JPS60221371A - Manufacture of ceramic foam - Google Patents

Abstract

(57)【要約】本公報は電子出願前の出願データであるた
め要約のデータは記録されません。(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

【発明の詳細な説明】 〔発明の技術分野〕 本発明は火山噴出物を一■いたセラミック発泡体の製造
方法に関する。DETAILED DESCRIPTION OF THE INVENTION [Technical Field of the Invention] The present invention relates to a method of manufacturing a ceramic foam containing volcanic ejecta.

〔従来技術〕[Prior art]

セラミック発泡体については過去多くの研究がなされて
いるが、すべて一長一短があった。A lot of research has been done on ceramic foams in the past, but all of them have had their pros and cons.

例えば、特開昭５６−１０９８５９号公報には高炉水砕
スラグに珪砂等の珪酸含有物、粘結剤、更に発泡助剤と
して炭化珪素を加えて、加熱発泡させる方法が記載され
ているが、高炉水砕スラグがどこでも入手できるもので
はなく、しかも品質が一定しない為に、品質一定の製品
ができ難い欠点があった。For example, JP-A-56-109859 describes a method in which granulated blast furnace slag is heated and foamed by adding a silicic acid-containing substance such as silica sand, a binder, and silicon carbide as a foaming aid. Granulated blast furnace slag is not available everywhere and its quality is inconsistent, making it difficult to produce products of consistent quality.

又、特公昭５６−Ｌ１４６２７号公報にはシラス等の火
山噴出物と高炉水滓と水ガラス系組成物を加熱発泡させ
ることが記載されているが、この方法でできた発泡体は
均一に発泡したものが得難く、又機械的強度も低い欠点
があった。Furthermore, Japanese Patent Publication No. 56-L14627 describes heating and foaming volcanic ejecta such as whitebait, blast furnace water slag, and a water glass composition, but the foam made by this method is not uniformly foamed. However, it is difficult to obtain such a material, and the mechanical strength is also low.

本発明者等はこれ等の欠点を解消すべく研究した結果、
日本全国に分布している火山噴出物や石灰石等のＣａＯ
化合物を用いて発泡体ができること、特にＣａＯ化合物
を入れることにより機械的強度の強い発泡体が得られる
ことを発見←、本発明を完成したのである。As a result of research to eliminate these drawbacks, the present inventors found that
CaO in volcanic ejecta, limestone, etc. distributed throughout Japan
He discovered that foams can be made using compounds, and in particular that foams with strong mechanical strength can be obtained by adding CaO compounds, and the present invention was completed.

〔発明の要旨〕[Summary of the invention]

即ち、本発明の要旨は、火山噴出物６０〜９０重量部、
ＣａＯ化合物４０〜１０重量部に、炭化珪素を添加し、
９００〜１４００℃に加熱することを特徴とするセラミ
ック発泡体の製造方法に存する。That is, the gist of the present invention is that 60 to 90 parts by weight of volcanic ejecta,
Adding silicon carbide to 40 to 10 parts by weight of the CaO compound,
The present invention relates to a method for producing a ceramic foam, which comprises heating to 900 to 1400°C.

〔発明の構成〕[Structure of the invention]

本発明に用いる火山噴出物としては、火山岩、火山灰な
どであり、その化学組成において、ＳｉＯ□が４５〜８
０％、ＡＩｚＯ＋が５〜２５％が含まれているものが好
ましい。上記火山噴出物としては、例えばシラス、黒曜
石、真珠岩、松脂岩、軽石などの火山灰、白土、ベント
ナイトなどの火山灰が変質したもの、安山岩、玄武岩、
抗火石、流紋岩、御影石、長石、蝋石、長石などの火山
岩などが挙げられる。The volcanic ejecta used in the present invention is volcanic rock, volcanic ash, etc., and in its chemical composition, SiO□ is 45 to 8
0% and 5 to 25% of AIzO+ is preferable. Examples of the above-mentioned volcanic ejecta include volcanic ash such as shirasu, obsidian, nacre, pinestone, and pumice, altered volcanic ash such as white clay, and bentonite, andesite, basalt,
Examples include volcanic rocks such as anti-firestone, rhyolite, granite, feldspar, Rouseki, and feldspar.

本発明に用いるＣａＯ化合物としては、酸化カルシウム
の他、分解してＣａＯとなる水酸化カルシウム、炭酸カ
ルシウム、シュウ酸カルシウムなども含むものであり、
−ａに天然に石灰石、石灰などとして多量に存在するも
のが使用できる。In addition to calcium oxide, the CaO compound used in the present invention includes calcium hydroxide, calcium carbonate, calcium oxalate, etc., which decompose into CaO.
-A, which naturally exists in large amounts as limestone, lime, etc., can be used.

