JP3523376B2 - Method for producing foamed building material and foamed building material - Google Patents

Description

Detailed Description of the Invention

[0001]

TECHNICAL FIELD The present invention relates to a method for producing a foam building material and a foam building material, and more particularly to a method for producing a foam building material by firing and foaming a raw material containing an inorganic foaming powder.

[0002]

2. Description of the Related Art A foamed tile as a foamed building material is lighter than a tile made by firing porcelain clay, and can reduce the weight of the entire building, and is therefore suitable for use as an exterior or interior of a building. Inorganic foamable powder is used as a raw material for the foam tile. The inorganic effervescent powder contains, for example, volcanic rock such as clay and clay, volcanic ash such as shirasu, feldspar, clay, glass powder, etc. as the main component, and glass powder, borax, etc. as a fluxing agent, and further as a foaming agent. It is manufactured by mixing bentonite and sodium nitrate and crushing the mixture. A conventional foamed tile is manufactured by filling a molding die with this inorganic expandable powder, press-molding it, and firing the molded product obtained by press-molding to foam it.

[0003]

In the conventional method for producing a foamed tile, the inorganic foamable powder having a low fluidity is directly filled in the mold, so that the inorganic foamable powder is quantitatively supplied to the mold. And it is difficult to uniformly fill the mold. If the quantitative amount of the inorganic expandable powder cannot be supplied to the molding die as described above, the thickness unevenness easily occurs in the foamed tile after the firing and foaming. Further, if the molding die cannot be uniformly filled with the inorganic expandable powder, foaming unevenness is likely to occur. For this reason, in the conventional method of manufacturing a foamed tile, it is difficult to stably manufacture a foamed tile having a constant shape due to variations in the shape after firing and foaming.

Further, in this type of foam tile, pinholes are apt to be generated on the surface due to foaming, and the surface becomes rough. Therefore, when used as the exterior of a building, there is a problem that the surface is likely to be contaminated. There is also a problem that the rough surface of the surface generated by the pinhole is easily worn. An object of the present invention is to provide a foam building material having a fixed shape and a method for manufacturing a foam building material capable of stably manufacturing the foam building material.

Another object of the present invention is to provide a foam building material which is resistant to contamination and has high abrasion resistance, and a method for producing the foam building material.

[0006]

According to a first aspect of the present invention, there is provided a method for producing a foam building material, which comprises mixing glass particles having a particle size of 0.3 to 8 mm with inorganic expandable powder having a particle size of 150 mesh or less. A mixing step of obtaining a mixture, a molding step of filling the mixture obtained in the mixing step into a molding die and press-molding, and a step of taking out the molded body obtained in the molding step from the molding die, followed by firing to foam. And a foaming process. Here, since glass particles are mixed with the inorganic expandable powder,
The apparent bulk density is reduced and the fluidity is increased. Also,
Even if the glass particles are fired, they do not foam and the weight does not decrease, so that the change in shape is reduced. For this reason, it becomes easy to supply the mixture to the mold in a fixed amount, it is easy to uniformly fill the mold, and the thickness unevenness and the foaming unevenness after foaming are reduced, and it is possible to stably manufacture a foamed tile having a certain shape. become.

According to a second aspect of the present invention, in the method for producing a foam building material according to the first aspect, the glass particles have a melting temperature higher than that of the inorganic expandable powder. Here, since the melting temperature of the glass particles is higher than the foaming temperature of the inorganic expandable powder, the glass particles do not dissolve into the inorganic expandable powder during firing and foaming, and the foaming is stable.

The method for producing a foam building material according to the invention of claim 3 is the method according to claim 1 or 2, wherein the inorganic expandable powder has a specific gravity of 0.5 to 1.
I use the one of 5. Here, the inorganic expandable powder is
Since the specific gravity of the simple substance after firing and foaming is 0.5 to 1.5, the pinhole on the surface becomes small and the foaming is surely performed.

A method for manufacturing a foam building material according to the invention of claim 4 is the method according to any one of claims 1 to 3,
30 to 300% by weight of inorganic expandable powder with respect to glass particles
Mixed. Here, since the inorganic expandable powder is mixed in an amount of 30 to 300% by weight with respect to the glass particles, the strength of the molded product after molding is high and the shape can be maintained even by handling. If the amount of the inorganic expandable powder is less than 30% by weight, the strength is low and the powder is easily damaged by handling. Also, 30
If it is more than 0% by weight, the inorganic expandable powder and the glass particles become non-uniform and it is difficult to obtain a stable product.

