Method for producing cured product

Abstract

In order to provide a method for producing a hardened product having high hardness, the hardened product is formed by mixing and stirring a powder obtained by pulverizing an inorganic substance, an adhesive, and ultra-fine bubble water, and hardening the mixture. The inorganic material contains industrial waste and natural materials, and the industrial waste contains concrete, mortar, tiles and the like generated when structures such as buildings are crushed. The natural objects comprise shells, rocks, sand, red soil, animal bones and the like. In addition, the inorganic substance includes a dehydrated cake. The average particle diameter of the ultrafine bubbles contained in the ultrafine bubble water is about 0.13 [mu] m or less, and the number of ultrafine bubbles contained per 1 cc is about one hundred million or more. Furthermore, an aramid fiber sheet may be attached to the surface of the cured product, or alumina may be added to the material of the mixed material.

Description

TECHNICAL FIELD

[0001] The present application relates to a method for manufacturing a hardened product. BACKGROUND

[0002] A method for manufacturing a hardened product containing at least one selected from lignin and cellulose and waste such as concrete is disclosed in the following Patent Literature 1. Lignin and cellulose can be obtained from plant-derived waste and the like.

[0003] Patent Literature 1 discloses a hardened product having sufficient strength, but it becomes possible to reduce the material by further improving the strength.

[0004] PRIOR ART DOCUMENT

[0005] PATENT LITERATURE

[0006] Patent Literature 1: Japanese Patent No. 7157984 SUMMARY

[0007] PROBLEMS TO BE SOLVED BY THE INVENTION

[0008] An object of the present application is to provide a method for manufacturing a hardened product having high hardness.

[0009] SOLUTION TO PROBLEM

[0010] The hardened product of the present application includes a step of generating a powdery body formed of inorganic matter; a step of mixing and stirring the powdery body, ultra-fine bubble water, and a binder to generate a mixed material; a step of flowing the mixed material into a mold; and a step of hardening the mixed material.

[0011] EFFECT OF THE INVENTION

[0012] According to the present application, by using ultra-fine bubble water, the ultra-fine bubble water penetrates deep into the powdery body, and a hydration reaction occurs deep into the powdery body, so that the hardened product can be made firm. BRIEF DESCRIPTION OF DRAWINGS

[0013] Figure 1 is a schematic view of pulverizing inorganic matter.

[0014] Figure 2 is a schematic view of stirring a mixed material.

[0015] Figure 3 is a schematic view of placing a mixed material into a mold and hardening it in an autoclave.

[0016] Figure 4 is a schematic view of a hardened product taken out of a mold.

[0017] Figure 5 is a schematic view of an aramid fiber sheet being attached to a hardened product.

[0018] Figure 6 Fig. 1 is a schematic view of a coated fiber sheet on which a surface coating material is applied. DETAILED DESCRIPTION

[0019] A method for manufacturing a hardened product according to the present application will be described with reference to the drawings. The drawings schematically show for the purpose of explanation.

[0020] [Embodiment 1]

[0021] The hardened product is formed by mixing and stirring a pulverized inorganic substance, a binder, and ultrafine bubble water, and hardening the mixed material.

[0022] The inorganic substance includes industrial waste and natural materials. The industrial waste includes concrete, mortar, tiles, and the like, which are generated when structures such as buildings are pulverized. The natural materials include shells, rocks, sand, laterite, animal bones, and the like. In addition, the inorganic substance includes dewatered filter cake or sludge, and the like.

[0023] The inorganic substance is pulverized to be a powder. The powder includes calcium or a calcium compound. The calcium compound includes calcium carbonate, calcium oxide, tricalcium silicate, dicalcium silicate, tricalcium aluminate, tetracalcium aluminoferrite, gypsum dihydrate, and the like. An example of the average particle diameter of the powder is about 300 μm, but can be appropriately changed depending on the hardness of the hardened product, and the like.

