JP2000290083A - Light-weight foamed ceramics, method for producing the same, lightweight foamed tile and tile-attached board - Google Patents

Abstract

(57) [Summary] [Problem] To provide a novel lightweight foam ceramics, a tile, and a tile-attached board that contribute to solving environmental problems. The raw material contains 5-95% by weight of fired ceramic waste material and the balance mainly clayey and / or feldspar, foamed by firing, and has a bulk specific gravity of 0.3 after firing.
Lightweight foamed ceramics in the range of ~ 2.0. A method for producing lightweight foamed ceramics in which a raw material consisting of fired ceramic waste material and the balance mainly composed of clay and / or feldspar is formed, fired and foamed. Tiles made of these lightweight foam ceramics, boards or panels to which these tiles are attached. The use of fired ceramic waste material as a raw material stabilizes foam firing, and contributes to the recycling of waste.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a lightweight foamed ceramic and a method for producing the same, and more particularly to a lightweight foamed tile and a tile-attached board or panel using the same.

[0002]

2. Description of the Related Art Conventionally, Japanese Patent Application Laid-Open No. 8-302962 discloses a lightweight foam ceramic tile material composition.
(1) Feldspar 70 parts by weight; clay 30 parts by weight; SiC 0.0
6 parts by weight; specific gravity of the composite tiles closely bonded to each other after firing 1.7 g / cm ³ ; (2) feldspar 50 parts by weight; pottery stone 20
30 parts by weight of clay; 0.04 parts by weight of SiC; and the same specific gravity of 1.82 g / cm ³ are proposed.

Japanese Utility Model Publication No. 301501/1999 discloses that a composition comprising ceramic fine hollow particles having a melting point of 1500 ° C. or higher and a ceramic composition of a glassy substance containing a material serving as a flux is kneaded to a tile-shaped arbitrary size. There has been proposed a foamed ceramic style formed by pressing and firing at 700 to 1300 ° C. to be used as a tile base material. As the ceramic fine hollow particles, there have been proposed those obtained by foaming a ceramic composition comprising alumina, silica and other components. In addition, as this flux, feldspar,
Limestone, magnesium carbonate, lime phosphate, lead oxide, borax, sodium carbonate, zinc oxide and the like have been proposed.

[0004]

However, the foam tile raw material proposed in the above-mentioned Japanese Patent Application Laid-Open No. 8-302962 is expensive, and foaming does not occur stably at the time of foaming firing. The properties and strength may be reduced. The foam tile raw material proposed in Japanese Utility Model Publication No. 301501 is produced through a complicated and multi-step manufacturing process, and thus has a problem that the price of the obtained foam tile is high.

An object of the present invention is to provide a novel lightweight foamed ceramic which contributes to solving environmental problems and a method for producing the same, especially a lightweight foamed tile and a tile-attached board or panel using the same.

[0006]

Means for Solving the Problems The present inventor has focused on waste ceramics and tiles which have not been saved in the past as raw materials for lightweight foamed ceramics. The present inventors have found that foaming occurs stably during firing, and that the uniformity and the compression and bending strength of the fired product are improved. As a result of further study, the present invention has been completed.

[0007] The present invention provides, in a first aspect,
The fired ceramic waste material is 5-95 wt%, the balance being mainly clayey or feldspar or clayey and feldsparous, foamed by firing, and having a bulk specific gravity of 0.3-0.3 after firing.
Provide lightweight foamed ceramics in the range of 2.0.

According to a second aspect of the present invention, a raw material consisting of fired ceramic waste material and the remainder mainly composed of clay is formed and fired to obtain at least a glaze component and / or a glaze component contained in the ceramic waste material. Alternatively, a production method for foaming a vitreous component in a matrix is provided.

According to a third aspect of the present invention, there is provided a tile made of the lightweight foamed ceramics according to the first and second aspects, or a tile-attached board or panel obtained by attaching these tiles to a board or panel. I do.

According to the present invention, waste materials of ceramics and tiles (ceramic waste materials, fired product waste materials) which have been mostly landfilled in the past are used as raw materials. Since fired waste materials such as ceramics and tiles have undergone a firing process,
The stability in the production process of foaming and firing using these as raw materials is extremely high.

