JP2006336388A - Ceramic tile - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a ceramic tile having a self-heating means therein for heating itself. <P>SOLUTION: Each ceramic tile comprises a main body 10 and a guard plate 11; a flat recess 15 is formed on the top surface of the main body 10; a carbon graphite sheet 12 sealed by an insulating film 21 is embedded inside the recess 15; and the carbon graphite sheet 12 is covered with the guard plate 11. An electric current is applied to the tile through lead wires 20 and terminal strips 19 thereby heating the carbon graphite sheet 12 placed inside the recess 15 of the main body 10 by means of Joule heat. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a ceramic tile and a method for manufacturing the ceramic tile, and more particularly to a ceramic tile formed by molding and firing clay and a method for manufacturing the ceramic tile.

  Ceramic tiles are widely used as interior materials or exterior materials for various buildings. For ceramic tiles, powders such as feldspar and quartz are added to clay, water is added to form a plate-like body of a predetermined size, dried and fired in a kettle, and then fired again with a glaze if necessary. Like to do. In the case of using glaze, the raw material is quartz, feldspar, limestone, carillon, potassium carbonate, etc., to which an oxide salt or boron is added.

  Such ceramic tiles are classified into ordinary ceramics, earthenware ceramics, porcelain ceramics, stoneware ceramics and the like. Ordinary ceramic is impure clay, the material is porous, and it is used as it is without baking glaze. Pottery tiles are made of slightly fine clay, and the base is porous and water-absorbing, usually with glaze applied. Porcelain tiles are made of high-quality clay, have a dense base, have no water absorption, are translucent, and have a glaze applied. Stone tiles are dense and have no water absorption but are opaque and many are not glazed.

  Conventional ceramic tiles of this type are solid inside and are not equipped with heating means. Therefore, for example, when it is used as an interior material of a house and it is desired to heat the part, it is necessary to use another heating means, and there is no way to use the ceramic tile itself as a heating means.

  An object of the present invention is to provide a ceramic tile which itself includes a heating means and can generate heat.

  Another object of the present invention is to provide a ceramic tile in which the ceramic tile itself is heated by heat generating means that is not exposed to the outside.

  Still another object of the present invention is to provide a ceramic tile capable of effectively generating heat with low power consumption.

  Still another object of the present invention is to provide a ceramic tile that can reliably protect the heat generating means embedded therein.

  Still another object of the present invention is to provide a ceramic tile in which a pattern, a picture, or the like can be formed on the outer surface as necessary.

  The above-described problems and other problems of the present invention will be clarified by the technical idea of the present invention described below and the embodiments thereof.

  The main invention of the present application relates to a ceramic tile obtained by molding and firing clay, and having a heat generating means embedded therein. Here, the heat generating means may be carbon graphite, and may generate heat by Joule heat when energized. Carbon graphite may be formed into a sheet shape and coated with an insulating material. Further, the carbon graphite may be formed into a sheet shape, provided with electrodes on both sides, and when a high frequency voltage is applied through the electrodes, heat may be generated by dielectric heating.

  Another invention of the present application is characterized in that the heating means is housed and held in a recess formed on the surface of the ceramic tile body, and a protective plate is joined so as to cover the surface of the heating means. It relates to a manufacturing method.

  Another invention related to a manufacturing method relates to a method for manufacturing a ceramic tile, characterized in that a heating means is disposed on a main body of the ceramic tile, and a protective layer is formed by spraying ceramic particles on the outer surface of the heating means. Is.

  Still another invention related to the manufacturing method relates to a method for manufacturing a ceramic tile, characterized by firing by sandwiching heat generating means between a clay material constituting a main body and a clay plate constituting a protective plate.

  Another ceramic tile invention relates to a ceramic tile obtained by molding and firing clay, wherein the pattern or pattern formed on the base sheet is transferred onto the outer surface. It is. Here, the formation of a pattern or a pattern on the base sheet may be performed by an ink jet printer.

  An invention relating to a method for producing a ceramic tile having such a pattern or picture is characterized in that a pattern or picture is formed on a base sheet by an ink jet printer and the pattern or picture on the base sheet is transferred to the surface of the ceramic tile. This relates to a method for producing a ceramic tile. Here, the pattern of the base sheet or the pattern may be transferred under heating.