本発明に用いる炭化珪素は発泡剤として働くものであり
、上記火山噴出物及びＣａＯ化合物と共に加熱すると、
９００℃以上になると、Ｓ　ｉ　Ｃ＋　２０□→ＳｉＯ
□＋ＣＯ，の如く分解し、炭酸ガスを発生ずるのである
。The silicon carbide used in the present invention acts as a blowing agent, and when heated together with the volcanic ejecta and CaO compound,
When the temperature exceeds 900℃, S i C+ 20□→SiO
It decomposes as □+CO, producing carbon dioxide gas.

本発明においては、上記火山噴出物とＣａＯ化合物とを
それぞれ６０〜９０重量部、４０〜１０重量部の割合で
混合するのであるが、火山噴出物とＣａＯ化合物との溶
融を助Ｌ−１発泡し易くする為に、助剤として水ガラス
、ガラス粉末、又は本発明の発泡体の破片を粉砕したも
のなどを加えてもよい。加える量は、水ガラス、ガラス
粉末では２０重量部以下が好ましく、１０重量部以下が
更に好ましい。２０重量部以上加えると耐熱性が劣り、
又均−に発泡し難くなってくる。発泡体の破片は、いく
ら加えても物性には関係なかった。発泡体の破片のよう
に一旦溶融したものを加えると、混合物の溶融が均一に
行くので特に好ましい。In the present invention, the volcanic ejecta and the CaO compound are mixed at a ratio of 60 to 90 parts by weight and 40 to 10 parts by weight, respectively. In order to facilitate the preparation, water glass, glass powder, or crushed fragments of the foam of the present invention may be added as an auxiliary agent. The amount added is preferably 20 parts by weight or less, more preferably 10 parts by weight or less for water glass or glass powder. Adding more than 20 parts by weight will result in poor heat resistance.
Also, it becomes difficult to foam evenly. No matter how much foam debris was added, it had no effect on the physical properties. Addition of once melted material, such as foam fragments, is particularly preferred since the mixture will melt more evenly.

炭化珪素は発泡剤となるものであり、製品の所望する発
泡倍率によって使用量が異なるが、多くの場合１重量部
以下で充分である。Silicon carbide serves as a foaming agent, and the amount used varies depending on the desired foaming ratio of the product, but in most cases, 1 part by weight or less is sufficient.

本発明においては、それぞれの組成物を微粉末状にし、
所望の割合に混合し、必要−な場合は水を加え、混練し
、成型するか、それぞれの微粉末状混合物をプレス成型
する。水を加えると粉末粒子どうしの密着がよくなり、
反応が均一に進む。この成型する形状はペレット状、う
どん状或いは最終製品の縮小した形状など任意の形状で
よい。このように成型したものを、電気炉、回転炉或い
はトンネル炉などを用いて加熱発泡させるのであるが、
ペレット状、或いはうどん状にしたものは、最終製品に
近い形状に集合させておき、加熱発泡時にお互いに融着
し、所望の形状になるようにしておく。In the present invention, each composition is made into fine powder,
Mix in desired proportions, add water if necessary, knead and mold, or press mold the respective fine powder mixtures. Adding water improves the adhesion between powder particles,
The reaction proceeds uniformly. The shape to be molded may be any shape such as a pellet shape, a noodle shape, or a reduced shape of the final product. The molded product is then heated and foamed using an electric furnace, rotary furnace, tunnel furnace, etc.
The pellets or noodles are aggregated into a shape similar to the final product, and are fused to each other during heating and foaming to form the desired shape.

加熱温度は９ｏｏ℃〜１４００　℃であり、好ましくは
１１００°Ｃ〜１３００℃である。加熱し、成型物を９
ｏｏ℃〜１４００　’ｃに約１０分間加熱し続りると均
一に発泡する。この発泡したものが、まだｇｏｏ℃前後
と熱いうちに、所望の形状に加圧成型する。その後徐冷
し、取り出し、最終製品形状に切断、切削加工する。The heating temperature is 90°C to 1400°C, preferably 1100°C to 1300°C. Heat and mold into 9
Continue heating from oo°C to 1400'c for about 10 minutes to foam uniformly. While this foamed material is still hot at about 0.05°C, it is pressure molded into a desired shape. After that, it is slowly cooled, taken out, and cut into the final product shape.

