JPH01219073A - Ceramic construction material and its production - Google Patents

Abstract

PURPOSE:To produce easily and inexpensively the subject ceramic construction material having a desired size, light weight, high mechanical strength, high weather resistance, high fire resistance, and high durability by calcining a mixture of an aggregate consisting of amorphous glass fiber and a binder consisting of inorganic powder in a specified proportion, after molding the mixture. CONSTITUTION:A mixture consisting of 15-85wt.% aggregate consisting of amorphous glass fiber obtd. by melting a mixture of a fluororichterite raw material compsn. and at least one kind of material composed of Al2O3, ZrO2, P2O5, and PbO, and 85-35wt.% binder consisting of inorganic powder of a raw material for a ceramic which is transformed to a ceramic by calcining at 900-1,000 deg.C, is molded by, for example, screening a slurry prepd. from 100pts. wt. said mixture and 3-25pts.wt. pulp, etc. Obtd. plate, etc.-shaped molded body is then calcined at 900-1,000 deg.C. Thus, a fibrous structure of crystalline glass having high strength is transformed to ceramic structure, and the title construction body is obtd.

Description

Detailed Description of the Invention (Field of Industrial Application) This invention provides a lightweight ceramic structural material that has a porcelain-like fibrous structure of crystallized glass and has excellent mechanical strength, fire resistance, and weather resistance. It is related to.

(Prior Art) In recent years, with the increase in the height of buildings, lightweight, high-strength, and fire-resistant structural materials have been required, but materials that meet all of these requirements have not been put into practical use.

For example, fiber-reinforced concrete has greater strength than -a concrete, but it cannot be said to be lightweight.

In addition, there are lightweight heat insulating materials or insulation materials made of ceramic fibers, glass wool, rock wool, etc., made into blocks with adhesives, and lightweight wall materials with air bubbles left inside the molded body, such as aerated concrete. Insufficient strength.

On the other hand, crystallized glass is fired into heat-resistant glass products, interior building materials, etc., but it is heavy and, due to the molding method, there are limits to its molding dimensions. In addition, Japanese Patent Application Publication No. 4
No. 9-107005 uses heat-treated crystallized glass fiber as an aggregate as a means of manufacturing high-strength, large-area ceramic plates, and Japanese Patent Application Laid-open No. 164070/1982 and Japanese Patent Publication No. 1983/1983
As shown in No. 41182, there are related documents regarding methods and products using crystallized raw material glass powder.

(Problems to be Solved by the Invention) As described in the prior art, materials that satisfy the various requirements such as being lightweight, having high strength, and having fire resistance, which are required for building structures as buildings become taller. The problem is that it has not yet been put into practical use.

In view of the above, it is an object of the present invention to provide a ceramic structural material and a method for manufacturing the same, which can compensate for the drawbacks of conventional materials and also enable the formation of large structurally necessary molded products with uniform dimensions. .

(Means for Solving the Problems) In order to achieve the above-mentioned object, the ceramic structural material of the present invention contains 100 parts by weight of a mixture consisting of 35 to 85% by weight of binder and 15 to 65% by weight of aggregate, and 3 parts by weight of valves. ~25 parts by weight is added, formed by a papermaking method, and fired at 900 to 1000°C, the binder is an inorganic substance that becomes porcelain by firing at 900 to 1000°C, and the aggregate is a fluorinated richterite composition raw material. Al2O3, Zro2. P2O
It is an amorphous glass fiber formed by adding and melting at least one of 5 and PbO composition raw materials, and
This invention relates to a high-strength crystallized glass that can be obtained by heat treatment in a temperature range of 0° C., and a method for producing the same. The details of this invention will be explained below. In this specification, % indicates weight % unless otherwise specified.

To manufacture the ceramic structural material of this invention, first,
Using common ceramic raw materials such as feldspar, silica, kaolin, clay, limestone, and frit, we prepare an inorganic powder clay that can be fired at a temperature range of 900 to 1000°C to form porcelain, and use it as a binder, and then add sodium carbonate as a binder. 900~ using raw materials such as cryolite, fluorite, talc, dolomite, magnesium carbonate, alumina, zirconium silicate, white lead, and bone ash.
It has a composition that becomes crystallized glass mainly composed of fluorinated richterite crystals when heat treated at 1000°C, and has a temperature of 1350~
The aggregate is melted at 1450°C and made into amorphous glass fiber by a conventional method.

Next, add 3 to 25 parts by weight of pulp to 100 parts by weight of a mixture of 35 to 85% binder and 15 to 65% aggregate, add an appropriate amount of water and necessary chemicals (flocculant and emulsion type). (composed of a binder made of an organic substance) to form a slurry, which is formed into a plate shape of arbitrary dimensions by a papermaking method, dried, and fired at 900 to 1000°C to obtain a ceramic structural material.

