper and lower rollers are rolled through a film-like sheet to obtain a composite plate having a predetermined thickness of about 6 mm. Subsequently, the composite plate compacted by the rollers is humidified and dried. When the material is solidified, the upper and lower films are removed. After that, the composite plate is roughly cut into a predetermined size, and then heat-treated at 350 to 600 ° C.

Here, the operation of each compounding raw material used in the present invention will be described. First, as described above, most of the particle size composition of the main powder raw materials is from submicron to about 70 μm.
Formability can be enhanced by having a particle size of up to microns, with the largest being around 10 to 30 microns. In addition, a small amount of the fine powder of the blast furnace slag reacts with the alkaline solution to exhibit a kind of hydraulic property. In particular, in the presence of the alkaline solution, the small amount of the fine powder causes the coagulation to occur faster by humidification and drying. This speed has a correlation between the content of the blast furnace slag and the size of the particles, and the time for the molded body to develop the hardness having workability is 10 to
If it is 20 minutes, its content is within 10%, and if it is less than 3%, it takes 20 minutes or more. Further, carbon fibers are confused vertically and horizontally with the powder raw material to dramatically increase the bending strength and flexibility of the molded body, and strengthen the bond with the powder raw material by the binder.

[0013] Aluminum hydroxide, zinc oxide, sodium aluminate, boric acid and sodium silicate as raw materials for the slurry-like binder are made of high-strength sheet ceramic.
The kaolin fine powder, which constitutes a binder for the production of the metal mesh sheet composite molded article, and is selectively added at the same time, is a raw material for adjusting the viscosity of the binder. This binder greatly dissolves and gels the particle surface of the powder raw material, and at the same time wraps the suspended particles and carbon fibers evenly, and as the temperature rises, the powders and the powders and the carbon fibers cross each other as the temperature rises. It has the effect of strengthening the adhesion, and plays a role as a strong adhesive component for expressing sufficiently high strength between 350 ° C. and 600 ° C. of the target temperature while continuing the hardening effect along with the evaporation of moisture. is there.

In the operation of the compounding raw material according to the present invention, aluminum hydroxide generally has an average particle size of about 20 microns, and reacts with an alkaline solution to partially dissolve as sodium aluminate to exhibit an adhesive effect. When heated, the composition is sufficiently cured at a temperature of 200 ° C. or higher, and furthermore, with a rise in temperature, a part thereof becomes aluminum oxide to exhibit excellent effects such as an increase in fire resistance. Zinc oxide is
Precisely, the chemical formula is Zn _{1 + δ} O, where zinc is in excess of oxygen by δ, and this excess
It is not well known whether the n atoms are in excess or both, but the composition has a cocatalytic function and a activating effect by heating. It is thought that the compound exerts an effective action and exerts an effective action on binding. Sodium aluminate is stable in an alkaline solution, has high adhesiveness, and has a high melting point of 1,700 ° C. or more when dehydrated.
Boric acid works effectively as a binder to gel a part of the raw material added to the above-mentioned alkaline aqueous solution. Thereafter, sodium silicate is added, and further gelation and many hydrates are formed to complete the formation of the binder. The whole suspension containing the gel-like substance produced by the mutual reaction of the raw materials thus added exhibits high adhesive strength. Adjustment of viscosity can be controlled by adding kaolin fine powder.

