Fiber-reinforced inorganic molded body and method for producing same

Abstract

To provide a fiber-reinforced inorganic molded body which is lightweight, incombustible, and of good appearance.SOLUTION: A fiber-reinforced inorganic molded body 1 includes: a surface layer 2 containing a cured geopolymer 3; and a reinforced layer 5 that comprises a fiber base material 6 and a geopolymer 7 impregnated and cured in the fiber base material 6. The fiber base material 6 is a glass fiber base material or a basalt fiber base material. The fiber base material 6 is preferably a nonwoven fabric or a mat. The content of the fiber base material 6 in the reinforced layer 5 is preferably from 5 to 25 mass% based on the total mass of the reinforced layer.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a fiber-reinforced inorganic molded article and a method for producing the same. [Background technology]

[0002] Panels and monuments installed on the walls of buildings are often installed high above ground level, so they must be lightweight and strong. Fiber-reinforced plastics can be used to reduce the weight of the molded body while maintaining its strength, but they lack fire resistance. Fiber-reinforced concrete and fiber-reinforced gypsum are used when flame retardancy and fire resistance are required, but these are inferior to fiber-reinforced plastics in terms of lightness. Furthermore, gypsum cannot be used outdoors because it is not water-resistant, and it is also brittle. Glass fiber, on the other hand, is used in a wide range of applications due to its strength, non-flammability, heat resistance, electrical insulation, and chemical resistance.

[0003] Patent Document 1 discloses a fiber-reinforced silicate compound composite material in which glass fibers are contained in a matrix of hardened sodium silicate. This composite material uses water glass as the matrix, and the addition of glass fibers or glass fiber powder promotes the hardening of the matrix and compensates for the brittleness of the matrix, thereby improving the strength of the entire composite material. The composite material is molded into a predetermined shape by injecting a slurry obtained by mixing components such as an aqueous sodium silicate solution and glass fibers into a mold and subjecting it to hardening conditions.

[0004] Patent Document 2 discloses an inorganic hardening composition used for producing inorganic hardened bodies such as panels, etc. The composition contains metakaolin (inorganic powder), an aqueous potassium silicate solution, silica powder, wollastonite, vinylon fiber, and metallic silicon powder. [Prior art documents] [Patent documents]

[0005] [Patent Document 1] Japanese Patent Application Publication No. 05-330889 [Patent Document 2] Japanese Patent Application Laid-Open No. 2007-290316 Summary of the Invention [Problem to be solved by the invention]

[0006] However, when a molded body is highly filled with fibers to improve its strength, fiber marks may appear on the surface of the molded body, impairing the aesthetic appearance of the product. This problem is particularly pronounced when a molded body is highly filled with glass fibers to improve its non-combustibility, and the fiber marks are noticeable when the surface of the molded body is patternless.

[0007] Therefore, in one aspect, the present disclosure provides a fiber-reinforced inorganic molded article that is lightweight, non-flammable, and has a good appearance. [Means for solving the problem]

[0008] One embodiment of the present invention includes a surface layer including a hardened geopolymer, and a reinforcing layer including a fiber substrate and a geopolymer impregnated into the fiber substrate and hardened, wherein the fiber substrate is a glass fiber substrate or a basalt fiber substrate. The surface layer contains aggregate, and the 50% cumulative particle size of the aggregate is 50 to 1000 μm. , relates to fiber-reinforced inorganic moldings.

[0009] In one aspect, the present disclosure relates to a method for producing a fiber-reinforced inorganic molding, which comprises applying a first geopolymer composition to a mold, placing at least one fiber substrate impregnated with a second geopolymer composition on top of the first geopolymer composition applied to the mold to form a laminated structure, the fiber substrate being a glass fiber substrate or a basalt fiber substrate, and curing and demolding the laminated structure. [Effects of the Invention]

[0010] According to one aspect of the present disclosure, a fiber-reinforced inorganic molded article can be provided that is lightweight, non-flammable, and has a good appearance. [Brief explanation of the drawings]

