WO2024204119A1 - Method for producing hardened product - Google Patents

Abstract

In order to provide a method for producing a hardened product having high hardness, the hardened product is formed by mixing and stirring a powder obtained by pulverizing inorganic matter, an adhesive agent, and ultrafine bubble water, and hardening the mixture. The inorganic matter includes industrial waste and natural materials, and the industrial waste includes concrete, mortar, tiles, and the like generated when a structure such as a building is crushed. The natural materials include shells, rocks, sand, laterite, animal bones, and the like. The inorganic matter also includes dehydrated cakes. The average particle size of ultrafine bubbles contained in the ultrafine bubble water is approximately 0.13 μm or smaller, and the number of ultrafine bubbles per 1 cc is approximately one hundred million or more. In addition, an aramid fiber sheet may be attached to the surface of the hardened product, and alumina may be added to the mixture materials.

Description

Manufacturing method of the cured product

The present invention relates to a method for producing a cured product.

The following Patent Document 1 discloses a method for producing a hardened material containing at least one selected from lignin and cellulose and waste materials such as concrete. Lignin and cellulose can be obtained from plant-derived waste materials, etc.

Patent document 1 discloses that the material has sufficient strength, but by further increasing the strength, it would be possible to reduce the amount of material used.

Patent No. 7157984

The object of the present invention is to provide a method for producing a cured product with high hardness.

The process for producing the hardened product of the present invention includes the steps of producing a powder made of an inorganic substance, mixing and stirring the powder, ultra-fine bubble water and an adhesive to produce a mixture, pouring the mixture into a formwork, and hardening the mixture.

According to the present invention, ultra-fine bubble water is used, allowing the ultra-fine bubble water to penetrate deep into the powder, causing a hydration reaction deep inside the powder, making the hardened product stronger.

FIG. 2 is a schematic diagram showing the process of pulverizing an inorganic substance. FIG. 1 is a schematic diagram showing mixing of a mixture. This is a schematic diagram of the mixed material being poured into a mold and hardened in a pressure cooker. FIG. 2 is a schematic diagram of a cured product removed from a mold. FIG. 2 is a schematic diagram showing an aramid fiber sheet being attached to a cured product. FIG. 2 is a schematic diagram showing a topcoat applied onto an aramid fiber sheet.

The method for producing the cured product of the present invention will be described with reference to the drawings. The drawings are shown diagrammatically for the purpose of explanation.

[Embodiment 1]
The cured material is formed by mixing and stirring a powder of pulverized inorganic material, an adhesive, and ultra-fine bubble water, and curing the mixture.

Inorganic materials include industrial waste and natural materials. Industrial waste includes concrete, mortar, roofing tiles, etc. that are generated when buildings and other structures are crushed. Natural materials include shells, rocks, sand, laterite, animal bones, etc. Inorganic materials also include dehydrated cake or sludge, etc.

The inorganic material is pulverized to a powder. The powder contains calcium or a calcium compound. Calcium compounds include calcium carbonate, calcium oxide, tricalcium silicate, dicalcium silicate, tricalcium aluminate, tetracalcium aluminate ferroaluminate, gypsum dihydrate, and the like . An example of the average particle size of the powder is about 300 μm, but this may be changed appropriately depending on the hardness of the cured product, etc.

Adhesives can be made from natural rubber, acrylic, epoxy, silicone or vinyl acetate materials. For example, latex (natural rubber) made from rubber trees is used as an adhesive. The average particle size of the adhesive is approximately 0.02 to 10 μm. The adhesive is attached around a single powder particle, joining the powder particles together. By using a natural rubber adhesive, it is possible to produce a cured product that places less of a burden on the environment.

Ultra-fine bubble water is a liquid that contains ultra-fine bubbles. The average particle size of the ultra-fine bubbles contained in ultra-fine bubble water is approximately 0.13 μm or less. There are approximately 100 million or more ultra-fine bubbles per cc. The ratio of the average particle size of the ultra-fine bubbles, the average particle size of the powder, and the average particle size of the adhesive is approximately 1:15,000:77.

Ultra-fine bubble water can penetrate deep into materials. Ultra-fine bubble water can penetrate deep into microscopic holes and cracks formed on the surface of powder. Powder contains calcium or calcium compounds, which undergo a hydration reaction with water and harden. In this case, the ultra-fine bubble water causes a hydration reaction deep into the powder. The hardness of the hardened material is increased.

