JP2000191381A - Production of lightweight pottery tile - Google Patents

Abstract

PROBLEM TO BE SOLVED: To obtain tiles which are light in weight, enable even an amateur to easily stick the tiles to a wall surface or the like and have a wide variety in appearance by placing the splinters of pottery having a melting point higher than the melting point of main raw material prepared by incorporating a foaming agent into pottery raw material to the surface layer of the main raw material and subjecting the main raw material to dry process press forming, then firing the press formed material. SOLUTION: The foaming agent is the agent which foams at temperature near the melting point of the pottery raw material and the firing is executed under the firing conditions of a heat curve at which the temperature near the melting point of the pottery raw material is the highest temperature. The main raw material is foamed by the firing and is expanded to irregular shapes, by which the splinters of the pottery having the high melting point are fixed on the surface and, therefore, the tiles may be stuck to the inside wall surface of a veranda and may be used as component members for gardening. Silicon carbide is incorporated as the foaming agent at 0.05 to 0.20 wt.% into the raw material of the ordinary pottery tiles and the raw material is fired at the heat curve at which the maximum temperature is 1200 to 1250 deg.C which is same as the foaming temperature of the silicon carbide. The foaming may be well effected by incorporating calcium oxide into the main raw material and adjusting the melting point.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a lightweight ceramic tile which is lightweight, has a rough surface, and has a brick-like appearance having irregular irregularities.

[0002]

2. Description of the Related Art Ordinary ceramic tiles have a specific gravity of 2.3 to 2.3.
Due to its heavy weight of 2.6, it was necessary to firmly attach it to the wall or the like with cement mortar or the like, and it was difficult for an amateur to construct even a small area, and the appearance was monotonous.

[0003]

The problem to be solved by the present invention is to produce a tile that is lightweight, can be easily attached to a wall or the like by a layman, and has a variety of appearances. It is.

[0004]

Means for Solving the Problems, Functions and Effects As a means for solving such problems, the invention of claim 1 is to provide a ceramic raw material with a foamed material which foams at a temperature near the melting point of the ceramic raw material. After placing the crushed ceramic having a melting point higher than that of the main raw material on the surface layer of the mixed main raw material and performing dry press molding, firing is performed using a heat curve having a temperature around the melting point of the ceramic raw material as the maximum temperature. As a result, the main material foams and expands into an irregular shape, and crushed ceramics with a high melting point adhere to the surface, so that the surface becomes rough and has a special aesthetic appearance like brick,
Since it is lightweight, even amateurs can easily attach it to the inner wall surface of the veranda of the apartment and use it as a component for gardening.

According to a second aspect of the present invention, in the first aspect of the invention, since the crushed material having a high melting point is a crushed refractory brick, it is manufactured by using a defective refractory brick or a used product as a raw material. Cost can be reduced.

According to a third aspect of the present invention, in the first or second aspect of the invention, the crushed material is mixed with a ceramic raw material having a melting point substantially the same as that of the main raw material. An object can be firmly fixed to the main body.

According to a fourth aspect of the present invention, in the third aspect of the present invention, the pigment which is colored by firing is mixed into the ceramic material mixed in the crushed material. The desired color can be obtained.

According to a fifth aspect of the present invention, in the third or fourth aspect of the present invention, vitreous particles are mixed in the ceramic raw material mixed in the crushed material, so that a shining point is formed on the surface of the fired tile. The appearance can be improved.

The invention according to claim 6 is the invention according to claims 1, 2, 3, and 4.
In the invention of the fifth aspect, since the glaze is applied after the dry press molding, the surface of the fired tile can be made into a desired color by using the conventional production line of the porcelain tile as it is.

The invention of claim 7 is based on claims 1, 2, 3,
In the invention of 4, 5 or 6, the glaze used for glazing contains 40 to 100% by weight of a pigment in a powder state, and has less vitreous components than a glaze for ordinary porcelain tiles. The surface of the later tile becomes rough, giving an appearance similar to brick.

According to an eighth aspect of the present invention, in the invention of the seventh aspect, since the pigment contains 70 to 100% by weight of the pigment in a powder state, the surface of the tile after firing becomes rougher and has an appearance closer to brick. Become.

According to a ninth aspect of the present invention, there is provided an image processing apparatus comprising:
In the invention of 4, 5, 6, 7 or 8, since the melting point of the main raw material is 1200 to 1250 ° C. and the foaming material is silicon carbide, the silicon carbide foams around the melting point of the main body to ensure a lightweight tile. Can be manufactured.

According to a tenth aspect of the present invention,
In the invention of 4, 5, 6, 7, 8 or 9, since calcium oxide is mixed in the main raw material, the melting point of the main body can be adjusted by adjusting the mixing amount, so that the foaming can be favorably performed. .

[0014] The eleventh aspect of the present invention is the first aspect of the present invention.
In the invention of 4, 5, 6, 7, 8, 9 or 10, since the main raw material is produced by drying the slurry with a spray drier and the foam contains a foaming material, The trouble of separately mixing the foam material can be omitted.

According to a twelfth aspect of the present invention,
In the invention of 4, 5, 6, 7, 8, 9, 10 or 11, the double-sided adhesive tape is stuck on the back surface of the fired tile, so that the layman can construct it very easily.