  The main invention of the present application is a ceramic tile formed by molding and firing clay, in which heat generating means is embedded. Therefore, according to such a configuration, the ceramic tile itself generates heat by the heat generating means embedded therein.

  In particular, if the heat generating means is carbon graphite and generates heat by Joule heat when energized, the heat generating means made of carbon graphite embedded therein generates heat by energization.

  Also, according to the configuration in which the carbon graphite has a sheet shape and electrodes are provided on both sides, and when a high frequency voltage is applied through the electrodes, heat is generated by dielectric heating, the carbon graphite sheet embedded therein is heated by dielectric heating. It will generate heat.

  The present invention will be described below with reference to embodiments shown in the drawings. FIG. 1 and FIG. 2 show the structure of a ceramic tile according to the present embodiment. This ceramic tile is attached to the upper side of a panel-shaped main body portion 10 having a predetermined thickness constituting the main portion thereof. And a carbon graphite sheet 12 tightly held between the main body portion 10 and the protection plate 11, and the carbon graphite sheet 12 disposed inside constitutes a heat generating means.

  Here, the carbon graphite sheet 12 constituting the heat generating means is housed and held in a recess 15 formed in the upper portion of the main body 10 as shown in FIGS. 1 and 2. The recess 15 is a shallow recess having a depth substantially equal to the thickness of the carbon graphite sheet 12. A notch 16 is formed so as to correspond to a predetermined position on the outer peripheral side of the recess 15 so that a lead wire described later can be drawn out.

  On the other hand, the carbon graphite sheet 12 buried inside is a natural carbon-based material. Carbon exists stably in the form of diamond, graphite (graphite), and amorphous carbon. In particular, the graphite is black and opaque, has a hexagonal crystal structure, and is an electrical and thermal conductor. In particular, a graphite sheet can be obtained by rolling naturally occurring graphite. Graphite sheets produced by rolling from natural graphite are characterized by low cost.

  When an organic synthetic film such as an acrylic resin film using acrylonitrile is baked in the absence of oxygen instead of using natural graphite, a sheet-like graphite is obtained. A graphite sheet made of a polymer material has the advantages of flexibility and compression elasticity and good compatibility with the other party. Therefore, as the carbon graphite sheet 12 that is embedded inside and generates heat, a graphite sheet obtained by baking acrylonitrile or the like can be used in addition to those manufactured from natural graphite.

  Such a carbon graphite sheet 12 is punched into a predetermined shape as shown in FIG. 3, and a terminal plate 19 made of a copper plate or a copper foil is attached to each end of the connecting terminal. A lead wire 20 is further connected to the terminal board 19. Moreover, the carbon graphite sheet 12 to which the terminal plate 19 is attached in this way is insulatively sealed by bonding insulating films 21 on both sides thereof, as shown in FIG. The insulating film used here may be a heat resistant resin film such as a liquid crystal resin film. Instead of insulating and sealing with the insulating film 21, a liquid crystal paint, an epoxy paint, or other heat resistant resin paint may be applied to the outer surface of the carbon graphite sheet 12.

  Such a carbon graphite sheet 12 is disposed in the recess 15 of the main body 10 shown in FIG. 1, and the protective plate 11 is placed thereon, and the lower surface of the protective plate 11 is the peripheral edge of the outer periphery of the recess 15 of the main body 10. Adhering and fixing with an adhesive at the part. Then, heat generating means made of the carbon graphite sheet 12 is embedded in the ceramic tile.

  Since the lead wire 20 connected to the terminal plate 19 of the carbon graphite sheet 12 is drawn out through the notch 16 of the main body portion 10, the carbon graphite sheet 12 is energized through the lead wire 20. Is possible. Since the carbon graphite sheet 12 itself has a predetermined resistance value, when it is energized, an electric current flows through the inside, thereby causing the carbon graphite sheet 12 to generate heat due to Joule heat. Therefore, the ceramic tile embedded inside generates heat. This provides a ceramic tile that itself generates heat.

  The carbon graphite sheet 12 of the above embodiment performs heat generation by Joule heat due to its own resistance value by passing an electric current through the carbon graphite sheet 12, but instead of such a configuration, It is also possible to generate heat by dielectric heating. That is, as shown in FIG. 5, electrodes 23 are joined to the surfaces on both sides of the carbon graphite sheet 12, and a high frequency power circuit 24 is connected between these electrodes 23, whereby the high frequency power is supplied to the carbon graphite sheet 12 through the electrode 23. A voltage will be applied.

