U.S. patent application number 11/932569 was filed with the patent office on 2008-03-13 for construction material composition, construction material, coating composition and waste construction material soil conversion method.
This patent application is currently assigned to MITSUBISHI SHOJI CONSTRUCTION MATERIALS CORPORATION. Invention is credited to Yoshiaki Fukuda, Kazuo Ishihara, Toshihiko Mita, Motomasa Okubo, Hirofumi Shiochi, Fumiyuki Yahagi.
Application Number | 20080060316 11/932569 |
Document ID | / |
Family ID | 27554868 |
Filed Date | 2008-03-13 |
United States Patent
Application |
20080060316 |
Kind Code |
A1 |
Fukuda; Yoshiaki ; et
al. |
March 13, 2008 |
CONSTRUCTION MATERIAL COMPOSITION, CONSTRUCTION MATERIAL, COATING
COMPOSITION AND WASTE CONSTRUCTION MATERIAL SOIL CONVERSION
METHOD
Abstract
The object of the present invention is to provide a construction
and coating composition that effectively utilizes vermiculite as a
natural resource and is able to satisfy requirements for humidity
control and/or deodorizing as well as an attractive appearance,
while also offering superior balance between the amount and rates
of moisture absorption and release, in particular. This object is
achieved by a composition in which non-expanded vermiculite is
blended into a base material so that the blended amount is 5-70 wt
% of the total composition (solid portion). In addition, the above
construction material can be converted into soil by crushing when
it has become a waste construction material.
Inventors: |
Fukuda; Yoshiaki; (Ohta-ku,
JP) ; Shiochi; Hirofumi; (Chiba-shi, JP) ;
Okubo; Motomasa; (Kitasouma-gun, JP) ; Yahagi;
Fumiyuki; (Setagaya-ku, JP) ; Mita; Toshihiko;
(Saitama-shi, JP) ; Ishihara; Kazuo;
(Yokohama-shi, JP) |
Correspondence
Address: |
MERCHANT & GOULD PC
P.O. BOX 2903
MINNEAPOLIS
MN
55402-0903
US
|
Assignee: |
MITSUBISHI SHOJI CONSTRUCTION
MATERIALS CORPORATION
Shibuya-ku
JP
|
Family ID: |
27554868 |
Appl. No.: |
11/932569 |
Filed: |
October 31, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10181216 |
Jul 9, 2002 |
|
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|
PCT/JP01/09847 |
Nov 9, 2001 |
|
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11932569 |
Oct 31, 2007 |
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Current U.S.
Class: |
52/741.3 ;
52/232; 52/309.17; 52/745.19 |
Current CPC
Class: |
C04B 28/08 20130101;
B09B 3/0041 20130101; C04B 28/18 20130101; C04B 2111/00482
20130101; C04B 14/202 20130101; C04B 2111/00775 20130101; C04B
28/02 20130101; E04F 13/148 20130101; C04B 28/14 20130101; C09D
7/61 20180101; C08K 3/34 20130101; B09B 3/00 20130101; C04B 14/202
20130101; C04B 20/02 20130101; C04B 28/02 20130101; C04B 14/202
20130101; C04B 40/02 20130101; C04B 28/18 20130101; C04B 14/202
20130101; C04B 40/024 20130101; C04B 28/02 20130101; C04B 14/043
20130101; C04B 14/047 20130101; C04B 14/08 20130101; C04B 14/10
20130101; C04B 14/202 20130101 |
Class at
Publication: |
052/741.3 ;
052/232; 052/309.17; 052/745.19 |
International
Class: |
E04G 21/28 20060101
E04G021/28 |
Foreign Application Data
Date |
Code |
Application Number |
Nov 10, 2000 |
JP |
2000-343469 |
Mar 23, 2001 |
JP |
2001-085952 |
Nov 7, 2001 |
JP |
2001-342044 |
Nov 7, 2001 |
JP |
2001-342073 |
Nov 7, 2001 |
JP |
2001-342082 |
Nov 7, 2001 |
JP |
2001-342085 |
Claims
1. A construction material composition comprising: a base material
comprising calcium silicate and 5-70 wt % of the total composition
of an unexpanded, activated vermiculite, wherein the vermiculite is
activated by a steam treatment to produce a material with improved
moisture conditioning and adsorption performance.
2. The construction material composition according to claim 1
wherein the base material has 10-50 wt % of vermiculite.
3. The construction material composition according to claim 1
wherein the base material is hydrophilic.
4. The construction material composition according to claim 1
wherein the vermiculite is activated after blending.
5. The construction material composition according to claim 1
wherein the steam is a saturated vapor pressure steam at
105-200.degree. C.
6. The construction material composition according to claim 1
further comprising a reinforcing material.
7. A production method of a construction material composition
comprising: activating a non-expanded vermiculite; and blending a
base material with 5-70 wt % of the total composition of the
vermiculite, wherein the vermiculite is activated to produce a
material with improved moisture conditioning and adsorption
performance.
8. The production method according to claim 7 wherein the base
material is calcium silicate.
9. A construction article comprised of a composition according to
claim 1.
10. The construction article according to claim 9 wherein the
construction material is an interior material.
11. A construction material according to claim 1 wherein moisture
absorption and release rates in the case of changing the relative
humidity from 60-90% are 90% or more of the equilibrium value in 30
minutes for moisture absorption, and equilibrium in 25 minutes or
less for moisture release.
12. A construction material production method comprising:
activating non-expanded vermiculite; and blending a base material
with 5-70 wt % of the total composition of the vermiculite, wherein
the vermiculite is activated to produce a material with improved
moisture conditioning and adsorption performance.
13. A construction material composition comprising: a base material
comprising calcium silicate, blended with 2.5-20 wt % of the total
composition of expanded vermiculite, and 5-70 wt % of the total
composition of an unexpanded vermiculite in an activated state,
wherein the unexpanded vermiculite is activated by steam treatment
to produce a material with improved moisture conditioning and
adsorption performance.
14. The construction material composition according to claim 13
wherein the amount of unexpanded vermiculite in an activated state
is 10-50 wt % of the total composition.
15. A production method of a construction material composition
comprising: blending a base material with 5-70 wt % of the total
composition of non-expanded vermiculite in an activated state and
2.5-20 wt % of the total composition of an expanded vermiculite to
obtain a construction material composition, and further comprising
molding the blended material composition to produce a construction
material.
16. The construction material production method according to claim
15 wherein molding is sheet molding, extrusion molding, press
molding or casting.
17. The construction material according to claim 13 wherein the
construction material is an interior material.
18. A construction material composition comprising: a base material
comprising calcium silicate blended with 0.5-70 wt % of the total
composition of an unexpanded vermiculite in an activated state,
wherein the unexpanded vermiculite is activated by a steam
treatment, wherein the portion of the vermiculite having a particle
size of 300 .mu.m or less is 0.5-15 wt % of the total
composition.
19. The construction material composition according to claim 18
wherein the unexpanded vermiculite in an activated state is a fine
powder, of which 90% or more is 300 .mu.m or less, blended into the
base material in an amount of 0.5-15 wt % of the total
composition.
20. The construction material composition according to claim 18
wherein the unexpanded vermiculite in an activated state is a fine
powder, of which 90% or more is 300 .mu.m or less, blended into the
base material in an amount of 0.5-10 wt % of the total
composition.
21. The construction material composition according to claim 18
wherein the unexpanded vermiculite in an activated state is a fine
powder of which 90% or more is 300 .mu.m or less, blended into the
base material in an amount of 1-5 wt % of the total
composition.
22. A production method of a construction material composition
comprising: blending a base material with 0.5-70 wt % of the total
composition of a non-expanded vermiculite in an activated state,
vermiculite is 0.5-70 wt % of the total composition, wherein the
vermiculite is blended so that the portion of the non-expanded
vermiculite in an activated state with particle size of 300 .mu.m
or less is 0.5-15 wt % of the total composition.
23. The production method of a construction material composition
according to claim 34 wherein non-expanded vermiculite in an
activated state is a fine powder, of which 90% or more is 300 .mu.m
or less, blended into the base material in an amount of 0.5-15 wt %
of the total composition.
24. The production method according to claim 22 wherein the base
material is calcium silicate.
25. A construction article comprised by forming the construction
material composition according to claim 18.
26. A construction material production method comprising the steps
of: blending a base material with 0.5-70 wt % of the total
composition of non-expanded vermiculite in an activated state,
wherein the activated vermiculite having a particle size of 300
.mu.m or less is 0.5-15 wt % of the total composition to obtain a
construction material composition; and further comprising molding
the blended material to obtain a construction material.
27. The construction material production method according to claim
26, wherein non-expanded vermiculite in an activated state is a
fine powder of which 90% or more is 300 .mu.m or less, blended into
the base material in an amount of 0.5-15 wt % of the total
composition.
