Concrete tile and molding material for same

Patent metadata

Field	Value
Publication number	US-2016237686-A1
Application number	US-201615141232-A
Country	US
Kind code	A1
Filing date	Apr 28, 2016
Priority date	Nov 6, 2013
Publication date	Aug 18, 2016
Grant date	—

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/mm 2 .

First claim

What is claimed is:

1 . 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/mm 2 .

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 1.5 to 2.2.

4 . The concrete tile according to claim 1 , wherein an average diameter of the alkali-resistant fibers is 1 to 200 μm, and an aspect ratio of each of the alkali-resistant fibers is 50 to 1000.

5 . The concrete tile according to claim 1 , wherein the alkali-resistant fibers are polyvinyl alcohol 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 ,
the molding material including at least a cement, a fine aggregate, an alkali-resistant fiber, and water, wherein a water cement ratio (W/C) is 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 fiber in a solid content is 0.1 to 2% by mass, and the alkali-resistant fiber does not substantially exist as a fiber-containing granular body in the molding material.

9 . The concrete tile molding material according to claim 8 , wherein an aspect ratio of each of the alkali-resistant fibers is 50 to 1000.

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

11 . The concrete tile molding material according to claim 8 , further including a functional aggregate.

12 . Use of alkali-resistant fibers for manufacturing the concrete tile according to claim 1 , the alkali-resistant fibers comprising at least one member selected from the group consisting of polyvinyl alcohol-based fibers, polyethylene fibers, polypropylene fibers, acrylic fibers, and aramid fibers, the alkali-resistant fiber being.

13 . A method of manufacturing a concrete tile through a roller/slipper method, the method comprising:
performing supply of the molding material according to 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.

14 . The method of manufacturing a concrete tile according to claim 13 , wherein
the supply of the molding material comprises a preparation of the molding material, and the preparation includes dispersing the alkali-resistant fibers in a mixture including a cement, an aggregate, and water while avoiding substantial occurrence of the alkali-resistant fibers as a fiber-containing granular body.

Assignees

• Kuraray Co

Inventors

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

Classifications

• C04B16/0641

  Polyvinylalcohols; Polyvinylacetates · CPC title

• E04D1/04

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

• B28B5/028

  the moulding surfaces being of definite length, e.g. succession of moving pallets, and being continuously fed (feeding B28B13/02) · CPC title

• E04D3/26 Primary

  of concrete or ceramics · CPC title

• C04B16/0633

  Polypropylene · CPC title