Patent Application
20080072797
In the following paragraphs, some preferred embodiments of the invention will be described with reference to the attached drawing by way of example and not limitation.
It should be understood based on this disclosure that various other modifications can be made by those in the art based on these illustrated embodiments.
Examples 1-16 and Comparisons 1-11 will be illustrated by Embodiment 1 of the present invention.
Table 1 shows the compositions of the raw materials used in Examples 1 to 16 according to the present invention.
The raw materials are mixed in the composition shown in the table, and water is added thereto to give the slurry of raw materials having a solid concentration of 10% by mass.
The slurry is caused to flow down on a felt and formed with dehydration to give a green sheet.
The green sheet is rolled up around a making roll to give a multilayer structure.
When the thickness of the sheet reaches a predetermined value, the sheet is separated from the making roll to give a green mat.
The mat is pressed with a pressure of 5 MPa, hardened and cured at 80° C. for 15 hours, and further cured in an autoclave at 170° C. for 7 hours to provide a fiber reinforced cement product.
Table 2 shows physical properties of the products of Examples 1 to 16 according to the present invention.
Bending strength and Young's modulus are measured using a test piece of 70×200 mm (according to JIS A 1408).
Elongation ratio through water absorption is an elongation ratio of a test piece before and after absorption of water caused by air conditioning the test piece at 60° C. for 3 days and then immersing it in water for 8 days to allow absorption of water.
Contraction ratio through moisture effusion is a contraction ratio of a test piece before and after moisture effusion caused by air conditioning the test piece at 20° C. under RH of 60% for 10 days and then drying it at 80° C. for 10 days to allow moisture effusion.
Microcracking test (cycle) means the number of cycles until cracks occur, wherein one cycle consists of a water absorption-drying procedure repeated 3 times in one week, said procedure consisting of carbonation for 4 days, water absorption for 7 hours and drying at 120° C. for 17 hours.
Freezing and fusion resistance is a percentage of expansion in thickness after 300 cycles according to ASTM C166-B method.
Nailing performance is determined by observing generation of cracks when two fiber reinforced cement products which are laid to overlap with each other by 30 mm according to the lap boarding are pegged with nails of 2.3 mm in diameter and 38 mm in length by means of a nailer gun at the positions of the overlapped part of the products 20 mm inside from the edges of the overlapped part in the longitudinal direction and in the shorter direction in compliance with actual installation.
The mark “◯” denotes no cracking and the mark “×>” denotes generation of cracks.
The presence of crystalline silica was determined by appearance of the peaks observed in crystalline silica such as quartz, tridymite or cristobalite in an X-ray diffraction.
The fiber reinforced cement product of Example 1, in which the amount of fly ash is 14% by mass and the amount of finely dividing fly ash is 42% by mass, has excellent physical properties such as bending strength, elongation ratio through water absorption, contraction ratio through moisture effusion, microcracking test, freezing and fusion resistance, nail performance.
The fiber reinforced cement product of Example 2, in which the amount of fly ash is 28% by mass and the amount of finely dividing fly ash is 28% by mass, has excellent physical properties such as bending strength, elongation ratio through water absorption, contraction ratio through moisture effusion, microcracking test, freezing and fusion resistance, nail performance.
The fiber reinforced cement product of Example 3, in which the amount of fly ash is 42% by mass and the amount of finely dividing fly ash is 14% by mass, has a slightly poor freezing and fusion resistance but has excellent physical properties such as bending strength, elongation ratio through water absorption, contraction ratio through moisture effusion, microcracking test, nail performance.
The fiber reinforced cement product of Example 4, in which the amount of pearlstone is 14% by mass and the amount of finely dividing pearlstone is 42% by mass, has excellent physical properties such as bending strength, elongation ratio through water absorption, contraction ratio through moisture effusion, microcracking test, freezing and fusion resistance, nail performance.