28. A coating composition comprising (A) substantially non-expanded
vermiculite in an activated state; (B) organic binder; and/or (C)
inorganic binder; and a hygroscopic material in which the specific
surface area as determined by BET is 10 m.sup.2/g or more.
29. The coating composition according to claim 28 wherein the (B)
organic binder is selected from a paint and/or paste.
30. The coating composition according to claim 29 wherein the paint
is selected from an acrylic, urethane, epoxy, polyester, silicone,
vinyl chloride, vinyl acetate, polyvinyl alcohol, polyvinyl butyral
or styrene-butadiene resin or emulsion paints.
31. The coating composition according to claim 29 wherein the paste
is selected from the group consisting of alginates, starch, mannan,
dextrin, protein and methylcellulose pastes.
32. The coating composition according to claim 28 wherein the (C)
inorganic binder is a hydraulic material.
33. The coating composition according to claim 32 wherein the
hydraulic material is cement or hemihydrate gypsum.
34. The coating composition according to claim 28 wherein the
hygroscopic material is selected from the group consisting of
calcium silicate, diatomaceous earth, zeolite or allophane.
35. The coating composition according to claim 28 comprising (A)
substantially non-expanded vermiculite in an activated state at
5-70 wt %; (B) organic binder; and/or (C) inorganic binder at 5-40
wt %; and (D) hygroscopic material at 0-70 wt % relative to the
total composition solid portion.
36. A coated body comprising the coating of an article to be coated
with the coating composition according to claim 28.
37. The coated body according to claim 36 wherein the article to be
coated is a construction material, architectural interior, indoor
fixture or any members thereof.
38. The coated body according to claim 36 wherein the article to be
coated is a joint or repaired portion.
39. A soil conversion method for waste construction materials
comprising: converting waste construction materials to soil by
crushing waste construction materials comprising a construction
material that has been molded from a construction material
composition comprising non-expanded vermiculite blended into a
calcium silicate construction material.
40. A soil conversion method for waste construction materials
comprising: converting waste construction materials to soil by
crushing waste construction materials comprising a construction
material that has been molded from a construction material
composition comprising non-expanded vermiculite blended into a
calcium silicate containing construction material, and then
performing steam treatment.
41. A soil conversion method for waste construction materials
comprising: converting waste construction materials to soil by
performing steam treatment on waste construction materials
comprised of a construction material that has been molded from a
construction material composition comprised by blending
non-expanded vermiculite into a calcium silicate construction
material, and then crushing.
42. The waste construction material soil conversion method
according to claim 39 wherein the blended amount of non-expanded
vermiculite is 5-70 wt % of the construction material
composition.
43. The construction material soil conversion method according to
claim 40 wherein steam treatment is carried out at 100-200.degree.
C.
44. The soil conversion method according to claim 39 comprising
adding a fertilizer component.
45. A construction material comprising a fastener joined with a
construction material formed by molding a construction composition
comprising 5-70 wt % of the total composition of a substantially
non-expanded vermiculite into a base material.
46. The construction material according to claim 45 wherein the
fastener is a nail, machine screw, bolt and nut, tack, staple or
pin.
47. The construction material according to claim 45 wherein the
construction material is an interior material.
48. The construction material according to claim 45 wherein the
surface of the construction material is shaved with a plane.
49. The construction material according to claim 45 wherein the
surface of the construction material is carved.
50. The construction material according to claim 45 wherein the
blended amount is 10-50 wt % of the total composition.
51. The construction material according to claim 45 wherein the
base material is calcium silicate.
52. The construction material according to claim 45 wherein the
vermiculite is activated.
53. The construction material according to claim 45 wherein the
molding is sheet molding, extrusion molding, press molding or
casting.
54. A construction material comprising a construction material
composition comprising 5-70 wt % of the total composition of a
substantially non-expanded vermiculite in an activated state
blended into a base material, further comprising a construction
material with a surface formed by molding and shaving with a
plane.
55. A construction material comprising a construction material
composition comprising 5-70 wt % of the total composition of
vermiculite in an activated state blended into a base material,
wherein a surface of the construction material is formed by molding
and carving.
56. A construction material joining method comprising joining with
a fastener a construction material obtained by blending 5-70 wt %
of the total composition of a substantially non-expanded
vermiculite in an activated state into a base material, followed by
molding that construction material composition.
57. The construction material joining method according to claim 56
wherein the fastener is a nail, machine screw, bolt and nut, tack,
staple or pin.
58. The construction material joining method according to claim 56
wherein the surface of the construction material to be joined is
shaved with a plane.
59. The construction material joining method according to claim 56
wherein the surface of the construction material is carved.
60. The construction material soil conversion method according to
claim 41 wherein steam treatment is carried out at 100-200.degree.
C.
61. The construction material production method according to claim
12 wherein molding is sheet molding, extrusion molding, press
molding or casting.
Description
[0001] This application is a Continuation of application Ser. No.
10/181,216, filed Jul. 9, 2002, and which applications are
incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field
[0003] The present invention relates to a construction material
composition, a construction material that uses it, and their
production methods. Moreover, the present invention relates to a
coating composition and a coated object that is coated therewith.
Moreover, the present invention relates to a soil conversion method
for construction materials.
[0004] 2. Background Art
[0005] In the past, during the manufacturing of construction
materials, base materials were selected for various purposes, and
various materials were frequently blended into each type of those
base materials.
[0006] One particular example of a mineral-based material is
vermiculite. This vermiculite is a clay mineral that resembles
biotite, and expands remarkably at high temperatures in the
direction perpendicular to the stratum due to dehydration,
transforming it into a porous form that extends in the manner of a
leech. Consequently, as it has superior heat insulating properties
and sound absorption properties, it is frequently used as a
material blended into base materials (filler, thickener), and as a
base material for various construction materials including heat
insulating materials and soundproofing materials, for the
additional purpose of reducing weight. On the other hand, as the
moisture absorption ability of vermiculite is not very high, its
use as a moisture conditioner has not been considered at all.
[0007] Thus, in the case of blending vermiculite into construction
materials as described above, expanded vermiculite is normally used
for the purpose of reducing weight and so forth. For example, it is
used as a lightweight aggregate in cement products such as mortar
and concrete. In contrast, as non-expanded vermiculite does not
offer advantages such as reducing weight as described above, small
amounts on the order of several percent are only blended into base
materials for special purposes to take advantage of its acid
resistance, alkali resistance and other properties. In addition,
although attempts have been made to use boards made substantially
of non-expanded vermiculite for the prevention of the spreading of
fires by fastening it to back sides of interior walls and allowing
it to expand when a fire occurs, the vermiculite in this case is
used as a specific base material which utilizes its fire
resistance.
[0008] On the other hand, the imparting of various functions has
been proposed for construction materials themselves for the purpose
of distinguishing them from competitive products. Among these,
although various studies have been conducted on construction
materials provided with moisture conditioning (moisture absorption
and release) and/or deodorizing and an attractive appearance,
satisfactory results have yet to be found. Namely, although certain
results are obtained by using construction materials having a large
specific surface area, there are many cases in which water
retention and moisture retention capabilities are excessively
powerful causing problems in the rate of moisture release.
[0009] (A) Therefore, the inventors of the present invention
conducted various studies to find a construction material that
allows even more effective use of vermiculite as a natural
resource, is able to satisfy the requirements of moisture
conditioning and/or deodorizing and an attractive appearance, and
offers a particularly superior balance between the amount and rates
of moisture absorption and release.
[0010] As a result, it was unexpectedly found that by blending 5-70
wt % of non-expanded vermiculite into a base material, and
particularly, a hydraulic material having moisture absorption but
inadequate moisture release, moisture absorption and release
capabilities are remarkably improved and the above problems can be
solved, thereby leading to completion of the present invention.
[0011] (B) The object of the present invention is to provide a
construction material composition that is able to yield a
construction material having more improved design, sound absorption
and low weight properties as a part of these studies.
[0012] (C) As a result of conducting additional studies as a part
of these studies for the purpose of improving productivity in the
case of using this non-expanded vermiculite, it was unexpectedly
found that, together with having a superior balance between the
amount and rate of moisture absorption and release by using a
specific amount of fine powder, improvements are also obtained in
bending strength, flexibility and productivity, and improvements
are obtained bending strength, flexibility and productivity even if
the blended amount of non-expanded vermiculite is less than 5 wt %,
thereby leading to completion of the present invention.
[0013] (D) As a result of conducting still more studies as a part
of these studies, it was unexpectedly found that the above problems
can also be solved by applying a coating composition containing
non-expanded vermiculite to construction materials and so forth,
thereby leading to completion of the present invention.
