JPH10204809A - Production of sintered body and water-permeable sintered body - Google Patents

Abstract

PROBLEM TO BE SOLVED: To use a large quantity of natural raw material which can be supplied costlessly as aggregate and effectively use waste materials simultaneously generated. SOLUTION: Ignous rocks such as basaltic or diabasic rocks containing SiO2 of 45-75wt.%, Al2 O3 of 13-18wt.%, and Fe2 O3 of 2-12wt.% in the oxide composition and alkali-metal oxides, are crushed. Ceramic soil that waste sludge clay and waste glaze sludge are mixed with aggrerate composed of sized crushed stones and sand, is pressurized and molded and then burned at 1150-1200 deg.C to produce a water-permeable paving block.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a water-permeable sintered body used for a water-permeable pavement block or an exterior porcelain plate, and more particularly to a sintered body using crushed stone or crushed sand of igneous rock as a main raw material. And a water-permeable sintered body.

[0002]

2. Description of the Related Art Conventionally, a permeable pavement block is manufactured as follows. For example, ordinary porcelain greenware such as for porcelain tiles is formed into coarse particles having a diameter of about 1 to 3 mmφ, fired, and the resulting sintered coarse particles are used as aggregates, which are melted at a relatively low temperature. If a compound appropriately added with a molten material including an artificially produced glass frit or the like is formed into a required shape and fired, the coarse particles are fused together and a space between them is formed. It will remain as countless communication holes. As described above, the plate-shaped and block-shaped sintered body having innumerable communication holes therein can transmit water through the internal communication holes, and thus has water permeability,
Because of the high strength sintered at high temperature,
In recent years, it has been widely used as a permeable pavement block.

However, since pavement blocks are used in large quantities, it is necessary to stably produce and supply them, and it is particularly important to produce them at low cost. In terms of stable supply, although the pavement block obtained by the above method is preferable, there is a problem that it is difficult to reduce the cost because a normal ceramic green body is applied and the firing step is performed twice. Was.

In order to solve such a problem, attention is paid to fired cullets generated in a tile factory or the like, that is, defective tiles to be discarded such as defective tile shape or poor color tone, and these cullets are crushed by a crusher. do it,
It has been put to practical use that required coarse particles are sieved and collected, and this is used as the aggregate. By this method,
Although the above-mentioned cost problem can be solved to some extent, on the other hand, calcined cullet is not always supplied in large quantities constantly, and there is a problem in production technology that the quality of cullet varies depending on the type of the product of the supplier. there were. In addition, in any of the above-mentioned manufacturing methods, a feldspar having a relatively low melting point or a glass frit that is a factory-produced product is used as a molten material for fusing the aggregates together. There were factors that were difficult.

[0005]

DISCLOSURE OF THE INVENTION The present invention has been made to solve the above problems, and has been used in large quantities as an aggregate which is a main constituent material of a permeable pavement block or the like.
Provided are a method for manufacturing a sintered body and a water-permeable sintered body capable of applying a natural material that can be supplied at a low cost and effectively utilizing a waste material generated at the same time.

[0006]

It was possible to solve the above problems BRIEF SUMMARY OF THE INVENTION The method of manufacturing a sintered body of the present invention, SiO ₂ 45 to 75% by weight in oxide composition, Al ₂ O ₃ 13 to 18 % By weight, _{2 to} 12% by weight of Fe ₂ O _3, and aggregates of coarse particles of igneous rocks such as andesitic, basaltic, amphibolite or diorite containing alkali metal oxides and waste mud clay and It is characterized by forming cup clay mixed with waste glaze sludge and firing it to form a sintered body having water permeability.

[0007] The present invention also provides a method for molding a pottery in which a decorative pigment is added to a surface layer of the pottery at the same time as molding the pottery, and integrally forming the pottery. The present invention can be embodied in a form in which the decorative layer is coated with a decorative pigment in which the decorative pigment is added to the surface layer. And the sintered body thus obtained is very suitable as a pavement block or an exterior porcelain plate.

