JP3196611B2 - Manufacturing method of non-fired cured product - 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 a non-sintered hardened material containing clay, which is suitable as a pavement material or a building material having a natural texture.

[0002]

2. Description of the Related Art Unfired tiles mainly composed of clay and calcium hydroxide (slaked lime) are described in JP-A-7-157346. The unfired tile of the same publication is composed of 5-70% by weight of clay, 15-80% by weight of calcium hydroxide,
A mixture of 100 parts by weight of a tile raw material containing 10 to 80% by weight of silica-based mineral particles and 0 to 30 parts by weight of plant fibers is dry-pressed, dried and cured.
This unfired tile has moderate hardness and has almost no reverberation when walking. Good feeling and excellent walking sensation.
Relatively high water absorption and non-slip. It is rich in taste and naturalness, harmonizes well with the surrounding natural environment, and has excellent aesthetics. Various colors and textures can be obtained by changing the type and proportion of the clay to be compounded, and the design is rich. And the like.

[0003]

Problems to be Solved by the Invention
The unfired tile disclosed in Japanese Patent Publication No. 6 has a problem to be solved in that the strength tends to be slightly insufficient as a pavement material or a building material (floor material). In particular, in the case of a pavement material, since the reference value of the interlocking block is a standard, it is necessary that the bending strength be 50 kgf / cm ² (4.9 MPa) or more.

[0004] An object of the present invention is to provide a method for producing a non-sintered cured product having a soil texture and high strength (particularly bending strength).

[0005]

Means for Solving the Problems The unfired cured product of the present invention is
The production method consists of clay, slaked lime and / or quicklime, and the CaO / quartz (SiO ₂ ) molar ratio is 0.1 to
A raw material containing a blend of 0.5 (hereinafter sometimes referred to as a main raw material) is molded and autoclaved .
And features .

The unsintered cured product produced by the method of the present invention has a CaO / quartz (SiO ₂ ) molar ratio of 0.1 to 0.5, so that the texture of the soil can be improved when any clay is used as a raw material. It has strength enough to withstand pavement and flooring. Further, according to the method of the present invention,
The hardened body that is manufactured is
Compared to tiles, it absorbs the impact of walking, so it is less likely to fatigue. The Shore hardness Hs of this cured product is about 15 to 22 and the sand falling wear according to JIS A 5209 is 0.1 g or less.

In the method of the present invention, it is preferable to add silica sand having a particle size of 1 mm or more in a proportion of 10 to 50 parts by weight based on 100 parts by weight of the above-mentioned composition. The appearance of the silica sand on the product surface improves the slip resistance and further enhances the atmosphere of the soil. Further, swelling due to water absorption can be suppressed.

[0008]

BEST MODE FOR CARRYING OUT THE INVENTION In order to produce an unsintered cured product according to the method of the present invention, first, the amount of quartz contained in the clay or siliceous raw material is calculated from the chemical analysis values of the raw material by norm calculation. Is calculated. Molar ratio of CaO in slaked lime or quicklime (in the case of slaked lime, Ca (OH) ₂ is converted to CaO) and the amount of quartz in clay (or clay and siliceous raw material) determined by the norm calculation method,
That is, the CaO / quartz (SiO ₂ ) molar ratio is set to 0.1.
What is blended so as to be 1 to 0.5 is used as a main raw material.

When the CaO / quartz (SiO ₂ ) molar ratio is less than 0.1, the strength of the unsintered cured product becomes low, and when it is more than 0.5, the hardness becomes excessively high and unreacted after curing. Ca (OH) _{2 in the} state remains in the cured product and causes efflorescence.

[0010] As clay, red clay, ocher, black clay, loam layer, diatomaceous earth, white clay, etc. can be used. And a loam layer.

The slaked lime or quicklime and the siliceous raw material as an optional additive are blended to obtain sufficient strength by the reaction between Ca (OH) ₂ and SiO ₂ . Siliceous raw materials mainly include silica stone, foundry dust and the like.

If the particle size of the siliceous raw material is large, Ca
Since the reactivity with (OH) ₂ is lowered and the strength may be insufficient, the particle size is 300 μm or less, particularly 200 μm.
It is preferable to use those having m or less.