[0011] [Figure 1] FIG. 1 is a schematic perspective view of a fiber-reinforced inorganic molded article according to one embodiment of the present disclosure. [Figure 2] FIG. 2 is a schematic perspective view of a fiber-reinforced inorganic molded article according to one embodiment of the present disclosure. [Figure 3] 3A to 3E are process diagrams illustrating a method for producing a fiber-reinforced inorganic molded body according to one embodiment of the present disclosure. [Figure 4] 4A to 4E are process diagrams illustrating a method for producing a fiber-reinforced inorganic molded body according to one embodiment of the present disclosure. [Figure 5] FIG. 5 is a photograph of the surface of the molded body of Example 1. [Figure 6] FIG. 6 is a photograph of the surface of the molded body of Comparative Example 1. [Figure 7] FIG. 7 is a photograph of the surface of the molded body of Example 2. [Figure 8] FIG. 8 is a photograph of the surface of the molded body of Comparative Example 2. [Figure 9] FIG. 9 is a photograph of the surface of the molded body of Example 3. DETAILED DESCRIPTION OF THE INVENTION

[0012] In one aspect, the present disclosure provides a fiber-reinforced inorganic molded product (hereinafter sometimes abbreviated as "molded product") comprising a surface layer and a reinforcing layer. The matrix materials of both the surface layer and the reinforcing layer are hardened geopolymers (hereinafter sometimes abbreviated as "GP"), and the reinforcing fibers contained in the reinforcing layer are glass fibers or basalt fibers. Therefore, the molded product is lightweight and non-flammable. Because the molded product has a surface layer provided on a reinforcing layer containing glass fibers or basalt fibers, even if the reinforcing layer is highly filled with glass fibers or basalt fibers, fiber marks are prevented from appearing on the surface of the molded product. Therefore, in one aspect, the present disclosure can provide a fiber-reinforced inorganic molded product that is lightweight, non-flammable, and combines good appearance with high strength. The "surface of the molded product" refers to the front surface of the molded product, i.e., the surface that comes into contact with the inner surface of the mold during molding within the mold.

[0013] Hereinafter, embodiments of the present disclosure will be described in more detail with reference to the drawings, but the present invention is not limited to those shown in the drawings.

[0014] [Fiber-reinforced inorganic molding] Fig. 1 is a schematic perspective view illustrating a fiber-reinforced inorganic molded body according to one embodiment of the present disclosure, and Fig. 2 is a schematic perspective view illustrating a fiber-reinforced inorganic molded body according to another embodiment of the present disclosure. As shown in Figs. 1 and 2, molded body 1 includes a surface layer 2 and a reinforcing layer 5 bonded to surface layer 2.

[0015] [Surface layer] The surface layer 2 contains a hardened GP body 3 as its main component. GP is a general term for amorphous condensation polymers formed by the reaction of a raw material (hereinafter also referred to as "active filler") whose main component is amorphous aluminum silicate with at least one aqueous solution (alkaline solution) of an alkali metal silicate, carbonate, or hydroxide. Unlike cement, GP is not a hydrate produced by reacting with water, so its bonds do not break even at high temperatures. Its strong inorganic polymer structure makes it resistant to deterioration factors such as wind, rain, sunlight, acid, and temperature changes.

[0016] Examples of active fillers (not shown) include amorphous aluminum silicate, and typical examples include metakaolin, fly ash, sewage sludge slag, and granulated blast furnace slag. Of these, metakaolin is preferred because it is white, reacts quickly, and has little variation in quality.

[0017] The alkali metal silicate is preferably at least one selected from the group consisting of sodium silicate, potassium silicate, and lithium silicate, more preferably potassium silicate, and even more preferably potassium silicate. The aqueous solution of the alkali metal silicate can also be prepared by mixing an alkali metal hydroxide, amorphous silica, and water.

