JP2709744B2 - Method of manufacturing ceramic products - Google Patents

Description

Description: TECHNICAL FIELD The present invention relates to a porcelain product used for interior and exterior finishing, and relates to a method for easily producing a large long plate or a plate having an irregular cross-sectional shape.

(Prior art and its disadvantages) Ceramic products are generally used for interior and exterior finishes because of their excellent durability. However, since the clay component is mainly used, strength before firing is low, and drying shrinkage and deformation due to firing are large, so that a large long plate or a molded product having an irregular cross-sectional shape cannot be produced with high dimensional accuracy.

For this purpose, a method of manufacturing a ceramic product, which is obtained by mixing a hydraulic substance such as cement, hydrating and hardening, and then firing the mixture, has been invented. In this method, as shown in JP-B-61-44829, a hydraulic substance, a flux that melts at 900 ° C. or less, and water are mixed, fired at 1000 ° C. or less, and then hydrated and hardened. Then, the above-mentioned hydraulic substance is disclosed as a hydration aid such as limestone which does not soften before firing and hydrates and hardens after firing, hydrates and hardens before firing and does not hydrate and hardens after firing. Further, in the flux, shirasu, volcanic ash, and glass powder are described.

On the other hand, Japanese Patent Publication No. Sho 62-9556 describes that a surface of a base material formed of a hydraulic material such as cement is glazed and fired at 770 ° C. or higher.

However, the above prior art required a step of rehydration and hardening after firing, for example, steam curing, autoclave or underwater curing for 1 to 28 days after firing.

In addition, if only glaze materials with a firing temperature of 1000 ° C or less can be used for glaze, applicable types are limited, so glaze-like makeup full of changes unique to ceramics cannot be made, and it will be expensive. There was a disadvantage.

Although the above prior art does not disclose the suitability of extrusion molding, extrusion molding is used to form a long plate or a plate having an irregular cross section.

In this case, the mixture of cement and inorganic powder generally has high resistance to the extrusion die, and it is necessary to mix water of 25% by weight or more.

However, according to the study of the inventor, when such excess moisture is large, drying shrinkage and voids occur during sintering, warpage, deformation, cracks are likely to occur, and cement grains are mutually broken, resulting in low strength. There was a disadvantage.

(Object of the present invention) The present invention has been made to solve the above-mentioned drawbacks,
It has good extrusion suitability to obtain long plates and plates with irregular cross-sectional shapes, has a predetermined strength without rehydration curing after firing, and has a method of manufacturing ceramic products that can be fired at high temperatures and have small shrinkage. To provide.

(Means for Solving the Problems) The present invention provides first means as a means for solving such problems.
In the claims, cement, an inorganic powder containing 50% or more of vitreous material that exhibits strength when fired at 1000 ° C. or more,
Extrusion molding of a cement mixture containing 10 to 20% by weight of water as an essential component with respect to the weight of the entire mixture, extruding a soft glass ground powder softening from 0 ° C., a thickener, and
It is fired at 00 ° C. or higher.

In the second aspect, after hydration hardening, the glaze raw material is applied before firing and fired at 1000 ° C. or more.

 The technical means that is adopted.

In the third aspect, after extrusion molding, the surface is subjected to mechanical processing such as embossing or cutting, and after hydration hardening, is fired at 1000 ° C. or more.

In the fourth aspect, after extrusion molding, the surface is subjected to mechanical processing such as embossing or cutting, and after hydration hardening, glaze raw material is applied before firing and fired at 1000 ° C. or more.

 The technical means that is adopted.

(Function) With the above configuration, the presence of the soft glass broken powder improves the slipperiness with the mold, and the addition of the thickener imparts plasticity, so that good extrusion suitability can be obtained.

Good shape retention after extrusion, less sagging and deformation.

As a sintering binder, an inorganic powder containing 50% or more of vitreous material that develops strength when sintering at 1000 ° C or more and 700
Since soft glass crushing that softens from the temperature C is used, it can be fired at a temperature exceeding 1000 ° C. At a temperature of 1000 ° C. or less, the soft glass acts as a binder by softening and melting and exhibits a predetermined strength.

Further, if it exceeds 1000 ° C past the pour point, rapidly changing viscosity to the liquid phase of 10 ⁵ poise or less and is in viscous it is because bonding force is reduced lower. On the other hand, inorganic powder containing 50% or more of vitreous material has a high pour point and does not rapidly change to a liquid phase even when softened. A porous ceramic product is obtained without being promoted. Accordingly, a ceramic product having a predetermined strength with a small amount of firing deformation can be obtained without steam curing, autoclave, or underwater curing after firing.

Water vaporization is small during firing, and shrinkage and gaps during firing are small in combination with fusion of soft glass and the like.

In the second aspect, the glass component contained has good reactivity with the glaze at the time of firing, so that the adhesion of the glaze is good and cracks are not easily generated.

Since it is fired at 1000 ° C. or higher, glazes of high temperature firing which can be used for general ceramics and have a wide variety of types and excellent cosmetic properties can be used.

According to the third aspect, since the shape retention after extrusion molding is good, the shape can be maintained when the surface is embossed or cut.

