Fiber reinforced cement composition and products and manufacturing process
The problems to be solved by the invention are to provide a fiber reinforced cement composition for obtaining a fiber reinforced cement product which is inexpensive and economical, and to provide pushing forward disposal of defective products. Namely, the fiber reinforced cement composition comprises a hydraulic inorganic material, a siliceous material, a woody reinforcement, a finely dividing fiber reinforced cement product and/or a finely dividing intermediate of fiber reinforced cement product which is produced by said raw materials.
1. A fiber reinforced cement composition comprising the following raw materials:
a hydraulic inorganic material;
a siliceous material, a woody reinforcement;
fiber reinforced cement particles of a fiber reinforced cement product and/or fiber reinforced cement particles of a fiber reinforced cement intermediate product;
mica; and
polyvinyl alcohol resin, wherein
the hydraulic inorganic material is contained in the amount of 28-45% by mass,
the fiber reinforced cement particles of the fiber reinforced cement product has average particle size of 15-50 μm,
the fiber reinforced cement particles of the fiber reinforced cement intermediate product are obtained by grinding and/or milling a green sheet which is obtained by forming slurry of raw materials and/or a green mat which is obtained by rolling up on a making roll to have a multi-layer structure and separating from the making roll and/or a press mat which is obtained by pressing a green mat and/or a hardening mat which is hardened by a press mat and/or a cured mat which is obtained by curing the hardening mat and/or a defective article thereof,
the fiber reinforced cement particles of the fiber reinforced cement product is contained in the amount of 1-5% by mass and/or the fiber reinforced cement particles of the fiber reinforced cement intermediate product is contained in the amount of 3-10% by mass, and
the woody reinforcement comprises needle-leaves-tree unbleached kraft pulp and/or needle-leaves-tree bleached kraft pulp and used newspaper.
2. The fiber reinforced cement composition according to claim 1 , wherein
the ratio of the total amount of the fiber reinforced cement particles of the fiber reinforced cement intermediate product being obtained by grinding and/or milling the green sheet and/or the green mat and/or the press mat to the total amount of the fiber reinforced cement particles of the fiber reinforced cement intermediate product being obtained by grinding and/or milling the hardening mat and/or the cured mat and/or the fiber reinforced cement product is in a range of from 9:1 to 5:5 by mass.
3. A fiber reinforced cement composition comprising the following raw materials:
not less than 28% by mass and not more than 32% by mass of a hydraulic inorganic material;
not less than 54% by mass and not more than 58% by mass of a siliceous material;
not less than 8% by mass and not more than 12% by mass of a woody reinforcement;
not less than 1% by mass and not more than 5% by mass of a fiber reinforced cement particles of a fiber reinforced cement product;
not less than 3% by mass and not more than 10% by mass of fiber reinforced cement particles of a fiber reinforced cement intermediate product;
not less than 2% by mass and not more than 5% by mass of mica; and
not less than 0.5% by mass and not more than 1.25% by mass of polyvinyl alcohol resin, wherein
the fiber reinforced cement particles of the fiber reinforced cement product has average particle size of 15-50 μm,
the fiber reinforced cement particles of the fiber reinforced cement intermediate product are obtained by grinding and/or milling a green sheet which is obtained by forming slurry of raw materials and/or a green mat which is obtained by rolling up on a making roll to have a multi-layer structure and separating from the making roll and/or a press mat which is obtained by pressing a green mat and/or a hardening mat which is hardened by a press mat and/or a cured mat which is obtained by curing the hardening mat and/or a defective article thereof, and
the woody reinforcement comprises needle-leaves-tree unbleached kraft pulp and/or needle-leaves-tree bleached kraft pulp and used newspaper.
4. The fiber reinforced cement composition according to claim 3 , wherein
the hydraulic inorganic material is portland cement,
the siliceous material is pearlstone and fly ash,
the amount of fly ash is not less than 25% by mass and not more than 75% by mass of the whole siliceous material consisting of pearlstone and fly ash,
the amount of the used newspaper is not less than 20% by mass and not more than 50% by mass of the whole woody reinforcement consisting of used newspaper and the needle-leaves-tree unbleached kraft pulp and/or the needle-leaves-tree bleached kraft pulp.
5. The fiber reinforced cement composition according to claim 1 , wherein,
the amount of the siliceous material is not less than 50% by mass and not more than 65% by mass,
the amount of the woody reinforcement is not less than 5% by mass and not more than 12% by mass,
the amount of the mica is not less than 1% by mass and not more than 7% by mass, and
the amount of the polyvinyl alcohol resin not less than 0.25% by mass and not more than 1.5% by mass.