[0018] The surface layer 2 may contain reinforcing fibers (not shown) dispersed in the GP as needed to reinforce the surface layer 2. Any reinforcing fibers can be used depending on the application of the molded body 1. From the viewpoints of improving the surface appearance of the molded body 1 and achieving high reproducibility of a design when the design is formed on the surface of the molded body 1, preferred reinforcing fibers include vinylon, acrylic, PE, PP, cellulose, aramid, carbon fiber, alumina fiber, and glass fiber. From the viewpoint of durability, the surface layer 2 preferably does not contain glass fibers such as E-glass, which are vulnerable to alkalis. However, alkali-resistant glass fibers may be contained within a range that does not affect the surface properties of the molded body 1. The content of these reinforcing fibers in the surface layer 2 is preferably 0.3 to 1.0 mass% of the total mass of the surface layer 2 from the viewpoints of improving strength, achieving high appearance of the surface of the molded body 1, and achieving high reproducibility of a design when the design is formed on the surface of the molded body 1. From the viewpoint of improving strength and dispersibility of the reinforcing fibers, the fiber diameter of the reinforcing fibers is preferably 10 to 50 μm, and the fiber length is preferably 1 to 10 mm.

[0019] The surface layer 2 may contain, as needed, an aggregate 4 that is insoluble in water and does not react with alkali metal silicates in order to reinforce the surface layer 2. In particular, when forming a design on the surface of the molded body 1, it is preferable to contain the aggregate 4 from the viewpoint of preventing a decrease in strength due to fine irregularities and the occurrence of cracks. Examples of the aggregate 4 include wollastonite, zircon sand, silica sand, crystalline alumina, mica, copper tangle, limestone, and municipal solid waste slag. These may be used alone or in combination of two or more. Among these, wollastonite is preferred because it is acicular and has the effect of preventing shrinkage.

[0020] The particle size of the aggregate 4 is preferably 50 to 1000 μm, more preferably 50 to 200 μm, from the viewpoints of good appearance and high reproducibility of the design. The content of the aggregate 4 in the surface layer 2 is preferably 10 to 50 mass % of the total mass of the surface layer 2, from the viewpoints of improving strength, good appearance of the surface of the molded body 1, and high reproducibility of the design. In this specification, the term "particle size" refers to the 50% (weight) cumulative particle size, that is, the particle size when the particle size reaches 50% by weight of the total aggregate when accumulating from smallest particle sizes.

[0021] The preferred thickness of the surface layer 2 varies depending on the use of the molded body 1 and whether or not a design is formed, but from the viewpoint of the strength and good appearance of the entire molded body, it is preferably 0.3 to 2.0 mm, more preferably 0.5 to 1.0 mm.

[0022] The surface of the surface layer 2, i.e., the surface of the molded body 1, may be a smooth surface without any pattern as shown in Fig. 1, or may have a design formed thereon as shown in Fig. 2. Examples of designs include traditional Japanese patterns such as tortoise shell patterns, checkered patterns, and shippo-tsunagi patterns, as well as geometric patterns, leather grain patterns, rock surfaces, wood grain, wood surfaces (bark), comb-hiki patterns, scraped-off patterns, and chipped patterns.

[0023] [Reinforcement layer] The reinforcing layer 5 is bonded to the surface layer 2 and includes a fiber substrate 6, such as a glass fiber substrate, and a geopolymer 7 impregnated and hardened into the fiber substrate 6, such as a glass fiber substrate. Using a fiber substrate 6, such as a glass fiber substrate, allows the reinforcing layer 5 to be highly loaded with a reinforcing material such as glass fiber. The hardened GP 7 is the matrix material in the reinforcing layer 5. Similar to the hardened GP 3 in the surface layer, it is an amorphous condensation polymer formed by the reaction of an aqueous solution of an alkali metal silicate or the like with an activated filler. The fiber substrate constituting the reinforcing layer 5 may be a glass fiber substrate or a basalt fiber substrate. Basalt fiber is also called basalt fiber because it is obtained by melting and spinning basalt. Basalt fiber is known to have higher heat resistance and strength than glass fiber.