In addition, when the blending ratio of binder and aggregate is less than 15%, it is difficult to form using the papermaking method, resulting in a large bulk specific gravity and insufficient strength, and when it exceeds 65%, even if the strength is sufficient, it is difficult to form. The surface of the body becomes rough and the tips of the aggregate fibers are exposed, which may cause problems in handling safety.

The forming method of this invention is based on the papermaking method, but depending on the blending ratio of binder and aggregate, pulp is added to make the papermaking operation easier. If the amount is 3 to 25 parts by weight relative to 100 parts by weight, and exceeds 25 parts by weight, the firing density of the binder will decrease and the strength will decrease.

On the other hand, by using the papermaking method, separation of the binder and aggregate can be prevented, and a large plate-shaped molded product with uniform thickness and uniform thickness can be obtained, and at the same time, a molded product with a low molding density can be obtained.

It should be noted that the molding density can be adjusted by increasing or decreasing the amount of pulp added, which has the advantage of reducing the weight of the fired product.

As shown in the enlarged cross-sectional structure diagram in Figure 1, the ceramic structural material thus obtained is a porcelain base P containing residual pores H larger than the water absorption pores of the ceramic base, and a fibrous structure of high-strength crystallized glass. A ceramic structural material S can be obtained in which a directional structure G is formed, which has extremely high mechanical strength and has a low bulk specific gravity.

(Function) As explained in the above-mentioned technical means, the ceramic structural material of the present invention can use general ceramic raw materials as the raw material for the binder, and can also be used as aggregate using general glass raw materials. It can be easily produced like glass fiber, and can be continuously formed into large-sized plates using the papermaking method.
can be manufactured at a relatively low firing temperature as below, and therefore has a great effect of being expected to reduce manufacturing costs.

In addition, by matching the temperature at which the binder is fired and turned into porcelain and the heat treatment temperature at which the aggregate crystallizes and becomes dense, the density of the molding can be adjusted, making it possible to reduce weight and make it easier to fire further. It also has a great effect of providing excellent weather resistance and fire resistance.

Incidentally, the ceramic structural material of the present invention has an average strength several times that of general concrete, while its bulk specific gravity is on the contrary about half as low.

(Example) Examples and comparative examples of the present invention will be described in detail below. Note that this invention is not limited to this.

Examples 1 to 10 and Comparative Examples 11 and 12゜Binding materials made of inorganic powders of three examples a, b, and C according to the mixing ratios shown in Table 1 and A, B, and C with the compositions shown in Table 2 aggregate and pulp made of three types of amorphous glass fibers.
The raw materials of Examples 1 to 1o were prepared by blending in the parts by weight shown in the table, and an appropriate amount of water, a flocculant, an organic binder, etc. were added, and the slurry was formed into a plate shape by a papermaking method. A rectangular parallelepiped with dimensions corresponding to each performance test was cut out from the plate-shaped molded product dried at a temperature, and as shown in the firing curve shown in Figure 2, the temperature was raised to a maximum temperature of 950 ° C after 8 hours and held for 15 minutes. A test piece was prepared by cooling naturally.

Table 4 shows the results of measuring or observing the bulk specific gravity, bending strength, compressive strength, heat resistance, fire resistance, and cold resistance of the obtained test pieces under the performance test conditions shown below.

The conditions for this performance test are as follows.

Measure the weight, length, width and thickness of bulk specific gravity specimens and calculate the volume! 1) It was calculated using the formula.

Bulk specific gravity = weight particle volume (11) The bending strength test piece was placed in a three-point loading type bending tester with an edge spacing d" = 100 m, and the test piece was tested at a speed of about 25 kg/min at a / 2
The load at the position was increased, the load P at which breakage occurred was determined, and the bending strength S was determined using equation (2).

5=3aP/2bh (2) where b is the width of the test piece and h is the thickness.

Compressive Strength A cubic test piece with a side of 30 mm is pressurized in the direction of the arrow perpendicular to the direction of the directional arrangement of the fibrous structure of the aggregate as shown in Figure 3, and the load is calculated when the test piece breaks. was calculated by dividing by the pressurized area of the test piece. However, the speed of applying the load was 1 kg/ad per second.

Heat resistance test The test piece was placed in a constant temperature dryer, heated at 150°C for 30 minutes, placed in water at 30°C, and observed for damage such as cracks. This operation was repeated 30 times.

Fire resistance test A test piece was placed on a gas stove, ignited and heated for 30 minutes, and after cooling, changes in appearance were observed.

