U.S. patent application number 10/565035 was filed with the patent office on 2006-08-24 for mortar tile and method for production thereof.
Invention is credited to Katsuyuki Nakano, Tetsuro Oike, Nobuyoshi Yukihira.
Application Number | 20060185307 10/565035 |
Document ID | / |
Family ID | 34056096 |
Filed Date | 2006-08-24 |
United States Patent
Application |
20060185307 |
Kind Code |
A1 |
Yukihira; Nobuyoshi ; et
al. |
August 24, 2006 |
Mortar tile and method for production thereof
Abstract
The present invention provides a mortar tile which can reduce
labor, time and cost required for installation without reducing a
harmful substance decomposing ability using a photoresist. To
achieve such an object, a mortar which is molded in a tile shape is
manufactured by forming a formed article in a state that a
photocatalyst is added to the mortar and, thereafter, the
pressure-forming is performed at a pressure which allows the
formation of open pores in a surface thereof, and a photocatalyst
is applied to a surface of the formed article.
Inventors: |
Yukihira; Nobuyoshi;
(Fukuoka, JP) ; Oike; Tetsuro; (Fukuoka, JP)
; Nakano; Katsuyuki; (Fukuoka, JP) |
Correspondence
Address: |
JORDAN AND HAMBURG LLP
122 EAST 42ND STREET
SUITE 4000
NEW YORK
NY
10168
US
|
Family ID: |
34056096 |
Appl. No.: |
10/565035 |
Filed: |
July 14, 2004 |
PCT Filed: |
July 14, 2004 |
PCT NO: |
PCT/JP04/10054 |
371 Date: |
March 29, 2006 |
Current U.S.
Class: |
52/596 |
Current CPC
Class: |
C04B 41/009 20130101;
C04B 41/50 20130101; C04B 2111/00594 20130101; C04B 41/65 20130101;
C04B 2111/00827 20130101; C04B 28/02 20130101; B01J 35/004
20130101; C04B 41/009 20130101; C04B 41/009 20130101; C04B 28/02
20130101; C04B 41/5041 20130101; C04B 40/0259 20130101; C04B
38/0058 20130101; B28B 3/02 20130101; C04B 28/02 20130101; C04B
14/305 20130101 |
Class at
Publication: |
052/596 |
International
Class: |
E04C 2/04 20060101
E04C002/04 |
Foreign Application Data
Date |
Code |
Application Number |
Jul 15, 2003 |
JP |
2003-274883 |
Claims
1. A mortar tile being characterized in that a photocatalyst is
added to a mortar and, thereafter, the pressure-forming is
performed at a pressure which allows the formation of open pores in
a surface of the mortar.
2. A mortar tile being characterized in that a formed article is
formed by adding a photocatalyst to a mortar and, thereafter, by
performing the pressure-forming at a pressure which allows the
formation of open pores in a surface thereof, and a photocatalyst
is applied to a surface of the formed article.
3. A manufacturing method of a mortar tile being characterized in
that a mortar which is molded in a tile shape is manufactured by
adding a photo catalyst to the mortar and, thereafter, by
performing the pressure-forming at a pressure which allows the
formation of open pores in a surface of the mortar.
4. A manufacturing method of a mortar tile being characterized in
that a mortar which is molded in a tile shape is manufactured by
forming a formed article in a state that a photocatalyst is added
to the mortar and, thereafter, the pressure-forming is performed at
a pressure which allows the formation of open pores in a surface
thereof, and a photocatalyst is applied to a surface of the formed
article.
Description
TECHNICAL FIELD
[0001] The present invention relates to a mortar tile which is
formed in a tile shape using mortar as a raw material and a
manufacturing method thereof.
BACKGROUND OF THE INVENTION
[0002] Conventionally, a mortar has been popularly used as a wall
material since the mortar possesses respiratory property, water
resistant property and weatherability.
[0003] On the other hand, in recent years, the air pollution caused
by volatile harmful substances such as formaldehyde and formalin
has become a social problem.
[0004] Accordingly, lately, there has been developed a wall
material in which a photocatalyst having a function of decomposing
harmful substances with the irradiation of ultraviolet rays is
added to the mortar(for example, see Japanese Patent Laid-open
Publication Heill (1999)-264224).
