Construction material composition, construction material, coating composition and waste construction material soil conversion method

Abstract

The object of the present invention is to provide a construction and coating composition that effectively utilizes vermiculite as a natural resource and is able to satisfy requirements for humidity control and/or deodorizing as well as an attractive appearance, while also offering superior balance between the amount and rates of moisture absorption and release, in particular. This object is achieved by a composition in which non-expanded vermiculite is blended into a base material so that the blended amount is 5-70 wt % of the total composition (solid portion). In addition, the above construction material can be converted into soil by crushing when it has become a waste construction material.

1 . A construction material composition comprising: a base material comprising calcium silicate and 5-70 wt % of the total composition of an unexpanded, activated vermiculite, wherein the vermiculite is activated by a steam treatment to produce a material with improved moisture conditioning and adsorption performance.  
   
   
       2 . The construction material composition according to  claim 1  wherein the base material has 10-50 wt % of vermiculite.  
   
   
       3 . The construction material composition according to  claim 1  wherein the base material is hydrophilic.  
   
   
       4 . The construction material composition according to  claim 1  wherein the vermiculite is activated after blending.  
   
   
       5 . The construction material composition according to  claim 1  wherein the steam is a saturated vapor pressure steam at 105-200° C.  
   
   
       6 . The construction material composition according to  claim 1  further comprising a reinforcing material.  
   
   
       7 . A production method of a construction material composition comprising: activating a non-expanded vermiculite; and blending a base material with 5-70 wt % of the total composition of the vermiculite, wherein the vermiculite is activated to produce a material with improved moisture conditioning and adsorption performance.  
   
   
       8 . The production method according to  claim 7  wherein the base material is calcium silicate.  
   
   
       9 . A construction article comprised of a composition according to  claim 1 .  
   
   
       10 . The construction article according to  claim 9  wherein the construction material is an interior material.  
   
   
       11 . A construction material according to  claim 1  wherein moisture absorption and release rates in the case of changing the relative humidity from 60-90% are 90% or more of the equilibrium value in 30 minutes for moisture absorption, and equilibrium in 25 minutes or less for moisture release.  
   
   
       12 . A construction material production method comprising: activating non-expanded vermiculite; and blending a base material with 5-70 wt % of the total composition of the vermiculite, wherein the vermiculite is activated to produce a material with improved moisture conditioning and adsorption performance.  
   
   
       13 . A construction material composition comprising: a base material comprising calcium silicate, blended with 2.5-20 wt % of the total composition of expanded vermiculite, and 5-70 wt % of the total composition of an unexpanded vermiculite in an activated state, wherein the unexpanded vermiculite is activated by steam treatment to produce a material with improved moisture conditioning and adsorption performance.  
   
   
       14 . The construction material composition according to  claim 13  wherein the amount of unexpanded vermiculite in an activated state is 10-50 wt % of the total composition.  
   
   
       15 . A production method of a construction material composition comprising: blending a base material with 5-70 wt % of the total composition of non-expanded vermiculite in an activated state and 2.5-20 wt % of the total composition of an expanded vermiculite to obtain a construction material composition, and further comprising molding the blended material composition to produce a construction material.  
   
   
       16 . The construction material production method according to  claim 15  wherein molding is sheet molding, extrusion molding, press molding or casting.  
   
   
       17 . The construction material according to  claim 13  wherein the construction material is an interior material.  
   
   
       18 . A construction material composition comprising: a base material comprising calcium silicate blended with 0.5-70 wt % of the total composition of an unexpanded vermiculite in an activated state, wherein the unexpanded vermiculite is activated by a steam treatment, wherein the portion of the vermiculite having a particle size of 300 μm or less is 0.5-15 wt % of the total composition.  
   
   
       19 . The construction material composition according to  claim 18  wherein the unexpanded vermiculite in an activated state is a fine powder, of which 90% or more is 300 μm or less, blended into the base material in an amount of 0.5-15 wt % of the total composition.  
   
   
       20 . The construction material composition according to  claim 18  wherein the unexpanded vermiculite in an activated state is a fine powder, of which 90% or more is 300 μm or less, blended into the base material in an amount of 0.5-10 wt % of the total composition.  
   
   
       21 . The construction material composition according to  claim 18  wherein the unexpanded vermiculite in an activated state is a fine powder of which 90% or more is 300 μm or less, blended into the base material in an amount of 1-5 wt % of the total composition.  
   
   
       22 . A production method of a construction material composition comprising: blending a base material with 0.5-70 wt % of the total composition of a non-expanded vermiculite in an activated state, vermiculite is 0.5-70 wt % of the total composition, wherein the vermiculite is blended so that the portion of the non-expanded vermiculite in an activated state with particle size of 300 μm or less is 0.5-15 wt % of the total composition.  
   
   
       23 . The production method of a construction material composition according to  claim 34  wherein non-expanded vermiculite in an activated state is a fine powder, of which 90% or more is 300 μm or less, blended into the base material in an amount of 0.5-15 wt % of the total composition.  
   
   
       24 . The production method according to  claim 22  wherein the base material is calcium silicate.  
   
   
       25 . A construction article comprised by forming the construction material composition according to  claim 18 .  
   
   
       26 . A construction material production method comprising the steps of: blending a base material with 0.5-70 wt % of the total composition of non-expanded vermiculite in an activated state, wherein the activated vermiculite having a particle size of 300 μm or less is 0.5-15 wt % of the total composition to obtain a construction material composition; and further comprising molding the blended material to obtain a construction material.  
   
