Method for producing hydraulic hardening body

Abstract

To provide a hydraulic hardened body easy to obtain a desired efflorescence pattern, and a method for producing the same.SOLUTION: A hydraulic hardened body comprises: a hardening inhibitory substance inhibiting the hardening of a hydraulic material; and an efflorescence in a surface. It is preferable that the hardening inhibitory substance is comprised in a weak acid salt. It is preferable that the weak acid salt has a granular shape. It is preferable that a hydraulic hardened body 1 comprises: a base material 2; and a surface layer 3 provided on the surface of the base material 2, and the surface layer 3 comprises the hydraulic material and the hardening inhibitory substance.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a hydraulic hardened product. More specifically, the present invention relates to a method for manufacturing a hydraulic hardened product having efflorescence on its surface. body's The present invention relates to a method for manufacturing a hydraulic hardened product. More specifically, the present invention relates to a method for manufacturing a hydraulic hardened product having efflorescence on its surface. body's

Background Art

[0002] Inorganic building materials mainly composed of cement are known for building boards used for interior and exterior finishing materials. Such building boards are produced by making a cement sheet by lifting a slurry mainly composed of cement by a papermaking method, spraying a surface layer material with a low water content mainly composed of cement thereon, and pressing and molding with a press mold or a roll mold to impart a pattern. Then, it becomes a hardened body through steam curing by steam and further autoclave curing by high temperature and high pressure. And it is common to perform design expression on the hardened body by painting.

[0003] However, by performing painting, the design may be artificial and uniform. Therefore, as a design expression method without painting, a technique has been proposed to express a natural texture by generating cement reactants and precipitates (efflorescence (whitening)) on the surface of the hardened body by reducing the sealer concentration so as not to prevent the generation of cement reactants and precipitates during the curing process (see Patent Document 1).

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] ​In Patent Document 1, the pattern due to efflorescence (efflorescence pattern) is controlled by the application amount of the sealer, but there has been a demand to obtain a more desired efflorescence pattern.

[0006] The present invention has been made in view of the above circumstances, Method for producing hydraulic hardening body that can easily control the amount and position of efflorescence generation depending on the presence or absence of hardening inhibitor and an object thereof is to provide

Means for Solving the Problems

[0008] The method for manufacturing a hydraulic hardening body according to one aspect of the present invention includes a first step and a second step. In the first step, on the surface of a molded body mainly composed of a hydraulic material a part of is provided an efflorescence pattern generating material having a hardening inhibition function for inhibiting the hardening of the hydraulic material and an efflorescence generation nucleus function serving as a nucleus during the generation of efflorescence. granular sprayed In the second step, after the first step, the molded body is cured.

Effects of the Invention

[0009] According to the present invention, there is an advantage that the amount and position of efflorescence generation can be controlled by the presence or absence of a hardening inhibitor. sucked

Brief Description of the Drawings

[0010]

Figure 1

Figure 2

Figure 3

Modes for Carrying Out the Invention

[0011] (Embodiment) (1) Outline As in Patent Document 1, it is possible to generate or suppress efflorescence (whitening) on the surface of a hydraulic hardened body by the sealer concentration. However, there are states such as the entire surface becoming white and a small proportion of whitening, and it is difficult to control the amount of efflorescence generated and the pattern to achieve a natural texture.

[0012] On the other hand, the hydraulic hardened body according to the present embodiment has a hardening inhibitor and efflorescence on its surface. Here, the hardening inhibitor is a substance that inhibits the hardening of the hydraulic material. Therefore, on the surface of the hydraulic hardened body according to the present embodiment, there are portions where hardening is inhibited due to the presence of the hardening inhibitor and portions where hardening is not inhibited due to the absence of the hardening inhibitor. And in the portions where hardening is inhibited, the generation of efflorescence is suppressed. Therefore, it becomes easier to control the amount and generation position of efflorescence on the surface of the hydraulic hardened body depending on the presence or absence of the hardening inhibitor, and it becomes easier to obtain a desired efflorescence pattern (pattern formed by efflorescence) having the amount and pattern of efflorescence with a natural texture.

[0013] (2) Details <Hydraulic hardened body> The hydraulic hardened body according to the present embodiment is used as a building material such as a wall material, a roof material, an interior material, or an exterior material.