The first reason is that there is substantially no crystallization water in the ceramic (fired product) waste used as a raw material. The second reason is that the fire resistance of the ceramic (fired) waste material used as a raw material is constant. Thus, the foaming stability at the time of firing is increased, and the compression and bending strength of the fired ceramic is improved.

The foaming mechanism in the method for producing a lightweight foamed ceramic according to the present invention will be described. Since ceramic (fired) waste materials contain foaming components such as glaze or glass components in the base, these foaming components are melted due to the generation of gas from the waste materials during firing, resulting in expansion and foaming. I do. Further, glass components contained in fly ash, glass waste material, feldspar waste material, general or industrial waste molten slag, sewage sludge incineration ash, and glaze sludge are also melted, expanded and foamed by firing. Gases are generated by firing the ceramic waste material, and these glass components also serve as a gas (eg, O ₂ , CO ₂ ) source during firing to foam the glass components. Preferably, a foaming auxiliary component such as SiC or SiN is added in order to secure a predetermined amount of gas generation. Ceramic (fired) waste materials
Once fired, it does not substantially contain water of crystallization and has the property of having a constant fire resistance, so it does not cause problems such as coarse foaming, excessive foaming and uneven foaming, and uniformity of the structure Thus, a fired body having high compressive strength and high bending strength can be obtained in spite of its high weight and light weight.

Further, according to the present invention, since the raw material composition range, sintering temperature range, and atmosphere in which stable and uniform foaming is generated are wide, various lightweight foamed ceramics having characteristics according to the purpose can be obtained.

[0014]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, preferred embodiments of the present invention will be described. First, preferred raw materials will be exemplified.

[Ceramic waste material] Waste material of ceramic products mainly manufactured by artificial heat treatment, for example, waste material (cerven) such as pottery, stoneware, and porcelain, and tile waste material.

[Glass waste material] Waste materials (cullet) such as bottles and plate glass. In addition, the glass waste material acts as a foaming agent, a melting aid, and a foam forming agent.

[0017] One or more of ceramic waste materials and glassy waste materials may be used, if necessary, in their entirety to obtain a lightweight foamed ceramic having a predetermined bulk specific gravity. However, from the viewpoint of production, it is preferable that the used amount of these waste materials be 95 wt% or less. By using these waste materials in an amount of 1% or more, a predetermined effect can be obtained, which contributes to the recycling of the waste materials. However, in order to further increase the stability of foaming and to reduce the cost of the raw materials, these waste materials are used in the raw materials. It is preferable to use 5 wt% or more, more preferably 10 to 80 wt% or more, or particularly 50 wt% or more.

[Clay] In the raw materials, 5 to 95 wt.
% Can be used. Preferably, 15 to 40% by weight is used. Clay is a natural raw material that mainly contains fine powder and contains water and exhibits appropriate viscosity and plasticity, such as frog-eye clay, kibushi clay, and kaolin.

[Feldspar] Feldspar can be used in place of the above clay or in place of a part thereof.

[Other Melting Aids] As melting aids, besides glass waste materials, fly ash, glass waste materials, Niijima Koga stone waste materials (feldspar waste materials), industrial waste or general waste incineration ash (dust melting slag, etc.) ), The use of glaze sludge such as ceramic tiles, sewage sludge incineration ash, etc. increases the stability, strength and hardness of fired foam. It is preferable to add such a melting aid to 30 wt% or less, particularly about 5 to 25 wt%. Melting aids are not sticky and not too soft, up to a predetermined temperature below the maximum firing temperature, are in an appropriate viscosity range to cause fine foaming, do not lose shape,
It is preferable that the gas foamed by firing be taken into the inside.

[Other Raw Materials] Further, a predetermined amount of natural raw materials such as feldspar, pottery stone, wax stone, and silica stone may be contained. Limestone and pigment may be added.

[Foaming Aids] As foaming aids, silicon carbide, silicon nitride, calcium carbonate (pyrolysis temperature in air of 800 ° C.), bentonite, sodium nitrate, dolomite (pyrolysis temperature in air of 894 ° C.), etc. 10 parts by weight or less, particularly about several parts by weight, may be added to the ceramic waste material and the vitreous waste material.