On the other hand, when the binder is added to fly ash or silica fine powder, the surface of the particles of these fine powders is wet and a reaction occurs on the surface, and a gel-like substance is generated on the surface layer of the particles. This gel-like substance causes a strong bond between the particles, and as the heating proceeds, a coagulated state in which the gel and the crystal are entangled in the boundary region between the particles is formed to promote hardening. Hardening phenomena are clearly recognized even though the details of the blast furnace slag fine powder reacting with the alkali component of the binder and forming a new gel-like substance and many hydrated compounds have not been clarified yet. In general, it is characterized by alkali aluminate, etc., and in the process of heating from a hydrate to an anhydride, it hardens in a condensed state in which the gel and crystals are entangled, and dehydrates with increasing temperature and time. This results in a stronger strength. Wollastonite is used because it is suitable for adjusting the particle size with other powder raw materials, has high fire resistance, is most suitable as a low-cost, easily available mineral raw material. Even though not all of these reactions are evident, the presence of the amorphous and the hydrated compound and the suspended crystalline fine particles gelled by the mutual reaction of the raw materials constituting the added binder are shown in FIG. From the results of the X-ray analysis shown in FIG. 8, it can be clearly seen that in the heating range up to 600 ° C., it is almost amorphous and stable. In addition,
Fig. 2 shows the X-ray of aluminum hydroxide, Fig. 3 shows the X-ray of zinc oxide, and Fig. 4 shows the X-ray of sodium aluminate.
Fig. 5 shows the X-ray of boric acid. FIG.
FIG. 3 is an X-ray analysis of a heating product of a binder liquid manufactured from the raw materials shown in FIGS. 2 to 5 and sodium silicate (liquid), and shows 30 g of aluminum hydroxide, 60 g of sodium aluminate, 50 g of zinc oxide, and 50 g of silica. Sodium acid (water glass No. 1 (JIS)) 1500 g mixture at 80 ° C, 350
It is an X-ray analysis of each heating product of ℃ and 600 ℃. FIG. 7 shows a mixture of 30 g of aluminum hydroxide, 60 g of sodium aluminate, 1000 g of boric acid (saturated solution) and 1500 g of sodium silicate (water glass No. 1 (JIS)).
It is an X-ray analysis of each heating product of 0 degreeC, 350 degreeC, and 600 degreeC. FIG. 8 shows 30 g of aluminum hydroxide-60 g of sodium aluminate-50 g of zinc oxide-1000 of boric acid.
g (saturated solution) -sodium silicate (water glass No. 1 (J
IS)) 1500 ° C mixture at 80 ° C, 350 ° C and 60 ° C.
It is an X-ray analysis of each heating product at 0 degreeC.

Next, a composite plate is manufactured from the paste-like material produced in the second step by a roll forming method. The fineness of the powder raw material used in the roll forming method is preferably at least 70 μm or less for smoothing the surface of the molded body, and the surface smoothness of the molded body depends on the wire diameter of the embedded metal mesh sheet depending on the thickness of the molded body. There is a correlation with the aperture. According to many experimental results, the fineness of the compounding raw material is the above-mentioned size, and when the thickness of the molded body is about 6 mm, the linear thickness is 0.3 to 0.5 mm and the aperture is 6 mm. A range of about 15 mm is desirable.

Here, the reasons for limiting the respective numerical value ranges in the mixture of the first step according to the present invention will be described. 70-90 parts by weight fly ash, wollastonite 10-3
Kneading the binder in the second step with a mixture of the proper mixing ratio within the lower and upper limits of each raw material of 5 parts by weight, 5 to 10 parts by weight of blast furnace slag fine powder and 5 to 15 parts by weight of silica fine powder. However, since the kneaded material has a dilatancy-like viscosity, an experimental result has been obtained that is most preferable in forming these raw materials and the mixed material. Outside of these ranges, the "viscosity" when kneading with the addition of a binder in an appropriate mixing ratio is hard at the time of kneading in the next step (particularly at the time of vacuum kneading), causing cracks or "sagging" due to being too soft. It becomes difficult to form, for example, it cannot be moved to the next second step. As described above, even though the mixing relationship between the raw material and the binder is extremely narrow, the mixing ratio of the binder in the second step is 20 to 35% by weight based on the mixed raw material 100 in the first step. Department. These compounding condition ranges are all preferable for vacuum kneading and roll forming, and are ranges of minimum and maximum values calculated by experiments.