[0014] The hydraulic hardened body according to the present embodiment is a hardened product of a hydraulic material. The hydraulic material contains, as solid components, cement, a siliceous raw material, an extender, mica, reinforcing fibers, etc., and further contains water as necessary. The cement preferably contains, for example, Portland cement or the like. The siliceous raw material has, for example, an SiO2 content of 70% by mass or more and a Blaine value of 3000 cm 2It is preferable to contain at least one selected from the group consisting of the above-mentioned feldspar powder, feldspar powder other than the above, silica powder, blast furnace granulated slag, fly ash, pulp sludge incineration ash, and sewage sludge incineration ash. The extender preferably contains aggregate (fine sand), crushed products of recycled cement products, etc. The extender preferably has an average particle size within a range of less than 5 mm. The reinforcing fiber preferably contains at least one selected from the group consisting of pulp, vinylon fiber, polypropylene fiber, and rock wool.

[0015] For the hydraulic material, it is preferable that the cement content is 30 to 70 parts by mass, the silica raw material content is 30 to 60 parts by mass, the reinforcing fiber content is 3 to 6 parts by mass, the extender content is within a range of 5 to 40 parts by mass, and the mica content is within a range of 3 to 15 parts by mass with respect to 100 parts by mass of the solid content (components other than water).

[0016] For the hydraulic material, the ratio of the amount of water to the solid content (amount of water / solid content) is preferably within a range of 5 / 95 to 30 / 70. Note that the hydraulic material forming the surface layer 3 described later has a lower water content than the hydraulic material forming the base material 2. For example, the hydraulic material forming the surface layer 3 may not contain water. Also, the ratio of the molar amount of Ca in the hydraulic material to the molar amount of Si in the hydraulic material ((molar amount of Ca / molar amount of Si)) is preferably 0.5 or more and 0.9 or less. In this case, appropriate efflorescence is likely to occur on the surface of the hydraulic hardened body. Therefore, it is preferable to adjust the blending ratio of each component contained in the hydraulic material so that the ratio of the molar amount of Ca to the molar amount of Si is within the above range.

[0017] As shown in Fig. 1, the hydraulic hardening body 1 according to this embodiment includes a base material 2 and a surface layer 3. The surface layer 3 is formed on one surface of the base material 2 in the thickness direction. Both the base material 2 and the surface layer 3 can be formed of a hardened product of a hydraulic material, but the hydraulic material forming the base material 2 and the hydraulic material forming the surface layer 3 can have different compositions and properties. Also, the manufacturing methods of the base material 2 and the surface layer 3 can be made different. For example, the base material 2 can be formed by forming a slurry-like hydraulic material into a plate shape by a papermaking method and then curing it by curing. Also, the base material 2 can be formed by forming a viscous hydraulic material into a plate shape by an extrusion method and then curing it by curing. Further, the surface layer 3 can be formed by supplying (spraying) a dry or slightly water-containing hydraulic material in a layer on the surface of the base material 2 and then curing it together with the base material 2. When using a dry hydraulic material, after spraying it on the surface of the base material 2, water can be sprayed to provide a water-containing hydraulic material on the surface of the base material 2.

[0018] And the hydraulic hardening body 1 according to this embodiment contains a hardening inhibitor and efflorescence on its surface. Here, the surface of the hydraulic hardening body 1 is the surface that is constructed facing outward when used as a building material or the like. In the example of Fig. 1, the surface of the surface layer 3 (the surface opposite to the surface facing the base material 2) is formed as the surface of the hydraulic hardening body 1.

[0019] The hardening inhibitor is a substance that inhibits the hardening of the hydraulic material. That is, a part of the surface of the surface layer 3 has a hardening inhibitor, and in the part where the hardening inhibitor exists, the hardening of the hydraulic material is more likely to be inhibited than in the part where the hardening inhibitor does not exist. Therefore, in the part where the hardening inhibitor exists, the amount of calcium hydroxide, which is the main component for generating efflorescence, is small, and efflorescence is less likely to occur. On the other hand, on the surface of the surface layer 3, in the part where the hardening inhibitor does not exist, the hardening of the hydraulic material is less likely to be inhibited than in the part where the hardening inhibitor exists. Therefore, in the part where the hardening inhibitor does not exist, the amount of calcium hydroxide, which is the main component for generating efflorescence, is large, and efflorescence is likely to occur. In this way, on the surface of the hydraulic hardened body 1, the hardening inhibitor and efflorescence are in a mixed state.