ｆ発明の効果〕 本発明においては、日本全国いたる所に産出する火山噴
出物と石灰石などのＣａＯ化合物を用いるものであるか
ら、入手に困難がなく、又ＣａＯ化合物を加えであるか
ら、機械的強度の強いものが得られる。又、同一地域か
ら産出するものはほぼ同じ組成のものであり、従って製
品の品質のバラツキが少なく、良好な発泡体が得られる
。[Effects of the Invention] In the present invention, CaO compounds such as volcanic ejecta and limestone, which are produced all over Japan, are used, so there is no difficulty in obtaining them, and since CaO compounds are added, mechanical A strong product can be obtained. Moreover, products produced from the same region have almost the same composition, so there is little variation in product quality, and good foams can be obtained.

本発明のセラミック発泡体は、断熱材、耐火材として、
或いは建築物の外壁、屋根材などの建材、その他種々の
用途に好適に用い得るのである。ちなみにガラス繊維か
らなる断熱材の耐熱性は４００℃前後であるのに対し、
本発明のセラミック発泡体は９ｏｏ℃前後の耐熱性を有
する・ 次に本発明の実施例を示す。The ceramic foam of the present invention can be used as a heat insulating material and a fireproof material.
Alternatively, it can be suitably used for building materials such as outer walls of buildings and roofing materials, and for various other uses. By the way, the heat resistance of glass fiber insulation is around 400℃,
The ceramic foam of the present invention has a heat resistance of around 90° C. Next, examples of the present invention will be shown.

実施例１ 微粉末状にしたシラス（鹿児島県垂水市産、５ｉＯｚ７
１％、Ａｈ０３１４％含有）７５．５重量部、炭酸カル
シウム２４゜５重量部、炭化珪素０．３重量部、ガラス
粉５重量部、水２５５重量部を混合して混練し、ペレッ
ト状状に成型し、これを円形板状に並べ、電気炉で１２
００℃に１０分間加熱して、円形板状のセラミック発泡
体を得た。Example 1 Finely powdered whitebait (produced in Tarumi City, Kagoshima Prefecture, 5iOz7)
1%, Ah03 (containing 14%), 75.5 parts by weight of calcium carbonate, 24.5 parts by weight of calcium carbonate, 0.3 parts by weight of silicon carbide, 5 parts by weight of glass powder, and 255 parts by weight of water were mixed and kneaded to form pellets. Form it, arrange it into a circular plate shape, and heat it in an electric furnace for 12 minutes.
The mixture was heated to 00° C. for 10 minutes to obtain a circular plate-shaped ceramic foam.

得られたセラミック発泡体は比重０．３３、曲げ強度３
０Ｋｇ／ｃｌであった。The obtained ceramic foam has a specific gravity of 0.33 and a bending strength of 3.
It was 0 kg/cl.

実施例２ 微粉末状にした抗火石（東京都新島産、５ｉ０２７８．
７％、Ａ　Ｉ２０．１２．３％含有）７３．２重量部、
石灰石２６．５重量部、炭化珪素０．３重量部、水ガラ
ス５重量部を混合し、プレスで板状に成型し、電気炉で
１２５０℃に１０分間加熱して、板状のセラミック発泡
体を得た。得られたセラミック発泡体は比重０．４０、
曲げ強度４０ｈ／ｃｌであった・ 実施例３ 微粉末状にした火山灰（北海道支筋産、ＳｉＯ□７２．
４％、Δ１２０ｉ　１２．８％含有）６６重量部、石灰
石３４重量部、炭化珪素０．２重量部、水３０重量部を
混合し、混練し、板状に成型した。Example 2 Anti-flinder stone made into fine powder (made in Niijima, Tokyo, 5i0278.
7%, AI20.12.3%) 73.2 parts by weight,
26.5 parts by weight of limestone, 0.3 parts by weight of silicon carbide, and 5 parts by weight of water glass were mixed, molded into a plate shape using a press, and heated to 1250°C for 10 minutes in an electric furnace to form a plate-shaped ceramic foam. I got it. The obtained ceramic foam has a specific gravity of 0.40,
The bending strength was 40 h/cl. Example 3 Finely powdered volcanic ash (from Hokkaido spur, SiO□72.
4%, Δ120i 12.8%), 34 parts by weight of limestone, 0.2 parts by weight of silicon carbide, and 30 parts by weight of water were mixed, kneaded, and molded into a plate shape.

これを電気炉で１２５０℃に１５分間加熱して、板状の
セラミック発泡体を得た。得られたセラミンク発泡体は
比重０．６、曲げ強度７０　Ｋｇ　／　ｃｎＴであった
。This was heated in an electric furnace to 1250° C. for 15 minutes to obtain a plate-shaped ceramic foam. The obtained ceramic foam had a specific gravity of 0.6 and a bending strength of 70 Kg/cnT.