  As described above, when the carbon graphite layer 12 constituting the dielectric is inserted between the opposing electrodes 23 on both sides and a uniform high-frequency electric field E [V / cm] is applied, power given by the following formula is consumed in the dielectric. The

Po = KE ² = (5/9) · fε _s tan δ · E ² × 10 ⁻¹² [W / cm ³ ]
Here, K: equivalent conductivity [Ω ⁻¹ · cm ⁻¹ ], f: frequency [Hz], ε _s : relative permittivity, and δ: dielectric loss angle.

Thus, the power consumption, that is, the amount of heat generation, is proportional to the frequency f, the square of the electric field strength E, and ε _s · tan δ regardless of the size and shape of the dielectric. Here, ε _s · tan δ is called a loss coefficient, and is determined by the type, nature, state, temperature, and frequency of the dielectric.

  Therefore, according to such a carbon graphite sheet 12, a high frequency voltage is applied to the electrodes 23 on both sides by the high frequency power supply circuit 45, whereby a uniform high frequency electric field is applied to the carbon graphite layer 12 sandwiched between the electrodes 23 on both sides. Is added, power is consumed by the internal loss of the carbon graphite layer 12 itself, and the carbon graphite layer 12 itself generates heat as the power is consumed.

  In the above embodiment, the carbon graphite sheet 12 is housed in the concave portion 15 of the main body 10 and covered with the protective plate 11 from above. However, instead of the configuration in which the two members 10 and 11 are combined in this way. Then, as shown in FIG. 6, the protective layer 28 may be formed by thermal spraying of ceramic powder particles. In this case, the protection plate 11 made of another member is not necessary.

  FIG. 7 shows a thermal spraying apparatus using a plasma powder spray method for forming the protective layer 28 in particular, and in the hollow portion formed inside the cylindrical main body 30 on the center side thereof, A conical cathode 31 is disposed so as to protrude from the tip. A ring-shaped anode 32 is attached to the inside of the main body 30 with a predetermined gap so as to face the tip of the cathode 31. A water jacket 33 is formed inside the main body 30 and on the outer peripheral side of the cathode 31 and the anode 32 so that the cooling water supplied from the cooling water supply port 34 and discharged from the cooling water discharge port 35 circulates. It has become. Further, a spray material supply pipe 36 is arranged so as to be located on the side of the tip of the nozzle of the main body 30.

  With such an apparatus, when the thermal spraying is performed by plasma powder spraying, the protective layer 28 can be easily formed. When the working gas is supplied to the cavity of the main body 30 from the working gas supply port 39, the working gas is ionized by the arc 37 generated between the cathode 31 and the anode 32, and an extremely high temperature in which positive ions and electrons are mixed. A plasma jet 38 made of gas is jetted to the tip side of this nozzle. Accordingly, when powder of the thermal spray material is supplied from the thermal spray material supply pipe 36, the thermal spray material is melt-accelerated in the plasma jet 38, and thereby, the upper surface of the main body portion 10 shown in FIG. A protective layer 28 is formed.

  FIG. 8 shows a thermal spraying apparatus based on the low-rod-rod-spray method, in which a pair of supply rolls 41 are arranged opposite to each other in the main body 40, and a gas supply hole 43 is provided inside the nozzle 42. In addition, a compressed air supply hole 44 is formed on the outer peripheral side of the gas supply hole 43.

  When the ceramic rod is gradually extruded while being tightly attached by the pair of supply rolls 41, oxygen / acetylene gas supplied from the gas supply hole 43 of the nozzle 42 is in the compressed air supplied from the compressed air supply hole 44. The ceramic rod dissolves in the oxygen / acetylene flame. The droplets are accelerated and sprayed by the air jet of the nozzle 42. Accordingly, the protective layer 28 is thus formed on the surface of the carbon graphite sheet 12 of the main body 10. According to this method, since only the melted ceramic particles are sprayed, a thin film having a high interparticle bonding force can be obtained, and spraying at a lower temperature than the plasma spraying method is possible.

  FIG. 9 shows an apparatus for thermal spraying by a thermo-spray method. A gas supply hole 48 is formed in the central portion of the main body 47, and a spray material powder supply hole is laterally crossed so as to intersect the gas supply hole 48. 49 is connected in communication. A gas supply hole 50 is disposed around the outer periphery of the supply hole 49.

