JPH11180758A - Production of inorganic cureo booy - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a production method of an inorg. cured body excellent in strength, durability and productivity. SOLUTION: In the production method of a grid-shaped reinforcing material- containing inorg. cured body in which a slurried inorg. composition 3 consisting essentially of a SiO2 -Al2 O3 based powder, alkali metal silicate and water is injected into a lower die 1, and the grid shaped reinforcing material 2 consisting of an org. fiber or an inorg. fiber is disposed/sealed in the slurried inorg. composition 3, and the composition is cured by heating, the grid-shaped reinforcing material 2 is previously arranged at a bottom surface of the lower die 1, and after injecting the slurried inorg. composition 3, a forming mold is vibrated.

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 a cured inorganic material, which is a non-combustible material useful as a building member for inner and outer walls, partitions, floors and the like of houses and buildings, and has excellent strength, durability and appearance. And a method for producing a lightweight inorganic cured product.

[0002]

2. Description of the Related Art A lower mold is filled with a slurry-like inorganic composition mainly composed of an SiO2-Al2O3 powder and an aqueous alkali metal silicate solution, and the upper surface of the filled slurry-like inorganic composition is sealed with a mold. Japanese Patent Application Laid-Open No. 9-123155 describes a method in which a lattice-shaped product as a reinforcing material is sandwiched between the upper mold and the cured product to obtain a cured inorganic material.

The method described in the above publication is shown in FIGS.
As shown in (c), the lower mold 1 is filled with the slurry composition 3 (FIG. 2A), and the lattice-shaped product 2 formed of stainless steel or organic fiber or inorganic fiber is placed on the upper surface of the slurry composition 3. (FIG. 2B), and the lattice-shaped article 2 is sandwiched between the lower mold 1 and the upper mold 4 (FIG. 2C) to break bubbles generated on the upper surface of the slurry-like composition 3. As a result, the product back surface 31 is finely finished, and the effect of reinforcing the cured product by the lattice-shaped product 2 attached to the upper surface of the slurry-like composition 3, that is, the product back surface is obtained.

[0004]

However, in the method described in the above publication, the lattice-shaped article must be sufficiently fixed to the slurry-like composition in order for the lattice-shaped article to exhibit a reinforcing effect. After filling the slurry-like composition into the mold and placing the grid-like product on the slurry-like upper surface, work to apply the slurry-like composition with a brush, a spatula, or the like to make the grid-like product fit into the slurry-like composition. Otherwise, it cannot be clamped by the formwork, and there is a problem in productivity and efficiency. If the above operation is not performed, the reinforcing effect cannot be obtained, and the grid-shaped product peels off from the cured product before shipment or during use of the cured product, causing a serious problem in the quality of the product.

An object of the present invention is to solve the above-mentioned problems, and to provide a method for producing an inorganic cured product having excellent strength and durability and excellent productivity.

[0006]

Production method of the present invention inorganic hardened body [Means for Solving the Problems] is, SiO ₂ -Al ₂ O ₃ system powder, alkali metal silicates,
A slurry-like inorganic composition containing water as a main component is poured into a mold, and a lattice-like reinforcing material made of organic fibers or inorganic fibers is disposed and sealed in the slurry-like inorganic composition, and is cured by heating. In the method for producing a cured inorganic material containing a reinforcing material, a lattice-shaped reinforcing material is placed on the bottom surface of a mold in advance, and after the slurry-like inorganic composition is injected, a vibration is applied to the mold.

The above-mentioned SiO ₂ —Al ₂ O ₃ powder is SiO ₂ / Al ₂ O ₃
Those having a composition of 1/9 to 9/1 (weight ratio) are preferably used. The above-mentioned SiO ₂ -Al ₂ O ₃ powder is the above-mentioned SiO ₂ -Al ₂ O ₃
The component is a main component, and at least 5
Preferably, it accounts for 0% by weight or more. When the content of the above components is less than 50% by weight, the reactivity with the aqueous alkali metal silicate solution is reduced, and the mechanical strength of the obtained inorganic cured product is reduced.

