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

Patent metadata

Field	Value
Publication number	US-2016289119-A1
Application number	US-201615145502-A
Country	US
Kind code	A1
Filing date	May 3, 2016
Priority date	Nov 5, 2013
Publication date	Oct 6, 2016
Grant date	—

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

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

4 . The fiber-reinforced carbonated hydraulic inorganic molded plate according to claim 2 , wherein the reinforcing fiber is a polyvinyl alcohol fiber.

5 . A molded plate being a cured product of a composition comprising 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%.

6 . The fiber-reinforced carbonated hydraulic inorganic molded plate according to claim 5 , wherein the fiber-reinforced carbonated hydraulic inorganic molded plate has a carbonation reaction rate of higher than or equal to 50%.

7 . The fiber-reinforced carbonated hydraulic inorganic molded plate according to claim 5 , 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%.

8 . The fiber-reinforced carbonated hydraulic inorganic molded plate according to claim 5 , wherein the cement component is a cement containing a belite at a proportion of 18% by mass or more.

9 . The fiber-reinforced carbonated hydraulic inorganic molded plate according to claim 8 , wherein the belite has a reaction rate of higher than or equal to 70%.

10 . The fiber-reinforced carbonated hydraulic inorganic molded plate according to claim 5 , wherein the reinforcing fiber is a polyvinyl alcohol fiber.

11 . A method for producing a fiber-reinforced carbonated hydraulic inorganic molded plate recited in claim 1 , the method comprising:
pre-curing a composition that contains at least a cement component, a pulp, a reinforcing fiber having an aspect ratio in a range of 40 to 1000, and water to obtain a pre-cured body; and carbonation-curing the pre-cured body to obtain a fiber-reinforced carbonated hydraulic inorganic molded plate.

12 . The method for producing the fiber-reinforced carbonated hydraulic inorganic molded plate according to claim 11 , wherein
the composition includes, as the cement component, a cement containing a belite at a proportion of 18% by mass or more, and allows to be pre-cured to obtain a molded body having a sufficient hardness to be demoldable; and the molded body is carbonation-cured.

13 . The method for producing the fiber-reinforced carbonated hydraulic inorganic molded plate according to claim 11 , wherein the pre-curing is performed under an atmosphere having a humidity of 65 to 100%.

14 . The method for producing the fiber-reinforced carbonated hydraulic inorganic molded plate according to claim 11 , wherein the carbonation-curing is performed under an atmosphere containing carbon dioxide gas at a concentration of 5 to 30%.

15 . A method for producing a fiber-reinforced carbonated hydraulic inorganic molded plate recited in claim 5 , 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 containing at least a cement component, a pulp, a reinforcing fiber, and water; and carbonation-curing the obtained 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%.

16 . The method for producing the fiber-reinforced carbonated hydraulic inorganic molded plate according to claim 15 , wherein
the composition includes, as the cement component, a cement containing 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.

Assignees

• Kuraray Co

Inventors

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

Classifications

• C04B2111/00586

  Roofing materials · CPC title

• C04B16/0641 Primary

  Polyvinylalcohols; Polyvinylacetates · CPC title

• C04B28/02 Primary

  containing hydraulic cements other than calcium sulfates · CPC title

• C04B28/04

  Portland cements · CPC title

• C04B40/0236

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