Next, the reasons for limiting the respective numerical value ranges of the raw materials constituting the binder will be described. The relative proportions of the raw materials are also related. In general. Aluminum hydroxide is closely related to the type of aluminum hydroxide and the amount of sodium aluminate added, and is further closely related to the degree of melting depending on the amount of sodium silicate added. Therefore, the mutual ratio of aluminum hydroxide and sodium aluminate is usually set to 60 parts by weight or less when aluminum hydroxide is 10 parts by weight or more, and 30 parts by weight or less when aluminum hydroxide is 30 parts by weight or less. It is a desirable range from the viewpoint of the viscous state that the addition is performed in the range of the compounding weight set in parts by weight or more. On the other hand, the melting point of pure sodium aluminate against heating is 1,700 ° C. or more, which is refractory, and a part of aluminum hydroxide forms a high-temperature stable form at 1,500 ° C. as aluminum oxide by heating. In addition, since it begins to dehydrate at 150 ° C or higher and performs a catalytic action, in the heating temperature range of 350 to 600 ° C of the present method, it exhibits a bridging action like zinc oxide, and is useful for product strength and weather resistance. Mechanism of action. . If the distribution amount of carbon fibers in the first step is less than 1 part by weight, the amount occupied in the substrate is small. This amount was determined by microscopic observation from a cross section of the base material, and was further verified by a bending strength test. That is, when the carbon fiber is kneaded with the base material in an amount of less than 0.5 part by weight, the strength is about 100 kgf / c.
m ² and low fiber kneading compaction capable viscosity becomes difficult for the matrix is the matrix of the resulting not so be dry when the amount of the carbon fiber is more than 3.0 parts by weight.

[0019] Zinc oxide partially forms a zincate by an alkaline solution, but most of zinc oxide exerts a catalytic action similarly to aluminum oxide and is useful for improving product properties. Further, it is stable to heating up to 1,300 ° C. and has excellent concealing properties. Therefore, the range of 20 to 50 parts by weight is desired because a slightly excessive range of the addition amount is desired from experimental results. . A saturated solution of boric acid is used for performing a gelling reaction with another raw material in an alkaline solution using a weak acid. This gel substance adheres around small suspended particles such as binder,
Heat dehydration acts as a strong adhesive between these particles. This saturated solution of boric acid is 100 g around normal temperature.
Approximately 4 g is dissolved in water, so that the gelling reaction can be sufficiently performed by adding 500 g parts by weight at the minimum and 1,000 g parts at the maximum at the maximum according to the ratio of the added amount of each raw material. . From the above added amount of the binder, the minimum value of sodium silicate is 800 parts by weight. If less than this, less than 20 parts by weight of the binder is added to 100 parts by weight of the raw material mixture to form a paste-like material. However, the viscosity is insufficient. On the other hand, sodium silicate forms a binder at 1,500 parts by weight or less, and if an amount exceeding 35 parts by weight of the binder is added to 100 parts by weight of the mixture raw material, the paste-like material causes a so-called sagging phenomenon and cannot be formed. It becomes possible. Therefore, the appropriate addition amount range of sodium silicate is 800 to 1,500 parts by weight.

Next, a method of manufacturing a high-strength thin ceramic / metal mesh sheet composite plate of the present invention will be described with reference to a manufacturing apparatus (side view) shown in FIG. For example, after the paste-like material obtained in the second step is sufficiently degassed by a vacuum forming machine, a thick film is formed on the left side of the molding line as a udon-like, chip-like, or plate-like material 1 depending on the type of die. It is supplied on the sheet 3 with a thickness of about 3.5 mm and a constant width.
Next, the metal mesh sheet 2 is supplied to the upper surface of the material 1 on the thick film sheet 3. At this time, the metal plate 4 located below is raised and set on the lower surface of the sheet 3. The set metal plate 4 is transported rightward.
Then, adjacent to the supply of the metal mesh sheet 2,
On the right side, a material 1 similar to the above is a metal mesh sheet 2
Is supplied to the upper surface of the plate to form a sandwich. Thereafter, at the center of the drawing, the thin film sheet 5 is circulated and supplied endlessly from the upper surface of the sandwich. Further, the sandwich-like material whose upper and lower surfaces are sandwiched between the sheets 3 and 5 is rolled by rolling rollers 6.
In this case, two or three rows of rolling rollers are preferable. By this rolling, the width and thickness are adjusted, strong adhesion to the metal mesh sheet, partial defoaming by the first row of rollers, and homogenization of the base composition are achieved. The roller may be a roller having the same diameter on both the upper and lower sides (motor rollers 7 are arranged at the bottom in the figure).
Immediately after the molding by the roller, it is transferred to a humidifying and drying device. After drying and humidifying the composite board 10 in this process, the thin film sheet 5 on the upper surface is wound off and removed, and the thick film sheet 3 on the lower surface is also removed. 8 for rough cutting. As the metal mesh sheet 2, a method of intermittently inserting a fixed-size metal mesh sheet between the materials 1 and 1 'and burying the metal mesh sheet 2 may be adopted. In this case, the base material between the metal mesh sheets is used. Almost the center of the part is cut by a synchronous automatic cutting device (not shown). In this step, the upper thin film sheet 5, the lower thick film sheet 3, and the lower metal plate 4 rotate again and return to their original positions. The dried composite plate 10 cut to a predetermined size in this way is finally transferred to a heating device (not shown) such as a tunnel kiln and is heated to 350 to 60.
Heat treatment is performed at a temperature of 0 ° C. The forming speed, humidification drying, and heat treatment speed of the composite plate which is continuously formed and heat-treated in this manner are tuned to about 1 m per minute to produce a high-strength thin ceramic / metal mesh sheet composite plate of the final product. You.

