JPH06144951A - Ceramic foam and production thereof - Google Patents
Ceramic foam and production thereofInfo
- Publication number
- JPH06144951A JPH06144951A JP32472192A JP32472192A JPH06144951A JP H06144951 A JPH06144951 A JP H06144951A JP 32472192 A JP32472192 A JP 32472192A JP 32472192 A JP32472192 A JP 32472192A JP H06144951 A JPH06144951 A JP H06144951A
- Authority
- JP
- Japan
- Prior art keywords
- mica
- ceramic foam
- foam
- material composition
- raw material
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
Classifications
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B20/00—Use of materials as fillers for mortars, concrete or artificial stone according to more than one of groups C04B14/00 - C04B18/00 and characterised by shape or grain distribution; Treatment of materials according to more than one of the groups C04B14/00 - C04B18/00 specially adapted to enhance their filling properties in mortars, concrete or artificial stone; Expanding or defibrillating materials
- C04B20/02—Treatment
- C04B20/04—Heat treatment
- C04B20/06—Expanding clay, perlite, vermiculite or like granular materials
Landscapes
- Chemical & Material Sciences (AREA)
- Engineering & Computer Science (AREA)
- Ceramic Engineering (AREA)
- Materials Engineering (AREA)
- Structural Engineering (AREA)
- Organic Chemistry (AREA)
- Physics & Mathematics (AREA)
- Thermal Sciences (AREA)
- Compositions Of Oxide Ceramics (AREA)
- Porous Artificial Stone Or Porous Ceramic Products (AREA)
Abstract
Description
【０００１】[0001]
【産業上の利用分野】本発明は、新規なセラミックス発
泡体及びその製造方法に関るものである。さらに詳しく
いえば、本発明は、未利用資源である雲母石の焼成等で
得られる雲母類を主要成分として含有するセラミックス
発泡体及びこのものを効率よく製造する方法に関するも
のである。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a novel ceramic foam and a method for producing the same. More specifically, the present invention relates to a ceramic foam containing, as a main component, a mica obtained by firing of mica stone, which is an unused resource, and a method for efficiently producing the same.
【０００２】[0002]
【従来の技術】近年、セラミックス発泡体は軽量であ
る、圧縮強度や曲げ強度が高い、断熱性及び絶縁性に優
れる、吸水性が小さい、酸に侵されにくい、不燃性で耐
久性があるなどの特徴を有することから、種々の分野に
おいて用いられている。2. Description of the Related Art In recent years, ceramic foams are lightweight, have high compressive strength and bending strength, are excellent in heat insulation and insulation properties, have low water absorption, are resistant to acid, are nonflammable and durable. It is used in various fields because of its characteristics.
【０００３】このセラミックス発泡体は、従来、主要原
料として製陶原料、火山灰ガラス、坑火石などを用い、
これに黒曜石、真珠岩、長石、ドロマイト、炭酸バリウ
ム、炭酸カルシウム、リン酸カルシウム、サンゴ粉末な
どの発泡材料を加えて調製された粒状又は粉末状の発泡
性セラミックス原料組成物を、耐熱性型枠に充填して焼
成することにより製造される。This ceramic foam has hitherto been used as a main raw material for a ceramic raw material, volcanic ash glass, minestone, etc.
A heat-resistant mold is filled with a granular or powdery foamable ceramic raw material composition prepared by adding foaming materials such as obsidian, pearlite, feldspar, dolomite, barium carbonate, calcium carbonate, calcium phosphate, and coral powder to this. It is manufactured by firing.
【０００４】他方、近年、地球資源の涸渇により、未利
用資源の活用や産業廃棄物の再利用などが叫ばれてお
り、未利用資源の１つとして雲母石が知られている。On the other hand, in recent years, due to the depletion of global resources, the utilization of unused resources and the reuse of industrial waste have been exclaimed, and mica stone is known as one of the unused resources.