[0014] (E) Additionally, as a part of these studies, the present
invention does not place an excess burden on recovery and disposal
in the case where these construction materials have been used and
become waste construction materials, thereby promoting their
effective utilization.
[0015] (F) In the past, compound construction materials such as
calcium silicate, gypsum board and allophane baked board were
widely used as interior materials. However, as the use of fasteners
was difficult from the standpoint of joining strength when these
materials were joined, adhesives were typically used instead.
However, the use of adhesive makes the joining work bothersome and,
as high molecular weight monomers and solvents that compose the
adhesives are released, the use of adhesives is not favorable in
residential spaces. Moreover, the service life of these interior
materials is shortened by deterioration of the adhesive.
[0016] On the other hand, when manufacturing construction
materials, base materials are selected for various purposes, and
various materials are frequently blended into these base
materials.
[0017] As a part of the above study of construction materials, the
object of the present invention is to obtain construction materials
that can be joined using fasteners instead of adhesives, and it was
unexpectedly found the above object can be achieved by using
construction materials that contain the above-mentioned
non-expanded vermiculite.
DISCLOSURE OF THE INVENTION
[0018] I. The following provides an explanation of the means for
solving the object of the present invention described in (A)
above.
[0019] Namely, the gist of the present invention is a construction
material composition comprising the blending of non-expanded
vermiculite into a base material, the blended amount being 5-70 wt
% of the total composition (solid portion), a construction material
formed therewith, and their production methods.
[0020] Although there are no particular restrictions on the base
material used in the present invention provided it does not cause
any substantial deterioration of the properties of vermiculite to
be described later, from the viewpoints of moisture conditioning
and/or deodorizing, it is preferably hydrophilic. This is because a
hydrophilic base material itself has moisture conditioning and/or
deodorizing functions, and internally dispersed substances can be
adsorbed by non-expanded vermiculite on its surface. Examples of
such hydrophilic base materials include gypsum, cement, calcium
silicate, slag gypsum or their analogs. These can also be suitably
used in combination. The gypsum may be either an anhydrous or
hydrate salt, and various types of cement can be used, including
Portland cement. In this case, an aggregate and admixture are used.
In addition, although there are no particular restrictions on the
calcium silicate, that which is obtained by hydrothermically
reacting a siliceous raw material and lime in an autoclave
(tobemorite or xonotlite) is used most commonly. Slag gypsum
typically contains 20-40% blast furnace water-granulated slag
powder, and is mixed with 60-80% gypsum dihydrate (flue gas
desulfurized gypsum) and 1-5% Portland cement.
[0021] On the other hand, in the present invention, the vermiculite
blended into the above base material is a flake-like mineral having
for its main component SiO.sub.2, MgO and Al.sub.2O.sub.3, may
typically be either a biotite system or chlorite system, and can be
used even if there are differences in composition and so forth
depending on the origin. The specific surface area (nitrogen
adsorption method) is normally 10 m.sup.2/g or less. Although there
are no particular restrictions on particle size, it is normally 5
mm or less, preferably 3 mm or less and particularly preferably 0.5
mm or less. For example, although fine granular products having a
particle size of 0.25 mm or less are treated as non-standard
products due to tailing because they are not suitable for
applications of expanded vermiculite, as it was unexpectedly
determined that fine particles cause less dehydration deterioration
of the interlayer moisture of vermiculite (in which the bimolecular
layer of water between layers changes to a monomolecular layer)
during crushing, dressing, drying and sorting of the ore, they are
conversely used preferably in the present invention. This is
because a bimolecular layer of interlayer water is preferable for
moisture conditioning and deodorizing properties.
[0022] In the present invention, this vermiculite is used in the
substantially non-expanded state. Namely, the vermiculite normally
contains about 10-20% water, and expands considerably (the majority
expand to 10-30 times their original thickness in 1-2 seconds at
1000.degree. C.) as a result of dehydration due to rapid heating at
high temperatures (from about 320.degree. C. to 1000.degree. C.
when the interlayer water begins to dissociate). Thus, vermiculite
that substantially allows the obtaining of this degree of expansion
is used in the present invention.
[0023] Moreover, vermiculite that has been subjected to activation
treatment prior to blending into the base material is preferably
used in the present invention. The purpose of activation treatment
is to dissociate any organic or inorganic substances adhered to the
vermiculite to recompose and restore its inherent moisture
conditioning and adsorption performance. Although examples of
activation treatment include high pressure stream treatment and
salt water boiling treatment, activation treatment can preferably
be carried out by steam treatment at the saturated vapor pressure
and 105-200.degree. C.
[0024] In addition, in the case in which the base material is a
calcium silicate system in particular, even if vermiculite not
subjected to activation treatment is blended prior to the
hydrothermic reaction, since it is subsequently subjected to
autoclaving treatment at, for example, the saturated steam pressure
and 150-200.degree. C., it ultimately ends up being activated.
[0025] Blending of vermiculite into the base material is carried
out such that the blended amount is 5-70 wt %, and preferably 10-50
wt %, of the total composition (solid portion). Although selected
according to the type of base material and degree of moisture
conditioning and other aspects of performance of the target
construction material, at least 15 wt % is typically particularly
preferable for forming adequate vermiculite channeling (network) in
order to obtain the preferable amount and rate of moisture
absorption and release.
[0026] In addition to the above non-expanded vermiculite, various
blended materials uniquely used in the respective base materials of
construction materials for other purposes may also be suitably
blended into the construction material composition of the present
invention. The types and blended amounts of these blended materials
can be in accordance with routine methods. Examples of blended
materials that are suitably selected include pulp, cellulose fiber,
glass fiber, fumed silica, foam glass, shirasu balloons, alumina
balloons, pearlite, wallastonite, sepiolite, gravel, sand and
organic binder.
[0027] The resulting construction material composition of the
present invention can be formed into construction materials such as
boards of a desired shape and size in accordance with routine
methods such as sheet molding, extrusion molding, press molding and
casting. In general, in the case of boards, sheet molding using a
so-called sheet forming machine is selected industrially.
[0028] The construction material of the present invention
preferably demonstrates moisture absorption and release rates in
the case of changing the relative humidity from 60-90% in the
moisture absorption and release test, described in Reference
Example 1 described later, of 90% or more of the equilibrium value
in 30 minutes for moisture absorption, and equilibrium in 25
minutes or less, and preferably 20 minutes or less, for moisture
release.
[0029] Although a construction material obtained in this manner is
suitable for use as a wall material, ceiling material, divider
material or other interior material, is can also be used as eaves
and roof material or other exterior material.
[0030] The construction material of the present invention is able
to satisfy requirements for moisture conditioning and/or
deodorizing and an attractive appearance. In other words, the
construction material of the present invention is characterized as
follows:
[0031] 1. The construction material of the present invention has a
superior moisture conditioning function as a result of having
suitable moisture release characteristics. For example, the
balance, amount and rate of moisture absorption and moisture
release are all superior. Thus, it is capable of preventing
condensation of moisture, warping and so forth, while also
effectively suppressing the growth of mold, mites and so forth.
[0032] 2. The construction material of the present invention has a
superior deodorizing function. For example, the construction
material of the present invention is able to adsorb volatile
chemical substances or odorous gases such as formaldehyde, toluene
and xylene.
[0033] 3. Moreover, the construction material of the present
invention can be made to have a granite-like surface by embossing
non-expanded vermiculite particles by surface polishing and so
forth, thereby making it possible to easily provide boards and so
forth provided with an attractive appearance.
[0034] 4. Products having undergone autoclaving treatment in the
production process can be recycled by recovering the used
construction material of the present invention and subjecting it
directly to steam treatment in an autoclave at about
105-150.degree. C., This is because the vermiculite does not react
with the above base materials.
[0035] 5. Since non-standard fine grain articles can be conversely
used preferably as raw materials for the non-expanded vermiculite,
resources can be utilized effectively.
[0036] II. The following provides an explanation of the means for
solving the object of the present invention described in (B)
above.
[0037] This object is achieved by a construction material
composition and a construction material formed therewith comprising
a construction material composition consisting of blending
non-expanded vermiculite into a base material such that the blended
amount is 5-70 wt % of the total composition (solid portion);
wherein, non-expanded vermiculite is also blended at an amount in
which expanded vermiculite is blended at an amount of 2.5-20 wt %
of the total composition (solid portion).
[0038] Although there are no particular restrictions on the base
material used in the present invention provided it does not
substantially deteriorate the properties of the vermiculite in the
same manner as that described in I above, it is preferably
hydrophilic from the viewpoint of moisture conditioning and/or
deodorizing.
[0039] On the other hand, the vermiculite blended into the above
base material in the present invention is as was explained in I
above.
