Hard ceramic body

Abstract: A hard ceramic body is produced by mixing a first powder material which includes silicon dioxide, calcium oxide, and aluminum compound and a second powder material which serves as aggregates with water-glass, and curing a resultant mixture. The hard ceramic body is curable at a normal temperature and identical in physical characteristics to a common tile.

Description: The present invention relates to a hard ceramic body for use as an exterior-wall covering material for a building structure or as a heat-resistant covering material for a furnace. Tile is one of such exterior-wall covering materials. Tiles have good resistance to heat and weather as well as excellent appearance. When a building structure is covered with exterior tiles, its fire resistance and durability will be increased with better appearance. However, commercial tiles are produced through calcination at a high temperature and their size is thus limited to substantially 30 cm square at best. This increases the cost per piece and external walls covered with tiles will be highly expensive as compared with ordinary materials. In view of the forgoing aspects, we, the inventors, have developed a novel material which is identical to tiles in the resistance to heat and weather and good appearance but is produced without a calcinating process at a high temperature which restricts the overall size of the material. An object of the present invention is to provide a hard ceramic body which is cured at a normal temperature and has characteristics equal to those of a tile. EP-A-0417583 relates to a process for the preparation of a hardened body. A hard ceramic body according to the present invention is obtainable by mixing and curing ingredients, said ingredients comprising: (i) a first powder material composed of: (a) from 30 to 50 wt.% of an electric-furnace steelmaking slag in the form of granules of less than 120 µm in diameter, said slag including 15 wt.% or more of silicon dioxide and 25 wt.% or more of calcium oxide; (b) from 30 to 50 wt.% of silicon dioxide in the form of silica powders of from 0.1 µm to 1 µm in diameter; and (c) from 10 to 30 wt.% of either aluminium oxide or aluminium hydroxide in the form of granules of from 0.5 µm to 100 µm in diameter; (ii) a second powder material of silica sand in the form of aggregates; and (iii) water-glass. The hard ceramic body of the present invention has good resistance to heat and weather, and exhibits no change in both a heat-resistance test conducted at 1050 °C for three hours and a weather-resistance test conducted for 1,000 hours with the use of a weatherometer. Its compressive strength can be as high as 1,000 to 3,000 kgf/cm 2 and its hardness can be 4 to 6 in Mohs scale, which characteristics can meet properties required for use as exterior-wall covering materials, to the extent that can be provided by tiles. The hard ceramic body of the present invention is also desirable for use as a heat resistant material in a furnace. When cured at a normal temperature, the hard ceramic body of the present invention can provide so high strength characteristics as described above that its size can be easily increased to a large dimension over one meter. For example, a commonly available size such as a curtain wall panel for a building structure can be made of one or a minimum number of the hard ceramic bodies. Such an exterior-wall covering material made of one or more of the hard ceramic bodies will hence be reduced in the cost while having a quality equal to that of a conventional tile coating. The hard ceramic body of the present invention can be cured after sprayed or painted over a base material. This technique is useful for making external sidings of a building structure and particularly desirable for providing a heat-resistant wall in a furnace. The hard ceramic body of the present invention having the above ingredients is characterized by employing water-glass for mixing, and controlling the dosage of calcium oxide to a predetermined percentage. Mixing of the powder materials as formulated above with the water-glass guarantees a quality of the ceramic body. The predetermined percentage of calcium oxide determines curing speed, thereby various curing time required for forming a desired product can be secured. The relation between the curing time and the percentage of calcium oxide is shown in Fig. 1. As apparent, the dosage of calcium oxide in the total of the powder materials is preferably 0.05 to 20 wt%. The second powder material which serves as aggregates may preferably be silica sand of 0.1 to 2 mm in diameter. The physical characteristics of the finished hard ceramic body largely depend on the size of those powder materials and the above mentioned diameters are most desirable. The first powder material in the hard ceramic body is composed of a mixture of 30 to 50 wt% of an electric-furnace steelmaking slag, 30 to 50 wt% of silicon dioxide in the form of silica powders of 0.1 to 1 µ m in diameter, and 10 to 30 wt% of either aluminum oxide or aluminum hydroxide in the form of granules of 0.5 to 100 µ m in diameter. The slag is less than 120 µ m in granule diameter and includes 15 wt% or more of silicon dioxide, 25 wt% or more of calcium oxide. The slag is similar in the composition to slag produced by a common electric furnace steelmaking process and may hence be available from the electric furnace steelmaking industry. More particularly, the hard ceramic body according to the present invention preferably comprises 30 to 50 wt% of the first powder material, 30 to 50 wt% of the second powder material, and 10 to 30 wt% of the water-glass, in order to provide the foregoing characteristics. Fig. 1 is a graph showing a relation between curing time and dosage of calcium oxide. In one embodiment the components (weight percentage) of the first powder material,not in accordance with the present invention, are as follows: Common portland cement 8 Silica fume (SiO 2 ), 0.1 um in diameter 31 Fly ash, 0.7 to 70 um in diameter 61 The portland cement consists essentially of about 23 % of silica, about 5 % of alumina, and about 65 % of calcium oxide. The fly ash consists essentially of about 56 % of silica and about 30 % of aluminum oxide. The second powder material is silica sand of 100 to 300 µ m in granule diameter. The water-glass may be a potassium water-glass including 24 wt% of K 2 O, 21.4 wt% of SiO 2 , and 53.3 wt% of water, or a sodium water-glass including 17.9 wt% of Na 2 O, 25.9 wt% of SiO 2 , and 53.6 wt% of water. Lithium water-glass may also be used, however it is costly and impractical. A 10-mm thick board of hard ceramic body was produced by mixing the first and second powder materials with the water-glass in the following ratio (wt%), pouring a resultant mixture into a pair of molds, and maintaining the mixture for 24 hours for curing. First powder material 39.9 Second powder material 39.9 Water-glass 20.2 Then, the hard ceramic board was quickly dried out at 150°C for three hours and measured for physical characteristics. The resultant measurements are: Specific gravity 1.8 Compressive strength (kgf/cm 2 ) 1120 Mohs hardness 5 Water absorption (immersed in water at 20°C for 72 hours) 0.0002 Heat-resistance (at 1050°C for 3 hours) no change Weather-resistance (1000 hours with weatherometer) no change In an embodiment of the present invention, portland cement in the first powder material is substituted by slag. The slag is supplied from an electric furnace steelmaking plant (for example, Daido slag, a tradename of Daido Steel Co., Ltd.). The slag contains (wt%): Silicon dioxide (SiO 2 ) 20.56 Calcium oxide (CaO) 32.83 Total iron 13.67 Magnesium oxide (MaO) 9.28 Aluminum oxide (Al 2 O 3 ) 8.66 Manganese oxide (MnO) 4.21 Total chrome (Cr) 1.50 Titanium oxide (TiO 2 ) 0.46 Others 8.83 The first powder material comprises (wt%): Electric furnace slag with a granule diameter of under 97 µm 40 Silica fume (SiO 2 ) with a granule diameter of 0.2 to 0.5 µm 40 Aluminum hydroxide (Al(OH) 3 ) with a granule diameter of 1 to 10 µm 20 The second powder material is silica sand having a granule diameter of 0.2 to 1 mm. The water-glass is the same as of the previous embodiment. A 10-mm thick board of the hard ceramic body was produced by mixing the first and second powder materials with the water-glass in the following ratio (wt%), pouring a resultant mixture into a pair of molds, and maintaining the mixture for 6 hours for curing. First powder material 39.9 Second powder material 39.9 Water-glass 20.2 Then, the hard ceramic board was quickly dried out at 150 C for three hours and measured for physical characteristics. The resultant measurements are: Specific gravity 2.43 Compressive strength (kgfcm 2 ) 2870 Mohs hardness 6 Water absorption (immersed in water at 20°C for 72 hours) 0.0002 Heat-resistance (at 1050°C for 3 hours) no change Weather-resistance (1000 hours with weatherometer) no change

