JPH0829974B2 - Method for manufacturing wall materials and floor materials using inorganic waste such as blast furnace slag - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing wall materials, floor materials and the like using inorganic waste such as blast furnace slabs, sludge residues, stone powder and the like. And a manufacturing method capable of preventing cracks generated in a floor material.

[0002]

2. Description of the Related Art Conventionally, for example, in the case of making wall materials and floor materials by using blast furnace slag, a reinforcing material such as a reinforcing bar is inserted in the center of a mold made of the wall materials and floor materials. The waste is filled so as to fill the reinforcing material in the frame, dried for a certain period of time, then heated to a firing temperature of about 1200 to 1300 ° C., baked and molded into a plate-like body or a block body. ing.
However, the mere sintering process lacks the bonding force, and if a reinforcing material is inserted to compensate for this, the expansion coefficient of the reinforcing bars and reinforcing nets is ceramic, and the expansion coefficients of blast furnace slag and waste stone powder match. However, there was a drawback that the reinforcing bars and the net metal pieces expanded and cracked during firing. Conventionally, in order to prevent this, a method of applying a glue-like liquid to the reinforcing material, winding a paper tape, or applying a glue coating to the reinforcing material to alleviate the expansion of iron there were.

[0003]

However, in these methods, carbon powder or the like forms powdery crystals around the reinforcing bar as a reinforcing material during firing, and the reinforcing material is weak against impact and is reinforced in the fired plate. There was a problem that the result of playing was, and that air entered into the gaps and created the cause of rust such as reinforcing bars.
The present inventors have conducted extensive studies to solve these problems, focusing on the bottom melting point of aluminum and the metal strength after solidification, and succeeded in improving the strength as a plate material and a block material, The invention was completed.

[0004]

The waste subject to the present invention is not limited to blast furnace slag, but may include sludge residues, stone powder, and other pulverizable waste materials. These wastes can be used as they are if they are powdery particles, and can be used as powdery particles if they are lumps. For example, the case where blast furnace slag is used will be described. The components are as follows, for example.

[Table 1] Aluminum powder is prepared for the waste, and both are uniformly mixed and stirred. Aluminum powder granules
In addition to gin aluminum, recycled aluminum powder may be used. The mixing ratio of both is a ratio at which the binding action of aluminum described later works effectively, but generally a ratio of 5 to 10% with respect to the inorganic waste is effective.

After stirring the mixture of the above-mentioned inorganic waste and aluminum, a mold for a target wall material or floor material is prepared, and the powder / granular mixture is filled in the mold. This filling method is the case of inserting reinforcing materials such as reinforcing bars,
This differs from the case where no reinforcing material is used.

First, when the reinforcing material is not used, the powder / granular mixture is filled in the mold and a compaction is applied from above. Then, when a reinforcing material is used, the lower half of the mold is filled with the powder / granular mixture, a slight rolling pressure is applied, and the reinforcing material is placed thereon. As the reinforcing material, a reinforcing bar, a net-shaped iron plate called expanded metal, or the like can be used. Then, aluminum powder particles are scattered around the reinforcing material, and the periphery of the reinforcing material is surrounded by the aluminum powder particles. After spraying, the remaining mixture of powder and granules is filled up to the full size of the mold, and rolling pressure is applied (see FIGS. 2 and 3).

Next, the heating of the mold filled with the mixed powder and granules is started, the mold is put in the heating chamber, and first, 400 ° C to 50 ° C.
Heat to 0 ° C. Then, the aluminum powder begins to melt, softens from the surface, gradually enters the inside, or the aluminum sandwiched between the waste powder particles is deformed. Further, when the reinforcing material is added, since the periphery thereof is surrounded by the aluminum powder, the aluminum is melted and comes into contact with the reinforcing material to form a film on the periphery. If there is a possibility that a large amount of heat of oxidation will be generated due to the presence of oxygen during the temperature rising process, it is desirable to shut off the air or cover the surrounding atmosphere with an inert gas such as carbon dioxide or nitrogen.

Thereafter, in order to sinter the powder mixture, the heating chamber is further heated to a sintering temperature up to about 1300 ° C.,
As shown in the above formulation example, a mixture of powder and granules containing many inorganic substances is baked and solidified.

After the sintering, the material is cooled and gradually solidified. At this time, the molten aluminum is sandwiched by the above-mentioned mixture of particles and deformed to form a shape along the gap of the waste particles. Solidify as it is. Then, as shown in FIG. 1, a wedge is formed between the waste particles, depriving the waste particles of the degree of freedom, and the metal characteristic of aluminum has a strong physical strength. It has a large fastening force and strongly bonds waste particles together. At the same time, a force is applied to the waste particles to be solidified by sintering, so that they cooperate with each other to strengthen the bond, so that in the cooling process, distortion due to the difference in expansion coefficient, vibration after construction, etc. Even when receiving a crack, these external forces are suppressed to prevent the occurrence of cracks. Of course, the aluminum once softened sometimes adheres to the adjacent waste particles, in which case the bond between the two is further enhanced.