[0040] In the present invention, this vermiculite is used
substantially in the non-expanded state. Namely, the vermiculite
normally contains 10-20% water, and expands considerably (the large
part expands to 10-30 times its original thickness in 1-2 seconds
at 1000.degree. C.) as a result of dehydration due to rapid heating
at high temperatures (from about 320.degree. C. to 1000.degree. C.
when the interlayer water begins to dissociate). Thus, vermiculite
that substantially allows this degree of expansion is used in the
present invention.
[0041] Blending of vermiculite into the base material is carried
out such that the blended amount is 5-70 wt %, and preferably 10-50
wt %, of the total composition (solid portion). Although selected
according to the type of base material and degree of moisture
conditioning and other aspects of performance of the target
construction material, at least 15 wt % is typically particularly
preferable for forming adequate vermiculite channeling (network) in
order to obtain the preferable amount and rate of moisture
absorption and release.
[0042] In addition to the above non-expanded vermiculite, it is
also necessary to blend expanded vermiculite into the construction
material composition of the present invention at an amount of
2.5-20 wt % of the total composition (solid portion). When blending
the expanded vermiculite, the blended amount can be suitably
selected according to the target design and light weight
properties. In addition, although there are no particular
restrictions on the particle size, it is normally selected from
particle sizes of about 0.5-30 mm.
[0043] In the present invention, the combined use of this expanded
vermiculite makes it possible to impart light weight and various
designs to the construction material obtained from this
construction material composition, and in other words, makes it
possible to impart a flaky surface having a sense of
transparency.
[0044] Moreover, various blended materials uniquely used in the
respective base materials of construction materials for other
purposes can also be suitably blended into the construction
material composition of the present invention. The types and
blended amounts of these blended materials can be in accordance
with routine methods. Examples of blended materials that are
suitably selected include aggregates, reinforcing materials,
admixtures and weight reducing materials, and more specifically,
pulp, cellulose fiber, glass fiber, fumed silica, foam glass,
"shirasu" (sedimentary silica) balloons, alumina balloons,
pearlite, wallastonite, sepiolite, gravel, sand and organic
binder.
[0045] The resulting construction material composition of the
present invention can be formed into construction materials, such
as boards of a desired shape and size, in accordance with routine
methods such as sheet molding, extrusion molding, press molding and
casting. In general, in the case of boards, sheet molding using a
so-called sheet forming machine is selected industrially.
[0046] The construction material of the present invention
preferably demonstrates moisture absorption and release rates in
the case of changing the relative humidity from 60-90% in the
moisture absorption and release test described in Reference Example
1 described later of 90% or more of the equilibrium value in 30
minutes for moisture absorption, and equilibrium in 25 minutes or
less, and preferably 20 minutes or less, for moisture release.
[0047] Although a construction material obtained in this manner is
suitable for use as a wall material, ceiling material, divider
material or other interior material, it can also be used as eaves
and roof material or other exterior material.
[0048] In addition to the above light weight and diverse design
properties, the construction material of the present invention is
able to satisfy requirements for moisture conditioning and/or
deodorizing and an attractive appearance as previously
described.
[0049] III. The following provides an explanation of the means for
solving the object of the present invention described in (C)
above.
[0050] Namely, the gist of the present invention is a construction
material composition comprising a blend of non-expanded vermiculite
in a base material, the blended amount being 0.5-70 wt % of the
total composition (solid portion); wherein, the portion of the
non-expanded vermiculite that is 300 .mu.m or less is 0.5-15 wt %
of the total composition (solid portion), a construction material
formed therewith, and their production methods.
[0051] Although there are no particular restrictions on the base
material used in the present invention provided it does not
substantially deteriorate the properties of the vermiculite in the
same manner as that described in I above, it is preferably
hydrophilic from the viewpoint of moisture conditioning and/or
deodorizing.
[0052] On the other hand, the vermiculite blended into the above
base material in the present invention is as was explained in I
above.
[0053] In the present invention, the vermiculite is used
substantially in the non-expanded state. Namely, the vermiculite
normally contains 10-20% water, and expands considerably (the large
part expands to 10-30 times the original thickness in 1-2 seconds
at 1000.degree. C.) as a result of dehydration due to rapid heating
at high temperatures (from about 320.degree. C. to 1000.degree. C.
when the interlayer water begins to dissociate). Thus, vermiculite
that substantially allows this degree of expansion is used in the
present invention.
[0054] The non-expanded vermiculite is blended into the base
material in an amount in which the portion of the non-expanded
vermiculite that is 300 .mu.m or less is 0.5-15 wt % of the total
composition (solid portion) in a construction material composition
in which the blended amount of non-expanded vermiculite is 0.5-70
wt % of the total composition (solid portion). In this case,
although this composition can be obtained by blending a plurality
of types of non-expanded vermiculite having different contents of
portions of 300 .mu.m or less, for example, non-expanded
vermiculite fine powder of which 90% or more is 300 .mu.m or less
can also be blended into a base material such that the portion of
300 .mu.m or less is 0.5-15 wt %, 0.5-10 wt % or 1-5 wt % of the
total composition (solid portion).
[0055] If the amount of non-expanded vermiculite fine powder that
is 300 .mu.m or less is less than 0.5 wt %, the effects of the
present invention cannot be obtained, while if the amount exceeds
15 wt %, improvement of bending strength, which is the main object
of the present invention, reaches a maximum and then decreases.
[0056] Blending of vermiculite into the base material is carried
out such that the blended amount is 0.5-70 wt % of the total
composition (solid portion). Although selected according to the
type of base material and degree of moisture conditioning and other
aspects of performance of the target construction material, 5-70 wt
%, preferably 10-50 wt %, and at least 15 wt % is typically
particularly preferable for forming adequate vermiculite channeling
(networks) in order to obtain the most preferable amount and rate
of moisture absorption and release.
[0057] On the other hand, in the case of making the main object of
the present invention improving the bending strength, flexibility
and productivity of calcium silicate-based construction materials
instead of making the main object moisture conditioning,
vermiculite is preferably blended into the base material in an
amount of 0.5-15 wt %, preferably 0.5-10 wt %, and more preferably
1-5 wt %.
[0058] In the present invention, as the vermiculite easily and
uniformly disperses in water during mixing in a molding tank and so
forth as a result of blending in fine particles of non-expanded
vermiculite, production efficiency and yield can be improved,
resources that had been discarded due to unsuitability for
expanding uses can be used effectively, and a contribution to the
bending strength of calcium silicate-based construction materials
can be realized even if blended at 0.5-5 wt %. In this case, it is
preferable to use non-expanded vermiculite fine powder of which 90%
or more is 300 .mu.m or less. The blended non-expanded vermiculite
fine powder serves as the nuclei of epitaxial growth of tobemorite,
promotes the growth of calcium silicate hydration reaction
products, and brings about an improvement in bending strength and
flexibility (decreased elastic modulus) as a result of lowering the
content of unreacted raw materials. Thus, construction materials
can be obtained that have large breaking energy.
[0059] Various blended materials uniquely used in the respective
base materials of construction materials for other purposes can
also be suitably blended into the construction material composition
of the present invention. The types and blended amounts of these
blended materials can be in accordance with routine methods.
[0060] The resulting construction material composition of the
present invention can be formed into construction materials such as
boards of a desired shape and size in accordance with routine
methods such as sheet molding, extrusion molding, press molding and
casting. In general, in the case of boards, sheet molding using a
so-called sheet molding machine is selected industrially.
[0061] In the case the blended amount of vermiculite is 5-70 wt %
of the total composition (solid portion), the construction material
of the present invention preferably demonstrates moisture
absorption and release rates in the case of changing the relative
humidity from 60-90% in the previously described moisture
absorption and release test of 90% or more of the equilibrium value
in 30 minutes for moisture absorption, and equilibrium in 25
minutes or less, and preferably 20 minutes or less, for moisture
release.
[0062] Although a construction material obtained in this manner is
suitable for use as a wall material, ceiling material, divider
material or other interior material, is can also be used as eaves
and roof material or other exterior material.
[0063] In the case the blended amount of vermiculite is 5-70 wt %
of the total composition (solid portion), the construction material
of the present invention is able to satisfy the requirements of
moisture conditioning and/or deodorizing as well as an attractive
appearance as previously mentioned.
[0064] Moreover, the breaking energy of the construction material
of the present invention can also be improved as previously
mentioned even in the case the blended amount of vermiculite is
0.5-5 wt % of the total composition (solid portion).
[0065] IV. The following provides an explanation of the means for
solving the object of the present invention described in (D)
above.
[0066] The gist of the present invention is (1) a coating
composition comprising (A) non-expanded vermiculite, [0067] (2) a
coating composition comprising non-expanded vermiculite, (B)
organic binder and/or (C) inorganic binder, [0068] (3) a coating
composition comprising (A) non-expanded vermiculite, (B) organic
binder and/or (C) inorganic binder and (D) a hygroscopic material
in which the specific surface area as determined by BET is 10
m.sup.2/g or more, and [0069] (4) a coated body comprising coating
an article to be coated with these coating compositions.