[0020] And, on the surface of the hydraulic hardened body 1, a pattern (efflorescence pattern) formed by efflorescence is formed. However, it becomes easier to control the generation amount and generation position of efflorescence on the surface of the hydraulic hardened body 1 depending on the presence or absence of the hardening inhibitor, and it becomes easier to obtain a desired efflorescence pattern having the amount and pattern of efflorescence with a natural texture. For example, by causing the hardening inhibitor to be unevenly present in a part of the surface of the hydraulic hardened body 1, efflorescence can be generated unevenly in the part of the surface of the hydraulic hardened body 1 where the hardening inhibitor does not exist. Also, by causing the hardening inhibitor to be present almost uniformly on the entire surface of the hydraulic hardened body 1, efflorescence can be generated almost uniformly on the entire surface of the hydraulic hardened body 1. By controlling the amount and presence position of the hardening inhibitor in this way, it becomes easier to control and generate the amount and pattern of efflorescence with a natural texture.

[0021] Here, a hardening inhibitor is a substance having a hardening inhibition function that inhibits the hardening of a hydraulic material. The hardening inhibitor is contained, for example, in a salt obtained by a neutralization reaction between an acid and a base. In this case, the acid-derived portion in the salt acts as a hardening inhibitor. That is, an ion derived from the acid or a compound obtained from this ion acts as a hardening inhibitor. When the salt is a weak acid salt, the portion derived from the weak acid acts as a hardening inhibitor. For example, when the weak acid salt is potassium phosphate (K3PO4), phosphate ions (PO4 - ) and compounds obtained from phosphate ions act as hardening inhibitors. Also, when the weak acid salt is potassium acetate (CH3COOK), acetate ions (CH3COO - ) and compounds obtained from acetate ions act as hardening inhibitors. Note that the compound obtained from phosphate ions or acetate ions is a compound obtained by the reaction of phosphate ions or acetate ions with ions in the hydraulic material (for example, metal ions such as Ca 2+ , Na + ).

[0022] Also, when the hardening inhibitor is the acid-derived portion in the salt, the base-derived portion of this salt may act as an efflorescence-forming nucleus substance. The efflorescence-forming nucleus substance has an efflorescence-forming nucleus function that serves as a nucleus during the formation of efflorescence. That is, an ion derived from the base or a compound obtained from this ion acts as an efflorescence-forming nucleus substance. Since the efflorescence-forming nucleus substance serves as a nucleus and efflorescence appears, the efflorescence has a natural texture. When the salt is a weak acid salt, the portion derived from the weak acid acts as an efflorescence-forming nucleus substance. For example, when the weak acid salt is potassium phosphate (K3PO4) or potassium acetate (CH3COOK), potassium ions (K + ) and compounds obtained from potassium ions act as efflorescence-forming nucleus substances. The compound obtained from potassium ions is a compound obtained by the reaction of potassium ions with ions in the hydraulic material (for example, ions such as CO3 2- , SO4 2- ).

[0023] As described above, in the hydraulic hardening body 1 according to this embodiment, efflorescence is less likely to be generated on a part of the surface where the hardening inhibitor exists, and efflorescence is likely to be generated on a part of the surface where the efflorescence generation core substance exists. Therefore, it becomes easier to control the generation amount and generation position (pattern) of efflorescence and generate it.

[0024] <Method for manufacturing hydraulic hardening body> The method for manufacturing the hydraulic hardening body 1 according to this embodiment includes a first step and a second step. The first step is a step of providing an efflorescence pattern generation material on the surface of a molded body mainly composed of a hydraulic material. The molded body mainly composed of a hydraulic material becomes the base material 2 by curing. This molded body is formed in a plate shape by the above-described papermaking method or extrusion method. The efflorescence pattern generation material has a hardening inhibition function that inhibits the hardening of the hydraulic material and an efflorescence generation core function that serves as a core during the generation of efflorescence. The efflorescence pattern generation material preferably contains the above-described hardening inhibitor substance and efflorescence generation core substance. Therefore, the efflorescence pattern generation material can contain the above-described weak acid salt, and specifically, preferably contains at least one of potassium phosphate and potassium acetate.