[Specific Production Example] Next, an embodiment of a method for producing a high-strength thin ceramic / metal mesh sheet composite plate according to the present invention will be described with reference to FIG. Example 1 First, 70 parts by weight of fly ash, wollastonite 8
1 part by weight, 3 parts by weight of carbon fiber added to 10 parts by weight of blast furnace slag fine powder and 7 parts by weight of silica fine particles and sufficiently mixed and adjusted, and the powder and fiber obtained in the first step are adjusted. For 100 parts by weight of the mixture, 10 parts by weight of aluminum hydroxide, 20 parts by weight of zinc oxide and 5 parts by weight of sodium aluminate
A slurry-like binder obtained by adding 500 parts by weight of a boric acid saturated solution to the mixture to which 0 parts by weight has been added, further adding 800 parts by weight of sodium silicate, and then adding 10 parts by weight of kaolin fine powder and mixing well. In the second step of adding 20 parts by weight of pulp and thoroughly kneading it,
Get. The material 1 is supplied to the upper surface of the moving thick film sheet 3 by vacuum extrusion, and subsequently, the metal mesh sheet 2 is supplied to the upper surface. Next, after the vacuum-extruded material 1 ′ is added to the upper surface of the mesh sheet 2 and supplied, an endlessly moving thin film sheet 5 is supplied to the upper surface thereof. And then rolled again by the second rolling roller 6 'to about 6.0 mm to obtain a thin ceramic / metal mesh sheet composite plate. The composite plate was humidified and dried by a humidifying and drying device 7 to form a dry composite plate 10. The composite plate was cut into a length of about 2,500 mm by a cutter 8 and then introduced into a tunnel kiln and heated. The total heating time is 90 minutes, of which the maximum temperature of 350 ° C. is maintained for 10 minutes. As a result of such heating, a high-strength thin ceramic / metal mesh sheet composite plate was obtained. Table 1 shows the physical properties of the obtained products.

[0022]

[Table 1]