6. A fiber reinforced cement product comprising the following raw materials:
a hydraulic inorganic material;
a siliceous material, a woody reinforcement;
fiber reinforced cement particles of a fiber reinforced cement product and/or fiber reinforced cement particles of a fiber reinforced cement intermediate product;
mica; and
polyvinyl alcohol resin, wherein
the hydraulic inorganic material is contained in the amount of 28-45% by mass,
the fiber reinforced cement particles of the fiber reinforced cement product has average particle size of 15-50 μm,
the fiber reinforced cement particles of the fiber reinforced cement intermediate product are obtained by grinding and/or milling a green sheet which is obtained by forming slurry of raw materials and/or a green mat which is obtained by rolling up on a making roll to have a multi-layer structure and separating from the making roll and/or a press mat which is obtained by pressing a green mat and/or a hardening mat which is hardened by a press mat and/or a cured mat which is obtained by curing the hardening mat and/or a defective article thereof,
the fiber reinforced cement particles of the fiber reinforced cement product is contained in the amount of 1-5% by mass and/or the fiber reinforced cement particles of the fiber reinforced cement intermediate product is contained in the amount of 3-10% by mass, and
the woody reinforcement comprises needle-leaves-tree unbleached kraft pulp and/or needle-leaves-tree bleached kraft pulp and used newspaper.
7. The fiber reinforced cement product according to claim 6 , wherein
the ratio of the total amount of the fiber reinforced cement particles of the fiber reinforced cement intermediate product being obtained by grinding and/or milling the green sheet and/or the green mat and/or the press mat to the total amount of the fiber reinforced cement particles of the fiber reinforced cement intermediate product being obtained by grinding and/or milling the hardening mat and/or the cured mat and/or the fiber reinforced cement product is in a range of from 9:1 to 5:5 by mass.
8. The fiber reinforced cement product according to claim 6 , wherein,
the amount of the siliceous material is not less than 50% by mass and not more than 65% by mass,
the amount of the woody reinforcement is not less than 5% by mass and not more than 12% by mass,
the amount of the mica is not less than 1% by mass and not more than 7% by mass, and
the amount of the polyvinyl alcohol resin not less than 0.25% by mass and not more than 1.5% by mass.
9. A fiber reinforced cement product comprising the following raw materials:
not less than 28% by mass and not more than 32% by mass of a hydraulic inorganic material;
not less than 54% by mass and not more than 58% by mass of a siliceous material;
not less than 8% by mass and not more than 12% by mass of a woody reinforcement;
not less than 1% by mass and not more than 5% by mass of a fiber reinforced cement particles of a fiber reinforced cement product;
not less than 3% by mass and not more than 10% by mass of fiber reinforced cement particles of a fiber reinforced cement intermediate product;
not less than 2% by mass and not more than 5% by mass of mica; and
not less than 0.5% by mass and not more than 1.25% by mass of polyvinyl alcohol resin, wherein
the fiber reinforced cement particles of the fiber reinforced cement product has average particle size of 15-50 μm,
the fiber reinforced cement particles of the fiber reinforced cement intermediate product are obtained by grinding and/or milling a green sheet which is obtained by forming slurry of raw materials and/or a green mat which is obtained by rolling up on a making roll to have a multi-layer structure and separating from the making roll and/or a press mat which is obtained by pressing a green mat and/or a hardening mat which is hardened by a press mat and/or a cured mat which is obtained by curing the hardening mat and/or a defective article thereof, and
the woody reinforcement comprises needle-leaves-tree unbleached kraft pulp and/or needle-leaves-tree bleached kraft pulp and used newspaper.
10. The fiber reinforced cement product according to claim 9 , wherein
the hydraulic inorganic material is portland cement,
the siliceous material is pearlstone and fly ash,
the amount of fly ash is not less than 25% by mass and not more than 75% by mass of the whole siliceous material consisting of pearlstone and fly ash, and
the amount of the used newspaper is not less than 20% by mass and not more than 50% by mass of the whole woody reinforcement consisting of used newspaper and the needle-leaves-tree unbleached kraft pulp and/or the needle-leaves-tree bleached kraft pulp.
