JP4633067B2 - Composition for building materials - Google Patents

Description

  The present invention relates to a building material composition, a building material using the same, and a method for producing them.

  Conventionally, when manufacturing building materials, base materials are selected for various purposes, and various materials are often blended with the various base materials.

  Among them, vermiculite is one of the mineral materials. This vermiculite (hillstone) is a clay mineral similar to biotite, and expands remarkably in a direction perpendicular to the layer by dehydration at a high temperature, and becomes a porous body extending like a hill. For this reason, since it has excellent heat insulation and sound absorption properties, it is intended to reduce the weight of the building materials (fillers, fillers) to the base material, as well as various building materials such as heat insulation materials and sound absorption materials as the base material. Often used together. On the other hand, vermiculite is not considered as a humidity control material because it does not have a high moisture absorption capacity.

  Therefore, as described above, when vermiculite is blended with building materials, it is usual to use expanded vermiculite for the purpose of weight reduction and the like. For example, it is used as a lightweight aggregate in cement products such as mortar and concrete. On the other hand, unexpanded vermiculite does not provide the advantages such as the above-mentioned weight reduction, so a small amount of up to several percent is used as a base material for special purposes that make use of its acid resistance and alkali resistance characteristics. It is only blended. In addition, an attempt has been made to fix a board made of substantially unexpanded vermiculite as a base material to the back side portion of the inner wall, etc., and expand it in the event of a fire to prevent the spread of fire. It is used as a specific base material used.

  On the other hand, the building materials themselves have been proposed to be provided with various functions in order to be differentiated from competing products. Among them, various studies have been made on humidity control (moisture absorption / desorption) and / or deodorization, and also a building material with an aesthetic appearance, but no satisfactory one has been found yet. That is, these have obtained a certain result by using one having a large specific surface area, but in particular, there are many cases in which the moisture retention rate is too strong and the moisture release rate is difficult.

  Therefore, the present inventor has recently attempted to make more effective use of vermiculite as a natural resource, and can satisfy humidity control and / or deodorization, as well as aesthetic demands. Various investigations were conducted to find new building materials.

  As a result, surprisingly, moisture is released by blending 5 to 70% by mass of unexpanded vermiculite with a base material, particularly a hydraulic material that is hygroscopic but has insufficient moisture release. It has been found that the ability can be significantly improved and the above-mentioned problems can be solved.

  The present invention, as a part of this study, in the case of using this unexpanded vermiculite, as a result of further investigation aimed at improving productivity, surprisingly, by using a specific amount of fine powder, the amount and speed of moisture absorption and desorption In addition, the bending strength, the flexibility, and the productivity can be improved. Further, the bending strength, the flexibility, and the productivity can be improved even with an unexpanded vermiculite content of less than 5% by mass. The inventors have found that an improvement can be obtained and have reached the present invention.

That is, the gist of the present invention is that unexpanded vermiculite is blended with a substrate selected from calcium silicate or slag gypsum , and the blending amount is 5 to 70% by mass of the total composition (solid content). In the building material composition, a building material formed by molding a building material composition in which a portion of 300 μm or less of unexpanded vermiculite is 0.5 to 15% by mass of the total composition (solid content).

  In the case of using unexpanded vermiculite, the present invention is further studied to improve productivity, and by using a specific amount of fine powder, the amount and speed of moisture absorption and desorption are excellent in balance, as well as bending strength and It is possible to provide a building material composition capable of improving flexibility and productivity and a building material obtained therefrom.

  The substrate used in the present invention is not particularly limited as long as it does not substantially deteriorate the properties of vermiculite described later, but is preferably hydrophilic from the viewpoint of humidity control and / or deodorization. is there. This is because the hydrophilic substrate itself has a humidity control and / or deodorizing function, and further, the unexpanded vermiculite can adsorb the substance diffused from the surface. Such hydrophilic substrates include, for example, cement, calcium silicate, slag gypsum, or the like. These can be used together as appropriate. As the cement, various cements including Portland cement can be used. In this case, aggregates and admixtures are used. The calcium silicate is not particularly limited, but calcium silicate (tobermorite or zonotolite) obtained by hydrothermal reaction of a siliceous raw material and lime in an autoclave is common. The slag gypsum generally contains 20 to 40% of granulated blast furnace slag powder and 60 to 80% of dihydrate gypsum (exhaust gypsum) and 1 to 5% of Portland cement.

On the other hand, in the present invention, vermiculite blended in the base material is a flaky mineral mainly composed of SiO ₂ , MgO, Al ₂ O ₃ , and may be either a general biotite system or a chlorite system. Even if there is a difference in composition depending on the production area, it can be used. The specific surface area (nitrogen adsorption method) is usually 10 m ² / g or less.

  In the present invention, such vermiculite is used in a substantially unexpanded state. That is, vermiculite usually contains about 10 to 20% of water, and is dehydrated and expanded significantly by rapid heating at a high temperature (about 320 ° C. to 1000 ° C. at which interlayer water begins to desorb). 1-2 seconds, 10-30 times the original thickness). Accordingly, in the present invention, a material that does not substantially obtain such expansion is used.