[0005] However, although the above-mentioned conventional wall
material in which the photocatalyst is added to the mortar can
decompose the harmful substances due to an action of the
photocatalyst and can obtain an advantageous effect that the air
pollution can be prevented, in actually applying the mortar to a
wall surface, skilled workers are required and, at the same time,
the installation requires a considerable labor and time and hence,
there exists a possibility that a construction cost is sharply
pushed up.
[0006] Inventors of the present invention have made extensive
studies and have found that a tile-shaped formed article (molded
article) can be manufactured by pressure-forming (press molding) a
mortar to which a photocatalyst is added and it is possible to
reduce labor, time and cost required for installation by using the
mortar tile manufactured in such a manner as a wall material.
[0007] Further, the inventors of the present invention also have
found that although the mere pressure-forming of the mortar to
which the photocatalyst is added into a tile shape may overcome a
drawback on the installation, the ability to decompose the harmful
substances with a photocatalyst is lowered.
[0008] Upon investigating a cause which brings about the reduction
of the ability of the photocatalyst to decompose the harmful
substance by pressure-forming for the mortar to which the
photocatalyst is added, the inventors of the present invention have
found that when the mortar to which the photocatalyst is added is
subjected to pressure-forming at a relatively high pressure, a
surface of the mortar is made smooth and hence, the permeability
which the mortar originally possesses is impaired.
[0009] Accordingly, it is an object of the present invention to
provide a mortar tile which can enhance workability without
impairing the permeability which a mortar possesses and a
manufacturing method thereof.
DISCLOSURE OF THE INVENTION
[0010] The invention according to claim 1 provides a mortar tile
which is characterized in that a photocatalyst is added to a mortar
and, thereafter, the pressure-forming is performed at a pressure
which allows the formation of open pores (through holes) in a
surface of the mortar.
[0011] The invention according to claim 2 provides a mortar tile
which is characterized in that a formed article is formed by adding
a photocatalyst to a mortar and, thereafter, by performing the
pressure-forming at a pressure which allows the formation of open
pores in a surface thereof, and a photocatalyst is applied to a
surface of the formed article.
[0012] The invention according to claim 3 provides a method for
manufacturing a mortar tile which is characterized in that a mortar
which is molded in a tile shape is manufactured by adding a
photocatalyst to the mortar and, thereafter, by performing
pressure-forming at a pressure which allows the formation of open
pores in a surface of the mortar.
[0013] The invention according to claim 4 provides a method for
manufacturing a mortar tile which is characterized in that a mortar
which is molded in a tile shape is manufactured by forming a formed
article in a state that a photocatalyst is added to the mortar and,
thereafter, the pressure-forming is performed at a pressure which
allows the formation of open pores in a surface thereof, and a
photocatalyst is applied to a surface of the formed article.
BRIEF EXPLANATION OF THE DRAWINGS
[0014] FIG. 1 is an explanatory view showing a vacuum forming
machine.
[0015] FIG. 2 is a graph showing a result of a formaldehyde
decomposing test (a mortar).
[0016] FIG. 3 is a graph showing a result of a formaldehyde
decomposing test (a mortar tile).
[0017] FIG. 4 is a microscope photograph showing a surface of a
mortar tile (a specimen B).
[0018] FIG. 5 is a microscope photograph showing a surface of a
mortar tile (a specimen D).
BEST MODE FOR CARRYING OUT THE INVENTION
[0019] A mortar tile according to the present invention is
manufactured by pressure-forming a mortar to which a photocatalyst
is added and constitutes a raw material into a tile shape.
[0020] In a manufacturing method of the mortar tile, first of all,
a photocatalyst is added and mixed into the mortar using a
mixer.
[0021] Here, the mortar contains slaked lime as a main component
and also contains an inorganic material, fiber for plastering and
glue at proper ratios. The mortar may not contain fiber for
plastering and glue. As the inorganic material, calcium carbonate,
barium carbonate, barium hydroxide or the like may be used. As the
fiber for plastering, Manila hemp, Japanese paper, hemp palm,
wooden pulp, synthetic fiber, glass fiber, or the like may be used.