【０００５】一方、産業廃棄物としては、例えば各種熔
鉱炉から多量に排出されるニッケルスラグ、クロムスラ
グ、マンガンスラグ、銅スラグなどの鉱滓や焼却灰など
が知られている。On the other hand, as industrial wastes, for example, slags such as nickel slag, chromium slag, manganese slag, and copper slag, which are discharged in large amounts from various smelting furnaces, and incineration ash are known.
【０００６】[0006]
【発明が解決しようとする課題】本発明は、未利用資源
を主要原料源として有効利用しうる新規なセラミックス
発泡体を提供することを目的としてなされたものであ
る。SUMMARY OF THE INVENTION The present invention has been made for the purpose of providing a novel ceramic foam capable of effectively utilizing an unused resource as a main raw material source.
【０００７】[0007]
【課題を解決する為の手段】本発明者は、前記の特徴を
有する新規なセラミックス発泡体を開発すべく、前記雲
母石に着目し、鋭意研究を重ねた結果、該雲母石から得
られる雲母類が安定した焼結性を有すること、発泡材料
や産業廃棄物の鉱滓などと混ざりやすく、これらを含む
均質な発泡性セラミックス原料組成物を容易に与えうる
こと、そして、この組成物を焼結することにより、所望
の物性を有するセラミックス発泡体が得られることを見
出し、この知見に基づいて本発明を完成するに至った。DISCLOSURE OF THE INVENTION The inventors of the present invention have focused their attention on the above-mentioned mica stone in order to develop a novel ceramic foam having the above-mentioned characteristics, and as a result of earnest studies, as a result, mica obtained from the mica stone. Have stable sinterability, are easily mixed with foaming materials and industrial waste slag, etc., and can easily give a homogeneous foamable ceramic raw material composition containing them, and sinter this composition By doing so, it was found that a ceramic foam having desired physical properties was obtained, and the present invention was completed based on this finding.
【０００８】すなわち、本発明は、主要成分として雲母
類を含有して成るセラミックス発泡体を提供するもので
ある。That is, the present invention provides a ceramic foam containing mica as a main component.
【０００９】このセラミックス発泡体は、雲母類の粉末
又は顆粒５０重量％以上と発泡材料とを含有する原料組
成物を調製し、次いでこれを１０００℃以上の温度にお
いて焼結させることにより、製造することができる。This ceramic foam is produced by preparing a raw material composition containing 50% by weight or more of mica powder or granules and a foaming material, and then sintering this at a temperature of 1000 ° C. or higher. be able to.
【００１０】雲母類は耐火性であり、発泡材料や鉱滓と
混ざりやすく、例えば長石、珪石、カレットなどを混入
すれば取り扱いが容易になる。Mica is refractory and easily mixed with foamed materials and slag. For example, if feldspar, silica stone, cullet, etc. are mixed, it is easy to handle.
【００１１】雲母類の中でもセリサイトが以下の種々の
好ましい特性を有することから最も望ましい。 １．純白色で微粉が均一かつ滑らかである ２．耐酸・耐アルカリ性である ３．無害で耐火性がある ４．粘着性や可塑性が良好である ５．発泡材料や種々のスラグ等の他の材料と混ざりやす
いAmong the mica, sericite is most desirable because it has the following various preferable characteristics. 1. 1. Pure white with fine and uniform powder. Resistant to acids and alkalis 3. Harmless and fire resistant 4. Good adhesion and plasticity 5. Easy to mix with other materials such as foam materials and various slags
【００１２】前記原料組成物の調製方法については、特
に制限はなく、通常用いられている方法、例えば雲母類
の粉砕物と発泡材料とを、ボールミルなどの混練機によ
り、十分均質に湿式で粉砕混練したのち、乾燥するとい
った方法により調製することができる。該発泡材料とし
ては、従来セラミックス発泡体の製造において慣用され
ているものの中から任意のものを選択して用いることが
できる。この発泡材料としては、例えば黒曜石、真珠
岩、長石、ドロマイト、炭酸バリウム、リン酸カルシウ
ム、サンゴ粉末などが挙げられる。これらの発泡材料は
１種用いてもよいし、２種以上を組み合わせて用いても
よい。The method for preparing the raw material composition is not particularly limited, and a commonly used method, for example, a pulverized material of mica and a foam material is wet-milled sufficiently uniformly by a kneader such as a ball mill. It can be prepared by a method of kneading and then drying. As the foam material, any material can be selected and used from those conventionally used in the production of ceramic foams. Examples of the foam material include obsidian, pearlite, feldspar, dolomite, barium carbonate, calcium phosphate, and coral powder. These foam materials may be used alone or in combination of two or more.