  Furthermore, in the present invention, it is preferable to use a product that has been activated prior to blending the vermiculite into the substrate. The purpose of the activation treatment is to remove organic or inorganic substances adsorbed by vermiculite, and to reconstitute and recover the inherent humidity conditioning, adsorption performance, and the like. For example, pressurized steaming, boiling with saline, and the like can be mentioned, but steaming at a saturated steam pressure of 105 ° C. to 200 ° C. is preferable.

  In particular, when the substrate is a calcium silicate system, even if vermiculite that has not been activated is blended before the hydrothermal reaction, it is then autoclaved at a saturated vapor pressure of, for example, about 150 ° C. to 200 ° C. As a result, activation processing is performed.

  The unexpanded vermiculite is a building material composition whose blending amount is 0.5 to 70% by mass of the total composition (solid content), and the portion of the unexpanded vermiculite of 300 μm or less is 0% of the total composition (solid content). It is mix | blended with a base material in the quantity which is 5-15 mass%. In this case, a plurality of unexpanded vermiculite having a different content of 300 μm or less can be blended to obtain such a composition. For example, 90% or more of unexpanded vermiculite fine powder having a content of 300 μm or less is reduced to 300 μm or less. It can also mix | blend with a base material so that a part may become the quantity of 0.5-15 mass% of the whole composition (solid content), 0.5-10 mass%, or 1-5 mass%.

  If the unexpanded vermiculite fine powder of 300 μm or less is less than 0.5% by mass, the effect of the present invention cannot be obtained, whereas if it exceeds 15% by mass, the improvement in bending strength, which is the main purpose of the present invention, has reached its peak. Furthermore, it falls.

  The compounding of vermiculite to the substrate is carried out so that the compounding amount is 0.5 to 70% by mass of the total composition (solid content). It is selected according to the type of base material and the performance of the intended building material, such as humidity control, etc., but in the case of humidity control purposes, it is 5 to 70% by mass, preferably 10% to 50% by mass, In order to form sufficient channeling (network) of vermiculite to obtain a more suitable amount and rate of moisture absorption and release, generally 15% by mass or more is particularly preferable.

  On the other hand, in the case where the main purpose is to improve the bending strength and flexibility of the calcium silicate building material and the productivity without mainly adjusting the humidity, 0.5 to 15% by mass, preferably 0.5 to It is preferable to blend vermiculite with the base material in an amount of 10% by mass, more preferably 1 to 5% by mass.

  In the present invention, by mixing fine unexpanded vermiculite, vermiculite is easy to uniformly disperse in water at the time of mixing in a molding tank or the like, so that production efficiency and yield can be improved, and because it is not suitable for expansion, it is discarded at the base. In addition, it contributes to the improvement of the bending strength of the calcium silicate building material even if the blending is 0.5 to 5% by mass. In this case, it is preferable to use unexpanded vermiculite fine powder in which 90% or more is 300 μm or less. The blended unexpanded vermiculite powder becomes the core of tobermorite epitaxial growth, promotes the growth of calcium silicate hydrated reaction products, and also reduces the unreacted raw material content, thus improving bending strength and flexibility (decrease in elastic modulus). Bring. Therefore, a building material with a high breaking energy can be obtained.

  In the building material composition of the present invention, in addition to the unexpanded vermiculite, various compounding materials inherently used for each base material for building materials for other purposes, and other materials can be appropriately blended. . The kind and amount of blending can be determined by ordinary methods. For example, aggregates, reinforcing materials, admixtures, lightening materials, etc., more specifically pulp, cellulose fiber, glass fiber, fumed silica, foam glass, shirasu balloon, alumina balloon, perlite, wollastonite, sepiolite, Gravel, sand, organic binder and the like are appropriately selected.

  The resulting building material composition of the present invention can be made into a building material having a desired shape and size such as a board by conventional methods such as papermaking, extrusion, press molding, and casting. In general, in the case of a board, papermaking molding using a so-called papermaking machine is industrially selected.

  When the blending amount of vermiculite is 5 to 70% by mass of the total composition (solid content), the relative humidity is preferably changed to 60 to 90% in the moisture absorption / release test described below. In this case, the moisture absorption / release rate is 90% or more of the equilibrium value at 30 minutes, moisture release: 25 minutes or less, more preferably 20 minutes or less.

Measuring device: “IGA SORP” manufactured by Heiden Analylial Ltd.
Measuring method: In a measuring basket of about 1 cc, the powder sample remains as it is, and the sample
Is adjusted to about 2 to 3 mm, packed and measured.

Measurement item: Moisture absorption at relative humidity 0-90%
Moisture absorption at relative humidity 60-90%
Moisture absorption rate from 60% to 90% relative humidity
Moisture release rate from 90% to 60% relative humidity Moisture absorption and moisture release rates were repeated in 30 minute cycles.