As the glue, a natural glue such as glue, nonglutinous rice, konyak
powder, glue plant, or the like, a synthetic glue such as polyvinyl
alcohol, methyl cellulose, hydroxyl ethyl cellulose, hydroxyl
propyl cellulose or the like may be used.
[0022] Further, as the photocatalyst, it is possible to use a
photocatalyst having various kinds of crystal structure such as an
oxide semiconductor made of a titanium oxide, zinc oxide or the
like, a sulfide semiconductor made of cadmium sulfide, zinc sulfide
or the like.
[0023] Further, an inorganic binder which has the property to be
cured by reacting with a carbonic acid or moisture in the air may
be added to the mortar when necessary. Here, as the inorganic
binder, a material such as the slaked lime, a dolomite, a gypsum, a
magnesium hydroxide, a cement, or the like which easily reacts with
carbonic acid or water in air to form a cured body is used. One
material out of a group of slaked lime, dolomite, gypsum, magnesium
hydroxide, cement, and the like may be singularly used for the
inorganic binder. Alternatively, a mixture of two or more kind of
these materials may be used. Further, water may be added to and
mixed with the mortar until the mortar obtains a given moisture
content.
[0024] Next, a formed article is formed by pressure-forming the
mixture of the mortar and the photocatalyst in a substantial vacuum
using a forming machine. Here, the pressure for pressure-forming is
set to a relatively low pressure which allows the formation of open
pores in a surface of the formed article after
pressure-forming.
[0025] Finally, a photocatalyst is applied to a surface of the
formed article.
[0026] In this manner, according to the present invention, the
mortar tile is manufactured by performing the pressure-forming
after adding the photocatalyst to the mortar and hence, the present
invention can reduce labor, time and cost for installation.
[0027] Further, the forming pressure at the time of
pressure-forming is set to the pressure which allows the formation
of open pores on the surface thereof and hence, a surface of the
mortar is made smooth whereby it is possible to preliminary prevent
the permeability from being impaired thus producing a formed
article having the permeability. Accordingly, it is possible to
prevent the reduction of the decomposing ability of harmful
substances using the photocatalyst.
[0028] Particularly, the present invention can enhance the
decomposing ability of the harmful substances by applying the
photocatalyst to the surface of the formed article.
[0029] Further, the manufacturing method requires no heat treatment
such as baking, auto claving or the like. Accordingly, there is no
possibility that the environment is polluted with a flue gas
generated by the heat treatment. The environmental pollution can
also be prevented. Further, since the heat treatment is not
performed, the treatment cost can be reduced.
[0030] Further, various types of formed articles may be molded
depending on shapes of a mold which is used at the time of forming
thus manufacturing formed articles in a broad field.
[0031] Further, when the inorganic binder having the property to be
cured by reacting with a carbonic acid gas and the moisture in air
is mixed into a mixed body, the surface of the formed article can
be cut, ground and polished easily before natural curing. Further,
even when the surface of the formed article is cut, ground or
polished, the surface of the formed article is naturally cured thus
ensuring the strength of the surface of the formed article.
[0032] In the pressure-forming, a vacuum forming machine shown in
FIG. 1 is used. In the drawing, the vacuum forming machine 20 is
configured as follows. A lower mold 22 is arranged on a lower
portion of a frame 21. A hydraulic elevating cylinder 23 is
arranged on an upper portion of a frame 21 in a state that a distal
end of a cylinder rod 24 extends downwardly. An upper mold 25 is
connected to the distal end portion of the cylinder rod 24. Upon
actuation of the elevating cylinder 23, the upper mold 25 is
elevated toward or lowered away from a recessed portion 26 of the
lower mold 22. In the drawing, numeral 27 indicates a vacuum pump
27 which is communicably connected with the recessed portion 26 of
the lower mold 22, numeral 28 indicates a hydraulic pump 28, and
numeral 29 indicates a hydraulic control panel.
[0033] First of all, the mixture of a mortar, the photocatalyst and
the like which forms the raw material is filled into the recessed
portion 26 of the lower mold 22.
