Fiber-reinforced carbonated hydraulic inorganic molded plate and method for producing same

Patent metadata

Field	Value
Publication number	US-10093577-B2
Application number	US-201615145502-A
Country	US
Kind code	B2
Filing date	May 3, 2016
Priority date	Nov 5, 2013
Publication date	Oct 9, 2018
Grant date	Oct 9, 2018

Abstract

Provided is a fiber-reinforced carbonated hydraulic inorganic molded plate having a high bulk specific gravity, a high flexural strength, and a small dimensional change rate per specific gravity. (1) A fiber-reinforced carbonated hydraulic inorganic molded plate including: a cement component, a pulp, and a reinforcing fiber having an aspect ratio in a range of 40 to 1000; and being a carbonation-cured molded plate. (2) A molded plate being a cured product of a composition including at least a cement component, a pulp, and a reinforcing fiber, wherein the molded plate is a fiber-reinforced carbonated hydraulic inorganic molded plate and has a carbonation reaction rate of higher than or equal to 30%.

First claim

What is claimed is:

1. A fiber-reinforced carbonated hydraulic inorganic molded plate which is a carbonation-cured product of a composition comprising:
a cement component,
a pulp, and
a reinforcing fiber,
wherein the fiber-reinforced carbonated hydraulic inorganic molded plate has a carbonation reaction rate of higher than or equal to 30%.

2. The fiber-reinforced carbonated hydraulic inorganic molded plate according to claim 1 , wherein the fiber-reinforced carbonated hydraulic inorganic molded plate has a carbonation reaction rate of higher than or equal to 50%.

3. The fiber-reinforced carbonated hydraulic inorganic molded plate according to claim 1 , wherein the fiber-reinforced carbonated hydraulic inorganic molded plate has a dimensional change rate per specific gravity of less than or equal to 0.1%.

4. The fiber-reinforced carbonated hydraulic inorganic molded plate according to claim 1 ,
wherein the cement component comprises a belite at a proportion of 18% by mass or more.

5. The fiber-reinforced carbonated hydraulic inorganic molded plate according to claim 4 , wherein the belite has a reaction rate of higher than or equal to 70%.

6. The fiber-reinforced carbonated hydraulic inorganic molded plate according to claim 1 , wherein the reinforcing fiber is a polyvinyl alcohol fiber.

7. The fiber-reinforced carbonated hydraulic inorganic molded plate according to claim 1 , wherein the fiber-reinforced carbonated hydraulic inorganic molded plate is obtained by carbonation-curing under an atmosphere containing carbon dioxide gas at a concentration of 8 to 30%.

8. The fiber-reinforced carbonated hydraulic inorganic molded plate according to claim 1 , wherein the reinforcing fiber has an aspect ratio in a range of 40 to 1000.

9. The fiber-reinforced carbonated hydraulic inorganic molded plate according to claim 3 , wherein the reinforcing fiber is a polyvinyl alcohol fiber.

10. A method for producing the fiber-reinforced carbonated hydraulic inorganic molded plate according to claim 1 , the method comprising:
preparing a molded body having a permeability of higher than or equal to 0.1×10 −15 m 2 by pre-curing a composition comprising a cement component, a pulp, a reinforcing fiber, and water; and
carbonation-curing the molded body so as to produce a fiber-reinforced carbonated hydraulic inorganic molded plate having a carbonation reaction rate of higher than or equal to 30%.

11. The method according to claim 10 ,
wherein the composition comprises, as the cement component, a cement comprising a belite at a proportion of 18% by mass or more, and is rendered to be pre-cured to obtain a molded body having a sufficient hardness to be demoldable; and the molded body is carbonation-cured.

12. The method according to claim 10 , wherein
the reinforcing fiber has an aspect ratio in a range of 40 to 1000.

13. The method according to claim 12 , wherein
the composition comprises, as the cement component, a cement comprising a belite at a proportion of 18% by mass or more, and allows to be pre-cured to obtain a fiber-reinforced carbonated hydraulic inorganic molded body having a sufficient hardness to be demoldable; and
the fiber-reinforced carbonated hydraulic inorganic molded body is carbonation-cured.

14. The method according to claim 12 , wherein the pre-curing is performed under an atmosphere having a humidity of 65 to 100%.

15. The method according to claim 12 , wherein the carbonation-curing is performed under an atmosphere containing carbon dioxide gas at a concentration of 5 to 30%.

16. The method according to claim 10 , wherein the carbonation-curing is performed under an atmosphere containing carbon dioxide gas at a concentration of 8 to 30%.

17. The method according to claim 15 , wherein the carbonation-curing is performed under an atmosphere containing carbon dioxide gas at a concentration of 8 to 30%.

Assignees

• Kuraray Co

Inventors

• Hitomi Yoshinori
• Inada Shinya
• Iwasaki Yoshihiro
• Noritake Hiroaki
• Hada Saburo
• Morioka Minoru
• Higuchi Takayuki
• Shoji Makoto
• Iriuchijima Katsuaki

Classifications

• C04B40/0236

  Carbon dioxide post-treatment of already hardened material · CPC title

• C04B2111/0062

  Gypsum-paper board like materials · CPC title

• C04B2111/00586

  Roofing materials · CPC title

• C04B28/04

  Portland cements · CPC title

• C04B28/02 Primary

  containing hydraulic cements other than calcium sulfates · CPC title