JPH04321574A - Production of lightweight clay burnt product - Google Patents

Abstract

PURPOSE:To produce a lightweight clay burnt product lightened and capable of utilizing waste materials. CONSTITUTION:Cut fine powder produced in a cutting process in the production process of a phenol resin produce containing a reinforcing glass fiber and aluminum hydroxide used as fireproofing additive is added to clay at an amount of 5-15wt.% and uniformly kneaded with the clay and the kneaded material is shaped and fired. Thereby shrinkage and deformation of the burnt product is prevented by difference of reaction temperature areas of glass fiber and aluminum hydroxide and is made porous by gasification of phenol rein and lightened.

Description

Description: FIELD OF INDUSTRIAL APPLICATION [0001] The present invention relates to a method for producing lightweight fired clay products, and more particularly to a method for producing lightweight fired clay products having a foamed structure. [0002] Hitherto, fired clay products have been widely known as building materials such as tiles and ceramic plates. This type of fired clay product has very good weather resistance and is useful as outdoor equipment or outdoor decorative building materials, and is manufactured and used in various designs. [Problems with the prior art] However, the above-mentioned fired clay products show considerable shrinkage during firing, and it requires considerable experience and skill to fire a product of an accurate size, but anyone can easily do so. There is a problem that it cannot be molded, and the structure of baked clay products is dense, so they are heavy.When attaching many small pieces such as large products or tiles, the overall weight increases, making transportation and installation difficult. There were problems such as the need to make the support structure sturdy. [0004] Problems to be Solved by the Invention [0004] In view of the above-mentioned problems, the present invention aims to provide a method for manufacturing lightweight clay fired products that can reduce the weight of the fired clay products and can also utilize waste materials. It has been done. [Means for Solving the Problems] That is, the method for manufacturing a lightweight clay fired product of the present invention is a cutting process in the manufacturing process of a phenolic resin product containing reinforcing glass fiber and aluminum hydroxide as a fire protection additive. The resulting cutting powder is added to clay in an amount of 5 to 15% by weight, uniformly kneaded, shaped, and fired. [Function] In the method for producing a lightweight clay fired product of the present invention, the weight of the fired product is reduced by cutting that occurs in the cutting process in the manufacturing process of a phenolic resin product containing reinforcing glass fiber and aluminum hydroxide as a fire protection additive. Fine powder is used. That is, this industrial waste contains phenolic resin, aluminum hydroxide, and glass fiber, and the aluminum hydroxide reacts in the high temperature range during clay firing, and the glass fiber reacts in the low temperature range. Therefore, if these are uniformly mixed into the clay, the fired product will not be easily deformed due to the difference in reaction zone temperature between the two, and dimensional stability will be imparted. [0007] Furthermore, the phenol resin is gasified by firing, and this forms fine closed pores in the fired product, contributing to the weight reduction of the fired product. If too much of the above additive powder material is added, the clay loses its viscosity and the formability is inhibited, so the upper limit of the amount added is 15% by weight based on the total formulation. Note that if it is less than 5% by weight, deformation prevention properties and porosity cannot be achieved. [Example] Next, an example of the present invention will be described. 40% by weight of phenolic resin, 50% by weight of aluminum hydroxide,
Cutting powder generated in the cutting process of a phenolic resin molded product containing 10% by weight of glass fiber is collected using a pag filter, and this is mixed with 85% by weight of clay, 15% by weight of cutting powder, and similarly 90% by weight and 10% by weight of clay. It was added as a blending ratio of 95% by weight and 5% by weight and mixed uniformly in a clay kneading machine to a thickness of 5%.
A large number of tile-shaped molded bodies measuring 100 mm in length and width were molded using a press. [0009] This tile-shaped molded body was heated in the open fire for 10 days and 40 days.
It was dried by force drying at °C for 24 hours. Next, these dried products are transported to a kiln, and the initial temperature gradient is
100°C/hr for 2 hours, then 200°C/hr
The temperature was raised to 1200° C. over 5 hours, and firing was continued under this temperature condition for 3 hours. Next, it was slowly cooled to room temperature over a day and night to obtain a test piece. When the dimensional change and specific gravity of this test piece were measured, the results shown in Table 1 were obtained. [0010] As is clear from Table 1, it was found that the weight of the fired product decreased as more cutting powder was added, and the shrinkage rate also changed. Furthermore, there was a slight gloss on the surface due to traces of melting of the glass fibers, giving it a glazed appearance even though it was in an unglazed state. [0012] As explained above, according to the present invention, it is possible to effectively utilize the cutting waste generated in the manufacturing process of phenolic resin molded products, which was conventionally left to be discarded, and moreover, it is possible to effectively utilize the cutting waste generated in the manufacturing process of phenolic resin molded products. It has various effects such as improving molding accuracy and reducing weight.

Claims (1)

[Claims] Claim 1: Cutting fine powder generated in the cutting process in the manufacturing process of phenolic resin products containing reinforcing glass fibers and aluminum hydroxide as a fire protection additive is added to clay for 5 to 50 minutes.
A method for producing a lightweight clay fired product, characterized by adding 15% by weight of clay, uniformly kneading, shaping and firing.