JPS60166279A - Lightweight ceramic board and manufacture - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates primarily to an inorganic and lightweight ceramic board used as a core material for doors and partition panels, and a method for manufacturing the same.

A. Prior Art Conventionally, lightweight inorganic core materials such as aerated concrete boards, asbestos-cement perlite boards, and silica boards have been developed.

Aerated concrete boards (commonly known as ALC boards), which are made by mixing concrete with a foaming agent and curing in a foamed state, have a specific gravity of 0.5 to
It is relatively heavy at 0.7, and the bending strength, which is important for core materials, is 9/c in the range of 8 to 10 in ALCi with a specific gravity of 0.5.
J, the compressive strength is 20 to 40 ky/crd, and the water absorption rate is 35 to 40% (■08%).

Further, as with the ALC board, the asbestos cement perlite board takes time to harden and cure, and its specific gravity is also heavy at about 0.7. Furthermore, the Caical board also has the drawback of being heavy with a specific gravity of 0.6 to 0.8.

Synthetic resin foam has been developed as a core material with a specific gravity of 0.5 or less and strong strength, especially bending strength, but it lacks heat resistance and has the serious drawback of emitting toxic gas in the event of a fire accident. There is.

B9 Purpose of the present invention The present invention satisfies the characteristics of conventional core materials, eliminates these drawbacks, and is lightweight, strong, nonflammable, heat insulating, soundproof,
It is an object of the present invention to provide a lightweight ceramic board with low moisture absorption and high productivity, and a method for manufacturing the same.

C1 Structure of the present invention The lightweight ceramic board according to the present invention is one in which bone phase is dispersed in a sintering agent and sintered, the aggregate is a ceramic foam such as pearlite or fuyolite, and the sintering agent is The siliceous clay contains soda ash and sodium nitrate that foam during firing, and the sintering agent is attached to the aggregate surface moistened with an aqueous solution containing a binder and a flocculant, which is then molded into a certain shape. , and then sintered after being shaped.

D. Preferred Embodiment In order to clarify the structure and effects of the present invention, one embodiment of the manufacturing technique according to the present invention will be described in detail as follows.

The aggregate used is obsidian, commonly known as pearlite, or fuyolite, which is rapidly heated to approximately 1000°C and expanded into spherical bubbles, which are made into spherical bubbles with a diameter of less than 2 mm.
Particle size was adjusted using two types of diameters: 11 to 5jIIll. That is, Fuyolite 211IIφ or less 750 koku 2-5y
nmφ 1500n Moisture is added to the aggregate in order to apply +1 sintering agent to this bone phase. However, if the aggregate is simply moistened with water, the sintering agent will peel off from the aggregate after drying, and due to the low-temperature sintering, it will precipitate on the coating surface due to the water solubility of the added soda ash, and it will not be uniform. This causes problems such as not being able to obtain a proper sintered state.

This drawback can be overcome by attaching a binder and a coagulant to the surface of the aggregate. PVA or polyvinyl alcohol can be used as a binder, and aluminum phosphate added to water can be used as a flocculant.

That is, 4202 water, 17 g of PVA, and 2.1 cc of a 40% aluminum phosphate solution are mixed together with the bone phase in a mixer to impart wettability to the surface of the aggregate.

Sintering agent powder was added to this aggregate and coated on the surface of the aggregate in a mixer. The sintering agent consists of siliceous clay, soda ash, sodium nitrate, and dolomite. That is, 225 kg of silicic clay (1 g, 360 Jc9 of soda ash, 150 kg of sodium nitrate, and 240 kg of dolomite) are mixed and pulverized using a ball mill or the like, and then adhered to the surface of the aggregate.

After being coated with a sintering agent and allowed to rest in a storage room overnight, it was shaped into a desired size and fired at a firing temperature of 850°C for 1 hour. Thereafter, it was cut again to a desired size, for example, as a ceramic board core material, to obtain accurate dimensions according to the intended use.

The siliceous clay used in the present invention is as follows.

S! O2=72-00%, M2O5=13.50%,
Fe203=1.0%, Ti02=0.13%, Mg
0=0.20%, Ca0=0, 90%, K20=3.
50%, Na2O = 2, 20%, Soda ash (Na2C03) was light ash that is easily soluble in water and has an apparent specific gravity of 1.0 or less, but the apparent specific gravity is 1.2.
Reprints of the above were also available. Sodium nitrate (Na2C03)
Sodium nitrate is naturally occurring as so-called saltpeter, and is a colorless and transparent crystal with a melting point of 308°C and a specific gravity of 2.257.380°C, decomposing into nitrous acid.

Dolomite is a rock consisting of 3 (Ca, Mg), and theoretically consists of the following chemical components: VIgo 21.7% CaO30, 4% Co247, 9%, with impurities such as Sio2 and An
20. , Fe2O3, and P. Further, dolomite can be used either as a raw stone or in the form of dolomite clinker obtained by firing the raw stone at a high temperature. Dolomite suitable for the core material of the present invention is preferably Mg0 16% or more and 5i0245% or less P001% or CaO33% or more in the case of dolomite clinker, and MgO28% or more and 5i023% or lessP1% or less in the case of dolomite clinker. Good.