The above SiO 2 -Al 2 O 3 powder can be obtained from various raw materials and by various processing means. For example, fly ash containing 80% by weight or more of particles having a particle size of 10 μm or less, 400 An inorganic powder or a clay obtained by melting fly ash, fly ash or clay or a mixture thereof containing 80% by weight or more of particles having a particle size of 10 μm or less and fired at 1000 ° C. and spraying them in the air. Inorganic powder obtained by applying mechanical energy of 0.1 to 30 kgh / kg,
The inorganic powder obtained in the section, further 100 ~ 750 ℃
Inorganic powder obtained by heating to a temperature of
Examples include inorganic powder obtained by applying 0.1 to 30 kgh / kg of mechanical energy to metakaolin, ash of an electric dust collector for producing corundum or mullite, pulverized calcined bauxite, and metakaolin. These SiO ₂ —Al ₂ O ₃ -based powders may be used alone or in a combination of two or more.

The fly ash is JIS A6
Fine particle size ash collected by a dust collector from a pulverized coal combustion boiler specified in 201, SiO ₂ 40% or more, moisture 1%
Below, specific gravity 1.95 or more, specific surface area 2700 cm ² / g
As described above, 75% or more is passed through the 44 μm standard sieve.

The above-mentioned inorganic powders are disclosed in
It is a powder as described in Japanese Patent Publication No. 9060 and Japanese Patent Publication No. 4-45471. The above metakaolin is
There is no particular limitation, and for example, commercially available metakaolin is preferably used.

The alkali metal silicate used in the present invention is a silicate represented by M ₂ O · nSiO ₂ (M is one or more metals selected from potassium, sodium and lithium), When the value is small, a cured product having good appearance cannot be obtained, and when the value is large, gelation is likely to occur.
~ 8, more preferably 0.5 ~ 2.5
It is.

[0012] alkali metal silicate is preferably formulated as an aqueous solution, the concentration of the aqueous solution is reduced when the SiO ₂ -Al ₂ O
_When the reactivity with the ₃ series powder decreases and the concentration increases, an alkali metal salt is likely to be formed. Therefore, a concentration of 10 to 60% by weight is desirable. To make an alkali metal silicate aqueous solution,
The alkali metal silicate may be dissolved in water as it is under pressure and heat, but SiO ₂ components such as silica sand and silica stone powder are added to the aqueous alkali metal hydroxide solution so that n becomes a predetermined amount. You may melt | dissolve under heating.

When the amount of the alkali metal silicate is small, the curing is insufficient, and when the amount is large, the water resistance of the obtained cured product is reduced. Therefore, 1 to 100 parts by weight of the SiO ₂ —Al ₂ O ₃ powder is used. 300 parts by weight are preferred, and more preferably 10 parts by weight.
２５０250 parts by weight.

The total amount of water used in the present invention may be mixed as an aqueous solution of an alkali metal silicate, or a part of the total amount may be mixed as water different from the aqueous solution of an alkali metal silicate. Good. The amount of water becomes insufficient curing less, since the strength of many a cured product decreases, SiO ₂ -Al
_{The amount} is preferably from 10 to 1,000 parts by weight, more preferably from 10 to 750 parts by weight, and still more preferably from 50 to 500 parts by weight, per 100 parts by weight of the ₂ O ₃ -based powder.

The above-mentioned slurry-like inorganic composition comprising SiO ₂ —Al ₂ O ₃ powder, alkali metal silicate, and water may contain, if necessary, an inorganic filler, a reinforcing fiber, a lightweight aggregate, a pigment,
A foaming aid, a foaming agent, and the like can be added.

As the above-mentioned inorganic filler, those having low activity with respect to an aqueous alkali metal silicate solution can be used. Examples include silica sand, rock powder, volcanic ash (silas, anti-firestone, etc.), wollastonite, calcium carbonate, silica stone powder, diatomaceous earth, mica, mica, silica fume, etc. It is not limited to these.

The reason why an inorganic filler having a low activity with respect to an alkali metal silicate aqueous solution is desired is that if the activity is high, gelation of the alkali metal silicate aqueous solution proceeds rapidly, making mixing and molding difficult. is there. The amount of the inorganic filler with respect to SiO ₂ -Al ₂ O ₃ -based powder 100 parts by weight of 90
0 parts by weight is desirable. If it exceeds 900 parts by weight, the strength will be reduced.