[0008] Further, the above-mentioned problem is caused by the problem that S
iO_Two45 to 75% by weight, Al_TwoO _Three13-18 weight
%, Fe_TwoO_Three2-12% by weight and alkali metal oxidation
Andesitic, basaltic, amphibolite or diatomaceous material
The surface of the aggregate consisting of coarse-grained igneous rocks
For melting reaction of clay and waste glaze mixture with its aggregate
Therefore, the reaction layer in which the crystal and glass coexist
To form a smooth curved surface, and
Water-permeable sintered body characterized by being joined by a reaction layer
Can be solved by

[0009]

Next, an embodiment of a method for manufacturing a sintered body according to the present invention will be described. In the present invention, first,
The greatest feature is that coarse particles of igneous rocks such as andesitic, basaltic, amphibolite or diopside are used as aggregates. Table 1 should illustrate the different chemical composition of the igneous rocks of origin to, but in the present invention, igneous rock used is, SiO ₂ 45 to 75% by weight in oxide composition as chemical composition, Al
₂ O ₃ 13 to 18 wt%, it is necessary that contains Fe ₂ O ₃ 2 to 12 wt% and some alkali metal oxide.

[0010] The reason is that when there is a large amount of SiO ₂ and Al ₂ O ₃ , the reaction with the sintering aid does not easily occur, the fusion between the aggregates becomes insufficient, and it is difficult to obtain sufficient sintering strength. When the amount is small, the aggregate is partially melted at the time of firing, and the shape cannot be maintained. Also, Fe
If the content of ₂ O ₃ exceeds 12% by weight, a foaming phenomenon occurs during firing, and the sintered shape is broken.

[0011] In addition, JIS / A
Road crushed stone or crushed sand specified in 5001 can be suitably used. The coarse particles are preferably subjected to sieving or the like, and the average particle size thereof is preferably in the range of 3 to 8 mm for crushed stone and less than 3 mm for crushed sand.

The next feature is that waste mud clay and waste glaze sludge are mixed with the aggregate. This waste mud clay is a portion that is usually discarded as fine particles under the sieve when producing the crushed stone or crushed sand. The particle size distribution of this waste mud clay is 1-5% ≧ 100 mesh, 100-20
0 mesh is 5 to 15%, 200 to 325 mesh is 1
It is mainly composed of fine particles of 0 to 20% and 60 to 80% ≦ 325 mesh. When used together with the above-mentioned aggregate, the flow of the particles becomes lubricated at the time of vibration molding or pressure molding, so that there is an advantage that it functions as a molding aid. Further, although its chemical composition is similar to that of a rough stone, sintering starts at a relatively low temperature during firing, so that it is effective for mutual fusion of the aggregate of the present invention and has the advantage that resources can be used effectively. is there.

Further, waste glaze sludge used together with waste mud clay is waste of glaze generated when producing sanitary ware, ceramic tile, tableware and the like. This can not be regenerated because various pigments and fluxes are mixed variously,
Although there was no other way than to discard it, there were many that were originally adjusted to melt at a relatively low temperature of about 1000 to 1200 ° C. It has a function as a preferable sintering aid. At the same time, as in the case of waste mud clay, there is an advantage that resources can be used effectively.

[0014] The crushed stone is 55 to 6
It is appropriate that 5%, crushed sand 10-20%, waste mud clay 5-10%, and waste glaze sludge 10-15%. As other raw materials, for example, glass cullet powder for adjusting the melting temperature, plastic clay such as bentonite for adjusting the plasticity and increasing the drying strength, etc., may be blended within 10%. The glass cullet referred to here is a collection of waste glass products or defective products generated in a glass factory.
Means miscellaneous glass that can be recycled.

[0015] The composition thus obtained is humidified so as to have a water content of about 2 to 6% to form molding clay, and is processed in the order of molding, drying and firing to have water permeability. A sintered body is obtained. In this case, as the molding method, pressure molding using a molding die or vibration molding is particularly suitable. For firing, either a tunnel kiln or a shuttle kiln may be used, and an appropriate refractory container (sagger) may be used, but is not essential. The firing temperature is 105
Since a wide temperature range from 0 ° C. to 1350 ° C. can be applied, there is no need to install a firing furnace dedicated to this sintered body, and mixed firing can be performed in accordance with the firing temperature of other products.

The thus obtained sintered body having water permeability according to the present invention has a performance standard as a water-permeable pavement block, for example, a flexural strength of 30 kgf / cm ² or more (JIS / A52).
09 method), water permeability, 1 × 10 ^-2 cm / sec or more (Interlocking Block Association method), slip resistance,
Dry 90 or more, wet 50 or more (ASTM / E30
3 / 66T method).

