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
  • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
  • C04B28/24—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing alkyl, ammonium or metal silicates; containing silica sols
  • C04B28/26—Silicates of the alkali metals
• • 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
  • C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
  • C04B14/02—Granular materials, e.g. microballoons
  • C04B14/04—Silica-rich materials; Silicates
  • C04B14/043—Alkaline-earth metal silicates, e.g. wollastonite
• • 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
  • C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
  • C04B14/38—Fibrous materials; Whiskers
  • C04B14/42—Glass
• • 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
  • C04B14/00—Use of inorganic materials as fillers, e.g. pigments, for mortars, concrete or artificial stone; Treatment of inorganic materials specially adapted to enhance their filling properties in mortars, concrete or artificial stone
  • C04B14/38—Fibrous materials; Whiskers
  • C04B14/46—Rock wool ; Ceramic or silicate fibres
  • C04B14/4643—Silicates other than zircon
  • C04B14/4668—Silicates other than zircon of vulcanic origin
• • 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
  • C04B20/0016—Granular materials, e.g. microballoons
  • C04B20/002—Hollow or porous granular materials
  • C04B20/004—Hollow or porous granular materials inorganic
• • 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
  • C04B20/0048—Fibrous materials
• • 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
  • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
  • C04B28/006—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing mineral polymers, e.g. geopolymers of the Davidovits type
• • 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
  • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
  • C04B28/02—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing hydraulic cements other than calcium sulfates
  • C04B28/06—Aluminous cements
• • 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
  • C04B40/00—Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability
  • C04B40/0082—Processes, in general, for influencing or modifying the properties of mortars, concrete or artificial stone compositions, e.g. their setting or hardening ability making use of a rise in temperature, e.g. caused by an exothermic reaction
• • 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
  • C04B7/00—Hydraulic cements
  • C04B7/32—Aluminous cements
• • 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
  • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
  • C04B2111/20—Resistance against chemical, physical or biological attack
  • C04B2111/28—Fire resistance, i.e. materials resistant to accidental fires or high temperatures