  When oxygen-acetylene gas is supplied through the gas supply hole 50 and the spraying material supplied from the spraying material powder supply hole 49 is sent by the carrier gas supplied from the gas supply hole 43, the powder of the spraying material becomes oxygen-acetylene flame. It is sent in and sprayed while heating along the flow of the jet flame. Therefore, the protective layer 28 is formed on the surface of the carbon graphite sheet 12 on the recess 15 of the main body 10.

  10 and 11 show another process for embedding the carbon graphite sheet 12 in the ceramic tile. Here, the carbon graphite sheet 12 is embedded before firing. That is, the clay plate 53 constituting the main body portion and the clay plate 54 constituting the protective plate are each formed into a predetermined shape, and the carbon graphite sheet 12 is housed in the recess 55 on the surface of the clay plate 53 of the main body portion. . And in this state, it accommodates in the climbing pot 56 shown in FIG. 11, is made to burn with gas by the burner 57, thereby baking the clay plates 53 and 54, and baking the main-body part 10 and the protection board 11 together. Therefore, in this case, the carbon graphite sheet 12 is already embedded in the fired state. Since the carbon graphite sheet 12 is carbon as described above and does not contain hydrogen or oxygen, it has the property of withstanding high temperatures. Therefore, the carbon graphite sheet 12 itself is not damaged even if it is fired by the lifter 56. At this time, instead of the insulating film covering the carbon graphite sheet 12, insulation may be performed by wrapping with a glass cloth or the like.

  Next, a method for forming a pattern or a pattern on the surface of the ceramic tile will be described. As shown in FIG. 12, an inkjet printer 60 is used, a base sheet 61 is supplied as a medium to the inkjet printer 60, and a predetermined pattern or pattern is formed by the printer head 62 as shown in FIG. In addition, since the pattern or picture on the base sheet 61 is reversed left and right by the transfer, the signal supplied to the ink jet printer 60 may be reversed in advance.

  As shown in FIG. 14, the base sheet 61 to which the ink 67 for a predetermined pattern or pattern is adhered is overlapped with the surface of the ceramic tile in which the carbon graphite sheet 12 is embedded, and a heat transfer roll is applied from above. Apply pressure while heating by 65. The heating temperature at this time is preferably about 150 to 180 ° C. At this time, if the surface of the ceramic tile is subjected to primer treatment, better transfer becomes possible. The ink 67 on the base sheet 61 is transferred to the surface of the protection plate 11 by such transfer by the heat transfer roll 65.

  FIG. 15 shows the transfer for a normal ceramic tile without the carbon graphite sheet 12 embedded. That is, a base sheet 61 on which a predetermined pattern or pattern is drawn is overlapped on the surface of a normal ceramic tile 66 by an ink jet printer 60 and transferred by a heating transfer roll 65. Then, the ink 67 forming the pattern or pattern on the base sheet 61 is transferred to the surface of the ceramic tile 66.

  In FIG. 16, an ink 67 constituting a pattern or a pattern is transferred onto the surface of a ceramic tile protective plate 11 in which a carbon graphite sheet 12 is embedded and the surface is covered with a protective plate 11, and a protective coat layer 68 is further formed thereon. Formed. As the protective coat layer 68, various resin materials and ceramic materials can be used. Further, when the ink 67 itself is a sublimation ink that does not have peelability, it is not always necessary to form the protective coat layer 68.

  FIG. 17 shows a case where an ink 67 constituting a pattern or a pattern is formed on the outer surface of a normal ceramic tile 66 in which the carbon graphite sheet 12 is not embedded, and a protective coat layer 68 is further formed on the outer surface. It is formed so that the transferred pattern or pattern cannot be peeled off.

  By transferring the pattern formed by the inkjet printer 60 as described above to a ceramic tile in which such carbon graphite sheet 12 is embedded or not embedded, a pattern is formed on the outer surface as shown in FIG. Or the ceramic tile in which the pattern 67 was formed is obtained.

  Although the present invention has been described above with reference to the illustrated embodiments, the present invention is not limited to the above-described embodiments, and various modifications are possible within the scope of the technical idea of the invention included in the present application. For example, the thickness and size of the ceramic tile in the above embodiment can be variously changed according to the purpose and application of use. In addition, when a pattern or a pattern is formed on the surface, various patterns or patterns can be formed.