In the present invention, simultaneously with the molding of the clay, the surface of the molded article is covered with a decorative clay in which a decorative pigment has been added and molded integrally, or after molding, the molded article is molded. By means of covering the surface of the sintered body with a decorative pottery with a decorative pigment added,
A protective layer can be provided, and the sintered body thus obtained is very suitable as a pavement block or an exterior porcelain plate.

The decorative clay is made of an oxide composition of Si
_{O 2 70~75%, Al 2 O} 3 13~15%, and some alkali oxide as essential components, Fe ₂ optionally other
O ₃ 1 to 3%, it is suitably obtained by blending a decorative pigment,
When coating the sintered body as a base, the coating thickness is reduced so as not to close the water-permeable pores of the base, or the above-described aggregate is mixed in the decorative clay. It is preferred that the coating be performed so as not to impair the water permeability.

[0019]

[Table 1]

Next, one embodiment of the water-permeable sintered body of the present invention will be described. The water-permeable sintered body of the present invention is basically based on the point that an aggregate made of coarse-grained igneous rock forms a sintered body with a practical bonding strength while forming countless water-permeable communication holes therebetween. Structure. And, as the volcanic rock, andesitic and basaltic materials containing 45 to 75% by weight of SiO _2, 13 to 18% by weight of Al ₂ O ₃ , _{2 to} 12% by weight of Fe ₂ O ₃ and an alkali metal oxide in terms of oxide composition A coarse-grained material obtained by crushing and sizing igneous rocks such as amphibolite or diabaseite, for example, crushed stone having an average particle size of 3 to 8 mm or crushed sand of less than 3 mm alone or mixed And use it as aggregate.

The next important feature is that a coating material consisting of a mixture of waste mud clay and waste glaze, which has been previously adhered to the surface of the aggregate, is melted at the time of firing, so that the coating material between the underlying aggregate and The reaction layer, in which the crystal produced by the melting reaction and glass coexist, covers the entire surface of the aggregate and forms a smooth curved surface. In this way, the reaction layer generated by the melting reaction covers the surface of the aggregate smoothly, so the rough and sharp many irregularities seen on the surface of the crushed rock aggregate that crushed the volcanic rock become a smooth curved surface shape By being improved, it becomes particularly suitable as a water-permeable material, such as a water-permeable pavement block, which can pass through a considerable amount of dust and is therefore less likely to be clogged.

Further, the present invention is characterized in that a reaction layer generated by the melting reaction firmly bonds the aggregates to each other. Here, in a mixture of waste mud clay and waste glaze sludge that functions as a coating material, the waste mud clay is used as a molding aid to lubricate the flow of particles during molding, and the waste glaze sludge melts itself during firing. This not only covers the surface of the aggregate, but also functions as a sintering aid that strongly fuses and bonds the aggregates together. In this case, the combined use of the waste glaze sludge and the waste mud clay has an advantage that the melting temperature at which the reaction layer is generated can be appropriately adjusted.

In order to manufacture the water-permeable sintered body of the present invention, the above-described method for manufacturing a sintered body of the present invention may be used.
In addition, in mixing the raw materials, for example, waste mud clay 5 to 10
% And waste glaze 10-15% are mixed, and the aggregate prepared within the range of 55-65% of crushed stone and 10-20% of crushed sand is blended, and the coating is wrapped around the aggregate. It is preferable to attach them. For this purpose, an organic paste such as CMC or PVA may be appropriately blended in order to increase the adhesiveness and the drying strength. In addition, as other raw materials,
As described in the description of the production method, glass cullet, bentonite and the like can be used for adjusting the melting temperature or plasticity.

The water content of the composition obtained in this manner is adjusted to about 2 to 6% to form molding clay, which is treated in the order of molding, drying and firing to improve the water permeability of the present invention. A sintered body can be obtained. In this case, first, the coating material existing between the aggregate particles in the firing process has an apparent volume that is greatly reduced when melting starts, so that an infinite number of water-permeable holes are formed, and then the aggregate surface is formed. The coating material that has adhered to the surface begins to melt, but the surface tension causes the surface of the aggregate to be coated into a smooth curved surface. The aggregate joins both aggregates in the molten state.