The fiber reinforced cement product of Example 5, in which the amount of pearlstone is 28% by mass and the amount of finely dividing pearlstone is 28% by mass, has excellent physical properties such as bending strength, elongation ratio through water absorption, contraction ratio through moisture effusion, microcracking test, freezing and fusion resistance, nail performance.
The fiber reinforced cement product of Example 6, in which the amount of pearlstone is 42% by mass and the amount of finely dividing pearlstone is 14% by mass, has excellent physical properties such as bending strength, elongation ratio through water absorption, contraction ratio through moisture effusion, microcracking test, freezing and fusion resistance, nail performance.
The fiber reinforced cement product of Example 7, in which the amount of fly ash is 14% by mass and the amount of finely dividing peralstone is 42% by mass, has excellent physical properties such as bending strength, elongation ratio through water absorption, contraction ratio through moisture effusion, microcracking test, freezing and fusion resistance, nail performance.
The fiber reinforced cement product of Example 8, in which the amount of fly ash is 28% by mass and the amount of finely dividing pearlstone is 28% by mass, has excellent physical properties such as bending strength, elongation ratio through water absorption, contraction ratio through moisture effusion, microcracking test, freezing and fusion resistance, nail performance.
The fiber reinforced cement product of Example 9, in which the amount of fly ash is 42% by mass and the amount of finely dividing pearlstone is 14% by mass, has a slightly poor freezing and fusion resistance but has excellent physical properties such as bending strength, elongation ratio through water absorption, contraction ratio through moisture effusion, microcracking test, nail performance.
The fiber reinforced cement product of Example 10, in which the amount of finely dividing fly ash is 42% by mass and the amount of pearlstone is 14% by mass, has excellent physical properties such as bending strength, elongation ratio through water absorption, contraction ratio through moisture effusion, microcracking test, freezing and fusion resistance, nail performance.
The fiber reinforced cement product of Example 11, in which the amount of finely dividing fly ash is 28% by mass and the amount of pearlstone is 28% by mass, has excellent physical properties such as bending strength, elongation ratio through water absorption, contraction ratio through moisture effusion, microcracking test, freezing and fusion resistance, nail performance.
The fiber reinforced cement product of Example 12, in which the amount of finely dividing fly ash is 14% by mass and the amount of pearlstone is 42% by mass, has a slightly poor freezing and fusion resistance but has excellent physical properties such as bending strength, elongation ratio through water absorption, contraction ratio through moisture effusion, microcracking test, nail performance.
The fiber reinforced cement product of Example 13, in which the amount of finely dividing fly ash is 14% by mass and the amount of pearlstone is 34% by mass and the amount of silica fume is 8% by mass, has excellent physical properties such as bending strength, elongation ratio through water absorption, contraction ratio through moisture effusion, microcracking test, freezing and fusion resistance, nail performance.
The fiber reinforced cement product of Example 14, in which the amount of finely dividing fly ash is 28% by mass and the amount of fly ash is 20% by mass and the amount of blast furnace slag is 8% by mass, has excellent physical properties such as bending strength, elongation ratio through water absorption, contraction ratio through moisture effusion, microcracking test, freezing and fusion resistance, nail performance.
The fiber reinforced cement product of Example 15, in which the amount of finely dividing obsidian is 28% by mass and the amount of fly ash is 28% by mass, has excellent physical properties such as bending strength, elongation ratio through water absorption, contraction ratio through moisture effusion, microcracking test, freezing and fusion resistance, nail performance.
The fiber reinforced cement product of Example 14, in which the amount of finely dividing pearlstone is 28% by mass and the amount of bottom ash is 28% by mass, has excellent physical properties such as bending strength, elongation ratio through water absorption, contraction ratio through moisture effusion, microcracking test, freezing and fusion resistance, nail performance.
Table 3 shows the compositions of the raw materials of Comparisons 1 to 11 in which the fiber reinforced cement products were manufactured by a process similar to that in the examples.