[0013] 100 parts by weight of a main raw material composed of slaked lime and / or quicklime and clay, and a particle size of 1 m added as needed.
10 to 50 parts by weight (preferably 1 to 10 parts by weight)
10 to 30 parts by weight of 10 mm silica sand), siliceous raw material, vegetable fiber, other additives, and water are sufficiently stirred and mixed with an Erich mixer or the like. If the silica sand is smaller than 1 mm, the slip resistance is not improved. If it is larger than 10 mm, the moldability, especially the moldability by dry pressing, will be poor.

By adding the coarse-grained silica sand, a more earthy atmosphere is obtained. In addition, the appearance of the coarse-grained silica sand on the surface of the cured product improves slip resistance. Furthermore,
Swelling of the cured product due to water absorption can be suppressed.

In the present invention, by adding 5 parts by weight or less (preferably 1 part by weight or less) of vegetable fiber to these raw materials with respect to the main raw material, the preservation of a molded article is more efficient than that of the case where no vegetable fiber is blended. The shape is improved, and the shape is less likely to be deformed even when subjected to an external impact. In addition, the design of the resulting unfired cured product can be further improved. Various types of susa (straw), hemp, pulp and the like can be used as the plant fiber. Further, a pigment may be blended to change the color tone of the obtained unfired cured product. In order to mold these raw materials, water is added and mixed well, and then molded by dry press molding, extrusion molding, or the like.

In the case of dry press molding, it is preferable to add 5 to 15 parts by weight of water to 100 parts by weight of the main raw material. At the time of extrusion molding, it is preferable to add 15 to 30 parts by weight of water to 100 parts by weight of the main raw material.

The conditions of the autoclave curing are 110
It is preferable to carry out at a temperature of at least 140 ° C. (preferably 140 to 200 ° C.) for at least 1 hour. By this curing, as described above, Ca
(OH) ₂ and quartz (SiO ₂ ) in clay and siliceous raw materials
₂ ) reacts (hereinafter, may be referred to as a CSH system reaction) to provide sufficient strength.

After curing, if necessary, the product is subjected to sand blasting, mill polishing, etc. to obtain a product.

In the present invention, slip resistance is improved by adding additives such as shells, vermiculite, glass having a particle size of 5 mm or more, crushed ceramic pieces, and resin composition pieces to the raw materials. You can give the texture of. Further, among these additives, those mainly containing Ca or Si are, in the present invention, C-S in the obtained cured product.
Exist as 1 reactant -H based reaction, As a result, even though impact is applied from outside to the cured product of this, the additive is less likely to peel off the cured material.

In addition, the rejected product obtained when the cured product is produced by the method of the present invention, which has been crushed to 1 mm to 50 mm (preferably 1 mm to 30 mm), can be regenerated as a part of the raw material to prevent slipping. In this case, a different texture can be obtained. In this case, since the unreacted material in the crushed product of the rejected product reacts with other raw materials around it, the crushed product of the rejected product is less likely to come off the cured product.

[0021]

The present invention will be described more specifically with reference to the following examples.

Example 1 15 parts by weight of silica sand having an average particle size of 5 mm, 1 part by weight of straw and 10 parts by weight of water were added to 100 parts by weight of the following main ingredients, and the mixture was stirred and mixed by an Erich mixer. Main raw material composition Loess (production area; Toyota City, Aichi Prefecture) 20% Slaked lime 20% Silica with a particle size of 300 μm or less 60% CaO / quartz (SiO ₂ ) molar ratio 0.28

The obtained mixture was treated at 30 MPa at 200 × 2
Dry press molding to 00 x 60 mm
And cured in an autoclave for 6 hours to produce a non-sintered cured product (block). Table 1 shows the measurement results of the bending strength, Shore hardness, and sand falling abrasion (JISA 5209) of the unfired block.

The resulting unfired block is softer than a normal concrete block, has appropriate hardness and excellent abrasion resistance, and is a rich block having the texture and feel of natural soil. Was. When a walking test was performed on the floor on which the unfired block was laid,
There was almost no reverberation due to walking, the feel of the shoe sole was good, and the walking feeling was extremely excellent. Further, the floor surface of the block seemed like the ground at first glance, and was in harmony with the surrounding natural environment, and was extremely excellent in appearance.