Cold resistance test The test piece was immersed in water for 1 hour, frozen in a freezer, taken out and thawed in a dryer at 40°C, and the operation of observing changes in appearance was repeated 10 times.

As explained in the margins, Comparative Examples 11 and 12 shown in Table 4 are test results of structural materials made of ordinary Portland cement and early-strength Portland cement, respectively.

(The following is a margin) Table 2 (%) (Effects of the invention) Since this invention has the above configuration, it has the following effects.

(1) A binder consisting of an inorganic powder that turns into porcelain, which is fired by the manufacturing method of claim (1), and glass fiber, which is crystallized by heat treatment, are blended as an aggregate, shaped, and then hardened by firing. To obtain a lightweight structural material made of ceramics having sufficiently high mechanical strength and excellent durability.

(2) The molding method of claim (2) prevents the binding material and aggregate from intertwining and separating, and makes it possible to relatively easily obtain a lightweight, large-sized molded material with uniform thickness. can. Furthermore, since the compacted density can be adjusted by increasing or decreasing the amount of pulp added, the weight of the fired product can be reduced.

(3) The crystallized glass fiber of claim (3) is easy to manufacture in the same manner as general glass fiber using general glass raw materials, and is formed continuously into a large plate shape using a papermaking method at a relatively low temperature. Because it can be produced by firing, it is possible to obtain a lightweight structural material that is inexpensive and several times stronger than concrete.

(4) By forming the above-mentioned crystalline glass fiber composition on the porcelain base formed by using the raw material for ceramics according to claim (4) as the raw material for the composition of the binding material, both of them combine to produce a high-strength and inexpensive structural material. can be easily manufactured.

(5) Claim (5) is a ceramic structural material produced according to claim (1), which is lightweight and has high mechanical strength, has excellent weather resistance and fire resistance when fired, and is molded into a large plate shape. It is effective as a structural material for civil engineering and construction, which is easy to obtain and can be expected to be inexpensive.

(6) Claim (6) is made by molding and firing a raw material with a composition mainly composed of aggregates than the ceramic structural material manufactured according to claim (1), so it has even higher strength and excellent fire resistance. It is effective for specific applications because it allows the production of lightweight ceramic structural materials.

(7) Adding the agent according to claim (7) to papermaking facilitates the formation of a slurry consisting of raw materials and pulp and allows papermaking operations, thereby stably obtaining a plate-shaped molded material with a desired composition. What you can do.

[Brief explanation of the drawing]

Fig. 1 is an enlarged diagram of the structure of the cross section of a plate-shaped compact of the ceramic structural material of the present invention, Fig. 2 is an explanatory diagram of the firing temperature rise curve of the test piece of the ceramic structural material of the embodiment, and Fig. 3 is an illustration of the firing temperature rise curve of the test piece of the ceramic structural material of the present invention. It is a schematic diagram explaining the directional arrangement of fibrous tissue. ＼S Figure 1 Figure 2 Figure 3

Claims (7)

[Claims] (1) Aggregate consisting of amorphous glass fibers 15-65% by weight
and 35 to 85% by weight of a binder consisting of inorganic powder, which is molded and fired at a temperature range of 900 to 1000°C to form a porcelain-like fibrous structure of high-strength crystallized glass. Method of manufacturing structural materials. (2) The ceramic according to claim (1), characterized in that a slurry made by adding 3 to 25 parts by weight of pulp to 100 parts by weight of a mixture of aggregate and binder is formed into a plate shape. Method of manufacturing structural materials. (3) Amorphous glass fiber is used as a raw material for fluorinated richterite composition, including Al_2O_3, ZrO_2, P_2O_5 and Pb.
2. The method for manufacturing a ceramic structural material according to claim 1, wherein the ceramic structural material is formed by adding and melting at least one O-composition raw material. (4) Inorganic powder is heated to 900-1000℃ as a raw material for ceramics.
2. The method of manufacturing a ceramic structural material according to claim 1, wherein the ceramic structural material is made into porcelain by firing in a temperature range of . (5) A plate having a fired structure manufactured according to claim (1), in which a fibrous directional array structure of high-strength crystallized glass is intertwined with a porcelain base material, and a large number of residual pores are enclosed. A ceramic structural material characterized by being a shaped body. (6) A slurry made by adding 3 to 25 parts by weight of pulp to a composition raw material consisting of 65 to 100 parts by weight of aggregate made of amorphous glass fibers and 5 to 35 parts by weight of inorganic powder is formed into a paper, 1. A method for producing a ceramic structural material, which comprises firing at a temperature of 0.degree. (7) The method for manufacturing a ceramic structural material according to claim (2) or (6), characterized in that a binder consisting of a flocculant and an emulsion type organic substance is used as a chemical added to the papermaking process.