Concrete tile and molding material for same

Patent metadata

Field	Value
Publication number	US-10851545-B2
Application number	US-201615141232-A
Country	US
Kind code	B2
Filing date	Apr 28, 2016
Priority date	Nov 6, 2013
Publication date	Dec 1, 2020
Grant date	Dec 1, 2020

Abstract

A concrete tile comprising a tile body, the tile body having an upper face hardened through non-mold shaping, a lower face hardened through mold shaping, and a side surface that includes a cut end face in at least one side of the tile body, wherein the tile body contains alkali-resistant fiber in an entire thickness thereof in a state substantially free of fiber-containing granular bodies; the alkali-resistant fibers comprise at least one member selected from the group consisting of polyvinyl alcohol-based fibers, polyethylene fibers, polypropylene fibers, acrylic fibers, and aramid fibers; and a flexural strength of a 30 mm×150 mm sized cut piece of the tile body is not less than 6 N/mm2.

First claim

What is claimed is:

1. A concrete tile comprising a tile body,
wherein
the tile body has an upper face hardened through non-mold shaping, a lower face hardened through mold shaping, and a side surface that comprises a cut end face in at least one side of the tile body,
the tile body comprises alkali-resistant fibers in an entire thickness in a state such that the alkali-resistant fibers form fiber-containing granular bodies each having a circle equivalent diameter of less than 10 mm at a cut face of the tile which is cut at a randomly chosen position;
the alkali-resistant fibers comprise at least one member selected from the group consisting of polyvinyl alcohol-based fibers, polyethylene fibers, polypropylene fibers, acrylic fibers, and aramid fibers;
a flexural strength of a 30 mm×150 mm sized cut piece of the tile body is not less than 6 N/mm 2 ;
the alkali-resistant fibers have an aspect ratio of from 50 to 1000; and
the tile body is made from a molding material in which the alkali-resistant fibers are present in an amount of from 0.1 to 2% by mass relative to the solid content of the molding material, wherein the molding material further comprises an aggregate, and the aggregate comprises a light-weight aggregate in a proportion of not greater than 10% based on an amount of the aggregate.

2. The concrete tile according to claim 1 , wherein
a surface of the tile body is substantially free of protrusions caused by presence of the fiber-containing granular bodies.

3. The concrete tile according to claim 1 , wherein a specific gravity of the tile body is from 1.5 to 2.2.

4. The concrete tile according to claim 1 , wherein an average diameter of the alkali-resistant fibers is from 1 to 200 μm.

5. The concrete tile according to claim 1 , wherein the alkali-resistant fibers are polyvinyl alcohol-based fibers.

6. The concrete tile according to claim 1 that passes EN490 standard in a tile bending test performed in accordance with EN491:2011.

7. The concrete tile according to claim 1 , wherein the tile body is not substantially split-broken in a falling ball test performed with reference to JIS A 1408.

8. A concrete tile molding material for manufacturing the concrete tile according to claim 1 ,
wherein
the concrete tile molding material comprises a cement, an aggregate, alkali-resistant fibers, and water, wherein the aggregate comprises a light-weight aggregate in a proportion of not greater than 10% based on an amount of the aggregate,
a water to cement ratio (W/C) is from 20 to 50 mass %,
the alkali-resistant fibers comprise at least one member selected from the group consisting of polyvinyl alcohol-based fibers, polyethylene fibers, polypropylene fibers, acrylic fibers, and aramid fibers,
a proportion of the alkali-resistant fibers in a solid content is from 0.1 to 2% by mass, and
the alkali-resistant fibers in the concrete tile molding material form fiber-containing granular bodies each having a circle equivalent diameter of less than 10 mm.

9. The concrete tile molding material according to claim 8 , wherein an average diameter of the alkali-resistant fibers is from 1 to 200 μm.

10. The concrete tile molding material according to claim 8 , further comprising a functional aggregate.

11. A method of manufacturing a concrete tile by a roller/slipper method, the method comprising:
supplying the molding material of claim 8 to a hopper of a roller/slipper-type extruder;
filling the molding material supplied from a lower portion of the hopper into a plurality of pallets adjacent to each other;
compressing the filled molding material by using a roller and a slipper to form a band-shaped body that is continuously placed on the pallets adjacent to each other; and
cutting the band-shaped body with a cutting blade to form individual raw tiles on individual pallets.

12. The method of manufacturing a concrete tile according to claim 11 , wherein
the supplying of the molding material comprises a preparation of the molding material, and
the preparation comprises dispersing the alkali-resistant fibers in a mixture comprising a cement, an aggregate, and water while avoiding substantial occurrence of the alkali-resistant fibers as a fiber-containing granular body.

13. The concrete tile according to claim 1 , wherein the tile body comprises alkali-resistant fibers in an entire thickness in a state that the alkali-resistant fibers form fiber-containing granular bodies each having a circle equivalent diameter of less than 5 mm at the cut face of the tile cut at a randomly chosen position.

14. The concrete tile according to claim 1 , wherein the tile body comprises alkali-resistant fibers in an entire thickness in a state that the alkali-resistant fibers form fiber-containing granular bodies each having a circle equivalent diameter of less than 3 mm at the cut face of the tile cut at a randomly chosen position.

15. The concrete tile according to claim 1 , wherein the tile body comprises alkali-resistant fibers in an entire thickness in a state free of fiber-containing granular bodies.

16. The concrete tile according to claim 1 , wherein the tile body is made from a molding material in which the alkali-resistant fibers are present in an amount of from 0.3 to 1.8% by mass relative to the solid content of the molding material.

17. The concrete tile according to claim 1 , wherein the tile body is made from a molding material in which the alkali-resistant fibers are present in an amount of from 0.5 to 1.6% by mass relative to the solid content of the molding material.

Assignees

• Kuraray Co

Inventors

• Imagawa Akira
• Inada Shinya
• Iwasaki Yoshihiro
• Hada Saburo

Classifications

• E04D1/16 Primary

  of ceramics, glass or concrete, with or without reinforcement · CPC title

• E04D1/04

  of ceramics, glass or concrete, with or without reinforcement · CPC title

• C04B2111/2023

  Resistance against alkali-aggregate reaction · CPC title

• C04B2111/00594

  Concrete roof tiles · CPC title

• B28B3/123

  on material in moulds or on moulding surfaces moving continuously underneath or between the rollers, e.g. on an endless belt · CPC title