Next, a method for producing a hardened product will be described. (1) A powder made of inorganic matter is produced. The inorganic matter includes at least one of industrial waste concrete and mortar, naturally occurring shells (including shells after consumption), sand, and rocks. If the concrete contains reinforcing bars, the reinforcing bars are removed. As shown in FIG. 1, prepared industrial waste 12 and the like are crushed in a crushing device 14 to produce powder made of inorganic matter 16. The crushing device 14 is equipped with a plurality of cutters 18, and the industrial waste 12 and the like are crushed by the cutters 18. In addition, sludge and the like may be dehydrated to produce a dehydrated cake, and the dehydrated cake may be sieved to remove garbage and the like to produce a powder made of inorganic matter. Since inorganic matter is a recycled product or exists in abundance in nature, it has a small environmental impact.

(2) The powder 16, adhesive, and ultra-fine bubble water are mixed in a single container 20 and further stirred to form a mixture 22 (Figure 2). The ratio of the powder 16, adhesive, and ultra-fine bubble water is approximately 70-80% powder 16, approximately 20-10% adhesive, and approximately 10% ultra-fine bubble water. The ratio of the materials may be changed according to the hardness of the cured product, so that the total amount is 100%. Note that the ratio of the materials is one example and may be changed depending on the hardness and shape of the cured product.

To mix and stir, a stirrer 26 is used that stirs the materials placed in the container 20 with a propeller 24 or the like, a vibrator that directly or indirectly vibrates the mixed material 22, a tilting device that changes the angle of the container 20 for the mixed material 22, a blower that blows air on the mixed material 22 to stir it, and the like.

The powder 16, adhesive and ultra-fine bubble water may be placed one by one in the container 20 and mixed and stirred, or multiple of them may be placed in the container 20 at the same time and mixed and stirred. Alternatively, ultra-fine bubble water may be mixed through a shower head during or after mixing the powder 16 and adhesive. The ultra-fine bubble water is sprayed from the shower head in multiple directions, making it easier for the ultra-fine bubble water to mix with the powder 16 and adhesive. The powder 16 contains calcium or a calcium compound, and the ultra-fine bubble water causes a hydration reaction in the powder 16, causing it to harden.

(3) Pour the mixed material 22 into the formwork. To prevent air bubbles from forming in the mixed material 22 inside the formwork, a vibrating device may be placed inside the mixed material 22 and vibrated inside the mixed material 22 to allow air bubbles to escape upwards. A release sheet, resin film, etc. may be provided on the inner wall of the formwork so that the mixed material 22 can be removed from the formwork after it has hardened.

(4) The mixed material 22 poured into the formwork is hardened. Pressure is applied to the mixed material 22 during hardening. The formwork 30 and the mixed material 22 may be placed in a pressure cooker 28 that can be sealed and that can increase the atmospheric pressure inside (Figure 3). The heater 32 in the pressure cooker is turned on to generate heat, and the temperature inside the pressure cooker is increased. The mixed material 22 is heated, and the pressure inside the pressure cooker is increased by the moisture that evaporates from the mixed material 22 at that time. The top of the formwork 30 is open, and the mixed material 22 is pressurized by the steam 34. For example, the heater 32 is set so that the atmospheric temperature inside the pressure cooker 28 is the temperature at which water boils, for example, 100°C. The ultra-fine bubble water contained in the mixed material 22 expands to about 1,700 times by boiling and becoming steam, and the pressure inside the pressure cooker is increased. The pressure is determined and adjusted appropriately depending on the thickness of the hardened product. Although the atmospheric temperature inside the pressure cooker 28 is increased by the heater 32 inside the pressure cooker 28, a heater may be placed outside the pressure cooker 28, and the atmospheric temperature inside the pressure cooker may be increased from the heater. The pressure cooker 28 may be configured to be able to suck in and exhaust air, and the pressure inside the pressure cooker 28 may be adjusted.

(5) After the mixed material 22 has hardened, the formwork 30 is removed from the pressure cooker 28. The hardened material 10 is removed from the formwork 30, and the hardened material 10 is complete (Figure 4). The hardened material 10 is used for civil engineering structures, buildings, etc.

As described above, the present invention produces the hardened material 10 without using cement or aggregates (sand, gravel). Since the amount of cement and aggregates available on Earth is decreasing, it is possible to achieve a cement-free and aggregate-free construction. Since wood and the like are not used as in the conventional technology, a strong hardened material 10 can be produced. Since the strength of the hardened material 10 is increased, it is also possible to make the hardened material 10 used in structures thinner or finer, which allows for a reduction in the amount of material used and a reduction in _CO2 emissions.

[Embodiment 2]
An aramid fiber sheet may be attached to the periphery of the cured product 10 produced in the first embodiment. The aramid fiber sheet is composed of wholly aromatic aramid fibers. The aramid fiber sheet is formed into a sheet shape by arranging fibers in one or two directions. The aramid fiber sheet is wrapped around and attached to the surface of the cured product 10. By attaching the aramid fiber sheet to the cured product 10, it is possible to respond to large external forces (axial force, bending moment, shear force, etc.).

