JPH028990B2 - - Google Patents

Description

[Detailed description of the invention]

The present invention is a molded product of an alumina cement-based mortar composition, and although it is an unfired molded product rather than a fired product like so-called ceramic tiles, it is an excellent product for ceramic tiles. It has an attractive surface gloss, and also has excellent hardness.
The present invention relates to an alumina cement-based unfired building material for ceramic tiles that exhibits reduced water absorption and is excellent in terms of strength, acid resistance, heat resistance, weather resistance, etc., and is extremely useful in a wide range of building material fields. More specifically, in the present invention, out of a total of 100 parts by weight,
The following (1) to (4) (1) Alumina cement 93 to 77 parts by weight (2) At least one selected from montmorillonite, acid clay, and bentonite 3 to 10 parts by weight (3) At least one selected from zirconia and magnesia 3 to 10 parts by weight (4) At least one selected from alkali metal stearate and alkaline earth metal salts
A molded product of a mortar composition containing 0.5 to 3 parts by weight of composition A and about 1 to about 4 parts by volume of aggregate B per 1 part by volume of composition A, the molded product being unfired. This invention relates to a ceramic tile-like alumina cement-based unfired building material that is a molded product. Conventionally, so-called ceramic tiles have been used in a wide range of building material applications because they have excellent surface gloss, hardness, water resistance, strength, and other physical properties. However, since the product is made only after going through the firing process, it is inevitable that the firing operation and manufacturing equipment will be complicated and expensive, and for large products and ceramic tile products with complicated shapes, it will become even more complicated and expensive. There are many restrictions on its use due to the disadvantages that come with it. The present inventors have conducted research in order to develop a ceramic tile-like building material that can avoid the above-mentioned disadvantages that are the fate of ceramic building materials, and that is also satisfactory. As a result, an alumina cement mortar composition containing a composition A having a specific composition and an aggregate B can be formed into an excellent ceramic tile-like material even though it is an unfired product by simply molding it into a mold. It is a ceramic-like material that has an attractive surface gloss, exhibits excellent hardness, reduced water absorption, and has satisfactory physical properties such as strength, acid resistance, heat resistance, and weather resistance. It was discovered that fired building materials can be formed. According to the research conducted by the present inventors, the ceramic-like unfired building material can be easily manufactured by the same method as a cured product formed from a normal mortar composition. It has the advantage of being extremely easy and inexpensive to provide both in terms of equipment and price, and it also has the advantage of being able to provide large products and products with complex shapes that are inevitably more complicated and expensive than ceramic tiles. It has also been found that it has the advantage of being industrially extremely easy and inexpensive to manufacture. Furthermore, since it is possible to provide a molded product that is freely colored in a desired color tone simply by blending an appropriate pigment, there is no restriction on the change in color tone due to firing, as is the case with ceramic building materials.
It is easy to change and adjust the strength and unit volume weight as needed within a certain range, and it is also possible to select and change the strength and weight according to the purpose of use as a building material. It turns out that there are advantages in that it is possible. Therefore, the object of the present invention is to provide a molded product of a mortar composition, which, despite being an unfired molded product, has an excellent and attractive surface gloss similar to ceramic tiles, and has excellent physical properties. To provide an alumina cement-based ceramic tile-like unfired building material having the following features. The above objects and many other objects and advantages of the present invention will become more apparent from the following description. The alumina cement-based ceramic tile-like unfired building material of the present invention contains the following (1) to 100 parts by weight in total:
(4) A molded product of an alumina cement-based mortar composition containing a composition A consisting of: and about 1 to about 4 parts by volume of aggregate B per 1 part by volume of the composition A, It is characterized by being an unfired molded product. (1) Alumina cement 93 to 77 parts by weight (2) 3 to 10 parts by weight of at least one selected from montmorillonite, acid clay, and bentonite (3) 3 to 10 parts by weight of at least one selected from zirconia and magnesia (4) At least one selected from alkali metal salts and alkaline earth metal salts of stearate
0.5 to 3 parts by weight Total 100 parts by weight In the above composition, if the amount of (1) alumina cement is too small outside the above range, there will generally be a disadvantage that physical properties such as compressive strength will be reduced; Also,
If there is too much, as a result, (2)~ in the above composition A
Since a decrease in any of (4) causes an adverse effect, it should be selected appropriately within the above range. In addition, in the above composition A, if the amount of component (2) is too small outside the above range, the density of the alumina cement ceramic tile-like unfired building material tends to decrease, which is disadvantageous. If the amount is too large, the hardness will decrease, so the amount is appropriately selected within the above range. Furthermore, in the above composition A, if the amount of component (3) is too small outside the above range, there will be a problem that the water absorption tends to increase, and if it is too large, (1)