【００１３】本発明においては、該原料組成物中の雲母
類の含有量は５０重量％以上、好ましくは６０〜９０重
量％の範囲で選ばれる。この含有量が５０重量％未満で
は本発明の目的が十分に達せられない。また、発泡材料
の含有量は、好ましくは１０〜４０重量％の範囲で選ば
れる。さらに、該原料組成物には、所望に応じ、他の材
料、例えば製陶原料、火山灰ガラス、坑火石、アルミナ
あるいはニッケルスラグ、クロムスラグ、マンガンスラ
グ、銅スラグなどの鉱滓、焼却灰、ガラス屑、さらには
脂肪酸塩や界面活性剤などを添加することができる。特
に前記鉱滓や焼却灰、ガラス屑などの添加は、産業廃棄
物の再利用につながり、好ましい。In the present invention, the content of mica in the raw material composition is selected to be 50% by weight or more, preferably 60 to 90% by weight. If this content is less than 50% by weight, the object of the present invention cannot be sufficiently achieved. The content of the foam material is preferably selected in the range of 10 to 40% by weight. Furthermore, the raw material composition may further contain other materials, such as porcelain raw materials, volcanic ash glass, minestone, alumina or nickel slag, chromium slag, manganese slag, copper slag, and other slag, incineration ash, and glass scraps, if desired. Further, a fatty acid salt or a surfactant can be added. In particular, addition of the aforementioned slag, incineration ash, glass scraps, etc. leads to reuse of industrial waste and is preferable.
【００１４】このようにして調製された原料組成物は、
そのままであるいは顆粒状や団子状に造粒して耐熱性型
枠に充填して焼成してもよいし、また、顆粒状に造粒し
た場合は所望により該型枠を用いることなくトンネル炉
やロータリーキルンのような窯炉を用いて焼成してもよ
い。The raw material composition thus prepared is
It may be granulated as it is or in the form of granules or dumplings and filled in a heat-resistant mold, and then fired. If granulated into granules, a tunnel furnace or It may be fired using a kiln such as a rotary kiln.
【００１５】前記耐熱性型枠を用いる場合には、この中
に原料組成物を１／４〜１／２の高さまで充填したの
ち、１０００℃以上、好ましくは１１００〜１３００℃
の範囲の温度において焼成を行う。耐熱性型枠について
は特に制限はなく、従来セラミックス発泡体の製造に慣
用されているもの、例えばアルミナ、カーボランダム、
シリマナイトなどの耐火性材料から成る棚板で組み立て
られた型枠を用いてもよいし、あるいはこの型枠の内側
における発泡体と接触する面全体にわたって、アルミナ
粉末を含浸固着させたガラス繊維布から成る保護層を配
置したもの（特公平１−５５２２４号公報）などを用い
てもよい。加熱炉としては、例えば電気炉やトンネル炉
などが用いられる。焼成処理時間は、使用する原料組成
により変わるが、通常数時間ないし数１０時間の範囲で
ある。When the heat resistant mold is used, the raw material composition is filled therein to a height of 1/4 to 1/2 and then 1000 ° C. or higher, preferably 1100 to 1300 ° C.