[0024] The fiber substrate (glass fiber substrate or basalt fiber substrate) 6 may be in the form of a plain weave, satin weave, nonwoven fabric, mat, knitted fabric, braided fabric, or a combination of these, or a combination of these with chopped fibers. From the viewpoint of high loading of glass fibers or basalt fibers into the reinforcing layer 5, a nonwoven fabric or mat is preferred, and a mat is more preferred. Examples of mat types include chopped strand mats, in which glass fiber strands or basalt fiber strands cut to a predetermined length are randomly dispersed and layered to a uniform thickness and formed into a mat with a binder; stitched mats, in which glass fiber strands or basalt fiber strands cut to a predetermined length are sewn together with another continuous fiber to form a sheet; and continuous strand mats, in which continuous fibers are stacked, for example, in a spiral shape and formed into a mat with a binder. The preferred basis weight of one nonwoven fabric or mat is 30 to 600 g / m from the viewpoint of achieving both the impregnation of GP, the handleability of the mat itself, and the handleability of the polymer-containing fiber substrate (polymer-containing glass fiber substrate or polymer-containing basalt fiber substrate) impregnated with the second geopolymer composition described below. 2 The count of the glass fiber strands constituting the glass fiber substrate is preferably 5 to 500 tex, and the fiber length is preferably 1 to 100 mm, more preferably 20 to 100 mm. The count of the basalt fiber strands constituting the basalt fiber substrate is preferably 5 to 500 tex, and the fiber length is preferably 1 to 100 mm, more preferably 20 to 100 mm.

[0025] The number of layers of the fiber substrate (glass fiber substrate or basalt fiber substrate) 6 in the reinforcing layer 5 may be appropriately selected depending on the application of the molded article, and is, for example, 1 to 10 layers, preferably 3 to 5 layers. The fiber substrate (glass fiber substrate or basalt fiber substrate) 6 may also be formed by cutting roving into strands of 1 to 100 mm, preferably 20 to 100 mm, and spraying the resulting strands with a spray gun to form a layer on the substrate. From the viewpoint of improving strength, the content of the glass fiber substrate in the reinforcing layer 5 is preferably 5 to 25 mass % of the total mass of the reinforcing layer, more preferably 5 to 20 mass %. From the viewpoint of improving strength, the content of the basalt fiber substrate in the reinforcing layer 5 is also preferably 5 to 25 mass % of the total mass of the reinforcing layer, more preferably 5 to 20 mass %.

[0026] The reinforcing layer 5 may contain an inorganic filler (not shown) as needed, for example, to adjust the weight. Examples of inorganic fillers include talc, finely powdered wollastonite, silica powder, zeolite, calcium carbonate, aluminum hydroxide, barium sulfate, and crushed rocks. The particle size of the inorganic filler is not particularly limited as long as it does not interfere with the impregnation of the GP into the fiber substrate (glass fiber substrate or basalt fiber substrate) 6, and is preferably 5 μm or more and less than 50 μm. From the viewpoint of both improving strength and impregnating the GP into the fiber substrate (glass fiber substrate or basalt fiber substrate) 6, the content of the inorganic filler in the reinforcing layer 5 is preferably 50 mass% or less of the total mass of the reinforcing layer.

[0027] The preferred thickness of the reinforcing layer 5 varies depending on the intended use of the molded body 1, but is preferably 2.0 to 10 mm, more preferably 3.0 to 6.0 mm, from the viewpoint of improving the strength of the molded body.

[0028] The preferred thickness of the molded body 1 varies depending on the application of the molded body 1, but is preferably 2.3 to 12 mm, more preferably 3.5 to 7.0 mm, from the viewpoint of improving the strength of the molded body.

[0029] [Method of manufacturing fiber-reinforced inorganic molded body] Next, a method for producing a molded article according to one embodiment of the present disclosure will be described with reference to FIGS. In one aspect, the present disclosure relates to a method for producing a fiber-reinforced inorganic molded body, which comprises applying a first geopolymer composition (hereinafter sometimes abbreviated as "first GP composition") to a mold, placing one or more glass fiber substrates impregnated with a second geopolymer composition (hereinafter sometimes abbreviated as "second GP composition") on top of the first GP composition applied to the mold to create a laminated structure, curing the laminated structure to completely harden it, and then demolding it. In one aspect, the present disclosure relates to a method for producing a fiber-reinforced inorganic molded body, which comprises applying a first geopolymer composition (hereinafter sometimes abbreviated as "first GP composition") to a mold, placing one or more basalt fiber substrates impregnated with a second geopolymer composition (hereinafter sometimes abbreviated as "second GP composition") on top of the first GP composition applied to the mold to create a laminated structure, curing the laminated structure to allow it to fully harden, and then demolding it.