[0070] The following provides a detailed explanation of the present
invention. Although the present invention is a coating composition
comprising non-expanded vermiculite (A), the vermiculite used in
the present invention is the same as that described in I above.
[0071] In the present invention, this vermiculite is used
substantially in the non-expanded state. Namely, the vermiculite
normally contains 10-20% water, and expands considerably (the
majority expand to 10-30 times their original thickness in 1-2
seconds at 1000.degree. C.) as a result of dehydration due to rapid
heating at high temperatures (from about 320.degree. C. to
1000.degree. C. when the interlayer water begins to dissociate).
Thus, vermiculite that substantially allows the obtaining of this
degree of expansion is used in the present invention.
[0072] Although examples of organic binder used in the present
invention include paint and/or paste, paints that are normally used
for construction materials, architectural interiors and indoor
fixtures and so forth can be used for the paint. For example, the
paint can be suitably selected from resin or emulsion paints such
as acrylic, urethane, epoxy, polyester, silicone, vinyl chloride,
vinyl acetate, polyvinyl alcohol, polyvinyl butyral or
styrene-butadiene-based paints according to the purpose. Namely,
the paint can be arbitrarily selected by suitably considering the
type, material and so forth of the article to be coated.
[0073] Examples of pastes include those based on alginates such as
sodium alginate, starch such as wheat starch, mannan such as konjak
paste, dextrin obtained by heat treatment of starch, protein such
as casein, and methylcelluloses such as carboxymethylcellulose
(CMC), hydroxypropylmethylcellulose and
hydroxyethylmethylcellulose, while those of a natural origin are
particularly preferable.
[0074] Moreover, examples of inorganic binder used in the present
invention include cements such as Portland cement and white cement,
hydraulic materials such as water granulated slag and hemihydrate
gypsum, air hardening materials such as mortar, dolomite plaster
and magnesium oxychloride, and sodium silicate, and can be suitably
selected according to the purpose.
[0075] In the present invention, in the case of blending the above
organic binder and/or inorganic binder into the non-expanded
vermiculite, they are preferably blended at 5-70 wt % of
non-expanded vermiculite (A) and 5-40 wt % of organic binder (B)
and/or inorganic binder (C) relative to the total composition solid
portion, and more preferably at 0-30 wt % organic binder and 0-40
wt % inorganic binder.
[0076] A coating composition in which the above organic binder
and/or inorganic binder is blended into the non-expanded
vermiculite satisfies the requirements of moisture conditioning
and/or deodorizing as well as an attractive appearance when coated
onto an article to be coated, and although it demonstrates superior
balance between the amount and rate of moisture absorption and
release, it is particularly preferable for applying construction
materials or architectural interiors using said construction
materials comprising the formation of a construction material
composition in which the above non-expanded vermiculite is blended
into a base material, and the blended amount is 5-70 wt % of the
total composition (solid portion).
[0077] Moreover, in order to increase the moisture absorption of
the coating composition itself in the present invention, a coating
composition can be obtained in which a hygroscopic material (D) is
added having a specific surface area as determined by BET of 10
m.sup.2/g or more. Examples of this hygroscopic material that are
used preferably include calcium silicate, diatomaceous earth,
zeolite and allophane. The blended amount of this hygroscopic
material is such that it is preferably contained at 0-70 wt %
relative to the total composition solid portion. This coating
composition is able to widen the preferable application range of
the article to be coated more so than a coating composition to
which said hygroscopic material is not added with respect to
enhancing moisture absorption.
[0078] Various components can additionally be blended into the
coating composition of the present invention in addition to
components (A) through (D) above according to the purpose. For
example, aggregates such as silica sand and river sand, inorganic
powders such as wallastonite, calcium carbonate and sepiolite,
organic or inorganic fibers such as pulp and glass fiber, and so
forth can be suitably used, and in the case of not blending in
paint, some pigment components such as pigment and color developer
can also be used. In addition, expanded vermiculite can also be
blended to prevent running.
[0079] The coating composition of the present invention is coated
onto articles to be coated in the form of construction materials,
architectural interiors and indoor fixtures or their members.
Preferable examples of construction materials include inorganic
construction materials such as calcium silicate, cement, gypsum,
diatomaceous earth, zeolite, allophane and slag gypsum, as well as
wood-based construction materials such as particle board, and these
are normally coated in a factory. In addition, examples of
architectural interiors those that already compose a portion of the
inner walls, ceilings, room dividers, doors and so forth of a
building, and are normally coated at the construction site in the
form of so-called architectural coating. Moreover, examples of
indoor fixtures include those which are not substantially fixed to
a building such as furniture and personal effects. The above
members are members that compose a portion of the above
architectural interiors or indoor fixtures. In addition, the
article to be coated may be a joint or a repaired portion.
[0080] These can be applied in accordance with routine methods,
typical examples of which include brush coating, roller brush
coating and spray coating in the case of coating at the
construction site, or blower coating and roller coating in the case
of coating at a factory.
[0081] Although the film thickness of these articles to be coated
varies according to the material, type and so forth of the article
to be coated, it is normally selected from about 10 .mu.m to 5 mm,
and preferably from about 1 mm to 3 mm. In the case the article to
be coated is a construction material comprising by forming a
construction material composition in which the above non-expanded
vermiculite is blended into a base material, and the blended amount
is 5-70 wt % of the total composition (solid portion), an
architectural interior using said construction material, or an
indoor fixture, there is the advantage of the characteristics such
as moisture conditioning of said article to be coated not inhibited
even if the thickness of the coated film becomes quite large.
[0082] V. The following provides an explanation of the means for
solving the object of the present invention described in (E)
above.
[0083] The gist of the present invention is a soil conversion
method for waste construction materials comprising conversion of
waste construction materials to soil by crushing waste construction
materials comprised of a construction material that has been molded
from a construction material composition comprised by blending
non-expanded vermiculite into a calcium silicate-based base
material.
[0084] The construction material in the present invention is a
construction material that has been molded from a construction
material composition comprising the blending of non-expanded
vermiculite into a calcium silicate-based base material. Although
there are no particular restrictions on the calcium silicate-based
base material, that which is obtained by hydrothermally reacting a
siliceous raw material and lime in an autoclave (tobemorite or
xonotlite) is used most commonly.
[0085] On the other hand, the vermiculite blended into the above
base material in the present invention is as described below.
[0086] Blending of vermiculite into the base material is carried
out such that the blended amount is 5-70 wt %, and preferably 10-50
wt %, of the total composition (solid portion). Although selected
according to the type of base material and degree of moisture
conditioning and other aspects of performance of the target
construction material, at least 15 wt % is typically particularly
preferable for forming adequate vermiculite channeling (networks)
in order to obtain the preferable amount and rate of moisture
absorption and release.
[0087] Various blended materials uniquely used in the base material
calcium silicate of construction materials for other purposes can
also be suitably blended into the construction material composition
of the present invention in addition to the above non-expanded
vermiculite. Expanded vermiculite, for example, may be contained.
The types and blended amounts of these blended materials can be in
accordance with routine methods.
[0088] The resulting construction material composition of the
present invention can be formed into construction materials such as
boards of a desired shape and size in accordance with routine
methods such as sheet molding, extrusion molding, press molding and
casting. In general, in the case of boards, sheet molding using a
so-called sheet molding machine is selected industrially.
[0089] The construction material of the present invention
preferably demonstrates moisture absorption and release rates in
the case of changing the relative humidity from 60-90% in the
previously described moisture absorption and release test of 90% or
more of the equilibrium value in 30 minutes for moisture
absorption, and equilibrium in 25 minutes or less, and preferably
20 minutes or less, for moisture release.
[0090] Although a construction material obtained in this manner is
suitable for use as a wall material, ceiling material, divider
material or other interior material, it can also be used as eaves
and roof material or other exterior material.
[0091] The construction material of the present invention is able
to satisfy the requirements of moisture conditioning and/or
deodorizing as well as an attractive appearance as previously
mentioned.
[0092] The method of the present invention allows waste
construction materials to be converted to soil in the case such
construction materials have become waste construction materials
without being recycled into construction materials after they have
been used.
[0093] To begin with, although the waste construction material is
first crushed, this crushing can be in accordance with a typical
crushing means such as an ordinary crusher. During crushing, the
crushing means is selected in consideration of the amount of waste
construction material, crushing location and so forth. Crushing
treatment can also be carried out by carrying in a crushing means
to the location where the waste materials are generated.
[0094] Although there are no particular restrictions on the degree
of crushing, it is suitably selected according to the target soil
application, and crushing is most commonly performed, for example,
to about 5 mm or less.
