JP2008100882A - Lightweight porcelain including hollow pore layer and its manufacturing process - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing process of a lightweight, highly translucent and aromatized porcelain including a void pore layer. <P>SOLUTION: The manufacturing process comprises coating an alumina-free porcelain body slurry on both the sides of ceramic paper made of an alumina-free porcelain body as a filler, drying and firing the paper. The aromatization is made by impregnating the hollow pores formed after the firing in the porcelain green body with an aqueous aroma solution. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention is characterized in that it is fired after applying and molding a porcelain clay slurry that does not contain alumina on both the front and back surfaces, using a thin ceramic paper made with porcelain clay containing no alumina as a filler. The present invention relates to a method for manufacturing a lightweight porcelain in which a fine pore layer is embedded in a substrate.

In order to reduce the weight of the porcelain substrate, there is a method of adding pores in the porcelain clay and adding inorganic hollow particles or organic powders that are burned off by firing to create pores in the substrate to reduce the substrate density. There has been no example in which both a means for reducing the weight of the material and a means for reducing the thickness of the product itself by lightening the molding method have been realized at the same time.

  As a means for thinly forming ceramics, there is a method in which the ceramics are formed by cocoon molding or gypsum mold casting, then dried for a while and then thinned. Alternatively, a method of adding a large amount of an organic binder, thinly extending and thinning the ceramic sheet into a plate, and then performing a main firing after degreasing and firing can be considered. And takes time. The latter is unreasonable for forming complex products other than simple flat plates, and is not a material that can be used easily for crafts and is not practical.

In addition, there is a “manufacturing method for thin high-strength porcelain products” in which ceramic paper is used as a prototype, mud is attached to the entire surface, dried and fired. (See Patent Document 1) In this method, a high-strength porcelain clay in which 30% to 45% of alumina was added to both ceramic paper filler and adhering slurry was defined. The high-strength porcelain clay is a blended clay in which silica with a true density of 2.6 is replaced with alumina with a true specific gravity of 4. Compared with general porcelain with a true density of 2.6, When 30% alumina was added, the true density was increased to 2.94 when 45% was added, and 3.23 when the volume was the same, and the product weight was increased by 13% to 24%. If the significance of making thin porcelain products is to make lightweight porcelain products, the addition of alumina becomes a negative factor from the viewpoint of weight reduction.
JP-A-3-253305

There is a method to make ceramics by firing ceramic paper filled with clay at high density as it is as a ceramic material that produces a thin and paper-like texture. However, in a three-dimensional object made only of ceramic paper, it contains paper. When the pulp fiber was burned away, the shape was likely to be deformed. Further, a sufficient product density could not be obtained after firing, and there was a problem in strength. Further, in the above-mentioned “manufacturing method of thin high-strength porcelain products”, the molding procedure was made as a prototype of a required form using high-strength porcelain ceramic paper added with alumina, and then high-strength porcelain slurry was adhered. The ceramic paper that absorbs moisture in the slurry softens and loses its elasticity, and the adhered slurry does not immediately solidify and does not lose its fluidity, so the strength cannot be expected. It may become difficult to maintain the required form because it is unable to support the weight of the machine. In other words, it is not suitable for molding large three-dimensional objects and complicated bags.

Furthermore, in high-strength porcelain to which 30% or more of alumina is added, alumina that does not vitrify in the substrate blocks light and sacrifices the translucency that is the original characteristic of porcelain.

  With regard to products in which fragrance is imparted to ceramics, for example, there are already products made into aromatic bodies by combining unglazed dolls and liquid fragrances. However, since the unglazed base has relatively large pores and pores in the entire product, the fragrance has evaporated at once, and it has been difficult to control the fragrance to a small amount. In other words, there is no ceramic product that can be called an aromatic ceramic alone, which makes it seem as if the ceramic itself has fragrance by maintaining the fragrance little by little over a long period of time. In particular, there has been no example of imparting fragrance to a porcelain substrate characterized by having no water absorption.

  In view of the conventional problems as described above, the present invention solves the weight reduction of porcelain by means of both lowering the density of the substrate by forming a pore layer and forming it thinly. Providing a method for easily shaping complex forms, and at the same time, newly producing lightweight porcelain products that have a surface texture like paper, highlight translucency, and have a long-lasting fragrance It is aimed at things.

