Molded body formed from curable composition

Patent metadata

Field	Value
Publication number	US-11560335-B2
Application number	US-201816769720-A
Country	US
Kind code	B2
Filing date	Dec 18, 2018
Priority date	Dec 26, 2017
Publication date	Jan 24, 2023
Grant date	Jan 24, 2023

Abstract

To provide a molded body which has high strength, high ductility, and excellent dimensional stability while maintaining incombustibility and fire resistance.A molded body formed from a curable composition containing (A) at least one aluminosilicate source, (B) an alkali metal hydroxide, (C) a calcium ion source, and (D) an alkali resistant fiber, wherein the aluminosilicate source (A) has an SiO2 content of 50% by mass or more based on a total mass of the aluminosilicate source (A), an amorphous ratio of 50% by mass or higher, and an average particle diameter of 50 μm or smaller, and comprises an aluminosilicate source having an average particle diameter of 10 μm or smaller in an amount of 30% by mass or more based on the total mass of the aluminosilicate source (A).

First claim

The invention claimed is:

1. A molded body formed from a curable composition comprising (A) at least one aluminosilicate source, (B) an alkali metal hydroxide, (C) a calcium ion source, and (D) an alkali resistant fiber,
wherein the aluminosilicate source (A) has an SiO 2 content of 50% by mass or more based on a total mass of the aluminosilicate source (A), an amorphous ratio of 50% by mass or higher, and an average particle diameter of 50 μm or smaller, and comprises an aluminosilicate source having an average particle diameter of 10 μm or smaller in an amount of 30% by mass or more based on the total mass of the aluminosilicate source (A), and
wherein the curable composition comprises 10 to 140 parts by mass of the calcium ion source (C) based on 100 parts by mass of the aluminosilicate source (A).

2. The molded body according to claim 1 , comprising at least a volcanic ash-derived substance as the aluminosilicate source (A).

3. The molded body according to claim 1 , wherein the curable composition comprises 10 to 100 parts by mass of the alkali metal hydroxide (B) based on 100 parts by mass of the aluminosilicate source (A).

4. The molded body according to claim 1 , wherein a content of the alkali resistant fiber (D) is 0.1 to 5 parts by mass based on 100 parts by mass of the molded body.

5. The molded body according to claim 1 , wherein the alkali resistant fiber (D) has an average fiber diameter of 100 μm or smaller, and an aspect ratio of 50 to 2,000.

6. The molded body according to claim 1 , wherein a variation coefficient of an average content of the alkali resistant fiber (D) contained in 10 cut pieces with a weight of 20 g cut out from a whole or a part of the molded body is 30% or lower.

7. The molded body according to claim 1 , wherein the alkali resistant fiber (D) is at least one selected from the group consisting of a polyvinyl alcohol-based fiber, a polyethylene fiber, a polypropylene fiber, an acrylic fiber, and an aramid fiber.

8. A method for producing the molded body according to claim 1 , comprising
mixing a component comprising at least one aluminosilicate source (A), an alkali metal hydroxide (B), and a calcium ion source (C), with water,
preparing a curable composition by adding an alkali resistant fiber (D) to the obtained mixture and further mixing the mixture, and
obtaining the molded body by molding the obtained curable composition and then curing the curable composition.

9. The method according to claim 8 , wherein the aluminosilicate source (A) comprises at least a volcanic ash-derived substance.

10. A method for producing a molded body, comprising
mixing at least one aluminosilicate source (A) and an alkali metal hydroxide (B), with water,
forming a precursor by heating the obtained mixture to 50 to 180° C. to react the mixture, and then cooling the mixture to 50° C. or lower,
preparing a curable composition by adding a component comprising a calcium ion source (C) and an alkali resistant fiber (D) to the obtained precursor and further mixing the mixture, and
obtaining the molded body by molding the obtained curable composition and then curing the curable composition.

11. A molded body formed from a curable composition comprising (A) at least one aluminosilicate source, (B) an alkali metal hydroxide, (C) a calcium ion source, and (D) an alkali resistant fiber,
wherein the aluminosilicate source (A) has an SiO 2 content of 50% by mass or more based on a total mass of the aluminosilicate source (A), an amorphous ratio of 50% by mass or higher, and an average particle diameter of 50 μm or smaller, and comprises an aluminosilicate source having an average particle diameter of 10 μm or smaller in an amount of 30% by mass or more based on the total mass of the aluminosilicate source (A), and
wherein the molded body formed from a curable composition comprises at least a volcanic ash-derived substance as the aluminosilicate source (A).

Assignees

• Kuraray Co

Inventors

• Inada Shinya
• Ikehata Soichiro
• Hada Saburo

Classifications

• B28B1/525

  containing organic fibres, e.g. wood fibres (B28B1/526, B28B1/527 take precedence) · CPC title

• B28B1/50

  specially adapted for producing articles of expanded material, e.g. cellular concrete (chemical aspects {or making expanded aggregate} C04B) · CPC title

• C04B28/26 Primary

  Silicates of the alkali metals · CPC title

• C04B16/0641

  Polyvinylalcohols; Polyvinylacetates · CPC title

• C04B40/0046

  characterised by their processing, e.g. sequence of mixing the ingredients when preparing the premixtures · CPC title