JP2007246364A - Lightweight foamed tile and method of producing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a lightweight foamed tile and a method of producing the same by which a difference in height between a recessed part and a projecting part of the uneven surface is made large. <P>SOLUTION: In the method of producing the lightweight foamed tile carried out by forming a tile raw material to form recessed and projecting parts on the surface, drying the formed body and firing, a foaming agent is previously blended in the tile raw material. It is preferable that the average value of the distance from the deepest part of the recessed part to the topmost part of the adjacent projecting part of the uneven surface is 1-50 mm and the average value of the difference in height between the deepest part of the recessed part and the topmost of the adjacent projecting part is 0.5-20 mm. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a lightweight foam tile in which a foaming agent such as silicon carbide (SiC) is blended in a tile raw material and foamed during firing to reduce the weight, and a method for manufacturing the same.

  A method for producing a lightweight foam tile in which a foaming agent such as silicon carbide (SiC) is blended with a tile raw material and foamed during firing to reduce the weight is already known (for example, Japanese Patent Laid-Open No. 61-191577).

In addition, when manufacturing a tile, it is also well known to form a concavo-convex pattern on the surface of the molded body by pressing the surface of the molded body with a roller with a concavo-convex pattern (for example, Japanese Patent Laid-Open No. 8-72046, paragraph 0003).
JP 61-191577 JP-A-8-72046

  According to Japanese Patent Laid-Open No. 8-72046, a concavo-convex pattern is formed on the tile surface, and a certain design property is given. This pattern is formed by rolling with a roller, but the convex portion may be baked down during firing to reduce its height, and the height difference of the unevenness may be reduced.

  An object of the present invention is to solve the above-mentioned conventional problems, and to provide a lightweight foam tile that can increase the difference in height between the concave and convex portions on the surface and the manufacturing method thereof.

  The method for manufacturing a lightweight foam tile according to claim 1 is a method for manufacturing a tile in which a tile raw material is molded so that irregularities are formed on the surface, and the molded body is dried and then fired. It is characterized by keeping.

  According to a second aspect of the present invention, there is provided a method for producing a lightweight foam tile according to the first aspect, wherein the irregularities are formed by pressing an irregular surface of a roller or a mold against the surface of the molded body during molding.

  In the method for manufacturing a lightweight foam tile according to claim 3, in the tile according to claim 1 or 2, the average value of the distance from the deepest part of the concave and convex concave parts to the top of the adjacent convex part is 1 The average value of the height difference between the deepest part of the concave part and the top part of the adjacent convex part is 0.5 to 20 mm.

  A method for producing a lightweight foam tile according to a fourth aspect is characterized in that, in any one of the first to third aspects, the bulk specific gravity of the tile is 1.10 to 1.90.

  When a foamed light weight tile is manufactured by allocating a foaming agent to form a raw material and firing it, gas is generated from the foaming agent in the firing process. This gas moves mainly inside the molded body (sintered body) to the outside.

  According to the method for manufacturing a lightweight foam tile according to claim 1, irregularities are formed on the surface of the molded body, and the gas generated in the recesses in the molded body (fired article) rises to the convex portions located outside the concave portions. Then, the expansion of the convex portion is larger than the expansion of the concave portion. As a result, firing shrinkage (baking tightening) of the protrusions is suppressed, and a tile having unevenness with a large difference in height is produced on the surface.

  If unevenness is formed on the surface of the molded body by pressing the uneven surface of the roller or mold as in claim 2, the uneven protrusion is relatively lightly pressed by the roller or mold and relatively low. Because of the density, the shrinkage rate during firing is large, but because the gas generated by the foaming agent goes outward, it is located on the outer side and gathers at the part that is a convex part that is lower in density than the low part, It becomes easy to expand. On the other hand, since the concave and convex portions are relatively strongly pressed by a roller or a mold and have a relatively high density, expansion is smaller than that of the convex portion. As a result, the expansion of the convex portion on the tile surface is larger than that of the concave portion, and the difference in level of the concave and convex portions on the surface is increased.

  As in claims 3 and 5, the average value of the height difference between the deepest part of the concave part and the top part of the adjacent convex part is 1 to 50 mm, and the average value of both horizontal distances is 0.5 to 20 mm. Thus, the height difference between the concave portion and the convex portion is emphasized. The height difference between the deepest portion and the topmost portion of the adjacent convex portion refers to the length of a perpendicular line from the topmost portion of the convex portion adjacent to the deepest portion to the plane including the deepest portion.

  As described in claim 4, when the foam is appropriately foamed so that the specific gravity is about 1.10 to 1.90, a lightweight foam tile in which the height difference between the concave and convex portions on the surface is emphasized is obtained.

  Hereinafter, the present invention will be described in more detail.

  In the present invention, in a method for producing a lightweight foamed tile by molding a tile raw material containing a foaming agent, drying the molded body, and firing it, the surface of the molded body is preferably uneven by pressing with a mold or a roller. Form.