In order to achieve the above-mentioned object, the present invention uses porcelain ceramic paper as a core material, applies porcelain slurry on both the front and back surfaces, and dries for a while, so that the porcelain ceramic paper and the slurry coating layer are integrated and flexible. This is solved by the method according to claim 1 wherein the so-called semi-dried state is formed into a desired form, completely dried while maintaining the shape, and baked and manufactured. The filler used when making ceramic ceramic paper and the porcelain clay slurry to be applied use porcelain clay containing no alumina so as not to impair the translucency characteristic of porcelain. Alumina does not vitrify after firing and shields light, thus impairing translucency. Since the porcelain manufactured by the present invention is basically manufactured to be thin, it is assumed that the porcelain is used for a product that further utilizes the translucency that is a characteristic of the porcelain. Therefore, it is desirable to select a ceramic clay that becomes a base material with high translucency after firing for the ceramic paper filler and the ceramic clay slurry to be applied.

Ceramic paper is easy to cut and can be cut into the required shape and size with a scissors or a cutter knife. If it becomes semi-dry after applying the slurry, it can be bent or the sheets can be bonded together using porcelain slurry as a paste material. In addition, the slurry to apply | coat has a fluidity | liquidity by adjusting the water | moisture content from 28% to 50% with a suitable amount of peptizer and water for the porcelain clay, and is applied with a brush or the like.

  After applying the slurry on only one side of the ceramic ceramic paper, forming it, applying the uncoated surface, and finally applying the porcelain clay mud on both sides of the ceramic ceramic paper, When molding an object, the problem is that the mud layer on the outside of the three-dimensional object peels off during molding and soils the product surface. For example, when forming folded paper cranes with ceramic ceramic paper, the semi-dried porcelain sheet becomes thick and difficult to fold after applying mud on both sides, and the outer mud layer is peeled off, which increases the chance of contact during folding. easy. That said, with the conventional method of forming the required shape only with ceramic paper first and then applying the slurry later, the weight of the applied slurry is not supported only by the strength of the ceramic paper and the shape collapses. There is a risk. Furthermore, for example, when folding and forming a paper crane, there is a problem that it becomes difficult to attach the slurry to the inside of the body after forming without applying the slurry. The point of the present invention is that the semi-dried slurry coating layer is integrated with the ceramic paper to support the weight and maintain the shape of the three-dimensional object. Then, it is desirable that the applied slurry be uniformly attached to both surfaces of the ceramic paper. If the slurry is completely dried in a state where the slurry is applied on only one side, distortion of the shape is likely to occur due to a difference in contraction between the ceramic paper and the applied slurry. As described above, the molding can be performed while the slurry is applied to at least one surface of the ceramic paper and then in a semi-dried state, thereby solving the problem that the form of the three-dimensional object is deformed.

The third aspect solves the problem of forming a relatively large lightweight porcelain product.
The ceramic ceramic paper used in the present invention has a thickness of 0.1 mm to 0.6 mm, and the thickness of the porcelain slurry that can be applied is approximately the same as the thickness of the paper on one side. When applied to both sides of one ceramic paper, a base thickness of 0.3 mm to 1.8 mm is assumed, and the product strength may be insufficient for large porcelain products. At that time, the required strength can be ensured by laminating several ceramic ceramic papers coated with porcelain clay on both sides. The low-density layer having voids formed by the burning of the paper pulp fibers contained in the ceramic ceramic paper is lightweight because it becomes a base material that is built up as a number of layers. As a result, a lightweight large-sized porcelain plate having practical strength can be easily formed.

  The problem of imparting fragrance to a porcelain substrate is achieved by the method of claim 4 by impregnating a liquid fragrance into the pore layer contained in the substrate, which is a structural feature of the lightweight porcelain substrate according to the present invention. can be solved. When the ceramic ceramic paper is fired, the paper pulp fiber, which is an organic component thereof, is burned down to form a low-density porcelain layer including finely connected void holes. The low-density layer formed by the voids is sandwiched between the dense porcelain layers formed by the applied porcelain slurry layer. The liquid fragrance soaks only into the low-density porcelain layer by capillary action, does not penetrate into the dense porcelain layer, and does not evaporate from both surfaces of the substrate. In other words, the liquid fragrance once soaked into the substrate evaporates only from the cross section of the low density layer and emits the fragrance little by little. For example, once the liquid fragrance is soaked, it can be expected that the fragrance will last for more than one year. Therefore, the present invention makes it possible to produce a porcelain product that can be called an aromatic porcelain substrate.

  As is clear from the above description, the present invention is also a method for molding and manufacturing lightweight porcelain with the ease of paper craft, so that it is possible to present a new sense of porcelain product that has never existed before. Its features are light, thin, highly translucent, and a substrate that retains the surface form of the paper. In addition, a new lightweight porcelain product having aromaticity can be produced, and the craft, industrial and technical value is extremely large.