According to the fourth aspect, after extrusion molding, the surface can be machined, and a glaze to be fired at a high temperature can be coated with a raw material.

 There is an effect.

(Configuration of the Invention) Hereinafter, the configuration of the present invention will be described.

The cement used in the first aspect is Portland cement, alumina cement, fly ash cement or the like, which accounts for 10 to 50% by weight of the whole mixture. Of the waste, shirasu, anti-firestone, fly ash, slag, etc. constitute 10 to 70% by weight of the entire mixture.

This contributes to the development of strength when fired at 1000 ° C. or higher, and does not require rehydration hardening.

In the case of inorganic substances such as silica stone, kaolin, and talc, which have a glass content of less than 50%, fusion does not easily occur during firing.

Soft glass crushed powder is crushed alkali glass such as glass plate and glass bottle, and the particle size is under 500μ and desirably 50μ.
Using the under, add 2-40% by weight of the total mixture.

At the time of extrusion molding, the presence of the soft glass powder develops a slip property between the cement mixture and the inner surface of the mold, and the cement mixture which has been difficult to slide in the mold with a low water content can be easily extruded.

In addition, soft glass powder softens from about 700 ° C,
When the temperature exceeds 0 ° C., the viscosity becomes 10 ⁵ poise or less, and the viscosity is sufficiently dispersed between the cement and the inorganic powder, and uniform strength and dimensional stability are exhibited by firing.

In the present application, since the sintering temperature is 1000 ° C. or higher, a mixture of commonly used melting promoters such as NaNO ₃ , KNo ₃ , and Na ₂ CO ₃ is not required. It is preferable because it does not adversely affect the viscous effect.

Thickeners for improving plasticity and shape retention are methylcellulose, carboxymethylcellulose, PVA and the like, and 0.2 to 2% by weight of the whole mixture is added.

Water adds 10-20 weight cormorants based on the weight of the whole mixture. If it is less than 10%, extrusion is impossible, and if it exceeds 20%, shape retention after molding is deteriorated, and excess moisture is largely evaporated at the time of firing, so that gaps are generated and shrinkage and cracks occur.

In addition, mixing the above mixture with wollastonite or steel fiber as a reinforcing fiber or kaolinite,
Serpentine, talc, silica sand, chamotte and the like may be mixed.

The above mixture, for example, a pressure of 20 to 70 kg / cm ² , a degree of vacuum of 1 to
It is extruded at about 20 cmhg, cured for several hours to several days, and subjected to a hydration reaction.

As a result, the formed plate is softened to such an extent that it does not hinder transfer or deposition.

Then, it is placed in a firing furnace and fired at a maximum temperature of 1000 ° C. or more, preferably 1000 to 1300 ° C., for 10 minutes to several hours.

 Before and after the above-mentioned firing, a temperature raising and cooling step are appropriately included.

It should be noted that while the conventional ceramic products shrank by 10 to 15%, the shrinkage was in the range of 1 to 4% in the present invention, indicating that the dimensional stability during firing was improved.

In the second aspect, after the above hydration hardening, the glaze raw material is applied by spraying or the like, and then fired at 1000 ° C. or more.

Since the above glaze raw material is fired at 1000 ° C. or higher, it can be used for conventional ceramic products such as tiles, and it is possible to create a variety of makeup such as gloss and blur pattern.

Further, since the shrinkage due to the firing of the base material is small as described above, the adhesion of the glaze is good, cracks are hardly generated, and the gloss, surface hardness and stain resistance are good.

In the third aspect, after extrusion molding, the surface is subjected to mechanical processing such as embossing or cutting, and after hydration hardening, is fired at 1000 ° C. or more.

Provide a mold roll or mold belt near the mouth of the extruder, emboss it on the surface of the extruded uncured plate-like material, engrave the pattern, or use a feed conveyer to cut the surface with a router or saw. Cut and provide cosmetic joints such as grids and stripes.

According to the configuration of the present application, mold reproducibility and linearity are easily obtained because the shape retention after molding and the shrinkage during firing are small.

In the fourth aspect, after extrusion molding, the surface is subjected to mechanical processing such as embossing or cutting, and after hydration hardening, a glaze material is applied before firing and fired at 1000 ° C. or more.

This makes it possible to form a three-dimensional appearance and to maximize the advantages of a long plate or a plate having an irregular cross-sectional shape in which tile panels having a large number of pseudo joints can be produced at one time.

(Example) Hereinafter, an example is described.

Example 1 Cement 24, anti-firestone 24, soft glass powder 12, methyl cellulose 1, chamotte 6, wollastonite 6, silica sand 1
2. Mix 15% by weight of water and form a long plate with a hollow hole in the longitudinal direction of the material using a vacuum extrusion molding machine.
After standing for a day to allow a hydration effect, the temperature was raised at 500 ° C./hour and baked at a maximum temperature of 1180 ° C. for 30 minutes to obtain a ceramic plate.

The mixture has good shape retention at the time of extrusion molding, can be transferred after hydration and curing, and the drying shrinkage due to firing is the shrinkage ratio.
At 2.5 to 4%, no warpage or crack was observed.