Further, in the cooling process, when a reinforcing material is added, the reinforcing material such as a reinforcing bar is surrounded during melting and aluminum is solidified as it is. An oxide film is formed. as a result,
Even when it is subjected to air oxidation during use as a wall material or floor material, it functions as a protective film and suppresses the generation of iron rust and the like (see FIG. 3).

Further, the reinforcing material and the powder / granular mixture are easily separated from each other due to the difference in expansion coefficient and the difference in adhesiveness.
In the present invention, the aluminum contained in the powder mixture is fused with the aluminum surrounded by the reinforcing material, and due to its homogeneity, the bond is deepened and the reinforcing material and the mixture are integrated.

[0012]

According to the present invention having the above-described structure, when waste such as blast furnace slag is used as wall materials and floor materials,
An excellent effect that cracks can be prevented by increasing the bonding strength of a material that easily cracks during the manufacturing process or use is exhibited. Further, when a reinforcing material is added, it is a very advantageous invention which can suppress the generation of rust in the reinforcing material and increase the adhesion between the reinforcing material and the filling material to improve the durability.

[0013]

Example 1 Aluminum powder 1 in 9 kg of blast furnace slag
Mix kg and stir uniformly, and mix this with 300 x 400 x
It was filled in a mold of a wall material of 30 mm, and rolling pressure was applied by a roller. The mold filled with the mixture was placed in an electric furnace to prevent oxygen from flowing in as a closed chamber, first preheated at 250 ° C. for 40 minutes, and then heated up to 1300 ° C. over about 1 hour to remove aluminum powder. The sintering temperature was set such that a part of the blast furnace slag was made into ceramic while being melted. Then, it was left to stand at room temperature and cooled for about 1 hour, and in the process of cooling and solidification, the bonding of the blast furnace slag and molten aluminum was promoted to obtain a wall material of the above size. The wall material did not crack at all during the manufacturing process, and cracks did not occur even after about 6 months had passed since the manufacturing, and other changes did not occur.

[0014]

[Example 2] Aluminum powder 1 in 9 kg of blast furnace slag
Mix kg and stir uniformly, and mix this with 300 x 400 x
The lower half of the 30 mm wall material was filled in the mold and a roller was used to apply a rolling pressure. Expanded metal having a cross-sectional area of 6 mmφ was inserted into the mold as a reinforcing material, and 0.5 kg of aluminum powder was sprinkled around the expanded metal. The remaining upper half of the mold was filled with the above powder mixture, and a roller was used to apply a compaction pressure. The mold filled with the mixture is put into an electric furnace, firstly preheated at 250 ° C. for 40 minutes, and then heated to 1300 ° C. over about 1 hour to melt the aluminum powder and part of the blast furnace slag. It was set to the sintering temperature at which it was made into ceramic. afterwards,
It was left to stand at room temperature and cooled for about 1 hour, and in the process of cooling and solidification, the bonding of blast furnace slag and molten aluminum was promoted to obtain a flooring material of the above size. The flooring did not crack at all during the manufacturing process, no cracking occurred even after about 6 months from the manufacturing process, and the reinforcing material and the mixture were completely integrated without separation. It was

[Brief description of drawings]

FIG. 1 is a partially enlarged schematic view of a product based on the manufacturing method of the present invention.

FIG. 2 is a vertical sectional view showing a manufacturing method of the present invention.

FIG. 3 is a partially enlarged vertical sectional view showing the manufacturing method of the present invention.

[Explanation of symbols]

 1 Waste particles 2 Aluminum particles 3 Mixed powder particles 4 Reinforcing material 5 Formwork

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification code Internal reference number FI Technical indication C04B 35/63 35/74 E04F 13/14 103 A 9127-2E B09B 3/00 ZAB 303 D

Claims (2)

[Claims] 1. A powdery or powdered inorganic waste is used, and aluminum powder is mixed into the inorganic waste, the mixture is filled in a mold, and the mixture is passed through the melting point of aluminum. A method for producing a wall material or a floor material, which comprises heating the inorganic waste to a sintering temperature and promoting the binding between the molten aluminum and the waste particles in the process of cooling and solidifying after the sintering. 2. A granular or powdered inorganic waste is used, aluminum powder is mixed into the inorganic waste, and the mixture is filled in a part of a mold to form the mold. A reinforcing material is inserted in the frame, aluminum particles are filled around the reinforcing material, the rest is filled with a mixture, heated to the sintering temperature of the inorganic waste through the melting point of aluminum, and sintered. A method for producing a wall material and a floor material, which promotes the bonding of molten aluminum with waste particles and a reinforcing material in the subsequent cooling and solidification process.