Aluminum phosphate (FO4) has a melting point of 1500℃
An aqueous solution adjusted to 40% with white crystals was used.

In the examples of the invention, the aggregate, water and aluminum phosphate were measured by volume, and the sintering and binding agents were measured by weight. In particular, fuyolite has an apparent specific gravity of 1/10 to 1/20 that of sand, and is extremely lightweight, so its volume can be calculated accurately.

The larger the amount of aggregate mixed, the lighter the product will be, but the strength will be weaker, and the soundproofing properties at low frequencies will be reduced.

The lightweight ceramic board of the present invention preferably has an apparent specific gravity of 0.15 to 0.45. Based on this, the mixing ratio of bone phase is determined to be 5 to 20%, preferably 10 to 15% by weight.

As for the mixing ratio of the sintering agent, desirable results were obtained using the following blending range.

Silicic clay 50-80% Soda ash 10-20% Sodium nitrate 3-8% Dolomite 0-10% Also, the aqueous solution for wetting the aggregate is 15-20%
% (VOA) 0.5 to 0.6% (VOA) of the aluminum phosphate solution to the PVA aqueous solution (VOA) was suitable for stable production control.

In the lightweight ceramic board of the present invention, the sintering agent is also sintered in a foamed state. The sintering agent contains soda ash and sodium nitrate, which react to generate carbon dioxide gas and give a foamed state to the molten sintering agent. If the amount is larger than that of clay and dolomite, the foaming rate of the sintering agent will increase and the overall apparent specific gravity will decrease. A core material with a small apparent specific gravity has a relatively low strength. Therefore, the mixing ratio of soda ash and sodium nitrate is determined to be the optimum value for the application, taking into account the required strength and specific gravity and the amount of aggregate mixed.

In the above examples, PVC was used as the binder, but PVC
Alternatively, CMC, ie carboxymethylcellulose, can also be used. Further, it is also possible to use bitters, etc. as a flocculant.

The sintering conditions after the moistened aggregate is coated with sintering agent and molded into a certain shape are as follows: sintering temperature: 750°C to 1000°C
℃ and sintering time can be adjusted within the range of 30 minutes to 3 hours.

The manufacturing technique described above produces the following effects.

■ Since the ceramic lightweight aggregate is sintered with an inorganic sintering agent, a core material with strong physical and chemical strength and high heat resistance can be obtained.

■ Since the sintering agent itself melts and foams, a lightweight and strong core material can be obtained.

The core material prototyped by the present inventor has a specific gravity adjusted to 0.31, and achieves a bending strength of 10.8 kq/ant, and has a bending strength of approximately 10.5 kq/ant compared to the ACL board. It was possible to reduce it by half. Well, the water absorption rate is 14.
72% (Vo, g) It was reduced to about half that of the TE, Colemo AT, and C boards.

In addition, since the core material according to the present invention is a completely inorganic sintered body, it is heat resistant and nonflammable, and can be manufactured by firing in a short time, resulting in extremely high productivity, and does not use expensive raw materials. It has extremely significant features such as being able to be manufactured at low cost.

■ The surface of the aggregate is wetted with an aqueous solution containing a binder and a flocculant, a sintering agent is attached to the surface, the whole is shaped and retained in a certain shape, and the aggregate is sintered in this state. The aggregate is uniformly dispersed in the sintering agent and sintered firmly, and the sintering process is simple and efficient, improving productivity.

Procedural amendment (voluntary) Manabu Shiga, Commissioner of the Japan Patent Office1, Indication of the case 1982 Old Patent Application No. 90732 Title of the invention Lightweight ceramic board and its manufacturing method3 Patents related to the amended person case Applicant A (3 Japan, Otsu Co., Ltd. Address 015, Date of amendment order Voluntary 6, Number of inventions increased by amendment None 7, [Claims column] of the town specification subject to amendment, [Detailed Explanation Column] 8. Contents of the Amendment As shown in the attached sheet, Attachment 1 The "Claims" of the specification are amended as follows.

(1) Aggregate is dispersed and sintered in a sintering agent that is sintered in a foamed state, and the aggregate is ceramic foamed aggregate, which is mixed at a weight ratio of 5 to 20% The binder is a mixture of 50-80% silicic acid, 10-20% soda ash, 3-8% sodium nitrate, and 0-10% dolomite by weight to form a foamed sintered rod and sintered. A lightweight ceramic board with sometimes sintered aggregate.

The lightweight ceramic board according to claim 11, wherein the f2+ aggregate is pearlite, fuyolite, or a mixture of both.

(3) The lightweight ceramic board according to claim (1), wherein the aggregate is a mixture of multiple types having different average particle diameters.

(4) The lightweight ceramic board according to claim (1), wherein the mixing ratio of aggregate is 10 to 15 wt%.

(5) The lightweight ceramic board according to claim (1), wherein the silicic acid region is white clay.