[0095] Moreover, boiling or steam treatment at about
100-200.degree. C. in an autoclave can also be performed before or
after the above crushing as necessary to remove adhered substances
and so forth that have the potential of being contained in the
waste construction material.
[0096] The waste construction material crushed and treated in this
manner can be used as soil. Namely, the artificial soil having good
drainage obtained in the present invention can be used for purposes
including plant growth, soil improvement and foundation
improvement. Although this artificial soil fulfills the role of a
silicic acid fertilizer as is, other components can be added
according to the respective purpose. For example, various types of
fertilizer components selected from N, P, K and trace elements,
etc. can be added.
[0097] VI. The following provides an explanation of the means for
solving the object of the present invention described in (F)
above.
[0098] Namely, the gist of the present invention is a construction
material comprising joining with a fastener a construction material
comprised by molding a construction composition comprising the
blending of non-expanded vermiculite into a base material, and that
blended amount being 5-70 wt % of the total composition (solid
portion).
[0099] Although the base material used in the present invention is
as was previously described in I and is not subject to any
particular restrictions provided it does not cause any substantial
deterioration of the properties of vermiculite, from the viewpoints
of moisture conditioning and/or deodorizing, it is preferably
hydrophilic.
[0100] On the other hand, in the present invention, the vermiculite
blended into the above base material is as was previously
described.
[0101] In the present invention, this vermiculite is used
substantially in the non-expanded state. Namely, the vermiculite
normally contains about 10-20% water, and expands considerably (the
majority expand to 10-30 times their original thickness in 1-2
seconds at 1000.degree. C.) as a result of dehydration due to rapid
heating at high temperatures (from about 320.degree. C. to
1000.degree. C. when the interlayer water begins to dissociate).
Thus, vermiculite that substantially allows this degree of
expansion is used in the present invention.
[0102] Blending of vermiculite into the base material is carried
out such that the blended amount is 5-70 wt %, and preferably 10-50
wt %, of the total composition (solid portion). Although selected
according to the type of base material and degree of moisture
conditioning and other aspects of performance of the target
construction material, at least 15 wt % is typically particularly
preferable for forming adequate vermiculite channeling (networks)
in order to obtain the preferable amount and rate of moisture
absorption and release.
[0103] In addition to the above non-expanded vermiculite, various
blended materials uniquely used in the respective base materials of
construction materials for other purposes may also be suitably
blended into the construction material composition of the present
invention.
[0104] The resulting construction material composition of the
present invention can be formed into construction materials such as
boards of a desired shape and size in accordance with routine
methods such as sheet molding, extrusion molding, press molding and
casting. In general, in the case of boards, sheet molding using a
so-called sheet molding machine is selected industrially.
[0105] The construction material of the present invention
preferably demonstrates moisture absorption and release rates in
the case of changing the relative humidity from 60-90% in the
previously described moisture absorption and release test of 90% or
more of the equilibrium value in 30 minutes for moisture
absorption, and equilibrium in 25 minutes or less, and preferably
20 minutes or less, for moisture release.
[0106] Although a construction material obtained in this manner is
suitable for use as a wall material, ceiling material, divider
material or other interior material, it can also be used as eaves
and roof material or other exterior material.
[0107] The construction material of the present invention is able
to satisfy requirements for moisture conditioning and/or
deodorizing and an attractive appearance.
[0108] In the present invention, a construction material obtained
in this manner is joined with a fastener. Joining is typically
carried out between two construction materials or between a
construction material and another member or structural unit and so
forth. Examples of fasteners that are used preferably include
nails, machine screws, bolts and nuts, tacks, staples and pins.
These are suitably selected according to the purpose of joining.
There are no particular restrictions on the materials of these
fasteners, and any material may be used, examples of which include
metal, wood, bamboo, plastic and ceramic. The nails may be either
Western style nails or Japanese style nails, examples of which
include flat head, flat, square and round head nails. Examples of
machine screws include round head, semi-round, flat head and
cross-recessed head machine screws, while the bolts and nuts are
typically hexagon socket head bolts. Examples of pins include fine
small, ridged small, flat small, flat and round pins.
[0109] At the time of joining, as the construction material
according to the present invention has so-called grip strength that
is surmised to originate in the spring back action produced by the
non-expanded vermiculite, it may be present on the joining side or
the joined side. Examples of use on the joined side include
paintings, lights, railings and towel hangers. As the site at which
it is joined with a fastener has ample recovery, it can re-fastened
to the same site even after, for example, the screws have come
out.
[0110] Moreover, as the construction material according to the
present invention has satisfactory flexibility, no planar
resistance and shape retention, even if its surface is shaved with
a plane, the surface is not damaged and a smooth surface can be
formed without the generation of fine shavings. Since the
construction material according to the present invention does not
require the affixing of a finishing material such as cloth or wall
paper, thereby offering the additional advantage of not requiring
the use of adhesive for that purpose in this case.
[0111] Moreover, as the surface of the construction material
according to the present invention has ample carving ease and
allows processing by a router or engraver, it allows the obtaining
of a desired design, and is able to arbitrarily enhance the design
quality of the construction material by imparting trim, geometrical
patterns and so forth.
[0112] These construction materials that are shaved with a plane or
carved in the present invention can naturally also be joined with
fasteners as described above.
BEST MODE FOR CARRYING OUT THE INVENTION
[0113] Embodiments 1 through 5 described below solve the problems
described in the above-mentioned (A).
[0114] Next, although the following provides a more detailed
explanation of the present invention through its embodiments, the
present invention is not limited by these embodiments. The term
"parts" is hereinafter used to represent "parts by weight".
Embodiment 1
[0115] Using for the starting raw material 27 parts of quartzite
powder as the siliceous raw material, 27 parts of calcium hydroxide
as the calcareous raw material, 6 parts of pulp as reinforcing
fiber and 40 parts of non-expanded vermiculite (origin: South
Africa, particle size: 0.25-0.5 mm), water was added to this
starting raw material followed by mixing to form a slurry having a
solid portion of about 12%, and after forming a crude sheet using a
sheet molding machine, the sheet was pressure cured in an autoclave
(160-180.degree. C. for about 10 hours) and then dried to the
prescribed moisture content at under 80.degree. C. to obtain a
calcium silicate board (30 cm.times.30 cm.times.6 mm).
Embodiment 2
[0116] A calcium silicate board was obtained in the same manner as
Embodiment 1 using 42 parts of quartzite powder, 42 parts of
calcium hydroxide, 6 parts of pulp and 10 parts of non-expanded
vermiculite.
Embodiment 3
[0117] Water was added to 16 parts of slag powder, 38 parts of flue
gas desulfurized gypsum powder, 6 parts of pulp and 40 parts of
non-expanded vermiculite followed by mixing to form a slurry having
a solid portion of about 12%. Next, after forming a crude sheet
using a sheet molding machine, the sheet was steam cured for about
12 hours at about 80.degree. C. and then dried at under 80.degree.
C. to obtain a slag gypsum board (30 cm.times.30 cm.times.6
mm).
Embodiment 4
[0118] 60 parts of hemihydrate gypsum, 40 parts of non-expanded
vermiculite and 24 parts of water were mixed, and the resulting
mixture was cast molded in a prescribed mold into the shape of a
board, followed by curing at normal temperature and drying at under
80.degree. C. to obtain a gypsum board (30 cm.times.30 cm.times.6
mm).
Reference Example 1
[0119] (Moisture Absorption and Release Test)
[0120] The coefficient of moisture absorption and moisture
absorption and release rates of construction materials of the
present invention and commercially available construction materials
were measured according to the measurement method described
below.
[0121] (1) Measurement Method/Instrument
[0122] Measurement instrument: "IGA SORP", Hiden Analytical
Ltd.
[0123] Measurement method: [0124] Powdered samples were placed
directly in an approximately 1 cc measuring basket, while bulk
samples were placed in the measurement basket after being adjusted
to about 2-3 mm.
[0125] Measured parameters: [0126] Coefficient of moisture
absorption at relative humidity of 0-90% Coefficient of moisture
absorption at relative humidity of 60-90% Moisture absorption rate
from relative humidity of 60% to relative humidity of 90% Moisture
release rate from relative humidity of 90% to relative humidity of
60%
[0127] Moisture absorption and release rates were repeatedly tested
based on a 30 minute cycle.