[0030] The first GP composition contains, for example, the active filler and an alkaline aqueous solution such as an aqueous solution of an alkali metal silicate. The first GP composition may optionally contain the reinforcing fibers (reinforcing fibers) such as organic fibers, aggregates, and the like. Suitable alkaline aqueous solutions, active fillers, reinforcing fibers, and aggregates are as described above. The solid content of the first GP composition is preferably 70 to 85% by mass in terms of application properties. The preferred content of the alkali metal silicate in the first GP composition is 35 to 60 parts by mass per 100 parts by mass of the active filler, calculated as solid content. The preferred content of the aggregate 4 is 20 to 100 parts by mass per 100 parts by mass of the active filler in terms of shrinkage prevention and molded body strength.

[0031] The second GP composition contains, for example, an active filler and an alkaline aqueous solution such as an aqueous solution of an alkali metal silicate. The second GP composition may also contain an inorganic filler, if necessary. Details of suitable alkaline aqueous solutions, active fillers, and inorganic fillers are as described above. The solids concentration of the second GP composition is preferably 70 to 85% by mass from the viewpoint of impregnation into the fiber substrate (glass fiber substrate or basalt fiber substrate) 6. In the second GP composition, the preferred content of the alkali metal silicate, calculated as solids, is preferably 40 to 60 parts by mass per 100 parts by mass of the active filler. The preferred content of the inorganic filler is preferably 75 parts by mass or less per 100 parts by mass of the active filler from the viewpoint of strength and processability of the molded product.

[0032] The mold used in the method for producing a molded article according to one embodiment of the present disclosure may be made of, for example, urethane rubber, fiber-reinforced plastic, silicone rubber, etc. A mold release agent may be used as needed, such as a wax-based, silicone-based, fluorine-based, or surfactant-based mold release agent.

[0033] Next, as shown in Figures 3A and 4A, a first GP composition 30 containing aggregate 4 is applied to a mold 8 coated with a release agent. A fiber substrate (glass fiber substrate or basalt fiber substrate) 6 impregnated with a second GP composition 70 is then placed on top of the first GP composition 30 applied to the mold 8. Details of suitable glass fiber substrates and basalt fiber substrates are as described above. The fiber substrate (glass fiber substrate or basalt fiber substrate) 6 may be placed on top of the first GP composition applied to the mold while the geopolymer in the first GP composition 30 is still uncured, or while the geopolymer in the first GP composition 30 is cured but not completely cured.

[0034] The placement of multiple fiber substrates (glass fiber substrates or basalt fiber substrates) 6 impregnated with the second GP composition 70 on the first GP composition 30 applied to the mold 8 is carried out by either or both of the following methods (I) and (II). (I) As shown in FIG. 3B, a fiber substrate (glass fiber substrate or basalt fiber substrate) 6 is placed on the first GP composition 30, and then, as shown in FIG. 3C, the fiber substrate (glass fiber substrate or basalt fiber substrate) 6 is impregnated with a second GP composition 70 to form a polymer-containing fiber substrate (polymer-containing glass fiber substrate or polymer-containing basalt fiber substrate) 9. (II) As shown in Figure 4B, a polymer-containing fiber substrate (a polymer-containing glass fiber substrate or a polymer-containing basalt fiber substrate) 9 is prepared by impregnating a fiber substrate (a glass fiber substrate or a basalt fiber substrate) 6 with a second GP composition 70, and this is placed on top of the first GP composition 30 as shown in Figure 4C. That is, the fiber substrate (a glass fiber substrate or a basalt fiber substrate) 6 is impregnated with the second GP composition 70, and then the second GP composition 70 is placed on top of the first GP composition 30.