A method for producing a foam building material according to the invention of claim 5 is the method according to any one of claims 1 to 4,
Before the mixing step, a pigment addition step of adding a pigment to the inorganic expandable powder is further included. Here, since the pigment is added to the inorganic expandable powder before mixing, high designability can be obtained. In the method for manufacturing a foam building material according to the invention of claim 6, in the method according to any one of claims 1 to 5, the molding step includes a laminating step of laminating a decorative layer on the layer of the mixture. Here, since the decorative layer that does not foam is laminated on the layer of the mixture in the molding step, the surface after firing and foaming becomes a smooth surface, is less likely to be contaminated, and is also improved in abrasion resistance.

According to a seventh aspect of the present invention, in the method for producing a foam building material according to the sixth aspect, in the laminating step, granules of glaze powder are laminated as a decorative layer. here,
Since the granulated powder of the glaze powder is laminated as the decorative layer, the designability can be improved. In the method for manufacturing a foam building material according to the invention of claim 8, in the method of claim 6, in the laminating step, glass particles containing colored glass are laminated as a decorative layer. Here, since glass particles containing colored glass are laminated as a decorative layer, abrasion resistance can be further improved.

According to a ninth aspect of the present invention, in the method for producing a foam building material according to the sixth aspect, in the laminating step, glass particles coated with decorative powder are laminated as a decorative layer. Here, since the glass particles coated with the decorative powder are laminated as the decorative layer, the design and abrasion resistance can be further improved. A method for producing a foam building material according to the invention of claim 10 is the method according to any one of claims 6 to 9, wherein the decorative layer has a melting temperature higher than the foaming temperature of the inorganic expandable powder. Here, since the melting temperature of the decorative layer is higher than the foaming temperature of the inorganic expandable powder, the decorative layer does not melt into the inorganic expandable powder during firing and foaming, and the foaming is stable.

The foam building material according to the invention of claim 11 is manufactured by the method for manufacturing a foam building material according to any one of claims 1 to 10. Since it is manufactured by the manufacturing method described above, a foamed building material having a uniform shape with less unevenness in thickness and unevenness in specific gravity can be obtained. In addition, when a decorative layer is laminated, a foamed building material which has a smooth surface, is less likely to be contaminated, and has high abrasion resistance can be obtained.

[0014]

DETAILED DESCRIPTION OF THE INVENTION

[Embodiment 1] FIG. 1 is a schematic view showing a procedure of an embodiment of the method of the present invention. In FIG. 1, when carrying out the method of the present invention, first, a flux and a foaming agent are mixed with a main component such as volcanic rock and volcanic ash and pulverized to produce an inorganic foamable powder having a particle size of 150 mesh or less. To do. Here, as the main component, for example, anti-fire stone, clay, volcanic rock such as clay, volcanic ash such as shirasu, feldspar, clay, glass powder, etc. may be used.
Further, glass powder, borax, soda ash or the like may be used as the flux, and bentonite, sodium nitrate, silicon carbide, dolomite or the like may be used as the foaming agent.

These main components, flux and foaming agent are put into a dry ball mill 1 and ground and mixed to obtain an inorganic foamable powder 10 having a particle size of 150 mesh or less (FIG. 1 (A)). The specific gravity of the obtained inorganic expandable powder 10 is preferably in the range of 0.5 to 1.5, more preferably 0.6 to 1.2. The expandable powder 10 preferably has a foaming temperature lower than the melting temperature of the glass particles 11. Here, if the specific gravity of the inorganic expandable powder 10 after firing is less than 0.5, the shape retention during molding is impossible and the pinholes on the surface after firing and foaming become large. If the specific gravity exceeds 1.5, foaming is technically difficult. Further, cutting after foaming and firing is also difficult. Further, when the foaming temperature of the inorganic expandable powder 10 is lower than the melting temperature of the glass particles 11, the glass particles 11 are dissolved in the inorganic expandable powder 10 and the foaming becomes unstable.
That is, the contact portion between the glass particles 11 and the inorganic expandable powder 10 starts to melt quickly, the foaming gas is taken in quickly, large bubbles are formed, and foaming becomes unstable.