As the reinforcing fibers, those used in ordinary cement products can be used. For example, fibers of polypropylene, vinylon, rayon, alkali-resistant glass, carbon, acryl, aramid, acrylonitrile and the like can be used alone or in combination. Fiber size is 1-50
Those having a thickness of 0 μm and a length of 1 to 15 mm are preferred. 1μ diameter
If it is less than m, a fiber ball is formed at the time of mixing and the strength is liable to be reduced.
If it is less than m, a reinforcing effect such as improvement in tensile strength cannot be expected. On the other hand, if the fiber length exceeds 15 mm, the dispersibility decreases, and a cured product having uniform strength cannot be obtained. The amount of the reinforcing fibers relative to the SiO ₂ -Al ₂ O ₃ -based powder 100 parts by weight of 1
0 parts by weight or less is preferred. If it exceeds 10 parts by weight, the dispersibility of the fiber will be reduced.

As the lightweight aggregate, inorganic foams such as pearlite, glass balloon, silica balloon, fly ash balloon and shirasu foam, and organic foams such as phenol resin, urethane resin, polyethylene and polystyrene can be used. The amount of the lightweight aggregate is preferably 150 parts by weight or less based on 100 parts by weight of the SiO ₂ —Al ₂ O ₃ powder. 1
If the amount is more than 50 parts by weight, the strength, the surface smoothness, and the molding workability are reduced.

The opening of the grid-like reinforcing material comprising organic fibers and inorganic fibers used in the present invention is 0.5 to 1 cm ^2.
Ten are preferred. If the number is less than 0.5, the reinforcing effect of the cured body is reduced, and if the number exceeds 10, the lattice-like reinforcing material does not rise from the bottom surface of the mold even when vibration is applied, and is exposed to the product surface to significantly impair the appearance.

The organic fibers or inorganic fibers are not particularly limited as long as they have alkali resistance. For example, polypropylene fibers, polyethylene fibers, polyester fibers, polyamide fibers, vinylon fibers, rayon, carbon fibers And artificial fibers such as acrylic fibers, aramid fibers, acrylonitrile fibers, and alkali-resistant glass fibers, and natural fibers such as silk. These organic fibers or inorganic fibers are used alone or in combination.

The diameter of the fibers constituting the lattice in the vertical and horizontal directions is preferably 0.1 mm or more and 2 mm or less. If it is less than 0.1 mm, no reinforcing effect can be obtained, and if it is 2 mm or more, no further reinforcing effect can be expected, and the grid-like reinforcing material does not float from the bottom surface of the mold, and is exposed on the product surface and significantly impairs the appearance. .

By vibrating the mold into which the slurry-like inorganic composition has been injected, the lattice-like reinforcing material disposed on the bottom of the lower mold is raised, and the fibers of the lattice-like reinforcing material and the slurry-like composition are mixed. Improves conformability and discharges bubbles in the slurry composition.

The vibration intensity applied to the forming mold is 0.5 to 10
0G is preferable, and 1 to 50G is more preferable.
If it is less than 0.5 G, the effect of vibration does not appear, and the grid-like reinforcing material does not rise from the bottom surface of the mold. In addition, vibration is 10G
In order to exceed this, the device becomes larger and requires a large amount of energy, and measures against noise are also required.

The direction of vibration is effective in any of the vertical, horizontal, and three-dimensional directions. The method of generating vibration is not particularly limited, and examples thereof include a method of applying a vibration by fixing a molding die on a table vibrator and a method of attaching a vibrator to the molding die to apply vibration.

The time for applying the vibration is preferably about 10 seconds to 10 minutes. If it is shorter than this range, the effect of vibration does not appear, and if it is longer than this range, there is no further effect and it is uneconomical.

[0027]

BEST MODE FOR CARRYING OUT THE INVENTION

Embodiments of the present invention will be described below. The SiO ₂ -Al ₂ O ₃ -based powder of adjusting SiO ₂ -Al ₂ O ₃ -based powder A100 parts by weight mixed solution 0.5 parts by weight of triethanolamine 25 wt% and ethanol 75% by weight, ultra-fine mill (Mitsubishi Heavy Industries, zirconia ball 10mm used, ball filling rate 85
Supplied volume%), to give the SiO ₂ -Al ₂ O ₃ -based powder B by the action of mechanical energy of 10 kWh / kg. The applied mechanical energy was expressed by dividing the electric power supplied to the ultrafine mill by the unit weight of the treated powder.

