JPS5934158B2 - Manufacturing method of inorganic products - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing an inorganic product used for exterior materials, interior materials, etc. for buildings.

Cement-based and gypsum-based inorganic boards are generally used as exterior and interior materials for buildings. However, these inorganic plates have the drawbacks of being porous, causing easy surface wear, high water absorption, rough texture, poor appearance, and the tendency to develop efflorescence. had. In order to eliminate these drawbacks, a cement-based color fly layer is formed on the surface of the inorganic board. However, the color fly layer also had a rather rough texture and cracked during production, particularly during curing and drying, and was also difficult to process. In order to suppress such cracking and peeling, fibers have been included in the color fly layer, but this has the disadvantage that the texture of the color fly layer becomes coarse. Another idea was to apply a slurry mainly composed of blast furnace slag to the surface of the inorganic plate, and then cure and harden it. (formed on the surface of the plate) became rough, making it impossible to obtain a satisfactory product. Furthermore, forming a glass film on the surface of inorganic boards, especially slate boards, has been considered and is already being done in some cases, but manufacturing inorganic products in this way would complicate the manufacturing process. However, the problem was that the product was expensive. As a result of repeated research in view of these circumstances, the inventors found that by pulverizing blast furnace slag, forming a coating layer on the surface of an inorganic plate with a slurry made of the slag, and then curing and hardening it, the blast furnace This invention was completed by discovering that the slag can be properly cured, and that a fine-grained, glass-like cured material layer (produced by curing the coating layer) that does not cause cracks or peeling can be produced.

That is, the gist of the present invention is a method for producing an inorganic product, which is characterized by applying a slurry containing pulverized blast furnace slag as a main component to the surface of an inorganic substrate, followed by curing and curing.

Next, this invention will be explained in detail. In this invention, a slurry whose main component is pulverized blast furnace slag is used.

Such a slurry can be made by pulverizing blast furnace slag as it is in a ball mill, etc., adding water and kneading it to form a slurry (dry method), or by kneading blast furnace slag with water in advance to form a slurry. It is made by pulverizing it in a colloid mill (wet method). In this case, the pulverized blast furnace slag in the slurry has a particle size of 1 to 1
It is necessary that it be 0μ. That is, although there is no problem even if the particle size is less than 1 μm, it is difficult to actually grind the particles to that particle size. In addition, if the particle size exceeds 10μ, the hardening of the pulverized blast furnace slag becomes slow, and
This is because the resulting cured product layer tends to have a rough texture, resulting in poor appearance and waterproof properties. In addition, when making wet slurry whose main component is pulverized blast furnace slag, hydration during pulverization of the pulverized blast furnace slag (when slag becomes pulverized, reactivity improves and hydration occurs easily). In order to prevent this, it is preferable to add a curing retarder. If necessary, it may be added during dry slurry production. In addition, when a resin is added to the slurry whose main component is pulverized blast furnace slag, the resulting cured material layer becomes flexible and is prevented from cracking, and it also becomes more dense and the texture of the resulting hardened material layer becomes more flexible. becomes even more detailed.

As the resin to be contained in the slurry mainly composed of pulverized blast furnace slag, water-soluble resins such as polyacrylic acid and polyvinyl alcohol, vinyl acetate resins that can be formed into aqueous emulsions, SBR1 rubber latex, etc. are used. Resins that cannot be dispersed in water or are soluble only in organic solvents will not be uniformly dispersed in the slurry, and will significantly inhibit the hardening of the pulverized blast furnace slag. In order to incorporate the resin into the slurry, for example, the above-mentioned resin may be added to the slurry as it is, or it may be added to the slurry in the form of an aqueous solution or an aqueous emulsion. The resin content is preferably selected to be 2 to 30% by weight (solid content). That is, 2% by weight (hereinafter "
%], the effect of containing the resin will not be exhibited, and conversely, if it exceeds 30%, the surface hardness and water resistance of the resulting cured product layer tend to deteriorate. Examples of the inorganic substrate to which the slurry mainly composed of pulverized blast furnace slag is applied include those using a hydraulic inorganic binder such as cement, such as cement boards and gypsum boards.