  The building material thus obtained is preferably used as an interior material such as a wall material, a ceiling material, and a partition material, but can also be used as an exterior material such as an eaves ceiling material.

When the amount of vermiculite is 5 to 70% by mass of the total composition (solid content), the building material of the present invention can satisfy humidity control and / or deodorization, as well as aesthetic requirements. That is,
1. Since it has moderate moisture release characteristics, it has excellent humidity control function. For example, the balance, amount and speed of moisture absorption and moisture release are excellent. Therefore, dew condensation, warping and the like can be prevented, and further, the growth of mold, mites and the like can be effectively suppressed.

  2. Excellent deodorant function. For example, the building material of the present invention can adsorb volatile chemicals such as formaldehyde, toluene, xylene or odorous gases.

  3. Furthermore, the unexpanded vermiculite particles can be raised by surface polishing or the like to form a granite-like surface, and a board material or the like having a beautiful appearance can be easily provided.

  4). About the product which received the autoclave process in the manufacturing process, it is possible to collect | recover the used building materials of this invention, and to reproduce | regenerate by carrying out the steam process of about 105-150 degreeC with an autoclave as it is. This is because vermiculite does not react with the substrate.

  5. As a raw material for expanded vermiculite, a non-standard fine-grained product can be used rather preferably, so that resources can be used effectively.

  Furthermore, even if the building material of this invention is a case where the compounding quantity of vermiculite is 0.5-5 mass% of the whole composition (solid content), it can improve a fracture energy as mentioned above.

  EXAMPLES Next, although an Example demonstrates this invention further in detail, this invention is not limited by these Examples. The part represents part by mass.

Example 1
27 parts of silica powder as siliceous raw material, 27 parts of slaked lime as calcareous raw material, 6 parts of pulp as reinforcing fiber, and unexpanded vermiculite (from South Africa, the portion of 300 μm or less is about 5.0% of the total composition (solid content) (Mass%) 40 parts as a starting material, water was added to these and mixed to form a slurry having a solid content of about 12%, and a green sheet was formed by a paper machine, then in an autoclave (160 to 180 ° C., about 10 hours) ) And then dried to a predetermined moisture content at less than 80 ° C. to obtain a calcium silicate board (30 cm × 30 cm × 6 mm). In this example, blending fine unexpanded vermiculite facilitates uniform dispersion of vermiculite in water during mixing, improving production efficiency and yield.

Example 2
A calcium silicate board was obtained in the same manner as in Example 1 using 42 parts of quartzite powder, 42 parts of slaked lime, 6 parts of pulp, and 10 parts of unexpanded vermiculite powder having 90% or more of 300 μm or less.

Example 3
Water is added to and mixed with 16 parts of slag powder, 38 parts of flue gas desulfurized gypsum powder, 6 parts of pulp and 40 parts of unexpanded vermiculite (parts of 300 μm or less are about 5.0% by mass of the total composition (solid content)). A slurry having a solid content of about 12% was obtained. Next, a green sheet was formed with a paper machine, then steam cured at about 80 ° C. for about 12 hours, and further dried at less than 80 ° C. to obtain a slag gypsum board (30 cm × 30 cm × 6 mm).

Example 4
30 parts and 10 parts of siliceous powder and diatomaceous earth as siliceous raw materials, 40 parts of slaked lime as calcareous raw materials and 6 parts of pulp as reinforcing fibers, 10 parts of calcium carbonate as dimensional stabilizer, and 90% or more is 300 μm or less Using 4 parts of unexpanded vermiculite fine powder (from South Africa) as a starting material, water was added to these and mixed to form a slurry with a solid content of about 12%. After forming a raw sheet by a paper machine, 180 ° C., about 10 hours) and then dried to a predetermined moisture content below 80 ° C. to obtain a calcium silicate board (30 cm × 30 cm × 6 mm). The physical properties of this board were as follows. The bending strength was 13.1 N / mm2, the Young's modulus was 5.7 kN / mm2, and the bulk specific gravity was 0.75.

Comparative Example 1
A calcium silicate board (30 cm × 30 cm × 6 mm) was obtained in the same manner except that unexpanded vermiculite was not used in Example 4. The physical properties of this board were as follows. The bending strength was 11.6 N / mm2, the Young's modulus was 6.9 kN / mm2, and the bulk specific gravity was 0.75.

  The building material obtained by the present invention is excellent in balance in the amount and speed of moisture absorption and desorption, and can improve bending strength and flexibility.

Claims (2)

In a building material composition comprising unexpanded vermiculite blended with a substrate selected from calcium silicate or slag gypsum , and the blending amount is 5 to 70% by mass of the total composition (solid content), unexpanded vermiculite The building material formed by shaping | molding the building material composition whose 300 micrometers or less part is 0.5-15 mass% of the whole composition (solid content). Molding papermaking molding, extrusion molding, building materials according to claim 1, wherein the press-molding or cast molding.