As described above, the coating material melts and covers the aggregate, and binds the aggregates together. In the present invention, the components of the igneous rock as the aggregate and the waste mud clay as the coating material are used. The molten glaze and the components of the waste glaze form a glass that changes into high-strength crystalline material, for example, cristobalite, after cooling, so that sintering with stronger strength than when simply combined with vitreous material There is an advantage that the body can be produced.

[0026]

Next, the present invention will be described in detail based on one embodiment. First, as the clay for forming the main body of the sintered product, No. 7 crushed stone 61% by weight (the same applies hereinafter), crushed sand 15%, waste glaze sludge 12%, crushed stone waste mud clay 5%, bentonite 3
%, 4% of glass cullet powder and 5% of water were sufficiently mixed to prepare a raw clay for the main body.

As a surface decoration clay, feldspar 72
%, Crushed stone 9%, glass cullet powder 15%, crushed stone waste mud clay 4%, bentonite 3%, and water 5%. In this case, the crushed stone is a crushed stone obtained by crushing Sekimoto amphibolite, which is a kind of igneous rock, and its chemical composition is roughly the oxide composition, 48% SiO ₂ , Al ₂ O ₃ 1
5%, 11% of Fe ₂ O ₃ , 4% of total amount of Na ₂ O and K ₂ O, and 20% of others.

Next, the raw clay for the main body is primarily formed into a main body block of 234 × 115 × 55 mm by vibrating a forming die by a vibration molding machine, and further about 10 to 15% of the main body block. The secondary molding is performed in a state where the surface decorating clay equivalent to the weight is arranged around the main body block, and a molded block in which the surface decorating clay is integrally coated on the surface of the main body block is formed. Made.

After the molded block is sufficiently dried, the maximum temperature of the refractory container is set to 1 in a tunnel kiln.
It was fired in the range of 150 to 1200 ° C. to produce a sintered body. The sintered block thus obtained has a bending strength of about 50.
Kgf / cm ² (based on JIS / A5209), water permeability about 5 × 10 ^-2 cm / sec (based on the Interlocking Block Association Act), slip resistance, dry 100, wet 60 (based on ASTM / E303 / 66T) Were observed, all of which exceeded the criteria for the water-permeable block described above.

[0030]

The method for producing a sintered body and the water-permeable sintered body of the present invention are configured as described above.
Since crushed stone and crushed sand, which are coarse-grained igneous rocks such as andesite, are used as the main raw material, not only can the cost be reduced significantly, but also the raw material can be supplied stably. Further, since waste mud clay and waste glaze sludge can be used, resources can be reused, and there is an excellent effect that the cost can be further reduced. Furthermore, the sintered body of the present invention is not easily clogged because the inner surface of the water-permeable hole is gentle, not only has a high strength, but can also be recovered and reused after use, and a surface decoration cup on the surface. When a two-layer structure using soil is used, advantages such as a desired coloring can be obtained. Therefore, the present invention has a very large industrial value as a method for producing a sintered body and a water-permeable sintered body that have solved the conventional problems.

Claims (4)

[Claims] 1. An oxide composition comprising 45 to 75% by weight of SiO ₂ ,
It is composed of coarse particles of igneous rocks such as andesitic, basaltic, amphibolite or diorite containing 13 to 18% by weight of Al ₂ O ₃ , _{2 to} 12% by weight of Fe ₂ O ₃ and an alkali metal oxide. A method for producing a sintered body, comprising forming a cup of clay in which waste mud clay and waste glaze are mixed with an aggregate and firing the mixture to form a sintered body having water permeability. 2. The sintered body according to claim 1, wherein, at the same time as or after the molding of the clay, the surface layer of the molded product is covered with a decorative clay in which a decorative pigment is added, and is integrally molded. Manufacturing method. 3. The method for producing a sintered body according to claim 1, wherein the sintered body is a pavement block or an exterior ceramic plate. 4. An oxide composition comprising 45 to 75% by weight of SiO ₂ ,
It is composed of coarse particles of igneous rocks such as andesitic, basaltic, amphibolite or diorite containing 13 to 18% by weight of Al ₂ O ₃ , _{2 to} 12% by weight of Fe ₂ O ₃ and an alkali metal oxide. The surface of the aggregate is formed into a smooth curved surface by a reaction layer in which a mixture of waste mud clay and waste glaze sludge and a crystal produced by a melting reaction with the aggregate and glass coexist, and the aggregates are mutually connected. A water-permeable sintered body characterized by being bonded by the reaction layer.