[Preferred particle size of each raw material] The preferred particle size of each raw material for obtaining a predetermined effect is as follows: (1) Particle size of ceramic waste material: 10 to 300 μm; (2) Particle size of vitreous waste material (3) Particle size of other melting aids of about 10 to 300 μm; (4) Particle size of foaming aids of about 3 to 50 μm.

According to the present invention, the bulk specific gravity is 2.0
Hereinafter, preferably 0.3 to 2.0, more preferably 0.8 to 1.
5 lightweight foam tiles can be obtained. Therefore, a tile-attached board or panel to which a large number of these lightweight foam tiles are attached is lightweight and excellent in handleability.
Further, according to the lightweight foamed tile of the present invention, the load on the tile-attached board and the skeleton to which the tile-attached board is attached are reduced. Preferably, the lightweight foam tile according to the present invention is adhered to an ALC plate, a ceramic plate (for example, a cement slag papermaking plate) using a silicone adhesive or the like.
In addition, a predetermined effect can be obtained even when attached to various types of plates such as a wood plate, a metal plate, and a resin plate.

Since the lightweight foamed ceramics according to the present invention has closed cells, it has a high heat insulating property, and the outer wall board using the same has a characteristic that dew condensation hardly occurs. Further, according to the lightweight foamed ceramics of the present invention, at a bulk specific gravity of 1.0, characteristics having a compressive strength of 100 kgf / cm ² and a bending strength of 130 kgf / cm ² or more can be obtained.

Next, a preferred method for producing lightweight foamed ceramics will be described.

Crushing ceramic waste material, clay, other melting aids such as fly ash, koga stone waste material, glass waste material, waste melting slag, glaze sludge of ceramic tile,
Wet pulverization by adding a small amount of foaming aid (dry type may be used)
The mixture is mixed, dehydrated, dried, adjusted for water content, pulverized, and, if necessary, further sized, pressed, and fired.
Depending on the case, glaze may be applied or secondary firing may be performed.

[Firing temperature] The firing temperature is set according to the firing conditions and the raw material composition.
Preferably, the temperature is 300 ° C. As a result, sufficient foaming occurs, and a sufficiently lightweight foamed ceramic is obtained. For example, a lightweight foamed ceramic having an expansion coefficient of 3 to 15% before and after firing can be obtained.

[Foaming] Foaming is caused by melting and expanding glass components contained in the ceramic waste material, for example, the glass component in the glaze and the glass component in the matrix. In addition, foaming properties can be increased by adding vitreous waste, fly ash, glass waste, feldspar waste, general or industrial waste molten slag, sewage sludge incineration ash, and glaze sludge containing a foaming component or a foaming aid component. Increase. Further, other fluxes may be added, as described above,
An organic or inorganic foaming auxiliary component may be added separately.

[0030]

An embodiment of the present invention will be described below.

Example 1 Raw material composition: tile waste material 60 wt%; clay 20 wt%; glass waste material 20 wt%.

The raw material having the above composition is mixed and pulverized so as to have a particle size of 45 μm or less, and 0.2 parts by weight of SiC having a particle size of 3 μm as a foaming agent is added to 100 parts by weight of the mixed and pulverized raw material. Pulverized, spray-dried, pressed to form a tile, and roller hearth kiln,
It was fired at 1,180 ° C.

The obtained lightweight foamed ceramic had an expansion coefficient before and after firing of 5% and a bulk specific gravity of 1.38.

[Example 2] Raw material composition: tile waste material 50%; clay 30 wt%; Niijima Koga stone waste material 10 wt%; fly ash 10 wt%.

The raw material having the above composition is mixed and pulverized so as to have a particle size of 45 μm or less, and 3 parts by weight of lime as a foaming agent is added to 100 parts by weight of the mixed and pulverized raw material. , Pressed into a tile shape, and fired at 1,260 ° C in a tunnel kiln.

The obtained lightweight foamed ceramic had an expansion coefficient of 2.47% before and after firing and a bulk specific gravity of 1.29.

Example 3 Raw material composition: 33% by weight of clay; 7% by weight of molten slag; 60% by weight of ceramic waste.