Definitions

• This disclosure relates to composite materials and methods for manufacturing composite materials.
• FRP Fiber Reinforced Plastics
• a composite material that is more nonflammable than FRP is desired.
• One aspect of the present disclosure is a composite material containing a base material and an inorganic fiber.
• the base material contains (a) a dehydration condensation reaction product of sodium silicate and (b) an alumina cement.
• the composite material which is one aspect of the present disclosure, is highly nonflammable.
• Another aspect of the present disclosure is a method of manufacturing a composite material containing a base material and an inorganic fiber.
• the inorganic fiber is impregnated with a solution containing (A) sodium silicate and (B) alumina cement and heated to obtain the component (A). causes a dehydration condensation reaction.
• a highly nonflammable composite material can be produced.
• the composite material of the present disclosure includes a base material and an inorganic fiber.
• the base material is impregnated with inorganic fibers.
• the composite material is reinforced with inorganic fibers.
• the base material contains (a) the dehydration condensation reaction product of sodium silicate and (b) alumina cement.
• the component (a) is a product produced by dehydration condensation reaction of sodium silicate.
• the component (a) is, for example, a compound having a skeleton in which siloxane bonds are connected.
• the component (a) contains, for example, siloxane. As a result of the dehydration condensation reaction, 100 parts by mass of sodium silicate becomes 60 parts by mass of the component (a).
• the mass of the component (a) contained in the base material is larger than the mass of the component (b) contained in the base material.
• the mass of the component (a) is larger than the mass of the component (b), the nonflammability and strength of the composite material are higher.
• the base material preferably contains 5 parts by mass or more and 25 parts by mass or less of the component (b) with respect to 100 parts by mass of the component (a).
• the strength of the composite material is further higher.
• the base material may further contain other components.
• other components include shirasu balloons, silicate minerals and the like.
• silicate mineral include wollastonite and the like.
• the base material preferably contains 5 parts by mass or more and 20 parts by mass or less of a shirasu balloon with respect to 100 parts by mass of the component (a).
• the composite material becomes even lighter.
• the base material preferably contains 5 parts by mass or more and 15 parts by mass or less of a silicate mineral with respect to 100 parts by mass of the component (a).
• the blending amount of the silicate mineral in the base material is within the above range, the heat resistance of the composite material is further higher.
• Examples of the inorganic fiber include glass fiber and basalt fiber.
• the form of the inorganic fiber is preferably cross-shaped.
• Examples of the inorganic fiber include a glass cloth made of glass fiber, a glass cloth made of basalt fiber, and the like.
• glass fiber or basalt fiber is used as the inorganic fiber, the nonflammability of the composite material is higher than that when aluminum fiber or alumina fiber is used.
• basalt fiber is used as the inorganic fiber, the mechanical strength of the composite material is higher. It is presumed that the reason for the high mechanical strength is that the basalt fibers are not easily attacked even when the base material is alkaline.
• the inorganic fiber does not contain a binder made of an organic material.
• smoke and an offensive odor are unlikely to be generated from the composite material even when the composite material is heated to a temperature of 200 ° C. or higher.
• the composite material of the present disclosure can be produced, for example, by basically the same method as the conventional method for producing FRP.
• the conventional method for producing FRP uses a liquid resin composition
• a solution containing (A) sodium silicate and (B) alumina cement hereinafter referred to as. Then, use the solution for the base material).
• the mass of the component (A) contained in the base material solution is larger than the mass of the component (B) contained in the base material solution.
• the mass of the component (A) is larger than the mass of the component (B), the produced composite material is more nonflammable.
• the base material solution preferably contains 5 parts by mass or more and 50 parts by mass or less of the component (B) with respect to 100 parts by mass of the component (A).
• the blending amount of the component (B) in the base material solution is within the above range, the strength of the produced composite material is higher.
• the base material solution may further contain other components.
• other components include shirasu balloons, silicate minerals and the like.
• silicate mineral include wollastonite and the like.
• the base material solution preferably contains 5 parts by mass or more and 20 parts by mass or less of a shirasu balloon with respect to 100 parts by mass of the component (A).
• the composite material becomes even lighter.
• the base material solution preferably contains 5 parts by mass or more and 15 parts by mass or less of a silicate mineral with respect to 100 parts by mass of the component (A).
• the blending amount of the silicate mineral in the base material solution is within the above range, the heat resistance of the composite material is further higher.
• Examples of the method for manufacturing the composite material include a manufacturing method including the following steps (1) to (4) (hereinafter referred to as the first manufacturing method).
• the laminate is placed in a drying oven at 70 to 100 ° C. for 5 hours for each production type. At this time, the solvent of the base material solution is vaporized and the laminate is cured. Further, the sodium (A) sodium silicate contained in the base material solution becomes the component (a) by the dehydration condensation reaction. The component (a) is a dehydration condensation reaction product of sodium silicate. The (B) alumina cement contained in the base material solution functions as a curing accelerator. As a result, the laminate becomes a composite material.
• the composite material includes a base material and an inorganic fiber. The base material is impregnated with inorganic fibers. The composite material is reinforced with inorganic fibers.
• the base material contains the component (a) and the component (b).
• the composite materials of the present disclosure are more nonflammable than conventional FRP. Moreover, the composite material of the present disclosure has high strength.
• Example 1 Production of base material solution
• the base material solutions S1 to S3 having the following compositions were produced.
• the method for producing the base material solutions S1 to S3 is a method of mixing each component.
• composite material S1, S2, and S3 were produced by the above-mentioned first production method using the base material solution S2. Further, a composite material was produced by the above-mentioned first production method using the base material solution S3.
• the composite materials produced by using the base material solutions S1, S2, and S3 will be referred to as composite materials S1, S2, and S3, respectively.
• the inorganic fiber used in the production of the composite materials S1 to S3 was glass cloth (manufactured by Nitto Boseki, product number: WF350-100-BS6). Further, in the composite materials S1 to S3, the number of laminated layers of the inorganic fiber cloth was 11. In the drying and curing step, the temperature in the drying oven was 100 ° C.
• a bending test was performed in accordance with JIS K 7171, and the bending strength and the bending elastic modulus were measured.
• the bending strength of the composite material S1 was 108.3 MPa.
• the flexural modulus of the composite material S1 was 4.430 GPa.
• Each of the composite materials S1 to S3 was subjected to a heat generation test in accordance with ISO-5660. In the exothermic test, the test piece was heated for 20 minutes. The radiation intensity was 50 kW / m 2 .
• the total calorific value was 0.01 MJ / m 2 , which was very small.
• the maximum heat generation rate was 0.33 kW / m 2 , which was very low.
• Each of the composite materials S1 to S3 was subjected to a nonflammability test in accordance with ISO-1182.
• the test method was as follows. A cylindrical electric furnace was prepared. In addition, a test body was prepared. The shape of the test piece was a cylinder having a diameter of 44.6 mm and a height of 47.5 mm. The mass of the test piece before the test was 125.46 g.
• the temperature inside the electric furnace was adjusted to 750 ⁇ 5 ° C. After adjusting the temperature inside the furnace, the power consumption of the electric furnace was kept constant. After adjusting the temperature inside the furnace, the test piece was inserted into the furnace. After inserting the test piece, the temperature inside the furnace, the center temperature of the test piece, and the surface temperature of the test piece were continuously measured. In addition, the mass of the test piece was measured before and after the test. In addition, the shape of the test piece was observed before and after the test. The test was continued until the temperature inside the furnace reached the final equilibrium temperature. The final equilibrium temperature is the temperature inside the furnace when the temperature inside the furnace remains stable for 10 minutes within the range of ⁇ 2 ° C.
• the temperature inside the ascending furnace at the center of the test piece was 2 ° C.
• the ascending furnace temperature is a value obtained by subtracting the final equilibrium temperature from the maximum temperature in the furnace.
• the maximum temperature in the furnace is the maximum temperature in the furnace during the period from the insertion of the test piece to the end of the test.
• the temperature inside the ascending furnace on the surface of the test piece was 2.8 ° C.
• the mass reduction rate WR of the test piece was 12.0%.
• the mass reduction rate WR is a value represented by the following equation (1).
• W1 is the mass of the test piece before the test.
• W2 is the mass of the test piece after the test.
• the temperature inside the ascending furnace at the center of the test piece and the temperature inside the ascending furnace on the surface of the test piece were smaller than the standard 20 ° C. in ISO-1182. Further, in the composite material S1, the mass reduction rate WR was smaller than the standard of 30% in ISO-1182. Further, in the composite material S1, the shape of the test piece after the test did not change significantly as compared with the shape of the test piece before the test. The results of the nonflammability test show that the composite material S1 is highly nonflammable.
• Example 2 Production of base material solution A base material solution S4 having the following composition was produced.
• the method for producing the base material solution S4 is a method of mixing each component.
• the inorganic fiber used in the production of the composite material S4 was basalt fiber (manufactured by Arteplus, product number: AC1919G 102).
• the number of laminated inorganic fibers was 11.
• the temperature in the drying oven was 100 ° C.
• the composite material S4 was subjected to a tensile test in accordance with JIS K 7164, and the tensile strength was measured.
• the tensile strength of the composite material S4 was 34.1 MPa.
• the composite material S4 was subjected to a bending test in accordance with JIS K7171, and the bending strength and flexural modulus were measured.
• the bending strength of the composite material S4 was 57.1 MPa.
• the flexural modulus of the composite material S4 was 20.8 GPa.
• a plurality of functions possessed by one component in the above embodiment may be realized by a plurality of components, or one function possessed by one component may be realized by a plurality of components. May be good. Further, a plurality of functions possessed by the plurality of components may be realized by one component, or one function realized by the plurality of components may be realized by one component. Further, a part of the configuration of the above embodiment may be omitted. Further, at least a part of the configuration of the above embodiment may be added or replaced with the configuration of the other above embodiment.
• the present disclosure can be realized in various forms such as a system having the composite material as a component.