Example 2 First, 80 parts by weight of fly ash, 3 parts by weight of wollastonite, 5 parts by weight of blast furnace slag fine powder, and 10 parts by weight of silica fine particles, and 2 parts by weight of carbon fiber were added and mixed well. One process,
A mixture of 20 parts by weight of aluminum hydroxide, 30 parts by weight of zinc oxide and 40 parts by weight of sodium aluminate was added to a mixture of 100 parts by weight of the mixture of powder and fiber obtained in the first step, and a boric acid saturated solution was added. After adding 800 parts by weight, further adding 1,000 parts by weight of sodium silicate, adding 30 parts by weight of kaolin fine powder and mixing well, and adding 25 parts by weight of a slurry-like binder obtained The paste-like material 1 is obtained by the second step of kneading. After the paste-like material (kneaded material) 1 obtained in the second step is vacuum-extruded on a thick film sheet 3 into a flat plate shape, a metal mesh sheet 2 is formed.
Is placed on the upper surface, a flat kneaded material (paste-like material) 1 ′ extruded on the upper surface is further added on the upper surface, and the thin film sheet 5 is further supplied on the upper surface. Then, it is rolled again to about 6.0 mm with a rolling roller 6 'to obtain a thin composite plate. Then, the composite plate was subjected to a length of about 2,500.
After being cut into mm, it was dried by a humidifying and drying device 7 and then heated in a tunnel kiln (not shown). The total heating time was 90 minutes, of which the maximum temperature of 350 ° C. was maintained for 10 minutes. As a result of such heating, high strength
A metal mesh sheet composite plate was obtained. Table 1 shows the physical properties of the obtained products. The physical properties of the product are as shown in Table 2 .

[0024]

[Table 2]

Example 3 First, 90 parts by weight of fly ash, 3 parts by weight of wollastonite, 5 parts by weight of blast furnace slag fine powder, and 5 parts by weight of silica fine particles, and 1 part by weight of carbon fiber are added and mixed well. The first step and a mixture obtained by adding 30 parts by weight of aluminum hydroxide, 50 parts by weight of zinc oxide and 30 parts by weight of sodium aluminate to 100 parts by weight of the mixture of the powder and the fiber obtained in the first step. Was added with 1,000 parts by weight of a boric acid saturated solution,
After adding 500 parts by weight, add 50 parts by weight of kaolin fine powder and mix well to obtain 30 parts of the slurry-like binder obtained.
The kneaded product 1 of the paste-like material was produced in the second step of adding the parts by weight and kneading sufficiently. After kneaded material 1 was vacuum-extruded into a udon shape, chip-shaped kneaded material 1 in which metal mesh sheet 2 was vacuum-extruded on the upper surface was added using apparatus shown in FIG. 1 according to Examples 1 and 2. After that, it was rolled into a flat plate to a thickness of about 6.3 mm by the rolling roller 6. Further, after the thin composite plate obtained by compacting again to about 6.0 mm with the compacting roll 6 ′ is cut to a length of about 2,500 mm,
It was humidified and dried and heated in a tunnel kiln (not shown). The total heating time was 90 minutes, of which the maximum temperature of 350 ° C. was maintained for 10 minutes. As a result of such heating, a high-strength thin ceramic / metal mesh sheet composite plate was obtained. Table 3 shows the physical properties.

[0026]

[Table 3]

Example 4 First, 80 parts by weight of fly ash, 3 parts by weight of wollastonite, 5 parts by weight of blast furnace slag fine powder, and 2 parts by weight of carbon fiber were added to 10 parts by weight of silica fine particles, and the mixture was sufficiently mixed and adjusted. The first step and a mixture obtained by adding 15 parts by weight of aluminum hydroxide, 25 parts by weight of zinc oxide and 40 parts by weight of sodium aluminate to 100 parts by weight of the mixture of the powder and the fiber obtained in the first step. 800 parts by weight of a saturated solution of boric acid were added to
After adding 0 parts by weight, add 10 parts by weight of kaolin fine powder and mix well and add 25 parts by weight of a slurry-like binder obtained, and knead sufficiently to obtain a paste-like material 1. Obtained. Next, as described in Examples 1 to 3, the paste-like material 1 was vacuum-extruded into a flat plate, and then the metal mesh sheet 2 was disposed on the upper surface, and the vacuum-extruded plate-like material 1 ′ was further added on the upper surface. Thereafter, the sheet is rolled into a flat plate to a thickness of about 6.3 mm by a rolling roller 6 and further rolled to a thickness of about 6.0 mm by a rolling roller 6 ′ to produce a thin composite plate. After cutting to 2,500mm
The wet composite board 10 was obtained by humidifying and drying. The dried composite plate 10 was heated in a tunnel kiln (not shown). The total heating time was 90 minutes, of which the maximum temperature of 600 ° C. was maintained for 10 minutes. As a result of such heating, a high-strength thin ceramic / metal mesh sheet composite plate was obtained.
Table 4 shows the physical properties.

