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 excellent in bending strength, dimensional stability and installing property such as handling property, flexibility performance and nail performance, as well as a process for manufacturing the product. Namely, the fiber reinforced cement composition comprises the following raw materials: a hydraulic inorganic material, a siliceous material and a woody reinforcement, wherein the siliceous material is an inorganic hollow material and/or an inorganic spherical material and a finely dividing inorganic hollow material and/or a finely dividing inorganic spherical material. The effects of the present invention, it is possible to obtain a fiber reinforced cement product having good bending strength, dimensional stability and installing property such as handling property, flexibility performance and nail performance.
1. A fiber reinforced cement composition comprising the following raw materials:
a hydraulic inorganic material;
a siliceous material;
a woody reinforcement;
mica; and
polyvinyl alcohol resin, wherein
the siliceous material comprises an inorganic hollow material having average particle size of 50-300 μm and/or an inorganic spherical material having average particle size of 15-50 μm and a inorganic material having average particle size of 1-15 μm,
the inorganic hollow material having average particle size of 50-300 μm comprises at least one material selected from the group consisting of fly ash, expanded perlite and shirasu balloon,
the inorganic spherical material having average particle size of 15-50 μm comprises at least one material selected from the group consisting of fly ash and shirasu balloon,
the inorganic material having average particle size of 1-15 μm comprises at least one material selected from the group consisting of fly ash, expanded perlite and shirasu balloon, 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 inorganic hollow material having average particle size of 50-300 μm is expanded perlite and the inorganic spherical material having average particle size of 15-50 μm is fly ash.
3. The fiber reinforced cement composition according to claim 1 , wherein the hydraulic inorganic material is a portland cement.
4. The fiber reinforced cement composition according to claim 1 , wherein the woody reinforcement is a mixture of the needle-leaves-tree unbleached kraft pulp and/or the needle-leaves-tree bleached kraft pulp and used newspaper in a ratio of the needle-leaves-tree unbleached kraft pulp and/or the needle-leaves-tree bleached kraft pulp to the used newspaper in a range of from 1:1 to 4:1.
5. A fiber reinforced cement composition comprising the following raw materials:
not less than 25% by mass and not more than 45% by mass of a hydraulic inorganic material;
not less than 5% by mass and not more than 12% by mass of a woody reinforcement;
not less than 50% by mass and not more than 65% by mass of a siliceous material;
not less than 1% by mass and not more than 7% by mass of mica; and
not less than 0.25% by mass and not more than 1.5% by mass of polyvinyl alcohol resin, wherein
the siliceous material comprises an inorganic hollow material having average particle size of 50-300 μm and/or an inorganic spherical material having average particle size of 15-50 μm and a inorganic material having average particle size of 1-15 μm,
the inorganic hollow material having average particle size of 50-300 μm comprises at least one material selected from the group consisting of fly ash, expanded perlite and shirasu balloon,
the inorganic spherical material having average particle size of 15-50 μm comprises at least one material selected from the group consisting of fly ash and shirasu balloon,
the inorganic material having average particle size of 1-15 μm comprises at least one material selected from the group consisting of fly ash, expanded perlite and shirasu balloon,
the inorganic material having average particle size of 1-15 μm is contained in the amount of not less than 25% by mass and not more than 75% by mass of whole siliceous material consisting of the inorganic hollow material having average particle size of 50-300 μm and/or the inorganic spherical material having average particle size of 15-50 μm and the inorganic material having average particle size of 1-15 μm, and
the woody reinforcement comprises needle-leaves-tree unbleached kraft pulp and/or needle-leaves-tree bleached kraft pulp and used newspaper.
6. The fiber reinforced cement composition according to claim 5 , wherein
the hydraulic inorganic material is a portland cement,
the woody reinforcement is a mixture of the needle-leaves-tree unbleached kraft pulp and/or the needle-leaves-tree bleached kraft pulp and used newspaper in a ratio of the needle-leaves-tree unbleached kraft pulp and/or the needle-leaves-tree bleached kraft pulp to the used newspaper in a range of from 1:1 to 4:1, and
the inorganic hollow material having average particle size of 50-300 μm is expanded perlite and the inorganic spherical material having average particle size of 15-50 μm is fly ash.