  The invention of the present application can be widely used for ceramic tiles as building materials, building exterior materials, and interior materials.

It is a disassembled perspective view of a ceramic tile. It is a longitudinal cross-sectional view of the ceramic tile. It is the top view which fractured | ruptured a part of heat-generating means consisting of a carbon graphite sheet. It is a longitudinal cross-sectional view of the heat generating means. It is an expanded sectional view which shows the principle of the dielectric heating by a carbon graphite sheet. It is an expanded sectional view which shows formation of the protective layer by thermal spraying. It is principal part sectional drawing which shows the apparatus for thermal spraying by a plasma powder spray. It is principal part sectional drawing of the apparatus for the thermal spraying by the locusd rod spray method. It is a longitudinal cross-sectional view which shows the apparatus for thermal spraying by a thermo spray method. It is a longitudinal cross-sectional view of the clay board of the state which embedded the carbon graphite sheet before baking. It is a longitudinal cross-sectional view of the climbing pot which shows baking of a clay board. 1 is an external perspective view of an ink jet printer. It is an expanded sectional view showing formation of a pattern or a picture by a printer head of an ink jet printer. It is an expanded sectional view which shows transcription | transfer of the pattern or a pattern with respect to the ceramic tile which embed | buried the carbon graphite sheet. It is a longitudinal cross-sectional view which shows transcription | transfer of the pattern or a pattern with respect to the normal ceramic tile. It is a longitudinal cross-sectional view of the ceramic tile which embed | buried the carbon graphite sheet in which the pattern or the pattern was transferred. It is a longitudinal cross-sectional view of a normal ceramic tile to which a pattern or a pattern is transferred. It is an external appearance perspective view of the ceramic tile to which the pattern or the pattern was transferred.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Main-body part 11 Protection board 12 Carbon graphite sheet 15 Recessed part 16 Notch 19 Terminal board 20 Lead wire 21 Insulating film 23 Electrode 24 High frequency power supply circuit 28 Protective layer 30 Main body 31 Cathode 32 Ring-shaped anode 33 Water jacket 34 Cooling water supply port 35 Cooling water discharge port 36 Thermal spray material supply pipe 37 Arc 38 Plasma jet 39 Working gas supply port 40 Main body 41 Supply roll 42 Nozzle 43 Gas supply hole 44 Compressed air supply hole 47 Main body 48 Gas supply hole 49 Thermal spray material powder supply hole 50 Gas supply Hole 53 Clay plate (main part)
54 Clay board (protection board)
55 Concave portion 56 Lifting pot 57 Burner 60 Inkjet printer 61 Base sheet 62 Printer head 65 Heat transfer roll 66 Ceramic tile 67 Ink (pattern)
68 Protective coat layer

Claims (11)

In ceramic tiles made by molding and firing clay,
Ceramic tiles characterized by heat generation means embedded inside.   2. The ceramic tile according to claim 1, wherein the heat generating means is carbon graphite, and generates heat by Joule heat when energized.   The ceramic tile according to claim 2, wherein the carbon graphite has a sheet shape and is covered with an insulating material.   3. The ceramic tile according to claim 2, wherein the carbon graphite has a sheet shape, electrodes are provided on both sides, and heat is generated by dielectric heating when a high frequency voltage is applied through the electrodes.   A method for producing a ceramic tile, comprising: storing and holding the heat generating means in a recess formed on a surface of a main body of the ceramic tile; and bonding a protective plate so as to cover the surface of the heat generating means.   A method for producing a ceramic tile, comprising: heating means on a main body of the ceramic tile; and spraying ceramic particles on an outer surface of the heating means to form a protective layer.   A method for producing a ceramic tile, characterized by firing by sandwiching a heat generating means between a clay material constituting a main body and a clay plate constituting a protective plate. In ceramic tiles made by molding and firing clay,
A ceramic tile formed by transferring a pattern or a pattern formed on a base sheet onto an outer surface.   The ceramic tile according to claim 8, wherein formation of a pattern or a pattern on the base sheet is performed by an ink jet printer.   A method for producing a ceramic tile, comprising: forming a pattern or a pattern on a base sheet by an inkjet printer; and transferring the pattern or the pattern on the base sheet to the surface of the ceramic tile. The method for producing a ceramic tile according to claim 10, wherein the transfer of the pattern or the pattern of the base sheet is performed under heating.

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