The raw material having the above composition is mixed and pulverized so as to have a particle size of 45 μm or less. To 100 parts by weight of the mixed and pulverized raw material, 0.2 part by weight of SiC having a particle size of 21 μm is added as a foaming agent. The mixture was pulverized, spray dried, formed into a block shape, and fired at 1,260 ° C. in a tunnel kiln.

The obtained lightweight foamed ceramic had an expansion coefficient of 10.74% before and after firing and a bulk specific gravity of 0.65.

Example 4 Raw Material Composition: Clay (mixture of 4 types) 40 wt%; Niijima feldspar (produced in Tokyo) 10 wt%; Tile Cerben (0.5 mm under product) 50 wt
%.

To 100 parts by weight of the raw material having the above composition (dry weight), 0.2 part by weight of SiC was added and mixed, wet-pulverized by a ball mill (60 mesh through), and then dried by a spray dryer. The obtained granulated clay is 100 ×
Fill into a 100x10mm mold and mold pressure 200kg
/ cm ² , and a glaze (brick color) was applied thereon and fired at 1,250 ° C. in a tunnel kiln.

The bulk specific gravity of the obtained lightweight tile was 1.3.

Example 5 Lightweight tiles were prepared in the same manner as in Example 4 and subjected to bending strength and compression strength tests in accordance with JIS A5209-1994. The data shown in Table 1 below was obtained. Obtained.

[0044]

[Table 1]

[0045]

According to the present invention, various kinds of fired waste materials which have not been saved as raw materials for foamed ceramics and which have been landfilled can be used as raw materials. It greatly contributes to solving processing problems such as processing.

In addition, in the present invention, fired material waste such as porcelain and tiles used as a raw material has undergone a firing process once, so that the stability during the manufacturing process is extremely high. Among them, foaming stability is high, and the compression and bending strength of the fired ceramics is improved. Further, since the lightweight foamed ceramics of the present invention has a wide range of raw material composition, sintering temperature range, and atmosphere in which stable and uniform foaming occurs, various lightweight foamed ceramics having characteristics according to the purpose can be freely obtained by the present invention. be able to.

 ────────────────────────────────────────────────── ─── Continuing on the front page (72) Motomichi Kato Inventor F-term within Nagoya Mosaic Industry Co., Ltd. 2455-2, Kasahara-cho, Toki-gun, Gifu Pref. CA14 CA30 CA50 CB15 CB50 CC11 DA03 DA06 DA10 DA20 4G019 GA04

Claims (9)

[Claims] The raw material contains 5-95% by weight of fired ceramic waste material, the balance of which is mainly clayey and / or feldspar, foamed by firing, and has a bulk specific gravity of 0.3 after firing.
A lightweight foamed ceramic having a range of from 2.0 to 2.0. 2. The method according to claim 1, wherein said ceramic waste material is contained in a
2. The lightweight foamed ceramic according to claim 1, comprising 80% by weight. 3. The raw material of the present invention, wherein said ceramic waste material is reduced to 50 watts.
2. The lightweight foamed ceramic according to claim 1, wherein the content is at least t%. 4. The lightweight foamed ceramic according to claim 1, wherein the ceramic waste material includes at least one of ceramic waste material and tile waste material. 5. The raw material further comprises fly ash, glass waste, feldspar waste, molten slag of general or industrial waste,
The wastewater containing sewage sludge incineration ash and glaze sludge contains 30 wt% or less of at least one kind of waste.
5. The lightweight foamed ceramic according to any one of items 4 to 4. 6. A ceramic raw material which has been fired and a raw material mainly comprising clay and / or feldspar are formed and fired, and at least a glaze component and / or a base contained in said ceramic waste material. A method for producing lightweight foamed ceramics, characterized by foaming a vitreous component therein. 7. A lightweight foamed ceramic produced by the production method according to claim 6. 8. A tile comprising the lightweight foamed ceramic according to any one of claims 1 to 4 and 7. 9. The tile according to claim 8, wherein the tile is an ALC (autoclaved light weight concrete) board,
And a tile-attached board which is attached to one or more boards or panels including ceramic boards.