Firing is performed at a temperature in the range. There is no particular limitation on the heat-resistant mold, those conventionally used in the production of ceramics foam, such as alumina, carborundum,
A mold assembled from shelves made of refractory material such as sillimanite may be used, or a glass fiber cloth impregnated and adhered with alumina powder may be used over the entire surface of the mold that contacts the foam. A protective layer provided (Japanese Patent Publication No. 1-55224) may be used. As the heating furnace, for example, an electric furnace or a tunnel furnace is used. The firing treatment time varies depending on the raw material composition used, but is usually in the range of several hours to several tens of hours.
【００１６】ところで、セラミックス発泡体は、断熱材
であるので、これを全体にわたり均質に焼成することは
困難であり、大形のブロックを作成する場合には特に炉
内の雰囲気を均等にしてバラツキを起さぬような配慮、
例えば焼成法の変更などの工夫を要するという問題があ
った。[0016] By the way, since the ceramic foam is a heat insulating material, it is difficult to calcine it uniformly over the whole, and especially when making a large block, the atmosphere in the furnace is made uniform and the fluctuations occur. Consideration that does not cause
For example, there has been a problem that it is necessary to change the firing method.
【００１７】これを克服するには、上記原料組成物をプ
レス加工等により粒状、例えば１ｍｍ程度の顆粒状から
３０ｍｍ程度の団子状までの適宜の形態に成形して粒子
とし、これを焼成工程に用いて粒子同士の間隙に焔や火
炎をスムーズに行き渡らせて熱の対流を良好にするのが
好ましい。さらに有利には、窯炉にトンネル炉やロータ
リーキルンを用い、これに前記粒子を焼着防止のための
雲母類粉末特にセリサイト粉末とともに投入して粒子を
粉末中に分散させた状態で焼成するのが望ましい。この
ようにすることにより、熱分布が良好になり加熱雰囲気
のバラツキや不均衡を解消することができ、特に粒径の
大きい粒子を用いた場合には、優れた軽量骨材が得られ
る。In order to overcome this, the above raw material composition is granulated by pressing or the like into an appropriate form, for example, a granular form of about 1 mm to a dumpling form of about 30 mm to obtain particles, which are subjected to a firing step. It is preferable to use flames and flames to smoothly spread between the particles to improve heat convection. More preferably, a tunnel furnace or a rotary kiln is used in the kiln, and the particles are charged with mica powder for preventing seizure, especially sericite powder, and the particles are fired in a state of being dispersed in the powder. Is desirable. By doing so, the heat distribution becomes good, and it is possible to eliminate variations and imbalances in the heating atmosphere, and particularly when using particles having a large particle size, an excellent lightweight aggregate can be obtained.
【００１８】本発明のセラミックス発泡体は、通常圧縮
強度５０ｋｇ／ｃｍ２以上、曲げ強度２５ｋｇ／ｃｍ２
以上、かさ比重０．５以下、熱伝導率０．１５Ｋｃａｌ
・ｃｍ−１・℃−１・ｓｅｃ−１以下、吸水率０．２％
以下の優れた物性を有している。The ceramic foam of the present invention usually has a compressive strength of 50 kg / cm 2 or more and a bending strength of 25 kg / cm 2.
Above, bulk specific gravity 0.5 or less, thermal conductivity 0.15Kcal
・ Cm -1 · ° C -1 · sec -1 or less, water absorption 0.2%
It has the following excellent physical properties.
【００１９】[0019]
【発明の効果】本発明によると、セラミックス発泡体の
主要原料として、雲母類特に未利用資源の雲母岩を焼成
して得られる雲母類、中でもセリサイトを用い、発泡材
料及び場合により用いられる産業廃棄物などを含有する
原料組成物を容易に調製することができ、そして、この
原料組成物を焼結させることにより、所望物性を有する
セラミックス発泡体を得ることができる。INDUSTRIAL APPLICABILITY According to the present invention, as a main raw material of a ceramic foam, mica, especially mica obtained by firing unutilized resource mica rock, in particular, sericite, is used as a foam material and an industry optionally used. A raw material composition containing waste materials can be easily prepared, and a ceramic foam having desired physical properties can be obtained by sintering the raw material composition.