[0028]

[Table 4]

The present invention described in the embodiments and the like has the following advantages. (1). Heretofore, a thin ceramic / metal mesh sheet composite plate has not been commercially available. The reason is that, even if a metal mesh sheet is buried in a ceramic body and a thin plate ceramic / metal mesh sheet composite plate is to be manufactured by firing, a high temperature firing of about 1300 ° C. is required for firing the ceramic body. This is because the metal mesh sheet is melted or softened and damaged in the firing step, and only a defective product is obtained. However, according to the method of the present invention, a large, high-strength, thin ceramic / metal mesh sheet composite plate can be easily provided. (2). Large, thin, lightweight, 9 times or more the size of ordinary ceramic products, less than half the thickness, 2/3
A ceramic / metal mesh sheet composite plate weighing the following can be obtained, and even a 1 m ² square object has a total weight of less than 10 kg, and can be cut and drilled freely. Also,
The product has excellent dimensional accuracy, enables mechanization of mounting, and saves labor because no skilled person is required. (3). The product according to the present invention is a material in which the raw materials are all inorganic and are obtained from an inorganic-metal oxide-water-based intermediate product, which withstands a much higher temperature than commercially available materials, generates no harmful gas, and has no safety. Outstanding. In addition, it has excellent fire protection, heat retention and durability. On the other hand, general building materials, even cement / concrete products, are mixed with a few percent of organic matter and burn at low temperatures to generate odors. (4). Since the product has a configuration in which a metal mesh sheet is embedded in a sandwich shape in ceramic,
The drawbacks of ceramics that are inherently weak in impact are remarkably improved, and no scattering occurs even if the composite board product is broken. Furthermore, elasticity such as bending increases due to the action of apparent residual stress.

(5). In terms of economy, as a result of the selection of the raw materials and the continuous molding method, the raw material is very inexpensive because the ceramic powder as the main raw material is fly ash and the main binder is alkali silicate. Also, since mass production by continuous molding becomes possible, the price of the product is extremely low . Since the heating temperature of general ceramic products is high, around 1200 ± 50 ° C., the equipment of the combustion furnace is expensive, the combustion cost is high, and the exhaust gas countermeasures and management costs are high. However, according to the present invention, since the heating temperature for producing the product is 350 to 600 ° C., equipment costs, fuel costs, and management costs become extremely low.
There is no pollution due to exhaust gas, and it is an energy-saving and labor-saving type and is a pollution-free industry. (6). Since the main raw material is fly ash and a part of the auxiliary raw material is waste material such as blast furnace slag, it becomes an industrial waste recycling type industry. And in terms of using the obtained product,
It can be used in various fields such as house building materials, civil engineering building materials, wall materials for tunnels, roads, and railways.

[0031]

According to the method of the present invention described above, the following excellent effects can be obtained. The ceramic / metal mesh sheet composite plate obtained by the method of the present invention has high strength and high fire resistance, has resilience with the development of residual strength even at the time of breaking, and does not cause separation of ceramic and metal mesh sheets. It is excellent in safety. All the raw materials used in the present invention are inorganic, and there is no danger of burning and no generation of harmful gases even in the event of fire. Moreover, since the main raw material is industrial waste, the production cost of the product is low. Conventionally, a thin ceramic / metal mesh sheet composite plate has not been commercially available, but according to the method of the present invention, a large, high-strength, thin ceramic / metal mesh sheet composite plate can be easily provided.

[Brief description of the drawings]

FIG. 1 is a schematic side view of a manufacturing apparatus for a high-strength thin ceramic / metal mesh sheet composite plate.

Fig. 2 X-ray analysis of aluminum hydroxide

FIG. 3 X-ray analysis of zinc oxide

FIG. 4 X-ray analysis of sodium aluminate

FIG. 5 X-ray analysis of boric acid

FIG. 6 is an X-ray analysis of heat products of aluminum hydroxide-sodium aluminate-zinc oxide-sodium silicate at 80 ° C., 350 ° C. and 600 ° C.