11. A process for manufacturing a fiber reinforced cement product which comprises the following steps:
preparing a slurry of raw materials by dispersing in water following raw materials:
a hydraulic inorganic material;
a siliceous material, a woody reinforcement;
fiber reinforced cement particles of a fiber reinforced cement product and/or fiber reinforced cement particles of a fiber reinforced cement intermediate product;
mica; and
polyvinyl alcohol resin, wherein
the hydraulic inorganic material is contained in the amount of 28-45% by mass,
the fiber reinforced cement particles of the fiber reinforced cement product has average particle size of 15-50 mm,
the fiber reinforced cement particles of the fiber reinforced cement intermediate product are obtained by grinding and/or milling a green sheet which is obtained by forming slurry of raw materials and/or a green mat which is obtained by rolling up on a making roll to have a multi-layer structure and separating from the making roll and/or a press mat which is obtained by pressing a green mat and/or a hardening mat which is hardened by a press mat and/or a cured mat which is obtained by curing the hardening mat and/or a defective article thereof,
the fiber reinforced cement particles of the fiber reinforced cement product is contained in the amount of 1-5% by mass and/or the fiber reinforced cement particles of the fiber reinforced cement intermediate product is contained in the amount of 3-10% by mass, and
the woody reinforcement comprises needle-leaves-tree unbleached kraft pulp and/or needle-leaves-tree bleached kraft pulp and used newspaper;
forming the slurry of raw materials to obtain a green mat by;
press-molding the green mat to obtain a press mat; and
curing the press mat in autoclave.
12. The process for manufacturing the fiber reinforced cement product according to claim 11 , wherein
the ratio of the total amount of the fiber reinforced cement particles of the fiber reinforced cement intermediate product being obtained by grinding and/or milling the green sheet and/or the green mat and/or the press mat to the total amount of the fiber reinforced cement particles of the fiber reinforced cement intermediate product being obtained by grinding and/or milling the hardening mat and/or the cured mat and/or the fiber reinforced cement product is in a range of from 9:1 to 5:5 by mass.
13. The process for manufacturing the fiber reinforced cement product according to claim 11 , wherein,
the amount of the siliceous material is not less than 50% by mass and not more than 65% by mass,
the amount of the woody reinforcement is not less than 5% by mass and not more than 12% by mass,
the amount of the mica is not less than 1% by mass and not more than 7% by mass, and
the amount of the polyvinyl alcohol resin not less than 0.25% by mass and not more than 1.5% by mass.
14. A process for manufacturing a fiber reinforced cement product which comprises the following steps:
preparing a slurry of raw materials by dispersing in water following raw materials:
not less than 28% by mass and not more than 32% by mass of a hydraulic inorganic material;
not less than 54% by mass and not more than 58% by mass of a siliceous material;
not less than 8% by mass and not more than 12% by mass of a woody reinforcement;
not less than 1% by mass and not more than 5% by mass of a fiber reinforced cement particles of a fiber reinforced cement product;
not less than 3% by mass and not more than 10% by mass of fiber reinforced cement particles of a fiber reinforced cement intermediate product;
not less than 2% by mass and not more than 5% by mass of mica; and
not less than 0.5% by mass and not more than 1.25% by mass of polyvinyl alcohol resin, wherein
the fiber reinforced cement particles of the fiber reinforced cement product has average particle size of 15-50 μm,
the fiber reinforced cement particles of the fiber reinforced cement intermediate product are obtained by grinding and/or milling a green sheet which is obtained by forming slurry of raw materials and/or a green mat which is obtained by rolling up on a making roll to have a multi-layer structure and separating from the making roll and/or a press mat which is obtained by pressing a green mat and/or a hardening mat which is hardened by a press mat and/or a cured mat which is obtained by curing the hardening mat and/or a defective article thereof, and
the woody reinforcement comprises needle-leaves-tree unbleached kraft pulp and/or needle-leaves-tree bleached kraft pulp and used newspaper;
forming the slurry of raw materials to obtain a green mat by;
press-molding the green mat to obtain a press mat; and
curing the press mat in autoclave.
15. The process for manufacturing the fiber reinforced cement product according to claim 14 , wherein
the hydraulic inorganic material is portland cement,
the siliceous material is pearlstone and fly ash,
the amount of fly ash is not less than 25% by mass and not more than 75% by mass of the whole siliceous material consisting of pearlstone and fly ash, and
the amount of the used newspaper is not less than 20% by mass and not more than 50% by mass of the whole woody reinforcement consisting of used newspaper and the needle-leaves-tree unbleached kraft pulp and/or the needle-leaves-tree bleached kraft pulp.