[0025] The efflorescence pattern generating material is preferably granular. As described later, the efflorescence pattern generating material is used by being blended with a hydraulic material for forming the surface layer 2. Since the hydraulic material for forming the surface layer 2 contains little or no water, it is a substantially dry hydraulic material. Therefore, it is easier to mix the efflorescence pattern generating material in granular form than in liquid form. Also, the efflorescence pattern generating material may be directly sprayed onto the surface of the molded body. In this case, it is easier to spray the granular material than the liquid material. Furthermore, it is easier to control the generation of efflorescence when the efflorescence pattern generating material is present near the surface rather than inside the hydraulic hardened body 1. And, in the case of a liquid efflorescence pattern generating material, it is difficult to penetrate into the molded body and stay near the surface, but in the case of a granular efflorescence pattern generating material, it is difficult to penetrate into the molded body and easy to retain near the surface. The granular efflorescence pattern generating material preferably has a particle size of 2 μm or less, but is not particularly limited. In addition, the efflorescence pattern generating material can be one with a pH of 4 to 9 as an aqueous solution. For example, potassium phosphate shows a pH of 4 to 5 in an aqueous solution, and potassium acetate has a pH of 7 to 9 in an aqueous solution. Also, the efflorescence pattern generating material is preferably a weak acid salt rather than a strong acid salt. In the case of a strong acid salt, the action of the hardening inhibitor becomes large, and there is a risk that the generation of efflorescence is excessively inhibited.

[0026] The first step includes a step of layerwise supplying a hydraulic material for forming the surface layer 3 on the surface of the molded body. The hydraulic material for forming the surface layer 3 becomes the surface layer 3 on the surface of the base material 2 by curing. And an efflorescence pattern generating material may be blended in the hydraulic material for forming the surface layer 3. In this case, simultaneously with supplying (spraying) the hydraulic material for forming the surface layer 3 onto the surface of the molded body, the efflorescence pattern generating material can also be sprayed, enhancing productivity. Also, after layerwise supplying the hydraulic material for forming the surface layer 3 onto the surface of the molded body, the efflorescence pattern generating material may be sprayed on this hydraulic material. Further, after layerwise supplying the hydraulic material for forming the surface layer 3 onto the surface of the molded body, water may be sprayed on this hydraulic material, and the efflorescence pattern generating material may be contained in this water. Note that before supplying the hydraulic material for forming the surface layer 3 onto the surface of the molded body, a sealer paint may be applied to the surface of the molded body. In this case, the efflorescence pattern generating material may be blended in the sealer paint.

[0027] The second step is performed after the first step. The second step is a step of curing the molded body and the hydraulic material for forming the surface layer 3 supplied onto the surface of the molded body. By this curing, the base material 2 is formed from the molded body, and the surface layer 3 is formed from the hydraulic material for forming the surface layer 3. As the curing, one or more of natural curing, steam curing, and autoclave curing can be performed. For example, in the case of autoclave curing, in order to effectively cause efflorescence, it is preferably performed under the conditions of 160°C or higher and 180°C or lower, 0.5 MPa or higher and 0.9 MPa or lower, and 8 hours or longer and 13 hours or shorter.

[0028] When the second step is performed in this way, the hydraulic hardened body 1 including the base material 2 and the surface layer 3 is obtained. On the surface of the surface layer 3 of this hydraulic hardened body 1, a natural-textured efflorescence pattern is formed by the efflorescence pattern generating material.

[0029] (Modification example) The embodiment is merely one of various embodiments of the present invention. The embodiment can be variously modified according to the design and the like as long as the object of the present invention can be achieved.

[0030] As the hydraulic hardening body 1, a two-layer one including the base material 2 and the surface layer 3 has been described, but it is not limited thereto, and a hydraulic hardening body without the surface layer 3 may be used. In this case, the hydraulic hardening body is formed only in the portion corresponding to the base material.

[0031] The efflorescence pattern generating material may be liquid. In this case, it can be supplied to the surface of the molded body or to the layer of the hydraulic material for forming the surface layer 2 by means such as coating or spraying. Further, the liquid efflorescence pattern generating material may be blended with the hydraulic material for forming the surface layer 2.