[0034] Next, upon actuation of the vacuum pump 27, a pressurizing
space which is defined by the recessed portion 26 of the lower mold
22 and the upper mold 25 is set to an approximately vacuum state of
-80 KPa to -100 KPa, and the raw material is formed into a plate
shape or a block shape by the forming machine 20. Here, it is
preferable to set the pressurizing space to an approximately vacuum
state of -94 KPa to -100 KPa.
[0035] Here, a forming pressure which is applied to the raw
material by the pressure-forming is set to 15 MPa to 80 MPa. This
is because that when the forming pressure is 15 MPa or less, a
strength of the formed article is lowered, while when the forming
pressure is 80 MPa or more, as described later, the surface of the
formed article is made smooth and hence, the permeability which the
mortar originally possesses is impaired. This forming pressure
differs depending on the raw material to be formed and may be a
pressure which allows the formation of open pores in a surface of
the formed article after forming. Thus, the forming pressure is not
limited to the pressure range described above.
[0036] In this manner, by performing the forming in the
approximately vacuum, substantially no air remains in the inside of
the formed article thus capable of forming a formed article having
a high physical strength and a favorable dimensional accuracy.
[0037] Further, when the formed article is cured by leaving the
formed article in air or in the carbon dioxide gas atmosphere after
pressure-forming, slaked lime or the like which is contained in the
formed article absorbs the carbonic acid gas and forms carbonic
calcium and hence, it is possible to further increase the physical
strength of the formed article.
[0038] Further, different from the brick, tile or the like, the
heat treatment such as baking, autoclaving or the like is not
applied to the formed article. Accordingly, even when an inorganic
porous material, clay, a functional inorganic catalyst, an
antimicrobial and antifungal agent are applied to the mixed body,
there exists no possibility that these inorganic porous material,
clay and the like is influenced by heat and hence, it is possible
to form the molded product which holds characteristics which the
respective materials such as the inorganic porous materials, clay
and the like posses.
[0039] Further, since the heat treatment is not applied to the
molded product, the decoloration attributed to an unexpected change
in a kiln is not generated and hence, molded products having the
color equal to the mixed body before pressure-forming can be
produced on a mass production basis with sufficient
reproducibility.
[0040] Further, different from cement products, the raw material is
not prepared in a slurry state and hence, efflorescence is not
generated whereby it is possible to allow the formed article to
sufficiently develop color by merely mixing 5 parts by weight or
less of figment in the mixed body.
[0041] Further, it is possible to reinforce the bending strength of
the formed article by mixing fibers in the formed article.
[0042] Hereinafter, a decomposition effect of formaldehyde obtained
by the combination of mortar and the photocatalyst is explained in
conjunction with FIG. 2 and FIG. 3.
[0043] Here, a decomposition test is performed such that the
formaldehyde having the concentration of 1000 ppb is continuously
supplied to a room in which mortar or mortar tiles is applied to an
inner wall surface, and when a given time elapses after starting
the supply of formaldehyde, ultraviolet rays are irradiated to the
inner wall surface, wherein the concentration of the formaldehyde
is time-sequentially measured while setting a point of time that
the irradiation of light is started as the reference (0
minute).
[0044] FIG. 2 shows a result of a test when the mortar is applied
to the wall surface in the same manner as the conventional method
without forming the mortar in a tile pattern.
[0045] In FIG. 2, a specimen 1 is obtained by applying only the
mortar, a specimen 2 is obtained by applying the mortar in which
the photocatalyst is added, a specimen 3 is obtained by applying
the mortar in which the photocatalyst is added and, thereafter,
making a surface of the mortar into a rough surface using a wooden
trowel, and a specimen 4 is obtained by coating the mortar in which
the photocatalyst is added and, thereafter, by further applying the
photocatalyst to a surface of the mortar.
[0046] As can be understood from FIG. 2, in all specimens 1 to 4,
formaldehyde is absorbed in the mortar within a short time after
the supply of formaldehyde and hence, the concentration of the
formaldehyde is decreased.
[0047] However, an absorption strength of the mortar is gradually
decreased along with a laps of time and hence, the concentration of
the formaldehyde is gradually increased.
[0048] Then, as a matter of course, due to the irradiation of
light, in the specimens 2 to 4 which contain the photocatalyst,
formaldehyde is decomposed by the photocatalyst and hence, the
concentration of formaldehyde is decreased.