[0035] In method (I), the fiber substrate (glass fiber substrate or basalt fiber substrate) 6 is impregnated with the second GP composition by hand using, for example, a brush or roller. Air is removed from the fiber substrate (glass fiber substrate or basalt fiber substrate) 6 simultaneously with the impregnation. In method (II), the fiber substrate (glass fiber substrate or basalt fiber substrate) 6 is impregnated with the second GP composition by, for example, immersing the fiber substrate (glass fiber substrate or basalt fiber substrate) in the second GP composition. Air is removed from the fiber substrate (glass fiber substrate or basalt fiber substrate) 6 simultaneously with the immersion.

[0036] In method (I), when a design is formed on the surface of a molded article, a fiber substrate (glass fiber substrate or basalt fiber substrate) 6 is pressed against a molding die 8 to form a shape, and then the fiber substrate (glass fiber substrate or basalt fiber substrate) 6 is impregnated with a second GP composition 70. Alternatively, the second GP composition 70 is applied to the fiber substrate (glass fiber substrate or basalt fiber substrate) 6 by rubbing, and the fiber substrate (glass fiber substrate or basalt fiber substrate) 6 is shaped while the fiber substrate (glass fiber substrate or basalt fiber substrate) 6 is impregnated with the second GP composition 70. Alternatively, the fiber substrate (glass fiber substrate or basalt fiber substrate) 6 is shaped before and during the impregnation with the second GP composition 70. In method (II), the shaping of the fiber substrate (glass fiber substrate or basalt fiber substrate) 6 is carried out by pressing the polymer-containing fiber substrate (polymer-containing glass fiber substrate or polymer-containing basalt fiber substrate) 9 against the mold 8 when it is placed on the first GP composition 30.

[0037] For example, by performing method (I) and method (II) a predetermined number of times, a laminated structure 10 is formed in which multiple polymer-containing fiber substrates (polymer-containing glass fiber substrates or polymer-containing basalt fiber substrates) 9 are stacked on a mold 8 to which a first GP composition 30 has been applied, as shown in Figures 3D and 4D.

[0038] Next, the laminated structure 10 is cured, and after the geopolymer has completely hardened, it is demolded. As shown in Figures 3E and 4E, after curing, the first GP composition 30 becomes the surface layer 2, and the laminate of the polymer-containing fiber substrate (polymer-containing glass fiber substrate or polymer-containing basalt fiber substrate) 9 becomes the reinforcing layer 5. The curing temperature is preferably 10 to 90°C, and the relative humidity is preferably 50 to 90%. The curing time is preferably 2 to 24 hours.

[0039] 1 to 4 is a flat plate-like molded article of the present disclosure, but the molded article of the present disclosure is not limited to a flat plate-like molded article and may be a curved plate-like molded article. Furthermore, one form of the molded article of the present disclosure may be a three-dimensional object such as an artificial rock, an artificial tree, a monument, or a statue. [Example]

[0040] The present invention will be specifically described below using examples, but the present invention is not limited to the following examples.

[0041] [Raw materials used] The details of the raw materials used to prepare the geopolymer composition are as follows: Metakaolin (manufactured by Sobuekree) Potassium silicate aqueous solution (Osaka Silica Co., Ltd. 1.4 50° (molar ratio 1.4, solid content 45.4% by mass) Wollastonite (IMERYS NYAD-G)

[0042] Example 1 Metakaolin and potassium silicate aqueous solution were mixed in a mass ratio of 100:100 (100:45.4 in terms of solid content) to prepare a geopolymer mortar for the reinforcing layer (second GP composition). Metakaolin, potassium silicate aqueous solution, and wollastonite (aggregate) were mixed in a mass ratio of 100:90:30 (100:40.9:30 in terms of solid content) to prepare a geopolymer mortar for the surface layer (first GP composition). The molded body of Example 1 was produced by the hand layup method as follows. First, a wax-based mold release agent was applied to a urethane rubber mold without a pattern. Next, the first GP composition was applied to the urethane rubber mold. A glass chopped strand mat (manufactured by Nitto Boseki, basis weight 450 g / m) was then placed on the applied first GP composition. 2 ) was placed on the mat. Next, the second GP composition was applied to the mat by rubbing, and the mat was impregnated while removing the air from inside, to obtain a polymer-containing glass fiber substrate. This process was repeated four times. The resulting laminated structure was cured in an atmosphere at 60°C for 24 hours to completely cure the GP. The molded product was then demolded to obtain the molded article of Example 1. In the molded body of Example 1, the thickness of the surface layer is 1.0 mm, and the thickness of the reinforcing layer is 4.0 mm. The content of the aggregate contained in the surface layer is 17.6 mass% of the total mass of the surface layer, and the content of the mat contained in the reinforcing layer is 17 mass% of the total mass of the reinforcing layer.