[0032] The efflorescence pattern generating material is not limited to those having both a hardening inhibition function and an efflorescence generation nucleus function like weak acid salts, and may contain a hardening inhibitor and an efflorescence generation nucleus substance as separate compounds.

Example

[0033] (Examples 1 to 4, Comparative Examples 1, 2) A molded body mainly composed of a hydraulic material was molded by a papermaking method. After applying a sealer paint on the surface of this molded body, a hydraulic material containing an efflorescence pattern generating material was sprayed in layers. Thereafter, a hydraulic hardening body composed of a base material and a surface layer was formed by subjecting the molded body and the sprayed water constituent material to autoclave curing. As the efflorescence pattern generating material, potassium phosphate which is a weak acid salt was used. In Examples 1 and 2 and Comparative Example 1, the base material was black. In Examples 3 and 4 and Comparative Example 2, the base material was beige.

[0034] Table 1 shows the composition of the hydraulic material for forming the surface layer, the blending amount of the weak acid salt, the content ratio of Ca and Si (C / S), the dilution ratio of the sealer paint, and the coating amount of the sealer paint. Further, FIGS. 2A to 2C and FIGS. 3A to 3C show photographs of Examples 1 to 4 and Comparative Examples 1 and 2.

[0035]

Table 1

[0036] (Summary) As described above, the hydraulic hardening body 1 according to the first aspect contains a hardening inhibitor that inhibits the hardening of the hydraulic material and efflorescence on its surface.

[0037] According to this aspect, it is easy to control the amount and position of efflorescence generation depending on the presence or absence of the hardening inhibitor, and there is an advantage that a desired efflorescence pattern can be easily obtained.

[0038] The second aspect is the hydraulic hardening body 1 according to the first aspect, wherein the hardening inhibitor is contained in a weak acid salt.

[0039] According to this aspect, it is easy to control the amount and position of efflorescence generation depending on the presence or absence of the weak acid salt, and there is an advantage that a desired efflorescence pattern can be easily obtained.

[0040] The third aspect is the hydraulic hardening body 1 according to the second aspect, wherein the weak acid salt is granular.

[0041] According to this aspect, compared with the liquid case, the granular weak acid salt is easier to spread, and there is an advantage that productivity can be improved.

[0042] The fourth aspect is the hydraulic hardening body 1 according to any one of the first to third aspects, comprising a base material 2 and a surface layer 3 provided on the surface of the base material 2. The surface layer 3 contains the hydraulic material and the hardening inhibitor.

[0043] According to this aspect, there is an advantage that it is easy to control the amount and position of efflorescence generation in the surface layer 3 on the surface side of the base material 2.

[0044] The manufacturing method of the hydraulic hardening body according to the fifth aspect has a first step and a second step. In the first step, an efflorescence pattern generating material having a hardening inhibition function that inhibits the hardening of the hydraulic material and an efflorescence generation nucleus function that serves as a nucleus during the generation of efflorescence is provided on the surface of a molded body mainly composed of a hydraulic material. In the second step, after the first step, the molded body is cured.

[0045] According to this aspect, there is an advantage that it becomes easier to control the amount and position of efflorescence generation depending on the presence or absence of the efflorescence pattern generating material, and a desired efflorescence pattern can be easily obtained.

[0046] The sixth aspect is a manufacturing method of the hydraulic hardening body 1 according to the fifth aspect, wherein the efflorescence pattern generating material is granular, and in the first step, the efflorescence pattern generating material is sprayed and provided on the surface of the molded body.

[0047] According to this aspect, compared with the case of a liquid efflorescence pattern generating material, the granular efflorescence pattern generating material is easier to spray, and there is an advantage that productivity can be improved.

Explanation of Signs

[0048] 1 Hydraulic hardening body 2 Base material 3 Surface layer

Claims

1. A first step of spraying and providing a granular efflorescence pattern generating material having a hardening inhibition function for inhibiting the hardening of the hydraulic material and an efflorescence generation nucleus function serving as a nucleus during the generation of efflorescence on a part of the surface of a molded body mainly composed of a hydraulic material; A second step of curing the molded body after the first step; A method for manufacturing a hydraulic hardened body.

2. The efflorescence pattern generating material contains at least one of potassium phosphate and potassium acetate. The method for manufacturing a hydraulic hardened body according to Claim 1.

Images