However, it is not limited to this. In addition, inorganic substrates include not only hardened ones but also uncured ones, that is, those made by forming slurry using a hydraulic inorganic binder by papermaking, casting, etc. (before curing and hardening).
〇A slurry mainly composed of pulverized blast furnace slag is applied to the surface of such an inorganic substrate (troweling,
(spray, pour over, etc.).

At this time, a curing stimulator (
Alkaline substances) may be added to the slurry. When applying slurry, the thickness of the coating layer is 0.2 to 2 mm1.
It is preferable to do this as follows. The thickness of the coating layer is 0.
This is because it is difficult to apply the coating to a thickness of less than 2 mm, and conversely, no increase in the effect can be expected even if the coating is applied to a thickness of more than 2 mm. Next, the coating layer formed by coating the slurry is cured and cured to obtain the desired inorganic product. In this case, when the inorganic substrate is in an uncured state, curing of the coating layer and curing of the inorganic substrate occur almost simultaneously, so that the resulting cured product layer firmly adheres to the inorganic substrate. The inorganic products obtained in this way have a fine-grained glass-like cured material layer that does not cause cracks or peeling on the surface, so they have an extremely beautiful appearance, are highly water resistant, and are highly water resistant. It also has great efflorescence properties.

Further, it does not require a long time to manufacture, is easy to manufacture, and is inexpensive. Next, examples will be described together with comparative examples.

[Example 1] Equal amounts of granulated blast furnace slag (product name: Esment, manufactured by Shin Nippon Kagaku Co., Ltd.) and water were mixed to form a slurry, and this was applied to a colloid mill.

At this time, the material was passed through the colloid mill several times while gradually reducing the opening of the colloid mill to create a slurry containing pulverized blast furnace slag as a main component (slurry containing pulverized slag). The average particle size of the above pulverized slag is 5μ
It was hot. When this slurry was left at room temperature, it started to harden 30 minutes after pulverization. When hardening and heat curing, hardening started immediately after heating. Next, this slurry was applied to four inorganic substrates (cement board containing 10% pulp, 10cTrLx20C77L).
1 specific gravity (less than 1.3) in the following manner. 1 The above slurry was applied to the surface of an inorganic substrate and finished with a trowel.

2 The above slurry was applied to the surface of the inorganic substrate by spraying, and then smoothed using a roll.

Next, the two pieces to which the slurry was applied as described above 1
A total of two sets of inorganic substrates (on which the slurry was applied by methods 1 and 2 above) were cured in a humid atmosphere at room temperature for one week, and the other set was cured in a humid atmosphere at 80°C for 10 days.
I spent time curing it.

As a result, an inorganic product having a 0.5 mm thick cured material layer on the surface was obtained. This cured product layer was glassy and dense, and had high hardness. It also had an extremely good appearance, and even if water droplets were dropped on it, it did not absorb water for more than two hours and was extremely waterproof. [Example 2] The following raw materials were blended in the following proportions.

Next, the above mixture was kneaded with water to give a concentration of 10%.
Create a slurry of
A paper-made board (inorganic base) of water) = 6/4 was made.

Next, on the surface of this paperboard, a slurry containing finely ground slag prepared in the same manner as in Example 1 was rolled up into a layer to form a coating layer, and this coating layer was smoothed with a roll. Next, this was cured in a humid atmosphere at 80° C. for 10 hours to obtain an inorganic product. This product has excellent properties similar to those obtained in Example 1, and furthermore, since the inorganic substrate and the coating layer are cured at the same time, the cured product layer is firmly integrated with the substrate. It also had the advantage of being The obtained inorganic product has a substrate specific gravity of 1.1.
0, thickness 10n, . Specific gravity of cured material layer: 2.0, thickness: 0.3
It was ~0.5ml/L. [Example 3] Granulated blast furnace slag (esment) was pulverized in a ball mill to produce a pulverized product with an average particle size of 2 μm.