Subsequently, glass particles 11 having a particle size of 0.3 to 8 mm, preferably 0.3 to 3 mm are put into the concrete mixer 2. As the glass particles, ordinary glass particles such as soda lime glass, borosilicate glass, and aluminosilicate glass may be used. After the glass particles 11 are put in the concrete mixer 2, a 4% PVA (polyvinyl alcohol) solution is sprayed to wet the glass particles 11. Then, the inorganic expandable powder 10 is charged into the mixer 2 and the glass particles 11 and the inorganic expandable powder 10 are stirred and mixed.
As a result, as shown in FIG. 1 (B), the coating particles 13 in which the coating layer 12 of the inorganic expandable powder 10 is formed around the glass particles 11 are obtained. In addition, the mixing amount at this time was such that the inorganic expandable powder 10 was mixed with the glass particles 11 by 3 times.
It is preferable to mix 0 to 300% by weight. If the mixing amount is less than 30% by weight, the strength of the molded product becomes weak during press molding. On the other hand, if it exceeds 300% by weight, the inorganic foamable powder 10 and the glass particles 11 of the molded product are largely separated, and the quality is not stable. The range is more preferably 50 to 150% by weight. In addition, when the expandable powder 10 is colored by adding a pigment at the stage of manufacturing the inorganic expandable powder 10 of FIG. 1 (A), higher designability can be obtained.

When the glass particles 11 and the inorganic expandable powder 10 are mixed to obtain coating particles 13 in which the coating layer 12 is formed on the surface of the glass particles 11, subsequently, as shown in FIG. Then, a mixture of the inorganic expandable powder 10 and the coating particles 13 is filled. At this time, since the inorganic expandable powder 10 is coated on the peripheral surface of the glass particles 11, the flowability of the mixture becomes higher than that when only the inorganic expandable powder is filled, and the mixture is quantified in the mold 3. Easy to supply. Further, the inorganic expandable powder 10 can be uniformly filled in the mold 3.

Then, as shown in FIG. 1D, the mold 3 is placed in the press machine 5, and the mixture 14 is press-molded by the upper frame 6 attached to the press machine 5. At the time of this press molding, pressure molding is performed at a pressure of 19.6 MPa, for example. Finally, as shown in FIG. 1 (E), the molded mixture 14 is fired in the firing furnace 7 to form the inorganic expandable powder 10
Is foamed to obtain a foam tile 1. The firing temperature at this time is a temperature at which the glass particles 11 are not completely melted and the inorganic expandable powder 10 easily foams.

[Embodiment 2] In Embodiment 1, the foamed surface is exposed on the surface, but here, a decorative layer is laminated on the surface before molding to make the surface shape after firing and foaming flat. That is, in FIG. 2, (A) to (C),
(E) and (F) are the same steps as (A) to (E) shown in FIG. Here, in FIG. 2D, after the mixture 14 is filled in the mold 3, a decorative layer 15 made of, for example, glaze is further laminated thereon. Makeup layer 15 here
As the above, glass particles or coated particles obtained by coating glass particles with a cosmetic may be used without using a glaze.

By forming the decorative layer 15 in this manner, the surface of the foam tile can be made smooth, so that the surface is less likely to become dirty. Further, since pinholes and the like do not appear on the surface, abrasion resistance is improved.

[0021]

EXAMPLES Next, specific examples will be described. [Example 1] Bottle glass is crushed to have a particle size of 0.3 to 1.5.
1 kg of mm glass particles were prepared. As the inorganic foaming raw material powder, 52% by weight of white clay, 20% by weight of glass powder, 10% by weight of soda ash, 7% by weight of dolomite, 7% by weight of zircon flour, and 4% by weight of sodium nitrate were mixed, and the raw material was 20 kgw. Was charged in a ball mill, 250 kgw of iron balls of 15φ were charged therein, and the mixture was ground and mixed for 10 hours. Subsequently, 1 kgw of glass particles was put into a concrete mixer, and 15 g of 4 wt% PVA liquid was added by spraying to wet the glass particles. Then, 500 gw of the inorganic foamable powder produced by the ball mill was put into the concrete mixer and mixed. As a result, a mixture was obtained in which the glass particles were coated with the inorganic mixed expandable powder and the remainder was present between the glass particles. 150 x 150 m of this mixture
315 gw was put into a m frame and press-molded at a pressure of 19.6 MPa to obtain a molded product.