[0024] The binder can be exemplified by those composed of a natural rubber-based, an acrylic-based, an epoxy-based, a silicon-based, or a vinyl acetate-based material. For example, a latex composed of a rubber tree as a raw material (natural rubber) is used as the binder. The average particle diameter of the binder is about 0.02 to 10 μm. The binder is adhered to the periphery of one powder, and the powders are joined to each other. By using the natural rubber-based binder, a hardened product with a small environmental load can be manufactured.

[0025] The ultrafine bubble water is a liquid including ultrafine bubbles in water. The average particle diameter of the ultrafine bubbles included in the ultrafine bubble water is about 0.13 μm or less. The number of the ultrafine bubbles contained per 1 cc is about 100 million or more. The ratio of the average particle diameter of the ultrafine bubbles, the average particle diameter of the powder, and the average particle diameter of the binder is about 1:15,000:77.

[0026] The ultrafine bubble water can penetrate into the deep part of a substance. The ultrafine bubble water can penetrate into the deep part of a microscopically formed hole or a crack, and the like, on the surface of the powder. The powder includes calcium or a calcium compound, and is hydrated and hardened by water. This time, the hydration reaction is performed by the ultrafine bubble water until the deep part of the powder. The hardness of the hardened product is improved.

[0027] Next, the manufacturing method of the hardened product will be described. (1) A powder-like body formed of inorganic matter is generated. The inorganic matter includes at least one of concrete and mortar which are industrial waste, shells derived from nature (including the latter for eating), sand, rocks, and the like. In the case where reinforcing steel bars are contained in the concrete, the reinforcing steel bars are removed. As shown in FIG. 1, the prepared industrial waste 12 and the like are pulverized by a pulverizing device 14 to produce the powder-like body 16 formed of inorganic matter. The pulverizing device 14 is provided with a plurality of cutters 18 by which the industrial waste 12 and the like are pulverized. Alternatively, sludge and the like can be dehydrated to produce a dehydrated filter cake, and the dehydrated filter cake can be sieved to remove garbage and the like, thereby generating the powder-like body formed of inorganic matter. The inorganic matter is mostly present in recycled products or in nature, and thus has a small environmental load. Figure 1

[0028] (2) The powder-like body 16, the binder, and the ultra-fine bubble water are put into a container 20 and mixed, and further stirred to form a mixed material 22. Figure 2 The proportions of the powder-like body 16, the binder, and the ultra-fine bubble water are about 70 to 80% of the powder-like body 16, about 20 to 10% of the binder, and about 10% of the ultra-fine bubble water. The proportions of the materials can be changed in accordance with the hardness of the hardened product, and the total becomes 100%. Note that the proportions of the materials are one example, and can be changed depending on the hardness and shape of the hardened product, and the like.

[0029] For mixing and stirring, a stirrer 26 that stirs the materials put into the container 20 by a propeller 24 and the like, a vibration machine that directly or indirectly applies vibration to the mixed material 22, a tilting device that changes the angle of the container 20 of the mixed material 22, an air blower that blows air to the mixed material 22 and stirs it, and the like are used.

[0030] The powder-like body 16, the binder, and the ultra-fine bubble water can be put into the container 20 one by one and mixed and stirred, or a plurality of these can be put into the container 20 at the same time and mixed and stirred. Alternatively, the ultra-fine bubble water can be mixed by a spray head at the middle of mixing the powder-like body 16 and the binder or after the mixing. The ultra-fine bubble water is sprayed in a plurality of directions from the spray head, and the ultra-fine bubble water easily mixes with the powder-like body 16 and the binder. The powder-like body 16 contains calcium or a calcium compound, and the powder-like body 16 is hardened by a hydration reaction by the ultra-fine bubble water.

[0031] (3) The mixed material 22 is caused to flow into a mold. In order to not generate air bubbles in the mixed material 22 in the mold, a vibration device can be put into the mixed material 22, and the mixed material 22 is vibrated to cause the air bubbles to escape upward. In order to take out the mixed material 22 from the mold after hardening, a sheet or a resin film for demolding and the like can be provided to the inner wall of the mold.