実施例４ 寄居白土（埼玉県寄居産、５ｉｆ２７５．８％、Ａ１□
０３１２．８％含有）６４重量部、石灰３６重量部、炭
化珪素０．２重量部を混合し、電気炉で１３００℃に１
０分間加熱して、セラミック発泡体を得た。得られたセ
ラミック発泡体は比重０゜４０、曲げ強度５０Ｋｇ／−
であった。Example 4 Yorii white clay (from Yorii, Saitama Prefecture, 5if275.8%, A1□
03 (containing 12.8%), 36 parts by weight of lime, and 0.2 parts by weight of silicon carbide were mixed and heated to 1300°C in an electric furnace.
After heating for 0 minutes, a ceramic foam was obtained. The obtained ceramic foam has a specific gravity of 0°40 and a bending strength of 50 kg/-
Met.

実施例５ 微粉末状にした安山岩（群馬県渋川重度、Ｓｔ０□６０
．５％、八１２（Ｌ＋　１１．３％含有）７６重量部、
石灰石２４重量部、炭化珪素０．１５重量部に水３０重
量部を加え、充分混合混錬し、ベレント状に成型した。Example 5 Finely powdered andesite (Shibukawa Seki, Gunma Prefecture, St0□60
．． 5%, 812 (L+ containing 11.3%) 76 parts by weight,
30 parts by weight of water were added to 24 parts by weight of limestone and 0.15 parts by weight of silicon carbide, thoroughly mixed and kneaded, and formed into a belent shape.

これを３０分間回転炉に入れ最高温度１２００°Ｃに加
熱したところ、回転炉から発泡したペレットがでてきた
。まだ熱いうち（約１０００°Ｃ）にステンレス製の箱
型の容器に入れ、上から押さえ、各々の発泡Ｕたベレッ
トをお互いに密着さゼた。この箱型の容器乙こ入ってい
る発泡体を徐冷した後、取り出したところ矩形のブロッ
クができた。これを板状に切断し、板状のセラミック発
泡体を得た。この発泡体は比重０．６、曲げ強度７０Ｋ
ｇ／ｃＪであった。When this was placed in a rotary furnace for 30 minutes and heated to a maximum temperature of 1200°C, foamed pellets came out of the rotary furnace. While still hot (approximately 1000°C), each foamed pellet was placed in a stainless steel box-shaped container and pressed down from above to make the foamed pellets stick to each other. After slowly cooling the foam contained in this box-shaped container, I took it out and found a rectangular block. This was cut into plate shapes to obtain plate-shaped ceramic foams. This foam has a specific gravity of 0.6 and a bending strength of 70K.
g/cJ.

実施例６ 微粉末状にしたシラス（鹿児島県垂水重度）６７重量部
、炭酸カルシウム３３重量部、炭化珪素０．２重量部に
水３０重量部を加え、充分混合混練した後、真空押出機
を用い、うどん状に成型し、これをコンヘアー上に並べ
乾燥炉を通し乾燥させた後、トンネル炉で１２００　’
ｃに加熱したところ、うどん状組成物が発泡しお互いに
融着し板状になった。更に９００　’ｃ以上の熱いうち
にロールで上を押さえ平らにし、徐冷したところ、板状
発泡体が得られた。これを適当な長さに切断し製品とな
した。このものの比重は０．５であり、曲げ強度は５０
　Ｋｇ　／　ｃＪであった。Example 6 30 parts by weight of water were added to 67 parts by weight of finely powdered whitebait (Tarumi, Kagoshima Prefecture), 33 parts by weight of calcium carbonate, and 0.2 parts by weight of silicon carbide, and after thorough mixing and kneading, a vacuum extruder was used. This was formed into a udon shape, placed on a container, dried in a drying oven, and dried in a tunnel oven for 1200'.
When heated to c., the udon-like composition foamed and fused to each other to form a plate shape. Furthermore, when the top was flattened by pressing with a roll while it was still hot to 900'c or more, and it was slowly cooled, a plate-shaped foam was obtained. This was cut to an appropriate length to produce a product. The specific gravity of this material is 0.5, and the bending strength is 50
Kg/cJ.

特許出願人 積水化学工業株式会社 代表者　藤沼　基利patent applicant Sekisui Chemical Co., Ltd. Representative Motoshi Fujinuma

Claims (1)

【特許請求の範囲】[Claims] １、火山噴出物６０〜９０重量部、ＣａＯ化合物４０〜
１０、重量部に、炭化珪素を添加し、９００〜１４００
°Ｃに加熱することを特徴とするセラミック発泡体の製
造方法。1. Volcanic ejecta 60-90 parts by weight, CaO compound 40-90 parts by weight
10. Add silicon carbide to parts by weight, 900 to 1400
A method for producing a ceramic foam, characterized by heating to °C.