Example 2 The same procedure as in Example 1 was repeated except that the main raw materials were as follows, the amount of silica sand having an average particle size of 3 mm was 10 parts by weight, and the amount of straw was 2 parts by weight. A firing block was manufactured. This unfired block also had the same advantages as in Example 1. Table 1 shows the measurement results of the bending strength and Shore hardness of the unfired block. Main raw material composition Red clay (production area; Kuwana-shi, Mie) 10% Slaked lime 10% Foundry dust with a particle size of 300 μm or less 80% CaO / quartz (SiO ₂ ) molar ratio 0.16

Example 3 The same procedure as in Example 1 was repeated except that the main raw materials were as follows, the amount of silica sand having an average particle diameter of 1 mm was 30 parts by weight, and the amount of straw was 1 part by weight. A firing block was manufactured. This unfired block also had the same advantages as in Example 1. Table 1 shows the measurement results of the bending strength and Shore hardness of the unfired block. Clay (production area; Seto City, Aichi Prefecture) 95% slaked lime 5% CaO / quartz (SiO ₂ ) molar ratio 0.11

Example 4 The same procedure as in Example 1 was carried out except that the main raw materials were as follows, the amount of silica sand having an average particle size of 3 mm was 50 parts by weight, and the amount of straw was 1 part by weight. A firing block was manufactured. This unfired block also had the same advantages as in Example 1. Table 1 shows the measurement results of the bending strength and Shore hardness of the unfired block. Clay (production area: Tajimi-shi, Gifu) 80% slaked lime 20% CaO / quartz (SiO ₂ ) molar ratio 0.41

Example 5 The main raw materials were as follows, 50 parts by weight of silica sand having an average particle diameter of 1 mm and 22 parts by weight of water were added, and the mixture was stirred and mixed by an Erich mixer, and then kneaded with a clay kneading machine. 200 × 200
and extruded to a thickness of 60 mm. Then 1
Autoclave curing was performed at 80 ° C. for 6 hours to produce an unfired block. This unfired block also had the same advantages as in Example 1. Table 1 shows the measurement results of the bending strength and Shore hardness of the unfired block. Main raw material composition Red clay (production area; Seto City, Aichi Prefecture) 70% Slaked lime 25% Silica with a particle size of 300 μm or less 25% CaO / quartz (SiO ₂ ) molar ratio 0.36

Example 6 The procedure of Example 5 was repeated except that the main raw materials were as follows, the amount of silica sand having an average particle diameter of 5 mm was 20 parts by weight, and the amount of straw was 5 parts by weight. A firing block was manufactured. This unfired block also had the same advantages as in Example 1. Table 1 shows the measurement results of the bending strength and Shore hardness of the unfired block. Main raw material composition Black soil (producing area: Hokkaido) 70% Slaked lime 7% Foundry dust having a particle size of 300 μm or less 23% CaO / quartz (SiO ₂ ) molar ratio 0.25

Example 7 The main raw materials were as follows, the compounding amount of silica sand having an average particle diameter of 10 mm was 10 parts by weight, the compounding amount of straw was 0.5 parts by weight,
An unfired block was manufactured in the same manner as in Example 1 except that the amount of glass having a particle diameter of 7 mm was changed to 1 part by weight. This unfired block also has the same advantages as in Example 1, and a new design can be added by reflecting light from a street lamp or the like on the glass on the product surface. Table 1 shows the measurement results of the bending strength and Shore hardness of this unfired block.
Shown in Main raw material composition Loess (Production area: Tajimi-shi, Gifu) 60% Slaked lime 20% Silica with a particle size of 300 μm or less 20% CaO / quartz (SiO ₂ ) molar ratio 0.49

COMPARATIVE EXAMPLE 1 15 parts by weight of silica sand having an average particle size of 5 mm, 1 part by weight of straw and 10 parts by weight of water were added to 100 parts by weight of the main raw material having the following composition, and the mixture was stirred and mixed with an Erich mixer. Main raw material composition Loess (production area; Toyota City, Aichi Prefecture) 65% slaked lime 25% Silica with a particle size of 300 μm or less 10% CaO / quartz (SiO ₂ ) molar ratio 0.64

The obtained mixture was subjected to 200 × 2 at 30 MPa.
Dry press molding to 00 x 60 mm
And cured in an autoclave for 6 hours to produce a non-sintered cured product (block). Table 1 shows the measurement results of the bending strength, Shore hardness, and sand falling abrasion (JISA 5209) of the unfired block. As shown in Table 1, this cured product has a high bending strength, but has a high hardness and loses the softness of the cured product.