   
       27 . The construction material production method according to  claim 26 , wherein non-expanded vermiculite in an activated state is a fine powder of which 90% or more is 300 μm or less, blended into the base material in an amount of 0.5-15 wt % of the total composition.  
   
   
       28 . A coating composition comprising (A) substantially non-expanded vermiculite in an activated state; (B) organic binder; and/or (C) inorganic binder; and a hygroscopic material in which the specific surface area as determined by BET is 10 m 2 /g or more.  
   
   
       29 . The coating composition according to  claim 28  wherein the (B) organic binder is selected from a paint and/or paste.  
   
   
       30 . The coating composition according to  claim 29  wherein the paint is selected from an acrylic, urethane, epoxy, polyester, silicone, vinyl chloride, vinyl acetate, polyvinyl alcohol, polyvinyl butyral or styrene-butadiene resin or emulsion paints.  
   
   
       31 . The coating composition according to  claim 29  wherein the paste is selected from the group consisting of alginates, starch, mannan, dextrin, protein and methylcellulose pastes.  
   
   
       32 . The coating composition according to  claim 28  wherein the (C) inorganic binder is a hydraulic material.  
   
   
       33 . The coating composition according to  claim 32  wherein the hydraulic material is cement or hemihydrate gypsum.  
   
   
       34 . The coating composition according to  claim 28  wherein the hygroscopic material is selected from the group consisting of calcium silicate, diatomaceous earth, zeolite or allophane.  
   
   
       35 . The coating composition according to  claim 28  comprising (A) substantially non-expanded vermiculite in an activated state at 5-70 wt %; (B) organic binder; and/or (C) inorganic binder at 5-40 wt %; and (D) hygroscopic material at 0-70 wt % relative to the total composition solid portion.  
   
   
       36 . A coated body comprising the coating of an article to be coated with the coating composition according to  claim 28 .  
   
   
       37 . The coated body according to  claim 36  wherein the article to be coated is a construction material, architectural interior, indoor fixture or any members thereof.  
   
   
       38 . The coated body according to  claim 36  wherein the article to be coated is a joint or repaired portion.  
   
   
       39 . A soil conversion method for waste construction materials comprising: converting waste construction materials to soil by crushing waste construction materials comprising a construction material that has been molded from a construction material composition comprising non-expanded vermiculite blended into a calcium silicate construction material.  
   
   
       40 . A soil conversion method for waste construction materials comprising: converting waste construction materials to soil by crushing waste construction materials comprising a construction material that has been molded from a construction material composition comprising non-expanded vermiculite blended into a calcium silicate containing construction material, and then performing steam treatment.  
   
   
       41 . A soil conversion method for waste construction materials comprising: converting waste construction materials to soil by performing steam treatment on waste construction materials comprised of a construction material that has been molded from a construction material composition comprised by blending non-expanded vermiculite into a calcium silicate construction material, and then crushing.  
   
   
       42 . The waste construction material soil conversion method according to  claim 39  wherein the blended amount of non-expanded vermiculite is 5-70 wt % of the construction material composition.  
   
   
       43 . The construction material soil conversion method according to  claim 40  wherein steam treatment is carried out at 100-200° C.  
   
   
       44 . The soil conversion method according to  claim 39  comprising adding a fertilizer component.  
   
   
       45 . A construction material comprising a fastener joined with a construction material formed by molding a construction composition comprising 5-70 wt % of the total composition of a substantially non-expanded vermiculite into a base material.  
   
   
       46 . The construction material according to  claim 45  wherein the fastener is a nail, machine screw, bolt and nut, tack, staple or pin.  
   
   
       47 . The construction material according to  claim 45  wherein the construction material is an interior material.  
   
   
       48 . The construction material according to  claim 45  wherein the surface of the construction material is shaved with a plane.  
   
   
       49 . The construction material according to  claim 45  wherein the surface of the construction material is carved.  
   
   
       50 . The construction material according to  claim 45  wherein the blended amount is 10-50 wt % of the total composition.  
   
   
       51 . The construction material according to  claim 45  wherein the base material is calcium silicate.  
   
   
       52 . The construction material according to claim  45  wherein the vermiculite is activated.  
   
   
       53 . The construction material according to  claim 45  wherein the molding is sheet molding, extrusion molding, press molding or casting.  
   
   
       54 . A construction material comprising a construction material composition comprising 5-70 wt % of the total composition of a substantially non-expanded vermiculite in an activated state blended into a base material, further comprising a construction material with a surface formed by molding and shaving with a plane.  
   
   
       55 . A construction material comprising a construction material composition comprising 5-70 wt % of the total composition of vermiculite in an activated state blended into a base material, wherein a surface of the construction material is formed by molding and carving.  
   
   
       56 . A construction material joining method comprising joining with a fastener a construction material obtained by blending 5-70 wt % of the total composition of a substantially non-expanded vermiculite in an activated state into a base material, followed by molding that construction material composition.  
   
   
       57 . The construction material joining method according to  claim 56  wherein the fastener is a nail, machine screw, bolt and nut, tack, staple or pin.  
   
   
       58 . The construction material joining method according to  claim 56  wherein the surface of the construction material to be joined is shaved with a plane.  
   
   
       59 . The construction material joining method according to  claim 56  wherein the surface of the construction material is carved.  
   
   
       60 . The construction material soil conversion method according to  claim 41  wherein steam treatment is carried out at 100-200° C.  
   
   
       61 . The construction material production method according to  claim 12  wherein molding is sheet molding, extrusion molding, press molding or casting.