Alkali metal silicate aqueous solution manufactured by Nippon Chemical Industrial Co., Ltd. (water 55%, SiO ₂ 220%, K ₂ O 2
5%).

Preparation of Compound The following materials were mixed with 100 parts by weight of the SiO ₂ —Al ₂ O ₃ powder B. Mica (manufactured by Repco, product number "M-100"): 20 parts by weight Talc (manufactured by Nippon Talc, trade name "Talc S"): 30
Weight part Wollastonite (manufactured by Tsuchiya Kaolin Co., Ltd., trade name "Kemorit A-60"): 57.5 parts by weight Vinylon (manufactured by Kuraray, product number "RM182"): 0.5
Parts by weight The above materials were dry-mixed with an Erich mixer for 5 minutes to obtain a mixed powder.

Lattice Reinforcing Materials Eleven kinds of lattice reinforcing materials (produced by Kurabo Industries, using polypropylene fibers) having the wire diameters and openings shown in Table 1 were used.

Example 100 parts by weight of the above mixed powder and 50 parts by weight of an alkali metal silicate aqueous solution were mixed for 2 minutes by an omni mixer to prepare an inorganic slurry composition. As shown in FIG. 1 (a), the above-mentioned grid-like reinforcing material 2 is spread on the bottom surface in the lower mold 1, and as shown in FIG. 3 is filled in a required amount by a free-fall method, and then vibrated (in a three-dimensional direction, with a vibration intensity of 50 G for 1 minute) by a table vibrator (not shown). As shown in FIG. 2 was raised to the middle of the inorganic slurry composition 3. Thereafter, as shown in FIG. 1 (d), the resin was cured while being clamped by the upper mold 4.

(Comparative Example) As shown in FIG. 2, a lower mold 1 was filled with the same inorganic slurry composition 3 as that used in the example, and the upper surface of the inorganic slurry composition 3 was filled with the above-mentioned grid-like composition. The reinforcing material 2 was placed and sandwiched between the upper mold 1 and the lower mold 4. In this state, vibration was applied by a table vibrator under the same conditions as in the example, and then cured.

Evaluation The cured products obtained in Examples and Comparative Examples were tested for their initial impact strength (falling ball impact test, JISA 1421) and for the accelerated deterioration test after the durability test (JIS A 1435, freeze-thaw test 100 cycles). An impact strength test was carried out, and the drop heights at which cracks did not occur were determined as D ₀ and D
_1, and the strength retention rate (D ₁
/ D ₀ × 100) was evaluated. Table 2 and Table 3 show the above results.
Shown in

[0034]

[Table 1]

[0035]

[Table 2]

[0036]

[Table 3]

[0037]

According to the method for producing a cured inorganic material of the present invention, a lattice-shaped reinforcing material is embedded in an inorganic slurry-like composition and is cured in that state, so that the lattice-shaped reinforcing material is surrounded by the cured material. Therefore, the lattice-shaped reinforcing material is not exposed to the outer surface of the cured body, so that the lattice-shaped product does not peel off from the cured body, and has strength, durability, and appearance as a building member such as an inner or outer wall, a partition, a floor, etc. of a house or a building. Thus, an inorganic cured product having excellent lightweight strength and excellent durability can be obtained.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view showing an embodiment of a method for producing an inorganic cured product of the present invention.

FIG. 2 is a cross-sectional view showing a conventional method for producing a cured inorganic material.

[Explanation of symbols]

 1: Lower mold 2: Lattice reinforcing material 3: Inorganic slurry composition 4: Upper mold 31: Product back

Claims (1)

[Claims] 1. A slurry-like inorganic composition mainly composed of SiO ₂ —Al ₂ O ₃ -based powder, alkali metal silicate and water is poured into a mold, and a lattice reinforcing material made of organic fibers or organic fibers is provided. Is disposed and sealed in the slurry-like inorganic composition, and in a method for producing an inorganic cured body containing a grid-like reinforcing material cured by heating, the grid-like reinforcing material is previously arranged on the bottom of the mold, and the slurry-like inorganic composition A method for producing a cured inorganic material, which comprises applying vibrations to a molding die after injecting water.