The bending strength of the fired plate was 292 kg / cm ² on average, and it was found that the strength as an interior and exterior finishing material was sufficient.

Example 2 Cement 26, shirasu 32, soft glass crushed powder 6, methyl cellulose 1, chamotte 6, wollastonite 7, silica sand 6, water 16% by weight were mixed, and the mixture was hollowed out in the longitudinal direction of the material by a vacuum extrusion molding machine. Form a long rear with a hole,
After leaving to stand for a day to effect hydration, glaze was applied, the temperature was raised at 500 ° C./hour, and baked at a maximum temperature of 1170 ° C. for 30 minutes to obtain a ceramic plate.

It is extrudable, transportable after hydration hardening,
The drying shrinkage due to firing was 1.8 to 2.7%, and no cracks were observed on the glazed surface.

The bending strength of the fired plate was 197 kg / cm ² on average, and it was found that the strength as an interior and exterior finishing material was sufficient.

Example 3 In Example 1, a router was used immediately after extrusion molding.
Example 1 except that lattice-shaped grooves were cut at 10 cm intervals.
According to.

It was found that a grid-like straight line could be formed with high accuracy after firing, and was suitable for surface processing.

Example 4 In Example 3, it carried out according to Example 3 except that the glaze raw material was applied by spraying and calcined after cutting.

It was found that a long panel having a glossy tile panel-like appearance after firing could be formed with high accuracy.

(Effects of the Invention of the Present Application) As described above, the presence of the crushed soft glass powder improves the slipperiness between the mixture and the mold, and the addition of the thickener imparts plasticity, so that good extrusion suitability can be obtained. Since the shape retention after extrusion molding is good and sagging and deformation are unlikely to occur, a long plate or a plate having an irregular cross section can be obtained with high accuracy.

In addition, a soft binder that softens from 700 ° C as a firing binder and develops strength when fired at 1000 ° C or higher
Since inorganic powder containing glassy material of 50% or more is used, strength can be expressed at a wide range of temperatures from low temperature to high temperature exceeding 1000 ° C. Even if it is not provided, a predetermined strength can be exhibited, a firing deformation is small, a porous material can be obtained, and productivity is improved.

In addition, there is little volatilization moisture during baking, and there is little shrinkage or gap during baking in combination with fusing of soft glass, etc., it is hard to cause warpage or cracks, and good appearance and dimensional accuracy and predetermined strength can be obtained.

In the second aspect, since the shrinkage during firing is small, the glaze surface can be formed with good adhesion and cracks are hardly generated, and the glaze which is fired at a high temperature can be used, so that a variety of glazes with good cosmetic properties can be obtained. Appearance is obtained.

According to the third aspect, the shape retention after extrusion molding is good, so that when the surface is embossed or cut, the shape can be maintained, and a design rich in three-dimensional appearance can be obtained.

In the fourth aspect, after extrusion, the surface is machined,
Since glaze material can be glazed on it, it is possible to manufacture long and irregularly shaped ceramic products with high three-dimensionality and durability with high productivity. This has the effect.

──────────────────────────────────────────────────続 き Continuation of the front page (51) Int.Cl. ⁶ Identification number Office reference number FI Technical indication location C04B 28/02 C04B 28/02 (56) References JP-A-2-80363 (JP, A) Kaihei 1-172263 (JP, A)

Claims (4)

(57) [Claims] 1. An inorganic powder containing 50% or more of vitreous material, which exhibits strength when fired at a temperature of 1000 ° C. or more.
Extrusion molding of a soft glass crushed powder, a thickener, and a cement mixture containing water as an essential component in an amount of 10 to 20% by weight with respect to the whole mixture, which is softened from the temperature C, and after hydration hardening, is fired at 1000C or more. Method of manufacturing ceramic products. 2. An inorganic powder containing 50% or more of vitreous material, which exhibits strength when fired at a temperature of 1000 ° C. or more,
Extrusion molding of a soft glass crushed powder that softens from degree C, a thickener, and a cement mixture containing water as an essential component in an amount of 10 to 20% by weight with respect to the entire mixture, and after hydration hardening, applying a glaze material A method for producing ceramic products fired at 1000 ° C or higher. 3. An inorganic powder containing 50% or more of vitreous material, which exhibits strength when baked at a temperature of 1000 ° C. or more.
Extrusion molding of a soft glass crushed powder that softens from degree C, a thickener, and a cement mixture containing water as an essential component in an amount of 10 to 20% by weight based on the whole mixture, and machining the surface such as embossing and cutting. A method of manufacturing a ceramic product, which is applied, hydrated and hardened, and then fired at 1000 ° C. or higher. 4. An inorganic powder containing 50% or more of vitreous material, which exhibits strength when fired at a temperature of 1000 ° C. or more.
Extrusion molding of a soft glass crushed powder that softens from the degree C, a thickener, and a cement mixture containing 10 to 20% by weight of water as an essential component with respect to the total weight, and machining the surface such as embossing and cutting. A method of manufacturing a ceramic product, which is applied, hydrated and hardened, coated with a glaze material, and fired at 1000 ° C. or more.