Table 4 shows various physical properties of the fiber reinforced cement products of Comparisons 1 to 11 in which the fiber reinforced cement products were measured in a manner similar to that in the examples.
The fiber reinforced cement product of Comparison 1, in which siliceous materials is only fly ash and the amount of fly ash is 56% by mass, has a low absolute dry specific gravity, and has poor physical properties such as bending strength, elongation ratio through water absorption,
contraction ratio through moisture effusion, freezing and fusion resistance.
The fiber reinforced cement product of Comparison 2, in which siliceous materials is only finely dividing fly ash and the amount of finely dividing fly ash is 56% by mass, and has poor physical properties such as microcracking test, nail performance, and product is hard and fragile.
The fiber reinforced cement product of Comparison 3, in which siliceous materials is only pearlstone and the amount of pearlstone is 56% by mass, has a low absolute dry specific gravity, and has poor physical properties such as bending strength, elongation ratio through water absorption, contraction ratio through moisture effusion, freezing and fusion resistance.
The fiber reinforced cement product of Comparison 4, in which siliceous materials is only finely dividing pearlstone and the amount of finely dividing pearlstone is 56% by mass, and has poor physical properties such as microcracking test, nail performance, and product is hard and fragile.
The fiber reinforced cement product of Comparison 5, in which siliceous materials is pearlstone and fly ash, the amount of pearlstone is 14% by mass and the amount of fly ash is 42% by mass, has a low absolute dry specific gravity, and has poor physical properties such as bending strength, elongation ratio through water absorption, contraction ratio through moisture effusion, freezing and fusion resistance.
The fiber reinforced cement product of Comparison 6 in which siliceous materials is pearlstone and fly ash, the amount of pearlstone is 28% by mass and the amount of fly ash is 28% by mass, has a low absolute dry specific gravity, and has poor physical properties such as bending strength, elongation ratio through water absorption, contraction ratio through moisture effusion, freezing and fusion resistance.
The fiber reinforced cement product of Comparison 7, in which siliceous materials is pearlstone and fly ash, the amount of pearlstone is 42% by mass and the amount of fly ash is 14% by mass, has a low absolute dry specific gravity, and has poor physical properties such as bending strength, elongation ratio through water absorption, contraction ratio through moisture effusion, freezing and fusion resistance.
The fiber reinforced cement product of Comparison 8, in which siliceous materials is fly ash and silica fume, the amount of fly ash is 42% by mass and the amount of silica fume is 14% by mass, and has poor physical properties such as microcracking test, nail performance, and product is hard and fragile.
The fiber reinforced cement product of Comparison 9, in which siliceous materials is fly ash and silica fume, the amount of fly ash is 28% by mass and the amount of silica fume is 28% by mass, and has poor physical properties such as microcracking test and nail performance, and product is hard and fragile.
The fiber reinforced cement product of Comparison 10, in which siliceous materials is fly ash and silica fume, the amount of fly ash is 14% by mass and the amount of silica fume is 42% by mass, and has poor physical properties such as microcracking test and nail performance, and product is hard and fragile.
The fiber reinforced cement product of Comparison 11, in which siliceous materials is blast furnace slag and silica fume, the amount of blast furnace slag is 28% by mass and the amount of silica fume is 28% by mass, and has poor physical properties such as microcracking test and nail performance, and product is hard and fragile.
This application is a Continuation-in-Part Application of prior U.S. patent application Ser. No. 11/527,712, filed Sep. 27, 2006, the contents of which are incorporated herein by reference. PCT/JP2005/015667 U.S. patent application Ser. No. 11/215,964 U.S. patent application Ser. No. 11/354,241 U.S. patent application Ser. No. 11/410,311 U.S. patent application Ser. No. 11/431,652
| Number | Date | Country | |
|---|---|---|---|
| Parent | 11527712 | Sep 2006 | US |
| Child | 11598815 | US |