Comparative Example 2 The main raw materials were as follows, 50 parts by weight of silica sand having an average particle diameter of 1 mm and 22 parts by weight of water were added, and the mixture was stirred and mixed with an Erich mixer, and then kneaded with a kneading machine. , 200 × 20
It was extruded to 0 mm and cut to a thickness of 60 mm. afterwards,
Autoclave curing was performed at 180 ° C. for 6 hours to produce an unfired block. Table 1 shows the measurement results of the bending strength and the Shore hardness of the unfired block. As shown in Table 1, this cured product has low flexural strength and Shore hardness and a lot of sandfall wear. Main raw material composition Red clay (production area; Seto City, Aichi Prefecture) 20% Slaked lime 5% Silica with a particle size of 300 μm or less 75% CaO / quartz (SiO ₂ ) molar ratio 0.05

Comparative Example 3 20 parts by weight of straw and water were added to 100 parts by weight of the following composition described in the example of JP-A-7-157346, and the raw materials were mixed.
It was dry press-molded to × 60 mm, dried, and autoclaved at 180 ° C. for 6 hours to produce a non-sintered cured product (block). Table 1 shows the measurement results of the bending strength and the Shore hardness of the unfired block. As shown in Table 1, this cured product has low bending strength. Clay (raw material: Tajimi City, Aichi Prefecture) 45.5% Slaked lime 35.0% Silica sand with an average particle size of 3 mm 19.5%

[0035]

[Table 1]

[0036]

As described above, the product manufactured by the method of the present invention is used.
The obtained unsintered cured product has various excellent effects as follows. It has the texture of soil. Because it is soft, it absorbs the impact of walking compared to conventional blocks and tiles, so it is less susceptible to fatigue. Soft but has enough strength and wear resistance to withstand pavement and flooring. Excellent slip resistance. Low swelling due to water absorption.

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI C04B 18:16 C04B 18:16 14:10 14:10 Z 16:02) 16:02) Z (72) Inventor Kazuto Seki 5-1-1 Koiehonmachi, Tokoname-shi, Aichi Prefecture Inax Corporation (72) Inventor Yukito Muraguchi 5-1-1 Koiehonmachi, Tokoname-shi, Aichi Prefecture Inax Corporation (72) Inventor Yoshio Kamiya Tokoname, Aichi Prefecture 5-1-1 Koie Honcho Inax Co., Ltd. (56) References JP-A-9-132440 (JP, A) (58) Fields investigated (Int. Cl. ⁷ , DB name) C04B ^7/ 00-28 / 36

Claims (7)

(57) [Claims] 1. A method comprising a clay, slaked lime and / or quicklime, wherein the molar ratio of CaO / quartz (SiO ₂ ) is 0.1 to 1.
A method for producing a non-sintered cured product, which comprises molding a raw material containing a blend of 0.5 and autoclaving. 2. The unfired cured body according to claim 1, wherein the raw material further contains silica sand having a particle diameter of 1 mm or more in a ratio of 10 to 50 parts by weight with respect to 100 parts by weight of the compound. Manufacturing method . 3. The method according to claim 1, wherein the raw material is
Furthermore, a method for producing a non-sintered cured product , comprising a siliceous raw material having a particle size of 300 μm or less. 4. The non-calcined material according to claim 1, wherein the raw material further contains a plant fiber in a proportion of 5 parts by weight or less based on 100 parts by weight of the compound. A method for producing a cured product. 5. The unfired material according to claim 1, wherein the raw material further contains additives such as shells, vermiculite, glass having a particle size of 5 mm or more, or crushed ceramics. A method for producing a cured product. 6. The method according to claim 1, wherein the raw material further includes a material obtained by crushing the unsintered cured body according to any one of claims 1 to 5. A method for producing an unfired cured product. 7. A any one of claims 1 to 6, a manufacturing method of an unfired cured product, wherein the molding is press-molding or extrusion.