Since this results in a decrease in other components, such as the oxidation component, and has an adverse effect on strength, etc., it is appropriately selected within the above range. Furthermore, in the above composition A,
(4) If the amount of the component is outside the above range and is too small, there will be a drawback that bubbles are likely to occur on the surface of the alumina cement-based ceramic tile-like unfired building material, and if it is too large, the strength will decrease. Therefore, it is appropriately selected within the above range. Furthermore, these components (1) to (4) cooperate with each other to influence and support the combination of excellent properties of the ceramic tile-like alumina cement-based unfired building material of the present invention. Although it cannot be explained unambiguously, a suitable composition suitable for combining the desired properties can be easily selected and set experimentally in advance by selecting and combining the above-mentioned components within the range of amounts. In composition A, component (2), component (3), and component (4) are not limited to one type, but multiple types of each can be used in combination, but when multiple types are used in combination, the total of each component The total amount should be used within the above-mentioned range. For example, when using two components as (2), the total amount of those two components is 3 to 10
Used in combination as specified in the parts by weight range. Examples of the component (4) include sodium stearate, potassium stearate, magnesium stearate, and calcium stearate. In the present invention, the mortar composition contains composition A as described above and about 1 to about 4 parts by volume of aggregate B per 1 part by volume of composition A. As such aggregate B, various aggregates commonly used in mortar compositions can be used, and any natural or artificial aggregates can be used. In addition to ordinary aggregates, lightweight aggregates can also be used to adjust the weight of the ceramic tile-like unfired building material of the present invention. Such aggregates themselves are well known and can be used in the present invention. For example, aggregates mainly composed of expanded shale;
Examples include lightweight aggregates mixed with fly ash, blast furnace water slag, etc., perlite (artificial lightweight aggregates), and volcanic ash (natural lightweight aggregates). The weight of the invented ceramic tile-like unfired building material can be adjusted (adjustment of unit volume weight). In the present invention, the mortar composition may further contain other additive components. Examples of such other additive ingredients include coloring agents such as pigments, mineral fibers such as glass wool, rock wool, etc.
For example, The amount added can be changed as appropriate as long as it does not adversely affect the excellent surface gloss and physical properties of the ceramic tile-like unfired building material of the present invention. Examples include loadings such as 5.0% by weight of colorant, and about 0.5% to about 3% by weight of mineral fibers. Incorporation of mineral fibers helps improve bending strength. At that time, it is acceptable to add more than about 3% by weight, but since this does not further improve the bending strength, it is sufficient to add up to about 3% by weight. The ceramic tile-like alumina cement-based unfired building material of the present invention contains about 1 to about 4 parts by volume of aggregate B per 1 part by volume of the alumina cement composition A as described above, and further contains other additive components. A suitable amount of water, for example, to 1 part by volume of composition A, about 3 parts by volume of aggregate B and about 1.5 parts by volume of water are added to a mortar composition which may contain and kneaded, It can be formed by pouring into a suitable mold and molding. Forming means per se are well known and can be utilized in the present invention. Generally, this can be carried out by pouring into a mold, allowing it to stand for about 8 hours, and then removing it from the mold. When molding the ceramic tile-like alumina cement-based unfired building material of the present invention, it is particularly preferable to use a mold whose surface in contact with the surface of the molded product is smooth-finished. For example, by placing an arbitrary frame on a plate glass or plate and pouring the mortar composition of the present invention into the frame to a required thickness, a ceramic tile-like alumina cement-based unfired tile plate can be obtained. . If molds of various shapes are used instead of plate glass, roof tiles, paving stones, flower pots, etc. can be easily made. The ceramic tile-like alumina cement unfired building material of the present invention is useful in a wide range of building material fields, such as high-grade bricks, roof tiles, tiles, blocks for gates, tiles for the interior and exterior of houses, paving stones, bricks for flower beds, flower pots, etc. It has a wide range of uses, from use to construction materials for high-rise buildings. Hereinafter, several embodiments of the present invention will be illustrated in more detail by Examples together with Comparative Examples. Examples 1 to 5 and Comparative Examples 1 to 5 Each of Composition A having the composition shown in Table 1 below was added with ordinary aggregate B (crushed stone with particle size of 0 to 5 m/m,
(specific gravity 1.5t/m3 or ^more ) in a ratio of A:B = 2:8 (parts by volume), and 20 parts by weight of water for 100 parts by weight of the mixture.
Add parts by weight, knead, and measure the unconfined compressive strength by measuring 4 cm (vertical), 4 cm (width), and 10 cm (length).
The specular reflectance (of the surface of the molded product), water absorption, hardness, and number of air bubbles that appeared on the surface were measured by pouring into a three-part molding frame of 8 cm in height, 13 cm in width, and 2 cm in thickness. It was poured into a tile mold (a plastic mold with a smooth bottom surface) to obtain a cured molded product in the shape of a tile. Uniaxial compressive strength of the obtained molded product (7 days),
The test results for specular reflectance (surface of the molded product), water absorption, hardness, and number of bubbles appearing on the surface are shown in Table 1 below.