(6) Ceramic foam aggregate is wetted with an aqueous solution containing a binder and a flocculant, and its surface is coated with 50~3Qwt% silicic acid, 10~2[)wt% soda ash, and 3~Bwt% %
of sodium nitrate and 0 to iowt% of dolomite are deposited and molded into a certain shape, which is then fired to foam and sinter the sintering agent, dispersing the aggregate inside and sintering. A method for manufacturing a lightweight ceramic board.

(7) The method for manufacturing a lightweight ceramic board according to claim (6), wherein either or both of PVC and CMC is used as the binder.

(8) The method for manufacturing a lightweight ceramic board according to claim (6), wherein either or both of bitterness and aluminum phosphate is used as the flocculant.

(9) Sintering temperature is 700-1000℃, sintering time is 3
The method for manufacturing a lightweight ceramic board according to claim (6), wherein the manufacturing time is 0 minutes to 3 hours.

2. "Silicate clay" on page 5, line 4 of the specification is amended to read "silicic acid territory."

3. "Silicate clay" on page 7, lines 3 to 4, and line 6 of the specification is amended to read "silicic acid territory."

4. "Silicate clay" in the first line of page 8 of the specification is amended to read "silicic acid territory."

5. "Silicate clay" on page 11, line 15 of the specification is amended to read "silicic acid territory."

Procedural amendment (voluntary) May 4, 1985 Patent Application No. 019073 2, Title of invention: Lightweight ceramic board and its manufacturing method 3,
Relationship with the case of the person making the amendment Patent applicant No. 6 amends the "Claims" in Attachment 1 of the detailed description of the invention which is increased by the amendment as follows.

(1) The aggregate is dispersed and sintered in a sintering agent that is sintered in a foamed state. The binder is a mixture of 50 to 80% silicate loess, 10 to 20% sorta ash, nitric acid sorta, and 0 to 10% dolomite by weight, and is foamed and sintered. A lightweight ceramic boat.

(2) Claim (1) in which the sintering agent contains nitric acid sorter in a weight ratio of 3 to 8%! The lightweight ceramic boat described in i.

(3) ftU is here! The lightweight ceramic book-1 according to claim (1), which is a mixture of either or both of .

(4) The lightweight ceramic boat according to claim (1), wherein the aggregate is a mixture of a plurality of types having different average particle diameters.

(5) The lightweight ceramic hoard according to claim (1), wherein the mixing ratio of the scrap material is 10 to 15w16%.

(6) The lightweight ceramic board 1 according to claim (1), wherein the silicate layer is white clay.

(7) Ceramic foamed aggregate or aqueous solution containing binders and flocculants) wetted with α on its surface, 50-80 wL% silicic acid, 10-20 wL% sorter ash, nitric acid 0 to 10 wt% of dolomite is deposited on the sorter and molded into a certain shape, and this is fired to foam and sinter the sintering agent to disperse the aggregate inside 813 and sinter it. Features: Lightweight Ceramic Ball 1. Manufacturing method.

(8) The method for manufacturing a lightweight ceramic boat according to claim (7), wherein either or both of PVC and CMC is used as the binder.

(9) The method for producing a lightweight ceramic holder 1 according to claim (7), wherein either or both of bitterness and aluminum phosphate are used as the flocculant.

(10) The method for manufacturing a lightweight ceramic board according to claim (7), wherein the sintering temperature is 700 to 1000' (with a trowel, and the sintering time is 30 minutes to 3 hours).

Claims (1)

[Claims] (1) The aggregate is dispersed and sintered in a sintering agent sintered in a foamed state, and the aggregate is a ceramic foam aggregate,
This is mixed in a weight ratio of 5 to 20%, and the sintering agent is
By weight: 50-80% silicic clay, 10-20%
of soda ash, 3-8% sodium nitrate, 0-. A lightweight ceramic board that is foamed and sintered with 10% dolomite mixed in, and the aggregate is sintered during firing. f21 The lightweight ceramic board according to claim (1), which is a mixture of either or both of aggregate coverlite and fuyolite. (3) Claim 1, in which the aggregate is a mixture of multiple types with different average particle diameters (lightweight ceramic board according to claim 11); (4) Claim, in which the mixing ratio of bone phase is 10 to 15 wt% The lightweight ceramic board according to item m. (5) Claim 1, wherein the silicate clay is white clay.
Lightweight ceramic board as described in section. (6) Ceramic foam aggregate is wetted with an aqueous solution containing a binder and a flocculant, and its surface is coated with 50-3Qwt% silicate clay, 10-20wt% soda ash, and 3-Bwt% sodium nitrate. , 0 to 10 wt% of dolomite is deposited and molded into a certain shape, and this is fired to foam and sinter a sintering agent to disperse bone phase inside and sinter it. How to make ceramic board. (7) The method for manufacturing a lightweight ceramic board according to claim (6), wherein either or both of PvC and CMC is used as the binder. (8) The method for manufacturing a lightweight ceramic board according to claim (6), wherein either or both of bitterness and aluminum phosphate is used as the flocculant. (9) Sintering temperature is 700-1000℃, sintering time is 3
The method for manufacturing a lightweight ceramic board according to claim (6), wherein the manufacturing time is 0 minutes to 3 hours.