[0128] (2) Measured Samples
[0129] Present invention: The following boards obtained in
Embodiments 1 through 4 were used. [0130] Embodiment 1: Calcium
silicate board containing 40 wt % non-expanded vermiculite [0131]
Embodiment 2: Calcium silicate board containing 10 wt %
non-expanded vermiculite [0132] Embodiment 3: Slag gypsum board
containing 40 wt % non-expanded vermiculite [0133] Embodiment 4:
Gypsum board containing 40 wt % non-expanded vermiculite
[0134] Comparative articles: The following articles of A-H were
used. [0135] A: Allophane baked board (commercial product) [0136]
B: Allophane (origin: Tochigi prefecture, Japan) [0137] C: Slag
gypsum board containing 30 wt % zeolite (commercial product) [0138]
D: Zeolite (origin: Miyagi prefecture, Japan) [0139] E: Calcium
silicate board containing 40 wt % diatomaceous earth (commercial
product) [0140] F: Diatomaceous earth (origin: Akita prefecture,
Japan) [0141] G: Calcium silicate board containing 40 wt % expanded
vermiculite (obtained in the same manner as Embodiment 1 with the
exception of using expanding vermiculite) [0142] H: Calcium
silicate board (obtained by using 47 parts of quartzite, 47 parts
of calcium hydroxide and 6 parts of pulp in Embodiment 1)
[0143] (3) Measurement results are shown in Table 1. TABLE-US-00001
TABLE 1 Coefficient Coefficient Moisture of moisture of moisture
absorption Moisture absorption (%) absorption (%) rate release rate
(0-90%) (60-90%) (60.fwdarw.90%) (90.fwdarw.60%) Emb. 1 7.5 4.4
Near Equilibrium in equilibrium 15 minutes in 30 minutes Emb. 2 7.3
4.3 95% in 30 Equilibrium in minutes 25 minutes Emb. 3 7.5 4 Near
Equilibrium in equilibrium 20 minutes in 30 minutes Emb. 4 2.5 2.2
Near Equilibrium in equilibrium 10 minutes in 30 minutes Comp. Art.
A 3.4 2.8 85$ in 30 Equilibrium in minutes 30 minutes Comp. Art. B
29 14 75% in 30 60% in 30 minutes minutes Comp. Art. C 8.3 4.1 75%
in 30 Equilibrium in minutes 30 minutes Comp. Art. D 8.2 3.6 95% in
30 Equilibrium in minutes 15 minutes Comp. Art. E 18 12 70% in 30
55% in 30 minutes minutes Comp. Art. F 8.9 6.1 80% in 30
Equilibrium in minutes 18 minutes Comp. Art. G 6.5 3.7 95% in 30
Equilibrium in minutes 11 minutes Comp. Art. H 7.3 4.6 80% in 30
Equilibrium in minutes 30 minutes
[0144] These results indicate that the construction material of the
present invention exhibits superior balance between the amounts and
rates of moisture absorption and release characteristics. As a
result of testing moisture absorption and moisture release at 30
minute cycles, in the construction material of the present
invention, although the baseline during moisture release was
maintained constant due to the satisfactory balance between
moisture absorption and release, in the comparative articles
however, the baseline tended to shift upward on the right side over
time as a result of moisture release being unable to keep up with
moisture absorption. It was also determined from these findings
that the construction material of the present invention is
resistant to the condensation of moisture.
Reference Example 2
[0145] Vermiculite was treated in an autoclave at 180.degree. C. to
observe the effects of steam treatment on moisture absorption and
release characteristics. Those results are shown in Table 2.
TABLE-US-00002 TABLE 2 Coefficient Coefficient Moisture of moisture
of moisture absorption Moisture absorption (%) absorption (%) rate
release rate (0-90%) (60-90%) (60.fwdarw.90%) (90.fwdarw.60%)
Non-expanding/ 6.4 1.4 Equilibrium Equilibrium autoclave in 30
minutes in 7 minutes treatment: yes Expanding/ 5.7 1.9 95% in 30
Equilibrium autoclaving minutes in 11 minutes treatment: yes
Non-expanding/ 5.1 1.2 Equilibrium Equilibrium autoclaving in 30
minutes in 7 minutes treatment: no Expanding/ 4.5 1.6 Equilibrium
Equilibrium autoclaving in 30 minutes in 8 minutes treatment:
no
Embodiment 5
[0146] Water was added to 27 parts of quartzite powder, 33 parts of
calcium hydroxide and 40 parts of non-expanded vermiculite followed
by mixing to form a slurry having a solid portion of about 12%, and
this slurry was then pressure cured in an autoclave (190-200
.degree. for about 10 minutes). Next, this was then dried to the
prescribed moisture content to obtain a xonotlite-based calcium
silicate board.
[0147] According to the moisture absorption and release test
measured in accordance with the method described in Reference
Example 1, the amount of moisture absorption was slightly smaller
while the rate of moisture release was slightly greater as compared
with the calcium silicate of Embodiment 1.
[0148] Embodiments 6 through 10 described below solve the problems
described in the above-mentioned (B).
Embodiment 6
[0149] Using for the starting raw material 27 parts of quartzite
powder as the siliceous raw material, 27 parts of calcium hydroxide
as the calcareous raw material, 5 parts of expanded vermiculite, 6
parts of pulp as reinforcing fiber and 40 parts of non-expanded
vermiculite (origin: South Africa, particle size: 0.25-0.5 mm),
water was added to this starting raw material followed by mixing to
form a slurry having a solid portion of about 12%, and after
forming a crude sheet using a sheet molding machine, the sheet was
pressure cured in an autoclave (160-180.degree. C. for about 10
hours) and then dried to the prescribed moisture content at under
80.degree. C. to obtain a calcium silicate board (30 cm.times.30
cm.times.6 mm).
Emodiment 7
[0150] A calcium silicate board was obtained in the same manner as
Embodiment 6 using 40 parts of quartzite powder, 40 parts of
calcium hydroxide, 6 parts of pulp, 4 parts of expanded vermiculite
and 10 parts of non-expanded vermiculite.
Embodiment 8
[0151] Water was added to 16 parts of slag powder, 38 parts of flue
gas desulfurized gypsum powder, 6 parts of pulp, 4 parts of
expanded vermiculite and 40 parts of non-expanded vermiculite
followed by mixing to form a slurry having a solid portion of about
12%. Next, after forming a crude sheet using a sheet molding
machine, the sheet was steam cured for about 12 hours at about
80.degree. C. and then dried at under 80.degree. C. to obtain a
slag gypsum board (30 cm.times.30 cm.times.6 mm).
Embodiment 9
[0152] 60 parts of hemihydrate gypsum, 36 parts of non-expanded
vermiculite, 4 parts of expanded vermiculite and 24 parts of water
were mixed, and the resulting mixture was cast molded in a
prescribed mold into the shape of a board, followed by curing at
normal temperature and drying at under 80.degree. C. to obtain a
gypsum board (30 cm.times.30 cm.times.6 mm)
Example 10
[0153] Water was added to 27 parts of quartzite powder, 33 parts of
calcium hydroxide, 5 parts of expanded vermiculite and 40 parts of
non-expanded vermiculite followed by mixing to form a slurry having
a solid portion of about 12%, after which this was pressure cured
in an autoclave (190-200.degree. C. for about 10 hours). Next, it
was dried to the prescribed moisture content at under 80.degree. C.
to obtain a xonotlite-based calcium silicate board.
[0154] According to the moisture absorption and release test, the
amount of moisture absorption was slightly less while the rate of
moisture release was slightly higher than the calcium silicate of
Example 6.
[0155] The construction materials obtained according to Embodiments
6 through 10 all exhibited improved moisture conditioning along
with improved design quality, sound absorption properties and
handling, and had a flaky surface having a sense of
transparency.
[0156] Embodiments 11 through 14 described below solve the problems
described in the above-mentioned (C).
Embodiment 11
[0157] Using for the starting raw material 27 parts of quartzite
powder as the siliceous raw material, 27 parts of calcium hydroxide
as the calcareous raw material, 6 parts of pulp as reinforcing
fiber and 40 parts of non-expanded vermiculite (origin: South
Africa, portion of 300 .mu.m or less equal to about 5.0 wt % of the
entire composition (solid portion)), water was added to this
starting raw material followed by mixing to form a slurry having a
solid portion of about 12%, and after forming a crude sheet using a
sheet molding machine, the sheet was pressure cured in an autoclave
(160-180.degree. C. for about 10 hours) and then dried to the
prescribed moisture content at under 80.degree. C. to obtain a
calcium silicate board (30 cm.times.30 cm.times.6 mm). In the
present embodiment, as a result of blending a fine powder of
non-expanded vermiculite, the vermiculite easily dispersed
uniformly in the water during mixing, resulting in improved
production efficiency and yield.
Embodiment 12
[0158] A calcium silicate board was obtained in the same manner as
Embodiment 11 using 42 parts of quartzite powder, 42 parts of
calcium hydroxide, 6 parts of pulp and 10 parts of non-expanded
vermiculite fine powder of which 90% or more was 300 .mu.m or
less.