Next, add water to this and (water) / (slag) = 0.3
A slurry containing finely ground slag was prepared by adjusting and kneading the powder to give a finely ground slag. At this time, in order to delay the hardening of the pulverized slag, 1% sodium hexametaphosphate (
slag) was added. The curing delay time of this slurry containing a curing retarder was about 1 hour at a temperature of 30°C. Next, this slurry was applied to the surface of a paper board made in the same manner as in Example 2, a sheet was placed on top of it, and the whole was then turned over and cured as shown in FIG. 1 to obtain an inorganic product. In FIG. 1, 1 is a paper-made board, 2 is a coating layer, and 3 is a sheet. This inorganic product has the same excellent properties as the inorganic product obtained in Example 1, and also has the additional feature that the surface of the cured product layer is extremely smooth due to the transfer of the smooth surface of the sheet. had. 〔Example
4] A pulverized blast furnace slag was prepared in the same manner as in Example 3, and water was added thereto to adjust the ratio of (water)/(slag) to 20.50, and the mixture was kneaded.

At this time, add 2 sodium hexametaphosphate curing retarders.
% (based on slag). Next, this slurry was applied to the surface of a paper-made board made in the same manner as in Example 2 using a flow coater. Then, the whole was heated in a humid atmosphere at 80°C for 1 time.
After curing for 0 hours, an inorganic product was obtained. The obtained mineral product had excellent properties similar to those obtained in Example 1. [Example 5] A slurry containing pulverized slag was prepared in the same manner as in Example 1, and this was applied to the surface of lightweight concrete, smoothed with a trowel, and then covered with a sheet and cured.

The sheet is used to smooth the coating layer and prevent moisture from evaporating during curing, thereby facilitating curing. The obtained inorganic product is shown in FIG. In the figure, 4 is lightweight concrete and 5 is a hardened material layer. This inorganic product also had the same excellent properties as those obtained in Example 3. [Comparative Example 1] In place of the pulverized blast furnace slag, pulverized Portland cement was used.

However, during wet grinding of Portland cement in a colloid mill, the cement became hydrated and generated heat. The resulting finely pulverized material had been completely cured, and no cured material layer could be produced even when it was used. [Comparative Example 2] Portland cement was dry ground in a pot mill, and this was kneaded with water to make a slurry. Using this slurry, an inorganic product was made in the same manner as in Example 1.

In this case, the finely pulverized Portland cement hardened with significant heat while being kneaded with water, so a good hardened material layer was not formed and the hardened material layer became dry and prone to yoking. [Comparative Example 3] An inorganic product was obtained in the same manner as in Example 1, except that a slurry containing Portland cement was used instead of the slurry containing finely ground slag.

In this case, curing was carried out for one week at room temperature. The cured layer of the obtained inorganic product was partially cracked due to shrinkage during curing and drying, and sloshing occurred during the sloshing test. [Examples 6 to 15] A slurry containing pulverized slag was prepared in the same manner as in Example 1, and the resin shown in the table below was added in the amount (solid content) shown in the table based on the solid content of the slurry. did.

The dispersion state of the resin in the slurry at this time is shown in FIG. In the figure, 6 is water, 7 is pulverized slag, and 8 is water.
are resin particles. Next, this was applied to the surface of lightweight concrete, smoothed with a trowel, and then cured for 10 hours at 80°C in a humid atmosphere to obtain an inorganic product. The obtained inorganic product generally has the same excellent properties as Example 1, and further has a denser cured material layer on the surface.
It also had the characteristics of being highly flexible and difficult to break. In addition, Examples 6 to 15 obtained as described above
The individual performances of the cured layer of the inorganic product were as shown in the table below. In the table, Δ indicates that it is smaller than the standard value among Examples 6 to 15, ◯ indicates that it is standard, and ◎ indicates that it is better than standard. Flexibility was examined by checking the appearance of cracks when a 1 m long sample plate was bent to an arrow height of 10 cm.

[Brief explanation of the drawing]

Fig. 1 is an explanatory diagram of the manufacturing state of one embodiment of the present invention, Fig. 2 is a sectional view of an inorganic plate produced according to another embodiment, and Fig. 3 is an illustration of the dispersion state of resin in slurry. It is an explanatory diagram. 1... Paper-made board, 2... Coating layer, 3...
... Sheet, 4 ... Lightweight concrete, 5
......Cured material layer.

Claims (1)

[Claims] 1. A method for producing an inorganic product, which comprises applying a resin-containing slurry whose main component is pulverized blast furnace slag with a particle size of 1 to 10 μm to the surface of an inorganic substrate, followed by curing and curing.