FIG. 7: 80 ° C., 350 ° C., and 6 ° C. for aluminum hydroxide-sodium aluminate-boric acid-sodium silicate system
X-ray analysis of 00 ° C heating product

FIG. 8: 80 ° C., 35 ° C. of aluminum hydroxide-sodium aluminate-zinc oxide-boric acid-sodium silicate system
X-ray analysis of heating products at 0 ℃ and 600 ℃

[Explanation of symbols]

 1, 1 ': Paste material 2: Metal mesh sheet 3: Thick film sheet 4: Metal plate 5: Thin film sheet 6, 6': Roller roller 7: Motor roller 8: Cutter 10: Dry composite plate

──────────────────────────────────────────────────続 き Continued on the front page (58) Field surveyed (Int. Cl. ⁷ , DB name) C04B 35/00, 35/74 B32B 18/00

Claims (4)

(57) [Claims] 1. First, 3 to 10 parts by weight of wollastonite, 5 to 10 parts by weight of blast furnace slag fine powder and 5 to 15 parts by weight of silica fine particles are added to 70 to 90 parts by weight of fly ash and uniformly mixed.
Process, 100 parts by weight of the mixture obtained in the first step, aluminum hydroxide 10 to 30 parts by weight, zinc oxide 20 to
To 50 parts by weight and 30 to 60 parts by weight of sodium aluminate, 500 to 1,000 parts by weight of a boric acid saturated solution is further added, and 800 to 1,50% of sodium silicate is further added.
A second step of adding 20 to 35 parts by weight of a slurry-like binder obtained by thoroughly mixing after adding 0 parts by weight , and sufficiently kneading to obtain a paste-like material; A third step of embedding a metal mesh sheet in the paste-like material to form a thin plate and then humidifying and drying to obtain a dry composite plate; and heating the dry composite plate obtained in the third step at 350 to 600 ° C. And a fourth step of obtaining a ceramic / metal mesh sheet composite plate having high strength and high residual strength and excellent fire resistance.
Manufacturing method of metal mesh sheet composite board. 2. A first step in which 3 to 10 parts by weight of wollastonite, 5 to 10 parts by weight of blast furnace slag fine powder and 5 to 15 parts by weight of silica fine particles are added to 70 to 90 parts by weight of fly ash and uniformly mixed. 100 parts by weight of the mixture obtained in the first step, aluminum hydroxide 10 to 30 parts by weight, zinc oxide 20 to 20 parts by weight
To 50 parts by weight and 30 to 60 parts by weight of sodium aluminate, 500 to 1,000 parts by weight of a boric acid saturated solution is further added, and 800 to 1,50% of sodium silicate is further added.
After adding 0 parts by weight, add 20 to 35 parts by weight of a slurry-like binder obtained by adding 10 to 50 parts by weight of kaolin fine powder and mixing well, and knead well to obtain a paste-like material. And extruding the paste-like material obtained in the second step into a shape selected from the group consisting of udon, chip, and flat plate under reduced pressure. Is set on the upper and lower sides of a metal mesh sheet made of stainless steel or iron, and the upper and lower sides are rolled and rolled to form a plate having a thickness of several millimeters, then cut into a certain length, humidified and dried to dry A third step of obtaining a composite plate; heating the dried composite plate obtained in the third step at 350 to 600 ° C. to obtain a high strength ceramic / metal mesh sheet composite plate having a high residual strength and a high fire resistance. The fourth step of obtaining High-strength thin plate-like ceramic to -
Manufacturing method of metal mesh sheet composite board. 3. The high-strength thin plate-shaped ceramic according to claim 1, wherein, in the first step, 0.5 to 3.0 parts by weight of carbon fiber is added to the mixture, and the mixture is further sufficiently mixed.・ Method of manufacturing metal mesh sheet composite board. 4. In the second step, sodium silicate 80
After adding 0 to 1,500 parts by weight, kaolin fine powder 1
Claim, characterized in that the addition of 0-50 parts by weight of 1 or
4. The method for producing a high-strength thin ceramic / metal mesh sheet composite plate according to any one of 3.