The obtained molded product was placed in an electric furnace, heated for 2 hours to be fired and foamed at a maximum temperature of 860 ° C., cooled and taken out of the electric furnace to obtain a foam tile. The obtained foam tile had a stable shape and had relatively few surface irregularities. Further, there was almost no foaming unevenness or thickness unevenness. [Example 2] A pink pigment (outer coat-M66-manufactured by Nisto Sangyo Co., Ltd.) was added to 95% by weight of glass powder and 5% by weight of mizuhi clay as a makeup layer, and the mixture was pulverized to obtain 325 mesh under 9
A 5% pass glaze powder was obtained. A ball mill was also used for this mixing and pulverization. Then, the glaze powder was granulated with a pan-type granulator to obtain a glaze granule having a particle size of 0.5 to 2.5 mm. At this time, the glaze powder was bonded using a 10% water glass solution. The glaze granulated product thus obtained was used as a decorative layer and laminated on a mixture of inorganic expandable powder coated on glass particles, followed by press molding and firing foaming to obtain a foam tile. The foamed tile thus obtained had a decorative layer in which the glaze was melted on the surface, so the surface was smooth, the abrasion resistance was improved, and stain resistance was reduced.

Example 3 As the decorative layer, glass particles having a particle diameter of 0.5 to 1.5 mm obtained by crushing green bottle glass were used. This was laminated on the mixture and molded, and then fired and foamed at a maximum temperature of 900 ° C. to obtain a foam tile. In this case, a decorative layer of semi-molten glass particles was formed on the surface, and the same effect as in Experimental Example 2 was obtained.

[Example 4] As a decorative layer, glass particles obtained by mixing bottle glasses of a plurality of colors (for example, green, brown and transparent) were mixed with 80% of glass powder and 20% of clay, and further as a pigment. The pink pigment described above was added. 50 parts by weight of this was coated on 100 parts by weight of glass particles. The obtained coated particles were laminated as a decorative layer on a mixture of expandable powder and glass particles to produce a foam tile. The decorative layer thus obtained had more abrasion resistance, and the grain boundaries of the glass particles were raised on the surface, and the designability was more preferable.

Instead of manufacturing foam tiles, the manufacturing method of the present invention can be applied to foam roof tiles and other foam building materials. Alternatively, the decorative layer may be first charged into the mold and then the mixture of the expandable powder and the glass particles may be charged into the mold. In this case, by forming various pattern patterns on the bottom surface of the mold, various patterns can be easily transferred to the decorative layer, and the designability can be further improved.

[0026]

In the method for producing a foam building material according to claim 1, since the glass particles are mixed with the inorganic foamable powder,
The apparent bulk density is reduced and the fluidity is increased. Also,
Even if the glass particles are fired, they do not foam and the weight does not decrease, so that the change in shape is reduced. For this reason, it becomes easy to supply the mixture to the mold in a fixed amount, it is easy to uniformly fill the mold, and the thickness unevenness and the foaming unevenness after foaming are reduced, and it is possible to stably manufacture a foamed tile having a certain shape. become.

In the method for manufacturing a foam building material according to claim 2,
Since the melting temperature of the glass particles is higher than the foaming temperature of the inorganic expandable powder, the glass particles do not dissolve into the inorganic expandable powder during firing and foaming, and the foaming is stable. In the method for producing a foam building material according to claim 3, since the inorganic foamable powder has a specific gravity of 0.5 to 1.5 after firing and foaming by itself, the pinholes on the surface are reduced. And surely foams.

In the method for manufacturing a foam building material according to claim 4,
30 to 300% by weight of inorganic expandable powder with respect to glass particles
Since they are mixed, the strength of the molded product after molding is high and it is easy to maintain the shape. In the method for producing a foam building material according to the fifth aspect, since the pigment is added to the inorganic foamable powder before mixing, high designability can be obtained.