【００２０】本発明のセラミックス発泡体は、軽量であ
る、表面が滑らかである、圧縮強度や曲げ強度が高い、
断熱性及び絶縁性に優れる、吸水性が小さい、酸に侵さ
れにくい、不燃性で耐久性があるなどの好ましい性質を
有し、かつ通常のセラミックスと同様に普通のカッター
を用いて種々の形状に容易に加工しうることから、前記
性質が要求される用途に好適に用いられる。また、本発
明は、未利用資源の活用及び産業廃棄物の再利用につな
がり、工業的価値が極めて高い。The ceramic foam of the present invention is lightweight, has a smooth surface, and has high compressive strength and bending strength.
It has excellent properties such as excellent heat insulation and insulation properties, small water absorption, resistance to acid, nonflammability and durability, and various shapes using ordinary cutters like ordinary ceramics. Since it can be easily processed, it is suitable for applications requiring the above properties. Further, the present invention leads to utilization of unused resources and reuse of industrial waste, and has an extremely high industrial value.
【００２１】また、本発明のセラミックス発泡体のう
ち、原料組成物を粒子、特に粒径の大きい団子状の粒子
に成形したものを焼成して得られたものは、土木・建築
用などの軽量骨材として好適に用いられる。Further, among the ceramic foams of the present invention, those obtained by firing the raw material composition formed into particles, particularly particles having a large particle size, are lightweight for civil engineering and construction. It is preferably used as an aggregate.
【００２２】[0022]
【実施例】次に、実施例により本発明をさらに詳細に説
明するが、本発明はこれらの例によってなんら限定され
るものではない。The present invention will be described in more detail by way of examples, which should not be construed as limiting the invention thereto.
【００２３】実施例 セリサイト８０重量部に、発泡材料として、黒曜石２重
量部、ドロマイト２重量部、リン酸カルシウム１重量部
及び炭酸バリウム１重量部を、産業廃棄物としてカレッ
ト４重量部、カルミフラックス２重量部及びニッケルス
ラグ８重量部を加え、さらに適量の水を加えて、ボール
ミルにより湿式粉砕混練したのち、これを乾燥して粉末
状発泡性セラミックス原料組成物を調製した。Example: 80 parts by weight of sericite, 2 parts by weight of obsidian, 2 parts by weight of dolomite, 1 part by weight of calcium phosphate and 1 part by weight of barium carbonate as foaming materials, 4 parts by weight of cullet and 2 parts of carmiflux as industrial waste. 1 part by weight and 8 parts by weight of nickel slag were added, and further an appropriate amount of water was added, and the mixture was wet pulverized and kneaded by a ball mill, and then dried to prepare a powdery expandable ceramic raw material composition.
【００２４】次いで、この原料組成物を平均粒径１ｍｍ
の顆粒状に造粒したのち、縦１００ｃｍ、横５０ｃｍ、
高さ３０ｃｍの型枠に、高さ１０ｃｍまで充填した。次
にこの型枠をトンネル炉に入れ、温度を１５時間で１１
００℃まで昇温し、さらにこの温度で数時間保持して発
泡焼結させたのち、徐冷することにより、セラミックス
発泡体ブロック（１００×５０×２０ｃｍ）を得た。こ
のものは全く割れがなく、均質であった。Next, this raw material composition was treated with an average particle size of 1 mm.
After granulating into granules of 100 cm in length, 50 cm in width,
A mold having a height of 30 cm was filled up to a height of 10 cm. Next, the mold is put into a tunnel furnace and the temperature is set to 11 in 15 hours.
The temperature was raised to 00 ° C., and the temperature was further maintained at this temperature for several hours for foaming and sintering, followed by gradual cooling to obtain a ceramic foam block (100 × 50 × 20 cm). This product was homogeneous without any cracks.
Claims (6)
ラミックス発泡体。1. A ceramic foam containing mica as a main component.