The method of attaching the aramid fiber sheet will now be described. (1) The surface of the cured product 10 produced in embodiment 1 is primed. For example, the primed surface is polished with a polishing device. Note that if the primed surface is not required, it may be omitted.

(2) A primer is applied to the surface of the cured product 10 (primer treatment). An example of a primer is an epoxy resin. This strengthens the adhesive strength of the aramid fiber sheet.

(3) An intermediate coating material 36 is applied to the surface of the cured product 10, and an aramid fiber sheet 38 is attached to the surface of the cured product 10 (Figure 5). An example of the intermediate coating material 36 is epoxy resin. The undercoat material and intermediate coating material 36 may be made of different materials. The aramid fiber sheet 38 may be attached while removing air with a defoaming roller. The intermediate coating material 36 is attached before it dries.

(4) A topcoat material 40 is applied from the aramid fiber sheet 38 (Figure 6). By applying the topcoat material 40 so that the aramid fiber sheet 38 is not visible, a stronger cured product 42 is produced. Examples of topcoat materials include epoxy-based paint materials, and may be materials that are water-resistant, chemical-resistant, or oil-resistant.

The initial hardened material 10 can be reinforced by the aramid fiber sheet 38. The hardened material 10 has a stronger ability to resist axial force, bending moment, shear force, torsion, etc. This provides stronger reinforcement than putting reinforcing materials such as steel bars inside the hardened material 42. The aramid fiber sheet 38 has a higher tensile strength than steel bars, is lighter, and is less susceptible to deterioration.

Instead of the aramid fiber sheet 38, a carbon fiber sheet may be attached to the surface of the cured product 10. The carbon fiber sheet is a sheet made of carbon fiber, and is about 1/4 the weight of iron and about 10 times stronger than iron. This can increase the strength of the cured product 10.

[Embodiment 3]
In the first embodiment, the pressure in the pressure cooker is increased by the steam 34 to apply pressure to the mixed material 22 poured into the mold 30, but pressure may be applied by other methods. For example, pressure may be applied to the mixed material 22 by applying a load from above the mixed material 22 by heating and pressurizing using a hot press method.

[Embodiment 4]
In the first embodiment, the cured product 10 may be produced by including an admixture as necessary. The admixture may be mixed when the powder, adhesive, and ultra-fine bubble water are mixed to produce the admixture. Examples of the admixture include a water reducing agent, a quick-setting agent, a setting retarder, and a hydration heat inhibitor.

[Embodiment 5]
In the above embodiment, the powder, adhesive, and ultra-fine bubble water are mixed and stirred, but alumina (aluminum oxide) may be added to the powder, adhesive, and ultra-fine bubble water and mixed. The alumina is in powder form. The thermal conductivity of the cured product 10 can be increased by including alumina in the mixture. The ratio of alumina in the mixture is changed according to the desired thermal conductivity. For example, the temperature of the outer surface and the inside of the mixture can be made uniform during production, making it easier to produce a homogeneous cured product 10. In addition, by placing the cured product 10 on the ground, etc., heat exchange can be performed between the cured product 10 and the part where it is placed.

In addition, the present invention can be implemented in various forms with improvements, modifications, and changes based on the knowledge of those skilled in the art, without departing from the spirit of the invention. Each embodiment is not independent, but can be implemented in appropriate combinations based on the knowledge of those skilled in the art.

10, 42: Hardened material 12: Industrial waste 14: Crusher 16: Powder 18: Cutter 20: Container 22: Mixture 24: Propeller 26: Mixer 28: Pressure cooker 30: Formwork 32: Heater 34: Steam pressure 36: Undercoat material 38: Aramid fiber sheet 40: Topcoat material

Claims (3)

Producing a powder of inorganic matter, including concrete, mortar, roofing tiles, shells, rocks, sand, laterite, animal bones, dewatered cake or sludge;
a step of mixing and stirring the powder, ultra-fine bubble water, and a material containing an adhesive made of a natural rubber, acrylic, epoxy, silicone, or vinyl acetate material in a ratio of 70-80% powder, 20-10% adhesive, and 10% ultra-fine bubble water to a total of 100%, and allowing the ultra-fine bubble water to permeate holes and cracks in the powder to produce a mixture;
Pouring the mixture into a form;
A step of hardening the mixture by adhering the adhesive around the powder bodies and bonding the powder bodies together;
A method for producing a cured product comprising the steps of: The method for producing a cured product according to claim 1, wherein the step of curing the mixed material includes a step of curing the mixed material while applying pressure. The method for producing the cured product of claim 1 includes a step of attaching an aramid fiber sheet or a carbon fiber sheet to the surface of the cured product formed by curing the mixture.

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