Pore Control of Porous Insulation Ceramics for Building Materials Fabricated by in-situ Solidification Method

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Ceramic materials and processes should be developed capable not only in alleviating such environmental issues, but also providing a recycling system of generated waste. Developing a porous ceramics as outside construction materials will provide the ceramic tile not only lightness, but also other functions such as insulation, machinability and sound absorbability. In this study, the properties of the porous ceramics fabricated by gelcasting using waste resources were investigated. The gelcasting using waste resources has great benefit for the development of endless recycling system. Through gelcasting, the complex methods in the usual fabrication of construction materials are being simplified.This is because the conventional gelcasting system is neuro-toxin and suffered exfoliation under O2 atmosphere. With natural gel forming agent, the impediments of traditional gelcasting are being minimized and allows the porous shaping under ambient condition. The use of Japanese gelatine, as a gelling agent, enabled the setting of mechanically foamed waste-loaded slurry under ambient atmosphere. This process also allows a development of endless recycling system of waste resources to produce ceramic materials with characteristics. The porous ceramics from waste are potential sound insulator as depicted in their superior sound absorption profile upon comparison with commercially available porous ceramics. Porous materials from waste are good thermal insulators that provide coolness and ventilation. Moreover, gelcasting of waste resources offers the possibility of synthesizing the soil structure.Hollow particles are expected as material of porous ceramics. New synthesis process of inorganic hollow particles was developed. This new process to prepare hollow calcium carbonate particles uses bubbles as templates, and successfully prepared hollow calcium carbonate particles by bubbling CO2/N2 mixed gas into CaCl2.