Generally, porcelain is explained to be characterized by vitrification, translucency and translucency, whiteness, no water absorption, and a clear sound when struck. The lightweight porcelain produced by the present invention lacks one of the above features because of its structural absorption of water, but it instead gives rise to new features of lightening and imparting fragrance. The substrate itself must be a porcelain because it uses the original porcelain substrate. However, the characteristic of being translucent and translucent is important for enhancing the evaluation of porcelain substrates, so the translucency is reduced without vitrification in the raw materials such as alumina and zircon. Porcelain clay without added raw materials is used as raw material. In the present invention, the weight ratio of the porcelain clay used for the filler of the ceramic ceramic paper that is the core material of the lightweight porcelain is 60% to 95%, and the remainder is organic paper pulp fibers. Increasing the content of the porcelain clay increases the strength of the product after firing, but the tensile strength of the ceramic paper itself decreases, and the folded portion during molding may be broken. On the contrary, if the paper pulp fiber is made with a high content ratio of paper pulp, the applied slurry becomes easy to peel off when dried, the deformation after firing is increased, and the product strength is lowered. In order to increase the tensile strength of the ceramic paper, it is also effective to replace the pulp fiber with hemp fiber. Porcelain ceramic paper has a thickness of 0.2 mm to 0.6 mm, and can be bent or easily cut with a scissors or a cutter knife, as in general paper.

The porcelain mud applied to the ceramic paper does not necessarily need to use the same porcelain clay as the ceramic paper filler, but it should not contain alumina or zircon, and should be selected to have a high translucency and baked into a white base. Is desirable. For example, if a mud of bone china porcelain clay is used, lighter porcelain with higher translucency can be obtained. In the case of application, the water content is changed from 28% to 50% with a peptizer, and the slurry is fluidized and easily applied to porcelain ceramic paper. When the moisture is increased, the applied mud layer becomes thinner and it takes more time to become semi-dry. About 1 to 2 minutes after applying the slurry, it is preferable that the applied slurry is in a semi-dry state where the thickness is the same as the thickness of the ceramic paper. More thick coating of the slurry causes peeling of the slurry layer during drying and reduces the effect of weight reduction. In order to increase the dry strength, it is preferable to add an appropriate amount of an organic binder or the like in the slurry.

The porcelain ceramic paper is cut into a required shape and size and spread in a flat shape, and the porcelain slurry is uniformly applied to the entire surface. The method of application is by brushing, brushing, spraying, dipping in a slurry or squeegee method. When the slurry is applied, the ceramic paper absorbs the moisture in the slurry within a few minutes, the fluidity is lost, and the porcelain ceramic paper and the slurry are integrated into a flexible semi-life sheet. A state in which such a surface is not sticky and can be deformed and crafted is called a semi-dry state. Since the semi-dry state continues for at least 30 minutes, it is molded into the required form during that time. There are two molding procedures: a method in which mud adheres to both sides of porcelain ceramic paper, and a method in which mud adheres only to one side, and after the molding is finished, it is applied to the other remaining surface and finished. Is the method. The former is a method in the case of a simple shape, and the latter is a method in the case of a complicated shape with many bending processes. In particular, the latter is effective in the case of forming a bag. For example, it is effective when manufacturing an origami-like lightweight porcelain that is three-dimensionally formed by an origami technique. Molded with the surface to which the slurry is attached facing inward, and after the shape is complete, apply the slurry on the outside. In a state where the slurry is applied on both sides, the thickness makes the molding operation complicated, and the slurry layer applied on the outside is peeled off, so that it is forced to apply the slurry again.

After molding, the product is completely dried and subjected to a design. Then, a glaze is applied, and main firing is performed at a firing temperature corresponding to the porcelain clay, that is, generally around 1280 ° C. It is also possible to glaze and then baked after unglazed, but in the case of a thin three-dimensional product, it is desirable to maintain the shape after baked once and then fired at a slightly lower temperature than the baked .

The method of laminating a plurality of porcelain ceramic papers so as to be sandwiched between porcelain sludges is a method of laminating both sheets after they are semi-dried, and a method of laminating sheets after the two sheets are semi-dry. There is a laminating method in which the application of slurry and the operation of pressing and laminating ceramic paper are repeated continuously without waiting. In the former case, it is necessary to apply the same porcelain slurry as a paste material in order to bond the semi-dried sheets, but the latter can save the labor.

  In order to make aromatic porcelain, liquid fragrance is prepared as it is or appropriately diluted in a water tank, and the section of the light-weight porcelain after firing is placed so that it is immersed in the solution. Soak the agent. The penetration rate is slow and may take several hours.