Embodiment 13
[0159] Water was added to 16 parts of slag powder, 38 parts of flue
gas desulfurized gypsum powder, 6 parts of pulp and 40 parts of
non-expanded vermiculite (portion of 300 .mu.m or less equal to
about 5.0 wt % of the entire composition (solid portion)) followed
by mixing to form a slurry having a solid portion of about 12%.
Next, after forming a crude sheet using a sheet molding machine,
the sheet was steam cured for about 12 hours at about 80.degree. C.
and then dried at under 80.degree. C. to obtain a slag gypsum board
(30 cm.times.30 cm.times.6 mm).
Embodiment 14
[0160] Using for the starting raw material 30 parts and 10 parts,
respectively, of quartzite powder and diatomaceous earth as the
siliceous raw material, 40 parts of calcium hydroxide as the
calcareous raw material, 6 parts of pulp as reinforcing fiber, 10
parts of calcium carbonate as a dimensional stabilizer, and 4 parts
of non-expanded vermiculite fine powder of which 90% or more was
300 .mu.m or less (origin: South Africa), water was added to this
starting raw material followed by mixing to form a slurry having a
solid portion of about 12%, and after forming a crude sheet using a
sheet molding machine, the sheet was pressure cured in an autoclave
(160-180.degree. C. for about 10 hours) and then dried to the
prescribed moisture content at under 80.degree. C. to obtain a
calcium silicate board (30 cm.times.30 cm.times.6 mm). The physical
properties of the board were as follows: bending strength: 13.1
N/mm, Young's modulus: 5.7 kN/mm.sup.2, bulk density: 0.75.
Comparative Example 1
[0161] A calcium silicate board (30 cm.times.30 cm.times.6 mm) was
obtained in the same manner as Embodiment 14 with the exception of
not using non-expanded vermiculite. The physical properties of the
board were as follows: bending strength: 11.6 N/mm.sup.2, Young's
modulus: 6.9 kN/mm.sup.2, bulk density: 0.75.
[0162] Embodiments 15 through 21 described below solve the problems
described in the above-mentioned (D).
Reference Example 2
Production of Calcium Silicate Board
Containing Non-expanded Vermiculite
[0163] Using for the starting raw material 27 parts of quartzite
powder as the siliceous raw material, 27 parts of calcium hydroxide
as the calcareous raw material, 6 parts of pulp as reinforcing
fiber and 40 parts of non-expanded vermiculite (origin: South
Africa, particle size: 0.25-0.5 mm), water was added to this
starting raw material followed by mixing to form a slurry having a
solid portion of about 12%, and after forming a crude sheet using a
sheet molding machine, the sheet was pressure cured in an autoclave
(160-180.degree. C. for about 10 hours) and then dried to the
prescribed moisture content at under 80.degree. C. to obtain a
calcium silicate board containing non-expanded vermiculite (30
cm.times.30 cm.times.6 mm).
Reference Example 3
[0164] A calcium silicate board was obtained in the same manner as
Reference Example 2 using as starting raw material 47 parts of
quartzite powder as the siliceous raw material, 47 parts of calcium
hydroxide as the calcareous raw material and 6 parts of pulp as
reinforcing fiber.
Embodiment 15
[0165] A coating composition was prepared having the composition
indicated below.
[0166] Composition: (A) 65 wt % non-expanded vermiculite/(B) 35 wt
% acrylic emulsion coating
[0167] A coating composition was obtained by mixing using a Hobart
mixer followed by applying this coating composition to the calcium
silicate board containing non-expanded vermiculite obtained in
Reference Example 2 to a thickness of 2 mm using the roll coater
method to obtain the target coated calcium silicate board. This
coated calcium silicate board had a flexible coated film, and
exhibited superior characteristics for balance between the amount
and rates of moisture absorption and release.
Embodiment 16
[0168] Composition: (A) 40 wt % non-expanded vermiculite/(B) 25 wt
% acrylic emulsion coating/(C) 35 wt % calcium silicate
[0169] A coating composition was obtained by mixing using a Hobart
mixer followed by applying this coating composition to the calcium
silicate board containing non-expanded vermiculite, obtained in
Reference Example 3, to a thickness of 2 mm using the roll coater
method to obtain the target coated calcium silicate board. This
coated calcium silicate board had a flexible coated film, and
exhibited superior characteristics for balance between the amount
and rates of moisture absorption and release.
Embodiment 17
[0170] Composition: (A) 65 wt % non-expanded vermiculite/(C) 35 wt
% cement (mortar)
[0171] A coating composition was obtained by mixing using a Hobart
mixer followed by applying this coating composition to the calcium
silicate board containing non-expanded vermiculite obtained in
Reference Example 2 to a thickness of 2 mm using the roll coater
method to obtain the target coated calcium silicate board. This
coated calcium silicate board had a hard, hygroscopic coated film,
and exhibited superior characteristics for balance between the
amount and rates of moisture absorption and release.
Embodiment 18
[0172] Composition: (A) 35 wt % non-expanded vermiculite/(C) 30 wt
% cement (mortar)/(D) 35 wt % calcium silicate
[0173] A coating composition was obtained by mixing using a Hobart
mixer followed by applying this coating composition to the calcium
silicate board containing non-expanded vermiculite obtained in
Reference Example 2 to a thickness of 2 mm using the roll coater
method to obtain the target coated calcium silicate board. This
coated calcium silicate board had a hard, hygroscopic coated film,
and exhibited superior characteristics for balance between the
amount and rates of moisture absorption and release.
Embodiment 19
[0174] Composition: (A) 65 wt % non-expanded vermiculite/(B) 35 wt
% sodium alginate
[0175] A coating composition was obtained by mixing using a Hobart
mixer followed by applying the resulting coating composition to the
calcium silicate board obtained in Reference Example 3 to a
thickness of 2 mm using the roll coater method to obtain the target
coated calcium silicate board. This coated calcium silicate board
exhibited superior characteristics for balance between the amount
and rates of moisture absorption and release.
Embodiment 20
[0176] Composition: (A) 40 wt % non-expanded vermiculite/(B) 20 wt
% sodium alginate/(D) 40 wt % allophane
[0177] A coating composition was obtained by mixing using a Hobart
mixer followed by applying the resulting coating composition to the
calcium silicate obtained in Reference Example 3 to a thickness of
2 mm using the roll coater method to obtain the target coated
calcium silicate board. This coated calcium silicate board
exhibited superior characteristics for balance between the amount
and rates of moisture absorption and release.
Embodiment 21
[0178] Composition: (A) 35 wt % non-expanded vermiculite/(B) 5 wt %
sodium alginate/(C) 20 wt % mortar/(D) 40 wt % diatomaceous
earth
[0179] A coating composition was obtained by mixing using a Hobart
mixer followed by applying the resulting coating composition to the
calcium silicate board, obtained in Reference Example 3, to a
thickness of 2 mm using the roll coater method to obtain the target
coated calcium silicate board. This coated calcium silicate board
had a smooth surface and exhibited superior characteristics for
balance between the amount and rates of moisture absorption and
release.
[0180] Embodiments 22 through 27 described below solve the problems
described in the above-mentioned (E).
Embodiments 22-24
[0181] After allowing the calcium silicate construction materials
obtained in Embodiments 1, 2 and 5 to stand outdoors for six
months, they were respectively crushed to obtain particulate
products A through C having a particle size of about 3-5 mm. These
products were then used as artificial fertilizer containing
siliceous fertilizer and exhibiting satisfactory drainage to grow
plants.
Embodiments 25-27
[0182] The resulting particulate products A through C in
Embodiments 22-24 were processed in the same manner except for
additionally performing steam treatment for 1 hour at about
150.degree. C. to obtain artificial soils D through F.
[0183] Embodiments 28 through 30 described below solve the problems
described in the above-mentioned (F).
Embodiment 28
Joining: Attachment of a Railing
[0184] When a railing was attached to wall surface, that used the
calcium silicate board obtained in Embodiment 1 as an interior
material, with wood screws (thickness: 3.8 mm, length: 32 mm),
there were no problems whatsoever with fastening, and adequate
joining was obtained.
[0185] Furthermore, pulling strength was measured using a pulling
strength tester complying with the standards of the Building
Research Institute.
[0186] Test piece dimensions: 10 mm .times.300 mm .times.300 mm
[0187] Screw insertion sites: Center and 10 cm from end of test
piece
[0188] Test results: Wood screws--Center: 47 kgf End: 47 kgf
Embodiment 29
Planing
[0189] When the surfaces of the calcium silicate board, slag gypsum
board and gypsum board obtained in Embodiments 2 through 4 were
shaved with a flat plane, the shavings were the same as in the case
of planing wood, there was no generation of fine powder and smooth
planed surfaces were obtained.
Embodiment 30
Carving
[0190] The surface of the calcium silicate board obtained in
Embodiment 5 was carved into a lattice pattern using a router.
There were no observed deletions.
* * * * *