  As the tile raw material, 40 to 60 parts by weight of clay, 10 to 25 parts by weight of glass, 25 to 50 parts by weight of feldspar, and 0.01 to 5 parts by weight of SiC (100 parts by weight in total) as the foaming agent are suitable. Examples of the clay include, but are not limited to, montmorillonite, camelinite, glazed clay, and kibushi clay. As the glass, window glass, bottle glass, CRT glass and the like are suitable. In addition, you may add a refractory raw material, such as chamotte, porcelain stone, an alumina, a zircon, 30 wt% or less, preferably 10-20%, and a pigment as an aggregate to a raw material.

  The foaming agent is not limited to silicon carbide, and any foaming agent may be used as long as it generates gas by heating silicon nitride, boron nitride, or the like. This raw material is sufficiently finely mixed by a wet ball mill or the like, and then preferably extrusion-molded by an extruder, and then preferably presses a roller with a concavo-convex pattern on the surface of the extruded product to form a concavo-convex pattern on the surface of the molded product. Form. As for this unevenness | corrugation, it is desirable that the height difference of a convex part adjacent to a recessed part is 1-50 mm on the average, especially about 5-20 mm. In addition, the average distance from the concave and convex concave portions to the topmost portion of the adjacent convex portions is preferably about 0.5 to 20 mm, particularly about 1 to 5 mm.

  The molded product is cut to a predetermined size, dried, and then fired. A roller hearth kiln or a tunnel kiln can be used for this firing, but a tunnel kiln is preferably used.

  The firing temperature is preferably 1100 to 1300 ° C., and the firing time is preferably about 36 to 48 hours.

  The size of the tile is desirably about 50 to 200 mm on one side.

  By the above firing, a tile with a concavo-convex pattern having a bulk specific gravity of about 1.10 to 1.90 is produced. This uneven pattern is caused by the transfer pattern of the roller, but the gas generated inside during baking gathers at the convex part, and as a result of preventing or suppressing the firing shrinkage of the convex part, the uneven height difference is emphasized. It will be.

  In the present invention, the above-mentioned raw materials may be dry press-molded to form a molded body, which may be fired to produce a foam tile. In this case, unevenness is formed on the surface of the molded body by forming unevenness on the mold. The degree of the unevenness may be the same as described above.

Example 1
As shown in Table 1, 44.9 parts by weight of clay, 20 parts by weight of glass, 35 parts by weight of feldspar, and 0.1 parts by weight of SiC were used as tile raw materials.

  This raw material was finely ground and mixed in a wet ball mill for 24 hours, and then subjected to filter press. Next, after kneading, the film was continuously extruded to a width of 50 mm and a thickness of 11.5 mm using a vacuum extrusion molding machine, and then a concavo-convex patterned roller was pressed to transfer the concavo-convex to the surface. The height difference between the deepest portion of the concave and convex portions of the concave and convex portions on the surface of this molded body and the top portion of the adjacent convex portion was 1.8 mm on average, and the distance between both was 7.0 mm on average. This was cut into a length of 200 mm to obtain a molded body. After drying, it was fired at 1200 ° C. for 40 hours in a tunnel kiln. As a result, the tiles shown in FIGS. 1A and 1B were obtained. The irregularities on the tile surface were as shown in Table 1.

  The bulk specific gravity of the tile was 1.10.

Example 2
Tiles were produced in the same manner except that the formulation was as shown in Table 1. The uneven pattern shown in Table 1 was formed on the surface of the tile. The bulk specific gravity of the tile was 1.55.

Comparative Example 1
A tile was produced in the same manner as in Example 1 except that the formulation shown in Table 1 was used and no foaming agent was added. The uneven pattern shown in Table 1 was formed on the surface of the tile. The bulk specific gravity of the tile was 2.10.

  As these results shown in Table 1, the difference between Comparative Example 1 in which no SiC was mixed and Example 1 and Example 2 in which SiC was mixed was 8.2% and 4.2% with respect to the thickness. Yes, by adding a foaming agent, more remarkable unevenness could be imparted.

  From Table 1, according to the present invention, a lightweight tile in which the height difference of the surface irregularities is emphasized is manufactured.

It is sectional drawing and the perspective view of the tile manufactured in the Example.

Explanation of symbols

  1 tile

Claims (4)

In the tile manufacturing method in which the tile raw material is molded so that irregularities are formed on the surface, and the molded body is dried and then fired,
A method for producing a lightweight foam tile, wherein a foaming agent is blended in the tile raw material.   The method for manufacturing a tile according to claim 1, wherein the unevenness is formed by pressing an uneven surface of a roller or a mold against the surface of the molded body during molding.   In the tile according to claim 1 or 2, in the manufactured tile, an average value of a horizontal distance from the deepest part of the concave and convex concave part to the topmost part of the adjacent convex part is 1 to 50 mm, and the deepest part of the concave part and The method for producing a lightweight foam tile, characterized in that the average value of the height difference from the top of the adjacent convex portions is 0.5 to 20 mm.   The method for producing a lightweight foam tile according to any one of claims 1 to 3, wherein the tile has a bulk specific gravity of 1.10 to 1.90.

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