A thirteenth aspect of the present invention is the first aspect of the present invention.
In the invention of 4, 5, 6, 7, 8, 9, 10, 11 or 12, when the main raw material is mixed with a pigment that develops a color that is substantially the same as the surface by baking, the material is cut in the middle and used. In addition, the color of the cut is almost the same color as the surface, and the appearance after the construction is improved.

[0017]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS One embodiment of the present invention will be described below.

First, a raw material for a main porcelain tile is obtained by spraying a slurry obtained by mixing silicon carbide into a raw material of a normal porcelain tile into hot air and instantaneously drying the raw material into granules by using a spray drier. .

As the granular main raw material, a product number C-1451 manufactured by Marumi Ceramics Co., Ltd. is preferable, and 0.05 to 0.20% by weight of silicon carbide is mixed as a foaming material. The melting point is 1200 to 1250 ° C., which is almost the same as the foaming temperature of silicon carbide.

Here, if a pigment that develops a color substantially the same as the surface upon firing is mixed into the main raw material, if it is necessary to cut the tile at the time of construction, the cut end becomes the same color as the surface and the aesthetic appearance is obtained. improves.

Further, when calcium oxide is appropriately mixed in the main raw material, the melting point of the main body can be adjusted so that the foaming can be performed satisfactorily.

After the main raw material is placed in a mold and the surface thereof is leveled, crushed refractory bricks having a particle size of 2 mm or less are spread over the surface of the main raw material, and 150 to 200 kg / cm ^2.
Dry press molding at a pressure of 3 mm to form a layer of crushed refractory brick on the main body.

Any type of refractory brick can be used as long as its melting point is higher than that of the main raw material, but chamotte brick is easily available and inexpensive.

If the same porcelain raw material having substantially the same melting point as the main raw material is mixed into the crushed material, the porcelain raw material is melted by firing, and the crushed material can be firmly fixed mainly to the crushed material.

If a pigment that develops color by firing is mixed into the ceramic material, the surface of the fired tile can be made a desired color without glaze.

If 5-15% by weight of vitreous Niijima feldspar is mixed into the ceramic raw material, shining spots are formed on the surface of the fired tile to improve the aesthetic appearance.

If the glazing is performed after the dry press molding, the surface of the fired tile can be made to have a desired color by using the conventional porcelain tile production line as it is.

Next, the melting point of the main raw material, 1200 to 1
When firing with a heat curve with a maximum temperature of 250 ° C,
Since the main raw material expands and expands into an irregular shape, and crushed porcelain with a high melting point adheres to the surface, the surface becomes rough and has a special aesthetic appearance such as brick and specific gravity of 0. It is possible to obtain a tile that is lightweight and easy to work with a thickness of 0.8 to 1.0.

When a glaze having a large pigment content and a small vitreous component is diluted with a large amount of water and used as a glaze for glazing, the rough surface of the fired tile is maintained and the appearance of the tile becomes brick-like. Will remain.

If a double-sided adhesive tape is attached to the back surface of the tile, even a layman can easily perform the work.

Claims (13)

[Claims] Claims 1. A crushed ceramic material having a melting point higher than that of the main raw material is placed on the surface layer of the main raw material in which a foaming material that is foamed at a temperature near the melting point of the ceramic raw material is mixed into the ceramic raw material, and then subjected to dry press molding. A method for producing a lightweight ceramic tile which is fired by a heat curve having a maximum temperature near the melting point of the main raw material. 2. The method for manufacturing a lightweight ceramic tile according to claim 1, wherein the crushed ceramic having a high melting point is a crushed refractory brick. 3. The crushed material is mixed with a ceramic material having a melting point substantially equal to that of the main material.
Or the method for producing a lightweight ceramic tile according to 2. 4. The method for producing a lightweight ceramic tile according to claim 3, wherein a pigment that develops color by firing is mixed into the ceramic raw material mixed into the crushed material. 5. The method for manufacturing a lightweight ceramic tile according to claim 3, wherein glass material particles are mixed into the ceramic material mixed into the crushed material. 6. The method for manufacturing a lightweight ceramic tile according to claim 1, wherein glaze is applied after the dry press molding. 7. The method for producing a lightweight ceramic tile according to claim 6, wherein the glaze used for glazing contains 40 to 100% by weight of a pigment in a powder state. 8. The glaze comprises a pigment in powder form,
The method for producing a lightweight ceramic tile according to claim 7, wherein the content is 0 to 100% by weight. 9. The melting point of the main raw material is from 1200 to 125.
9. The method for producing a lightweight ceramic tile according to claim 1, wherein the temperature is 0 [deg.] C. and the foam material is silicon carbide. 10. The method according to claim 1, wherein calcium oxide is mixed into the main raw material.
10. The method for producing a lightweight ceramic tile according to 6, 7, 8 or 9. 11. The method according to claim 11, wherein the main raw material is produced by drying the slurry with a spray drier.
The method according to claim 1, 2, 3, 4, 5, 6, 7, 8, 9, or 10, wherein the foam material is mixed in the slurry. 12. The double-sided adhesive tape is attached to the back surface of the fired tile.
The method for producing a lightweight ceramic tile according to 4, 5, 6, 7, 8, 9, 10, or 11. 13. The method according to claim 1, wherein a pigment that develops a color substantially the same as the surface upon firing is mixed into the main raw material. 13. A method for producing a lightweight ceramic tile according to item 12.