[0032] ​(4) The mixed material 22 that has flowed into the mold is hardened. At the time of hardening, pressure is applied to the mixed material 22. The mold 30 and the mixed material 22 can be put in a pressure vessel 28 that can be closed and that can increase the pressure of the atmosphere inside Figure 3 ). The heater 32 inside the pressure vessel is made to generate heat, and the temperature inside the pressure vessel is increased. The mixed material 22 is heated, and at this time, the pressure inside the pressure vessel increases due to the water vapor that has evaporated from the mixed material 22. The upper portion of the mold 30 is open, and pressure is applied to the mixed material 22 by the water vapor 34. For example, the heater 32 is set in such a way that the temperature of the atmosphere in the pressure vessel 28 becomes the temperature at which water boils, for example, 100°C. The ultrafine bubble water contained in the mixed material 22 boils to become water vapor, and thus expands to about 1700 times, and the pressure inside the pressure vessel increases. The pressure is appropriately decided and adjusted according to the thickness of the hardened product. Note that the temperature of the atmosphere inside the pressure vessel is increased by the heater 32 located inside the pressure vessel 28, but it can also be a structure in which a heater is provided outside the pressure vessel 28, and the temperature of the atmosphere inside the pressure vessel is increased by the heater. It can also be a structure in which the pressure vessel 28 is constituted in such a way that it can take in and discharge air, and the pressure inside the pressure vessel 28 can be adjusted.

[0033] (5) After the mixed material 22 is hardened, the mold 30 is taken out of the pressure vessel 28. The hardened product 10 is taken off from the mold 30, and the hardened product 10 Figure 4 ) is completed. The hardened product 10 is used for civil engineering structures, buildings, and the like.

[0034] As described above, the present application does not use cement and aggregate (sand, gravel) to produce the hardened product 10. The amount of cement and aggregate available on the earth is decreasing, and thus it is possible to achieve a reduction in cement and aggregate. Since wood and the like are not used as in the related art, it is possible to produce a strong hardened product 10. The strength of the hardened product 10 is increased, and thus it is also possible to make the thickness of the hardened product 10 used for structures thin and thin, to reduce the amount of material, and to reduce the amount of CO2 emission.

[0035] [Embodiment 2]

[0036] An aramid fiber sheet can also be attached around the hardened product 10 produced in Embodiment 1. The aramid fiber sheet is constituted by all-aromatic polyamide fibers. The aramid fiber sheet is formed in a sheet shape with the fibers aligned in one direction or two directions. The aramid fiber sheet is wound around the surface of the hardened product 10 and attached. By attaching the aramid fiber sheet to the hardened product 10, it is possible to cope with large external forces (axial force, bending moment, shear force, and the like).

[0037] A method of adhering the aramid fiber sheet will be described. (1) The surface of the hardened product 10 manufactured in Embodiment 1 is subjected to a base treatment. The base treatment is performed by, for example, abrading the surface of the hardened product 10 with an abrading device. Note that the base treatment can be omitted if not needed.

[0038] (2) A primer material is applied to the surface of the hardened product 10 (primer treatment). As the primer material, an epoxy resin can be cited. The adhesion of the aramid fiber sheet is enhanced.

[0039] (3) A middle coat material 36 is applied to the surface of the hardened product 10, and the aramid fiber sheet 38 is adhered to the surface of the hardened product 10. Figure 5 As the middle coat material 36, an epoxy resin can be cited. The materials of the primer material and the middle coat material 36 can also be different. The aramid fiber sheet 38 can be adhered while air is discharged with a debubbling roller. The adhesion is performed before the middle coat material 36 dries.

[0040] (4) A top coat material 40 is applied to the aramid fiber sheet 38. Figure 6 By applying the top coat material 40 in such a manner that the aramid fiber sheet 38 cannot be seen, a more robust hardened product 42 is manufactured. As the top coat material, an epoxy-based coating material can be cited, and a material having water resistance, chemical resistance, or oil resistance can also be used.