[0049] Particularly, with respect to the specimen 4, it is possible
to remarkably decrease the concentration of formaldehyde to 20 ppb
or less.
[0050] On the other hand, FIG. 3 shows a result of a test when the
mortar tiles are applied to a wall surface.
[0051] In FIG. 3, a specimen A is obtained by applying mortar tiles
which are produced by pressure-forming using only the mortar as a
raw material, specimen B is obtained by applying mortar tiles which
are produced by pressure-forming at a forming pressure of 100 MPa
using mortar to which photocatalyst is added as a raw material, a
specimen C is obtained by applying mortar tiles which are produced
by pressure-forming at a forming pressure of 30 MPa using mortar to
which photocatalyst is added as a raw material, and a specimen D is
obtained by applying mortar tiles which are produced by
pressure-forming at a forming pressure of 30 MPa using mortar to
which photocatalyst is applied as a raw material and, thereafter,
by applying photocatalyst to a surface of the mortar tiles.
[0052] As can be understood from FIG. 3, in all specimens A to D,
formaldehyde is absorbed in the mortar tile within a short time
after the supply of formaldehyde and hence, the concentration of
the formaldehyde is decreased.
[0053] However, an absorption strength of the mortar is gradually
decreased along with a laps of time and hence, the concentration of
the formaldehyde is gradually increased.
[0054] Then, as a matter of course, due to the irradiation of
light, in the specimens B to D which contain the photocatalyst,
formaldehyde is decomposed by the photocatalyst and hence, the
concentration of formaldehyde is decreased.
[0055] Further, with respect to the specimen C and specimen D, it
is possible to decrease the concentration of formaldehyde to 100
ppb or less along with laps of time.
[0056] Particularly, with respect to the specimen D, it is possible
to remarkably decrease the concentration of formaldehyde to
approximately 20 ppb or less.
[0057] Here, to compare the specimen B and specimens C, D which
differ in the lowering of the concentration of formaldehyde after
the irradiation of light, it is understood that these specimens
differ in the pressure at the time of performing the
pressure-forming.
[0058] Accordingly, when inventors of the present invention studied
in detail the difference between the specimen B and the specimen C,
as shown in FIG. 4 and FIG. 5, it is found that the specimen B and
specimen C completely differ from each other with respect to the
configuration of surfaces thereof.
[0059] That is, FIG. 4 is a microscope photograph of 5000
magnifications of the surface of the specimen B. As can be
understood from FIG. 4, when the pressure-forming is performed at
the forming pressure of 100 MPa, the surface is made smooth and no
open pores are not found at all thus impairing the
permeability.
[0060] On the other hand, FIG. 5 is a microscope photograph of 5000
magnifications of the surface of the specimen C. As can be
understood from FIG. 5, when the pressure-forming is performed at
the forming pressure of 30 MPa, open pores are formed on the
surface and hence the permeability is not impaired.
[0061] In this manner, based on the comparison between the specimen
B and the specimen C, by adopting the pressure which allows the
formation of open pores on the surface at the time of performing
the pressure-forming, it is possible to prevent in advance the
situation that the surface of the formed article is made smooth
thus impairing the permeability whereby it is possible to produce
the formed article having the permeability. Accordingly, it is
possible to prevent the decomposition ability of harmful substances
due to the photocatalyst from being lowered.
[0062] Further, based on the comparison between the specimen D and
the specimen 4, it is found that by applying the photoresist to the
surfaces of the mortar tiles, it is possible to obtain the
decomposition ability of contamination substances which is
compatible to the decomposition ability which is obtained when the
photocatalyst is applied to the surface of the mortar to which the
photoresist is added.
INDUSTRIAL APPLICABILITY
[0063] The present invention can achieve advantageous effects
described below.
[0064] That is, according to the present invention, the mortar
tiles are manufactured such that the photocatalyst is added to the
mortar and, thereafter, the pressure-forming is performed at the
pressure which allows the formation of the open pores on the
surface and hence, it is possible to reduce labor, time and cost
required for installation without decreasing the decomposition
ability of harmful substances using the photocatalyst.
[0065] Particularly, by applying the photocatalyst to the surface,
it is possible to enhance the decomposition ability of the harmful
substances.
* * * * *