[0043] Example 2 A molded article of Example 2 was produced with the same configuration as Example 1, except that a urethane rubber mold with a wood grain pattern was used as the mold.

[0044] Example 3 The first and second GP compositions were prepared in the same manner as in Example 1, and the molded article of Example 3 was produced as follows. First, a wax-based mold release agent was applied to a urethane rubber mold with a wood grain pattern. Then, the first GP composition was applied to the urethane rubber mold. A basalt fiber mat (manufactured by Each DreaM, basis weight 450 g / m) was applied to the second GP composition. 2 Four polymer-containing glass fiber substrates were prepared by immersing the substrate in the first GP composition, and these were laminated on the first GP composition applied to the urethane rubber mold. The resulting laminated structure was cured in an atmosphere of 60°C for 24 hours to be completely cured. The molded product was then demolded to obtain the molded article of Example 3. In the molded body of Example 3, the thickness of the surface layer is 1.0 mm, the thickness of the reinforcing layer is 5.0 mm, the content of the aggregate contained in the surface layer is 17.6 mass% of the total mass of the surface layer, and the content of the mat contained in the reinforcing layer is 14 mass% of the total mass of the reinforcing layer.

[0045] (Comparative Example 1) A molded article having the same structure as in Example 1 was produced, except that no surface layer was provided.

[0046] (Comparative Example 2) A molded article having the same structure as in Example 2 was produced, except that no surface layer was provided.

[0047] <Appearance of the molded body surface> 5 and 6 are photographs of the surfaces of the molded bodies of Example 1 and Comparative Example 1, respectively. As shown in Fig. 6, many fiber marks are observed on the surface of the molded body of Comparative Example 1, but as shown in Fig. 5, no fiber marks are observed on the surface of the molded body of Example 1.

[0048] <Design reproducibility> Figures 7 and 8 are photographs of the surfaces of the molded bodies of Example 2 and Comparative Example 2, respectively. A comparison of Figures 7 and 8 reveals that the molded body of Example 2 has better pattern reproducibility than the molded body of Comparative Example 2. As shown in Figure 8, even in areas of the surface of the molded body of Comparative Example 2 where the glass fiber was covered with geopolymer, many fiber marks were observed. Figure 9 is a photograph of the surface of the molded body of Example 3, and it can be seen that even when basalt fiber was used as the fiber base material, the pattern reproducibility was good and there were few fiber marks.

[0049] <Accelerated stability test> 1.Water resistance test The molded articles of Examples 2 and 3 were subjected to a water resistance test. A molded body and water were placed in a sealed plastic container, and the molded body was immersed in the water. The container was then sealed with a lid and placed in an oven at 80°C for 28 days to examine the change in bending strength of the molded body over time. The average initial bending strength (n=5) of the molded body in Example 2 was 45.8 MPa, and the average bending strength (n=5) after the water resistance test was 37.7 MPa. The average initial bending strength (n=5) of the molded body in Example 3 was 57.9 MPa, and the average bending strength (n=5) after the water resistance test was 64.7 MPa. 2. Moisture resistance test The molded articles of Examples 2 and 3 were subjected to a moisture resistance test. A mesh with legs was placed in a sealed plastic container, water was poured under the mesh, and a molded body was placed on top of the mesh. The container was then sealed with a lid and placed in an oven at 80°C for 28 days to examine the change in bending strength of the molded body over time. The average initial bending strength (n=5) of the molded body in Example 2 was 45.8 MPa, and the average bending strength (n=5) after the moisture resistance test was 42.5 MPa. The average initial bending strength (n=5) of the molded body in Example 3 was 57.9 MPa, and the average bending strength (n=5) after the moisture resistance test was 57.2 MPa.

