JP2000301524A - Manufacturing method of deeply carved ceramic building materials - Google Patents

Abstract

(57) [Summary] [PROBLEMS] To provide a deeply carved concave and convex pattern on the surface of a ceramic building material produced by a wet production method by a production method with a low water content immediately after molding, such as a papermaking method. A raw material containing amorphous silica in a cement compounding of a ceramic building material in which fly ash or silica fume is added to cement as a silica component, and necessary aggregates, lightweight aggregates and inorganic reinforcing fibers other than organic or asbestos are added. Calcium silicate hydrate gelled by adding slaked lime and water to a hydrothermal reaction at 80 to 100 ° C. is replaced with the entire amount to a part of the silica content in the cement composition of the ceramic building material, and is mixed with water. It comprises a step of shaping a plate-like body by a manufacturing method, and then giving a concavo-convex pattern by pressing.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a deeply carved ceramic building material.

[0002]

2. Description of the Related Art Conventionally, as a building material such as a wall plate and a roof material, an inorganic plate material mainly composed of cement or the like has been widely used. In order to enhance the design of these inorganic plate materials,
It is common practice to impart a design with a concavo-convex pattern on the surface and finish the painting, and to deepen the concavo-convex pattern in some cases in order to further enhance the design.

In the meantime, the above-mentioned deeply carved concave and convex pattern must be used with a press plate because a roll press causes interference of a mold. In addition, the material of the ceramic plate is required to have a sufficient fluidity and shape retention for the press, and therefore it is necessary to have an appropriate water content.

[0004]

However, when a sheet material is manufactured by a papermaking method, which is a method of manufacturing an inorganic sheet material, the water content of the sheet material immediately after molding becomes too low, and the fluidity of the raw material deteriorates. There was a problem that a deep carved pattern could not be formed. That is, in the case of the round mesh papermaking method, the seed film machined in the round mesh cylinder is suction-dehydrated while being transferred on a felt belt, so that after laminating to a predetermined thickness on a making roll, it is cut open. When stretched flat, the moisture content is significantly reduced, making it very difficult to create a deeply carved texture even when pressed.

In the case of flow-on winding molding,
Since the cement material is supplied in layers on the dewatering belt and then dewatered, it is very difficult to form a deeply carved uneven pattern even when pressed as in the case of the round net making method. Therefore, there is a problem that it is difficult to form a deeply carved uneven pattern having a high deeply carved design on an uncured sheet material formed by a papermaking method such as a round net forming method or a flow-on molding method.

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned problem, and it is possible to easily form a deeply carved pattern on the surface of a ceramic building material by a paper-making method, and to provide a low-cost design. It was made to provide high-quality building materials.

[0007]

Means for Solving the Problems To solve the above problems, a method for producing a deeply carved ceramic building material according to claim 1 comprises:
In the cement compounding of ceramic building materials that add fly ash or silica fume as the silica component to the cement, and necessary aggregates, lightweight aggregates and inorganic reinforcing fibers other than organic or asbestos, slaked lime and water are added to the raw materials containing amorphous silica. Is added, and the calcium silicate hydrate gelled by a hydrothermal reaction at 80 to 100 ° C. is replaced with the entire amount to a part of the silica content in the cement composition of the ceramic building material and mixed with water. It is characterized by shaping the body and then applying a concavo-convex pattern by pressing.

[0008] Since the gelled calcium silicate hydrate functions as a water carrier and does not easily release water, when added to the cement compounding of ceramic building materials, it is formed without adversely affecting the shape retention of the shaped body. The water content of the form can be increased, and the gelled calcium silicate hydrate is bulky, so that even a ceramic building material formed by a papermaking method can have a deeply carved uneven pattern on the surface.

According to a second aspect of the present invention, in the above method, the raw material containing amorphous silica of gelled calcium silicate hydrate is either fly ash or silica fume. The molar ratio between the silica content in the raw material and the calcium oxide in the slaked lime is 0.65 to 1.0. Here, the amorphous silica is an amorphous silica having a temperature of 100 ° C.
It means that silica is eluted in water even at the following low temperature.

[0010]

Next, an embodiment of the present invention will be described. Based on the composition shown in Table 1, water was added and mixed to prepare a slurry A.