[0041] The aramid fiber sheet 38 can reinforce the initial hardened product 10. The hardened product 10 can be made more robust against forces such as axial force, bending moment, shear force, and torsion. The reinforcement can be more robust compared to the case where a reinforcing material such as a steel bar is embedded in the hardened product 42. The aramid fiber sheet 38 is stronger in tensile strength, lighter, and less likely to deteriorate than the steel bar or the like.

[0042] Instead of the aramid fiber sheet 38 described above, a carbon fiber sheet can be adhered to the surface of the hardened product 10. The carbon fiber sheet is a sheet formed of carbon fiber, is about 1 / 4 as heavy as iron, and has about 10 times the strength of iron. The strength of the hardened product 10 can be improved.

[0043] [Embodiment 3]

[0044] In Embodiment 1, the pressure of the mixed material 22 flowing into the mold 30 is applied by increasing the pressure in the autoclave using the water vapor 34, but the pressure can be applied by another method. For example, the pressure can be applied to the mixed material 22 by a hot-pressing method by applying a load from above the mixed material 22 by heating and pressurization.

[0045] [Embodiment 4]

[0046] In Embodiment 1, a hardening material 10 can also be manufactured by including an admixture as needed. The admixture can be mixed when mixing the powdery body, the adhesive, and the ultrafine bubble water to produce a mixed material. As the admixture, a water-reducing agent, a setting accelerator, a setting retarder, a hydration heat inhibitor, and the like can be listed.

[0047] [Embodiment 5]

[0048] In the above-described embodiments, the powdery body, the adhesive, and the ultrafine bubble water are mixed and stirred, but alumina (aluminum trioxide) can be further added to the powdery body, the adhesive, and the ultrafine bubble water and mixed. The alumina is in a powdery form. By including the alumina in the mixed material, the thermal conductivity of the hardening material 10 can be increased. The proportion of the alumina in the mixed material can be changed according to the desired thermal conductivity. For example, at the time of manufacturing, the temperature of the outer surface and the inside of the mixed material can be made uniform, and a homogeneous hardening material 10 can be easily manufactured. In addition, by providing the hardening material 10 to the ground or the like, heat exchange can be performed between the hardening material 10 and the provided portion.

[0049] Furthermore, the present application can be implemented in a manner applied with various improvements, modifications, and changes based on the knowledge of those skilled in the art without departing from the scope of the present application. The respective embodiments are not independent, and can be implemented in a manner appropriately combined based on the knowledge of those skilled in the art.

[0050] Explanation of Reference Numerals

[0051] 10, 42: Hardening material

[0052] 12: Industrial waste

[0053] 14: Pulverizing device

[0054] 16: Powdery body

[0055] 18: Cutter

[0056] 20: Container

[0057] 22: Mixed material

[0058] 24: Propeller

[0059] 26: Stirrer

[0060] 28: Autoclave

[0061] 30: Template

[0062] 32: Heater

[0063] 34: Vapor pressure

[0064] 36: Intermediate coating material

[0065] 38: aramid fiber sheet

[0066] 40: topcoat material

Claims

1. A method for manufacturing a hardened material, comprising: The process of generating a powdery substance from inorganic materials, including concrete, mortar, tiles, shells, rocks, sand, laterite, animal bones, dewatered filter cake, or sludge; The process involves mixing and stirring a material comprising the powder, ultrafine bubble water, and a binder in a manner where the powder comprises 70-80%, the binder comprises 20-10%, and the ultrafine bubble water comprises 10%, totaling 100%. This process allows the ultrafine bubble water to penetrate the pores and cracks of the powder to generate a mixed material. The binder is composed of materials that are natural rubber-based, acrylic-based, epoxy-based, silicone-based, or vinyl acetate-based. The process of allowing the mixed material to flow into the template; as well as The process of hardening a mixture by bonding the adhesive around the powder and joining the powders together.

2. The method for manufacturing the hardened material according to claim 1, wherein, The process of hardening the mixture includes a process of applying pressure to the mixture while it is hardening.

3. The method for manufacturing a hardened material according to claim 1, comprising the step of pasting an aramid fiber sheet or a carbon fiber sheet onto the surface of the hardened material formed by hardening the mixed material.

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