Porcelain ceramic paper was sprinkled with porcelain clay composed of 30% quartz, 32% Indian feldspar, and 38% New Zealand kaolin. The weight ratio of the porcelain clay and paper fibers in the filler was 90% porcelain clay filler, 5% pulp fiber, and 5% Manila hemp fiber, and weighed 380 g / m ² and had a thickness of 0.36 mm. The porcelain clay slurry for coating is a commercially available white water porcelain clay with a 0.3% phosphate-based peptizer added to a fluid state of 36% moisture, and a commercially available water-soluble to increase dry strength. A small amount of an organic binder was added. The porcelain ceramic paper was cut into a square of 60 cm square, and the porcelain clay slurry was applied to the upper surface with a brush. After being left for 2 minutes to be in a semi-dry state, the folded paper crane was folded by an origami technique and formed. At this time, the surface to which the slurry was applied was made to be inside the trunk. Next, porcelain slurry was applied to the unpainted surface of the folded paper crane, and the whole was uniformly covered with porcelain slurry. It was completely dried in about 3 hours, designed, sprayed with a thin transparent basket, and oxidized and fired at 1280 ° C. to produce a porcelain folded paper crane by hand folding. The thickness of the single substrate was 1 mm, and a light crane with high light-transmitting properties was created. FIG. 1 is a photograph in which a low density layer is clarified by impregnating red ink into a cross section of a pore layer of a lightweight porcelain substrate. FIG. 2 is a folding crane lighting fixture made in Example 1, with the upper side before lighting and the lower side when lighting.

Nine pieces of ceramic ceramic paper with the same raw material as the above ceramic ceramic paper, weighed 220 g / m ² , and with a thickness of 0.20 mm, were cut out into 60 cm squares. After the clay mud was applied uniformly and it was in a semi-dry state, it was turned over and the porcelain mud was applied in the same manner. Then, while the surface did not dry, a second piece of porcelain ceramic paper was laminated and pressed with a roller and pressed. Similarly, the process of continuously applying slurry and the process of laminating and pressing ceramic paper were repeated seven times to cover the front and back with porcelain slurry and to form a porcelain plate. Next, it was completely dried, the surface was designed, and transparent glaze was sprayed thinly, followed by oxidation baking at 1280 ° C. to produce a porcelain tile having a thickness of 4 mm and a size of 53 cm square. The bulk specific gravity of this tile was 2.1, and the weight was reduced by 14% compared to 2.5 for general porcelain. Furthermore, one end of the tile was submerged for 5 hours in a pallet containing a liquid obtained by diluting a commercially available perfume 10 times, so that the perfume liquid was infiltrated from the cross section. Laminated tiles soaked with perfume in this way still have a subtle fragrance even after one year. FIG. 3 is a photograph in which red ink is soaked into a laminated lightweight tile.

  Since the present invention can provide a porcelain product that is light, thin, highly translucent, and aromatic, it can be used for lighting equipment that utilizes translucency and interior products that are translucent and aromatic. Can be expected. Furthermore, since the molding method using ceramic paper as the core material is a new method for producing ceramics, it is possible to provide ceramic techniques and materials that have never existed before.

A cross-sectional photo of a lightweight porcelain. Photo of red ink soaked in the pore layer of ceramic ceramic paper. An example of a lighting fixture made by folding paper cranes with highly translucent lightweight porcelain. When the bottom is lit. A photograph in which red ink is soaked into the cross section of a tile on which nine pieces of ceramic ceramic paper with a thickness of 0.2 mm are laminated.

Claims (4)

Porcelain ceramic paper made with porcelain clay without added alumina as a filler is applied to the core, and porcelain clay slurry without addition of alumina is applied to both front and back surfaces, and after it is semi-dried, it is molded into the required shape. Alternatively, after applying a porcelain clay slurry to one side of the ceramic ceramic paper and becoming a semi-dry state, a three-dimensional object is formed so that the coated surface is on the inside, and then the porcelain cake is placed on the outer surface. A lightweight porcelain manufacturing method in which soil mud is applied and finally ceramic porcelain mud slurry is applied to both the front and back sides of the ceramic paper, and then completely dried and fired. An origami-style lightweight porcelain that is three-dimensionally molded and fired by the origami technique using the method described in the previous section. A plurality of sheets of ceramic ceramic paper according to claim 1 coated with porcelain clay mud slurry containing no alumina on both the front and back sides are laminated after the semi-dried state, or the second sheet of ceramic ceramic paper to be laminated After that, without waiting for a semi-dry state, a plurality of pieces are laminated together while sandwiching porcelain mud continuously, finally applying porcelain clay mud on the entire front and back of the laminated plate, A method of manufacturing lightweight porcelain that is molded into a required shape, then completely dried and fired. The porcelain ceramic paper coated on both sides with the porcelain clay according to claim 1 or 3 burns away the paper fiber component, which is an organic component, and becomes a low-density porcelain base layer having fine pores. , Sandwiched between dense porcelain base layers formed by the applied porcelain mud layer. Aromatic porcelain in which a liquid air freshener is impregnated into a fine pore layer contained in the substrate.

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