[Table] Examples 6 to 10 and Comparative Examples 6 to 10 In Examples 1 to 5 and Comparative Examples 1 to 5,
Light aggregate B (perlite,
Examples 1 to 5 and Comparative Examples 1 to 5, except that specific gravity 1.0 or less) was used in the ratio of A:B = 25:75 (parts by volume).
A tile-shaped cured molded product was obtained in the same manner as in 5. As shown in Table 2 below, the results were almost the same as those in Table 1, except that the uniaxial compressive strength was lower because lightweight aggregate B was used.

【table】

[Table] Hardness: Fluorite = 4, Apatite = 5: Orthoclase = 6
, quartz = 7
Number of bubbles: Number of bubbles remaining in the area of the bottom of the formwork (10 cm x 20 cm) Examples 11 to 14 Based on the total weight of composition A and aggregate B, glass wool was added to the mortar composition of Example 3. The same procedure as in Example 3 was conducted except that each of the components was added in the amounts shown in Table 3 below. The results of the bending strength (7 days) test were as shown in Table 3 below.

[Table] Examples 15 to 18 Except that glass wool was added to the mortar composition of Example 8 in the amounts shown in Table 4 below, based on the total weight of Composition A and Aggregate B. The procedure was as in Example 8. The results of the bending strength (7 days) test were as shown in Table 4 below.

【table】

Claims (1)

[Claims] 1 Out of a total of 100 parts by weight, the following (1) to (4) (1) Alumina cement 93 to 77 parts by weight (2) At least one selected from montmorillonite, acid clay, and bentonite 3 to 10 parts by weight Part (3) At least one selected from zirconia and magnesia 3 to 10 parts by weight (4) At least one selected from alkali metal stearate and alkaline earth metal salt
A molded product of a mortar composition containing 0.5 to 3 parts by weight of composition A and about 1 to about 4 parts by volume of aggregate B per 1 part by volume of composition A, the molded product being unfired. A ceramic tile-like unfired building material characterized by being a molded product. 2. The mortar composition comprises the composition A and aggregate B.
Ceramic tile-like green building material according to claim 1, further comprising 0.5 to 3% by weight of mineral fibers, based on the total weight of .