Claims: A hard ceramic body obtainable by mixing and curing ingredients, said ingredients comprising: (i) a first powder material composed of: (a) from 30 to 50 wt.% of an electric-furnace steelmaking slag in the form of granules of less than 120 µm in diameter, said slag including 15 wt.% or more of silicon dioxide and 25 wt.% or more of calcium oxide; (b) from 30 to 50 wt.% of silicon dioxide in the form of silica powders of from 0.1 µm to 1 µm in diameter; and (c) from 10 to 30 wt.% of either aluminium oxide or aluminium hydroxide in the form of granules of from 0.5 µm to 100 µm in diameter; (ii) a second powder material of silica sand in the form of aggregates; and (iii) water-glass. A hard ceramic body according to claim 1, wherein calcium oxide is included in the ingredients in an amount of from 0.05 to 20 wt.% A hard ceramic body according to claim 1 or 2 comprising from 30 to 50 wt.% of the first powder material (i), from 30 to 50 wt.% of the second powder material (ii), and from 10 to 30 wt.% of the water-glass (iii). A hard ceramic body according to any one of the preceding claims, wherein the second powder material (ii) is silica sand of from 0.1 to 2 mm diameter, preferably from 0.2 to 1 mm. A hard ceramic body according to any one of the preceding claims, wherein said electric-furnace steelmaking slag (a) in said first powder material (i) has a granule diameter of less than 97 µm. A hard ceramic body according to any one of the preceding claims, wherein said silicon dioxide in the form of silica powders (b) in said first powder material (i) is silica fume having a granule diameter of from 0.2 µm to 0.5 µm. A hard ceramic body according to any one of the preceding claims, wherein said aluminium hydroxide (c) in said first powder material (i) has a granule diameter of from 1 µm to 10 µm. An exterior-wall covering material for a building structure or for a heat-resistant covering material for a furnace, which covering material is formed from a hard ceramic body according to any one of the preceding claims. A process for making a hard ceramic body for use as an exterior-wall covering material for a building structure or for use as a heat-resistant covering material for a furnace, which process comprises: (1) mixing the following ingredients: (i) a first powder material composed of: (a) from 30 to 50 wt.% of an electric-furnace steelmaking slag in the form of granules of less than 120 µm in diameter, said slag including 15 wt.% or more of silicon dioxide and 25 wt.% or more of calcium oxide; (b) from 30 to 50 wt.% of silicon dioxide in the form of silica powders of from 0.1 µm to 1 µm in diameter; and (c) from 10 to 30 wt.% of either aluminium oxide or aluminium hydroxide in the form of granules of from 0.5 µm to 100 µm in diameter; (ii) a second powder material of silica sand in the form of aggregates; and (iii) water-glass; and (2) curing the resulting mixture.

Inventors: MATSUURA KATSUHARU, TANABE KEIZO, MATSUURA, KATSUHARU, TANABE, KEIZO, Tanabe, Keizo, c/o Kurosawa Construction Co., Ltd.
Applicants: KUROSAWA KENSETSU KK, REFLEX CO LTD, KUROSAWA CONSTRUCTION CO., LTD., REFLEX CO., LTD.
Application year: 1997
Main classification: C04B28
IPC codes: C04B28