[0050] (bending strength) The bending strength (MPa) of the molded articles of Examples 2 and 3 was measured as follows. The test pieces before and after the water resistance test and the humidity resistance test were subjected to a bending test in accordance with the three-point bending test of JIS A 1408 to measure bending strength. The unit of bending strength is MPa, and it is expressed in N / mm 2 It is sometimes written as:

[0051] When a molded body containing glass fiber as a reinforcing material is used, for example, outdoors or under high humidity, water that penetrates into the molded body becomes alkaline, and this alkaline solution deteriorates the glass fiber, which may eventually cause the strength of the molded body itself to decrease over time. However, in the above-mentioned accelerated stability test, the molded body of Example 2 maintained the general physical properties of glass fiber reinforced cement (for example, direct spray method, bending strength (breaking strength) 20 to 30 N / mm 2 (20-30 MPa), Source: "Physical Properties and Product Standards of GRC," Japan GRC Industry Association, HYPERLINK "https: / / www.grc.gr.jp / product / index3.html" https: / / www.grc.gr.jp / product / index3.html). For the molded article of Example 3, there was no substantial change in bending strength before and after the water resistance and humidity resistance tests. Therefore, the present disclosure can provide a molded article that is lightweight, non-flammable, and combines good appearance with high strength, as well as high durability. [Industrial Applicability]

[0052] Suitable uses of the molded article of the present disclosure include, for example, artificial rocks, artificial trees, monuments, statues, and flat, wavy, or dome-shaped building materials, panels, and the like, which are installed indoors or outdoors. [Explanation of symbols]

[0053] 1 Fiber-reinforced inorganic molding 2 Surface layer 3 Hardened geopolymer 30 First Geopolymer Composition 4 Aggregate 5 reinforcement layer 6. Fiber substrate 7 Hardened geopolymer 70 Second Geopolymer Composition 8 Molding mold 9 Polymer-containing fiber substrate

Claims

1. a surface layer including a hardened geopolymer; A reinforcement layer comprising a fiber substrate and a geopolymer impregnated in the fiber substrate and hardened; The fiber substrate is a glass fiber substrate or a basalt fiber substrate; The surface layer contains aggregate, and the 50% cumulative particle size of the aggregate is 50 to 1000 μm.

2. The fiber-reinforced inorganic molded article according to claim 1 , wherein the fiber substrate is a nonwoven fabric or a mat.

3. The fiber-reinforced inorganic molded body according to claim 1 or 2, wherein the content of the fiber base material contained in the reinforcing layer is 5 to 25 mass% of the total mass of the reinforcing layer.

4. 2. The fiber-reinforced inorganic molded body according to claim 1, wherein the content of the aggregate contained in the surface layer is 10 to 50 mass % of the total mass of the surface layer.

5. The fiber-reinforced inorganic molded product according to claim 1 or 2, wherein a design is formed on the surface of the surface layer.

6. applying a first geopolymer composition to the mold; At least one fiber substrate impregnated with a second geopolymer composition is placed on the first geopolymer composition applied to the mold to form a laminated structure, wherein the fiber substrate is a glass fiber substrate or a basalt fiber substrate; The laminated structure is cured and demolded.

7. The method for producing a fiber-reinforced inorganic molded body according to claim 6, wherein the first geopolymer composition contains 20 to 100 parts by mass of aggregate relative to 100 parts by mass of the active filler contained in the first geopolymer composition.

8. The method for producing a fiber-reinforced inorganic molded body according to claim 6 or 7, wherein the fiber substrate is placed on the first geopolymer composition, and then the fiber substrate is impregnated with the second geopolymer composition.

9. 8. The method for producing a fiber-reinforced inorganic molding according to claim 6 or 7, wherein the fiber substrate is impregnated with the second geopolymer composition and then placed on the first geopolymer composition.

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