In the method for manufacturing a foam building material according to claim 6,
In the molding process, because the decorative layer that does not foam is laminated on the layer of the mixture, the surface after firing and foaming becomes a smooth surface,
It is less likely to be contaminated and wear resistance is also improved. In the method for manufacturing a foam building material according to the seventh aspect, since granules of glaze powder are laminated as a decorative layer, the designability can be improved.

In the method for manufacturing a foam building material according to claim 8,
Since glass particles containing colored glass are laminated as a decorative layer, abrasion resistance can be further improved. In the method for manufacturing a foam building material according to the ninth aspect, since glass particles coated with decorative powder are laminated as a decorative layer, designability and wear resistance can be further improved.

In the method for producing a foam building material according to the tenth aspect of the present invention, since the melting temperature of the decorative layer is higher than the foaming temperature of the inorganic expandable powder, the decorative layer also has an inorganic expandable powder during firing and foaming. Stable foaming without melting. Since the foam building material according to the invention of claim 11 is manufactured by the above manufacturing method, it is possible to obtain a foam building material having a uniform shape with less thickness unevenness and uneven specific gravity. In addition, when a decorative layer is laminated, a foamed building material which has a smooth surface, is less likely to be contaminated, and has high abrasion resistance can be obtained.

[Brief description of drawings]

FIG. 1 is a schematic view showing a manufacturing procedure according to an embodiment of the present invention.

FIG. 2 is a diagram corresponding to FIG. 1 of another embodiment.

[Explanation of symbols]

10 Mixed powder 11 glass grains 12 coating layer 13 coated grains 14 mixture 15 Makeup layer

   ─────────────────────────────────────────────────── ─── Continued front page    (72) Inventor Shigeo Yoshida               1-4-1, Shinsenri Nishimachi, Toyonaka City, Osaka Prefecture                 National Housing Industry Co., Ltd. (72) Inventor Kimiaki Saita               2321 Tachi-cho, Toki City, Gifu Prefecture 2 Takasago Industry               Within the corporation (72) Inventor Taiji Yamauchi               2321 Tachi-cho, Toki City, Gifu Prefecture 2 Takasago Industry               Within the corporation                (56) References Japanese Patent Laid-Open No. 62-223074 (JP, A)                 JP-A-54-69115 (JP, A)                 JP 47-34507 (JP, A)                 JP-A-6-107475 (JP, A)                 JP-A-5-105543 (JP, A)                 JP-A-8-325075 (JP, A)

Claims (11)

(57) [Claims] 1. A glass grains having a grain size 0.3~8mm, 150
A mixing step of mixing an inorganic expandable powder having a particle size of mesh or less to obtain a mixture, a molding step of filling the mixture obtained in the mixing step into a molding die and press-molding, and a molding step obtained in the molding step. A method for manufacturing a foam building material, comprising: a firing and foaming step of firing a foam after taking out the molded body from a molding die. 2. The method for producing a foam building material according to claim 1, wherein the glass particles have a melting temperature higher than the foaming temperature of the inorganic expandable powder. 3. The method for producing a foam building material according to claim 1, wherein the inorganic expandable powder has a specific gravity of 0.5 to 1.5 after firing and foaming by itself. 4. The method for producing a foam building material according to claim 1, wherein in the mixing step, 30 to 300% by weight of the inorganic expandable powder is mixed with the glass particles. 5. The method for producing a foam building material according to claim 1, further comprising a pigment addition step of adding a pigment to the inorganic expandable powder before the mixing step. 6. The method for producing a foam building material according to claim 1, wherein the molding step includes a laminating step of laminating a decorative layer on the layer of the mixture. 7. The method for producing a foam building material according to claim 6, wherein in the laminating step, a granulated product of glaze powder is laminated as a decorative layer. 8. The method for producing a foam building material according to claim 6, wherein in the laminating step, glass particles containing colored glass are laminated as a decorative layer. 9. The method for manufacturing a foam building material according to claim 6, wherein in the laminating step, glass particles coated with a decorative powder are laminated as a decorative layer. 10. The method for producing a foam building material according to claim 6, wherein the decorative layer has a melting temperature higher than the foaming temperature of the inorganic expandable powder. 11. A foam building material manufactured by the method for manufacturing a foam building material according to any one of claims 1 to 10.