7. A fiber reinforced cement product manufactured from the fiber reinforced cement composition according to claim 5 .
8. A fiber reinforced cement product manufactured from the fiber reinforced cement composition according to claim 6 .
9. A fiber reinforced cement product manufactured from the fiber reinforced cement composition according to claim 1 .
10. A fiber reinforced cement product manufactured from the fiber reinforced cement composition according to claim 2 .
11. A fiber reinforced cement product manufactured from the fiber reinforced cement composition according to claim 3 .
12. A fiber reinforced cement product manufactured from the fiber reinforced cement composition according to claim 4 .
13. A process for manufacturing a fiber reinforced cement product comprising the steps of:
dispersing in water a raw material composition comprising as main raw materials:
a hydraulic inorganic material;
a siliceous material;
a woody reinforcement;
mica; and
polyvinyl alcohol resin, wherein
the siliceous material comprises an inorganic hollow material having average particle size of 50-300 μm and/or an inorganic spherical material having average particle size of 15-50 μm and a inorganic material having average particle size of 1-15 μm,
the inorganic hollow material having average particle size of 50-300 μm comprises at least one material selected from the group consisting of fly ash, expanded perlite and shirasu balloon,
the inorganic spherical material having average particle size of 15-50 μm comprises at least one material selected from the group consisting of fly ash and shirasu balloon,
the inorganic material having particle size of 1-15 μm comprises at least one material selected from the group consisting of fly ash, expanded perlite and shirasu balloon, and
the woody reinforcement comprises needle-leaves-tree unbleached kraft pulp and/or needle-leaves-tree bleached kraft pulp and used newspaper, so as to give a slurry of the raw materials;
forming a green mat from the slurry; and
pressing the green mat by press molding and thereafter curing the mat in an autoclave.
14. The process for manufacturing the fiber reinforced cement product according to claim 13 , wherein the inorganic hollow material is expanded perlite and the inorganic spherical material is fly ash.
15. The process for manufacturing the fiber reinforced cement product according to claim 13 , wherein the hydraulic inorganic material is a portland cement.
16. The process for manufacturing the fiber reinforced cement product according to claim 13 , wherein the woody reinforcement is a mixture of the needle-leaves-tree unbleached kraft pulp and/or the needle-leaves-tree bleached kraft pulp and used newspaper in a ratio of the needle-leaves-tree unbleached kraft pulp and/or the needle-leaves-tree bleached kraft pulp to the used newspaper in a range of from 1:1 to 4:1.
17. A process for manufacturing a fiber reinforced cement product comprising the steps of:
dispersing in water a raw material composition comprising as main raw materials:
not less than 25% by mass and not more than 45% by mass of a hydraulic inorganic material;
not less than 5% by mass and not more than 12% by mass of a woody reinforcement;
not less than 50% by mass and not more than 65% by mass of a siliceous material;
not less than 1% by mass and not more than 7% by mass of mica; and
not less than 0.25% by mass and not more than 1.5% by mass of polyvinyl alcohol resin, wherein
the siliceous material comprises an inorganic hollow material having average particle size of 50-300 μm and/or an inorganic spherical material having average particle size of 15-50 μm and a inorganic material having average particle size of 1-15 μm,
the inorganic hollow material having average particle size of 50-300 μm comprises at least one material selected from the group consisting of fly ash, expanded perlite and shirasu balloon,
the inorganic spherical material having average particle size of 15-50 μm comprises at least one material selected from the group consisting of fly ash and shirasu balloon,
the inorganic material having average particle size of 1-15 μm comprises at least one material selected from the group consisting of fly ash, expanded perlite and shirasu balloon,
the inorganic material having average particle size of 1-15 μm is contained in the amount of not less than 25% by mass and not more than 75% by mass of whole siliceous material consisting of the inorganic hollow material having average particle size of 50-300 μm and/or the inorganic spherical material having average particle size of 15-50 μm and the inorganic material having average particle size of 1-15 μm,
the woody reinforcement comprises needle-leaves-tree unbleached kraft pulp and/or needle-leaves-tree bleached kraft pulp and used newspaper, so as to give a slurry of the raw materials;
forming a green mat from the slurry; and
pressing the green mat by press molding and thereafter curing the mat in an autoclave.
18. The process for manufacturing a fiber reinforced cement product according to claim 17 , wherein
the hydraulic inorganic material is a portland cement,
the woody reinforcement is a mixture of the needle-leaves-tree unbleached kraft pulp and/or the needle-leaves-tree bleached kraft pulp and used newspaper in a ratio of the needle-leaves-tree unbleached kraft pulp and/or the needle-leaves-tree bleached kraft pulp to the used newspaper in a range of from 1:1 to 4:1, and
the inorganic hollow material is expanded perlite and the inorganic spherical material is fly ash.