のセラミックス発泡体。2. The ceramic foam according to claim 1, wherein the mica is sericite.
発泡材料とを含有する原料組成物を調製し、次いでこれ
を１０００℃以上の温度で焼結することを特徴とする請
求項１又は２記載のセラミックス発泡体の製造方法。3. A raw material composition containing 50% by weight or more of mica powder or granules and a foaming material, and then sintering the composition at a temperature of 1000 ° C. or higher. 2. The method for producing a ceramic foam according to 2.
記載の製造方法。4. The mica is a calcined product of mica rock.
The manufacturing method described.
発泡材料とを含有する原料組成物を加圧成形して粒子と
し、次いでこれを窯炉で焼成することを特徴とするセラ
ミックス発泡体の製造方法。5. A ceramic foam characterized in that a raw material composition containing 50% by weight or more of mica powder or granules and a foam material is pressure-molded into particles, which are then fired in a kiln. Manufacturing method.
窯炉に同時に投入して焼成することを特徴とするセラミ
ックス発泡体の製造方法。6. A method for producing a ceramic foam, which comprises simultaneously pouring mica powder together with the particles according to claim 5 into a kiln.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP32472192A JPH06144951A (en) | 1992-11-11 | 1992-11-11 | Ceramic foam and production thereof |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP32472192A JPH06144951A (en) | 1992-11-11 | 1992-11-11 | Ceramic foam and production thereof |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| JPH06144951A true JPH06144951A (en) | 1994-05-24 |
Family
ID=18168973
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP32472192A Pending JPH06144951A (en) | 1992-11-11 | 1992-11-11 | Ceramic foam and production thereof |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPH06144951A (en) |
Cited By (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| KR20010089976A (en) * | 2000-04-07 | 2001-10-17 | 신현택 | A process of the manufacturing bed soil aggregate radiating far-infrared rays using sericite |
| US6602449B1 (en) | 1998-04-06 | 2003-08-05 | Cellaris Limited | Method of producing ceramic foams |
| US6902688B2 (en) | 2001-04-06 | 2005-06-07 | World Properties, Inc. | Electrically conductive silicones and method of manufacture thereof |
| CN102515824A (en) * | 2011-11-30 | 2012-06-27 | 南京航空航天大学 | Super-light foam cement concrete and preparation method thereof |
| CN104177117A (en) * | 2014-07-29 | 2014-12-03 | 河北工业大学 | Method for preparing foamed ceramic from slag |
| CN115403404A (en) * | 2022-09-23 | 2022-11-29 | 北京科技大学 | Method for preparing porous material by electrolytic manganese slag short process |
-
1992
- 1992-11-11 JP JP32472192A patent/JPH06144951A/en active Pending
Cited By (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US6602449B1 (en) | 1998-04-06 | 2003-08-05 | Cellaris Limited | Method of producing ceramic foams |
| US8323742B2 (en) | 1998-04-06 | 2012-12-04 | Cellaris Limited | Method of producing ceramic foams |
| KR20010089976A (en) * | 2000-04-07 | 2001-10-17 | 신현택 | A process of the manufacturing bed soil aggregate radiating far-infrared rays using sericite |
| US6902688B2 (en) | 2001-04-06 | 2005-06-07 | World Properties, Inc. | Electrically conductive silicones and method of manufacture thereof |
| CN102515824A (en) * | 2011-11-30 | 2012-06-27 | 南京航空航天大学 | Super-light foam cement concrete and preparation method thereof |
| CN104177117A (en) * | 2014-07-29 | 2014-12-03 | 河北工业大学 | Method for preparing foamed ceramic from slag |
| CN115403404A (en) * | 2022-09-23 | 2022-11-29 | 北京科技大学 | Method for preparing porous material by electrolytic manganese slag short process |
| CN115403404B (en) * | 2022-09-23 | 2023-06-02 | 北京科技大学 | Method for preparing porous material by electrolytic manganese slag in short process |
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