[0011]

[Table 1] Next, the slurry A is supplied to the tank 1 as shown in FIG.
The seed film 3 is lifted up by a round mesh cylinder 2 to form a seed film 3 on a felt belt 2a. The film is conveyed while being dehydrated by a suction dewatering device 2b. The molded plate 5 is transferred to a pressing device 6 and has a brick joint shape of 10 cm × 5 cm, as shown in FIG. The concavo-convex pattern of 60 ° to 60 ° was compression-pressed with several types of press boards 6A at a press pressure of 15 MPa for 30 seconds.

After pressing, the formed plate 5 is cut to a length of 3.0.
A plate material having a thickness of 3 m, a width of 0.45 m and a thickness of 12 mm was formed, naturally cured for 24 hours, and then autoclaved at 170 ° C. for 15 hours. Example 1 Fly ash and quick lime were adjusted so that the molar ratio of silica content and quick lime (CaO) in fly ash was 0.6 to 1.0, and water was added thereto, and 80 ° C to 100 ° C was desirable. Mixing and stirring for 1 hour while heating at 95 ° C to 100 ° C,
Hydrogel reaction was carried out to produce gelled calcium silicate hydrate.

This calcium silicate hydrate gel was replaced with 50% of the fly ash in Table 1 above, uniformly mixed as shown in Table 2, and then the same plate was formed in the same manner as in Example 1. Example 2 The same gelled calcium silicate hydrate as in Example 1 is shown in Table 1.
Was replaced with the entire amount of fly ash, and uniformly mixed as the composition shown in Table 2. Thereafter, the same plate was formed in the same manner as in Example 1.

Example 3 The same plate was formed in the same manner as in Example 1 except that slaked lime was used in place of quick lime of Example 1. Example 4 The same plate was formed in the same manner as in Example 1 except that slaked lime was used instead of quick lime of Example 2.

[0015] Shapeability and quality performance tests of Examples 1-4 and those of the basic formulation yielded the results shown in Table 3.

[0016]

[Table 2]

[0017]

[Table 3] As is evident from Table 3, the groove depths in the presses of the examples were 2 to 2.5 mm for the same compressive force and the comparative examples were 2 to 2.5 mm. It was possible to press-mold a groove as deep as ~ 4 mm, and the angle of the side wall at the time of pressing also showed that the comparative example had a maximum angle of 45 ° or more. On the other hand, in the case of the example, molding at a steep slope of 55 ° to 60 ° becomes possible, and it is possible to press-mold deep and sharp grooves by supplying moisture by adding gelled calcium silicate hydrate. found.

Although the bending strength of the embodiment was slightly lowered, it was found that the bending strength was within a range having no practical problem.

[0019]

As described above, according to the present invention, even if a plate-like body is formed by a conventional papermaking method which is difficult to perform deep engraving press, the addition of gelled calcium silicate hydrate allows
Sufficient water is supplied to the shaped body, and the addition of the water and the gelled calcium silicate increases the bulk of the plate before pressing, so that a deeply carved uneven pattern can be press-formed.

Further, the moisture contained in the gelled calcium silicate hydrate is dehydrated at the time of pressing or evaporates soon, and thus has a hardened state at the time of drying to reduce the weight of the molded body.

[Brief description of the drawings]

FIG. 1 is a side view of an apparatus for performing the method of the present invention.

FIG. 2 is an enlarged sectional view of a concavo-convex pattern portion.

[Description of Signs] 1 Slurry tank 2 Round net cylinder 3 Seed membrane 4 Making roll 5 Forming plate 6 Press machine

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Claims (2)

[Claims] 1. A cement composition of a ceramic building material in which fly ash or silica fume is added as a silica component to a cement, and necessary aggregates, lightweight aggregates and inorganic reinforcing fibers other than organic or asbestos are added. Add slaked lime and water to the raw materials and add 80
Calcium silicate hydrate gelled by hydrothermal reaction at １００100 ° C. is replaced with the entire amount of silica in the cement composition of the ceramic building material to a part thereof and mixed with water to form a plate-like body by a wet process. A method of manufacturing a deeply carved ceramic building material, which is shaped and then pressed to form an uneven pattern. 2. A raw material containing amorphous silica of gelled calcium silicate hydrate is either fly ash or silica fume, and the molar ratio of silica in these raw materials to calcium oxide in slaked lime is 0.65. ~ 1.
2. The method for producing a deeply carved ceramic building material according to claim 1, wherein the value is 0.