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• Chemical & Material Sciences (AREA)
• Engineering & Computer Science (AREA)
• Ceramic Engineering (AREA)
• Organic Chemistry (AREA)
• Materials Engineering (AREA)
• Structural Engineering (AREA)
• Inorganic Chemistry (AREA)
• Chemical Kinetics & Catalysis (AREA)
• Civil Engineering (AREA)
• Life Sciences & Earth Sciences (AREA)
• Environmental & Geological Engineering (AREA)
• General Life Sciences & Earth Sciences (AREA)
• Geochemistry & Mineralogy (AREA)
• Geology (AREA)
• Compositions Of Macromolecular Compounds (AREA)
• Curing Cements, Concrete, And Artificial Stone (AREA)
• Solid-Sorbent Or Filter-Aiding Compositions (AREA)

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• 2020
  • 2020-09-18 EP EP20948450.0A patent/EP4190761A4/en active Pending
  • 2020-09-18 CN CN202080104156.8A patent/CN116134000A/zh active Pending
  • 2020-09-18 TW TW109132383A patent/TW202206400A/zh unknown
  • 2020-09-18 JP JP2022541102A patent/JP7626473B2/ja active Active
  • 2020-09-18 US US18/019,103 patent/US20240034681A1/en active Granted
  • 2020-09-18 WO PCT/JP2020/035627 patent/WO2022030026A1/ja not_active Ceased
  • 2020-09-18 KR KR1020237006728A patent/KR102879297B1/ko active Active

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