JP2838503B2 - Method for producing colored ceramic tiles - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a ceramic tile, and more particularly, to a method for manufacturing a transparent and colored backside ceramic tile.

[0002]

2. Description of the Related Art Colored ceramic tiles are manufactured by the following method. Mix the glass raw material and the colorant and put them in a crucible.
Heat to 00 to 1500 ° C to melt. Because the molten glass is heterogeneous and has bubbles inside,
The temperature is further increased to lower the viscosity, and the bubbles are floated and removed. This step is called a cleaning operation. In the cleaning operation, arsenous acid or antimony oxide is added together with alkali nitrate in order to quickly raise bubbles contained in the molten glass. The molten glass from which bubbles have been removed is formed by a pressing method. In the pressing method, a molten glass mold is cast and molded.

[0003] Through the above steps, a colored ceramic tile is manufactured. To color ceramic tiles,
Various metal oxides are used as colorants. For example,
Metal oxides color ceramic tiles from blue to yellow-green, manganese oxides from blue to purple, cobalt oxide and copper oxide blue, and chromium oxide green. In addition, colorants include:
Others color the ceramic tile by being colloidal or dispersed in glass. As the coloring agent, a coloring agent which is colored in red of gold, copper and selenium, yellow of silver, and brown of carbon and sulfur is used. Choose various colorants,
Further, by mixing a plurality of coloring agents, ceramic tiles colored in various colors can be manufactured.

[0004]

In the above manufacturing method, since ceramic tiles are manufactured one by one, it is difficult to mass-produce efficiently and at low cost. In addition, many molds need to be used to produce large numbers of ceramic tiles. The reason why a large number of molds are required is that the molten glass is cast into the molds and slowly cooled slowly over time so as not to break. Furthermore, in order to produce ceramic tiles of various shapes, a special mold is required for the ceramic tile. For this reason, it is necessary to use more molds, and there is a drawback that mass production at low cost is difficult.

Further, since the glass material is manufactured by adding a coloring agent to the glass material, the coloring agent is dispersed throughout the ceramic tile, and a colored surface is exposed on the surface. A ceramic tile having a colored surface is less glossy than a ceramic tile having a transparent glass layer on the surface. Applying a transparent paint to the surface of the paint is the same as adding gloss. A ceramic tile having a transparent glass layer on the surface cannot be manufactured by a manufacturing method in which a coloring agent is added to a glass raw material. In order to provide a transparent glass layer, it is necessary to apply a transparent wax to the surface of the manufactured ceramic tile and re-fire. Thus, the method of re-firing makes one expensive ceramic tile more expensive and its use is significantly limited.

The present invention has been developed to solve this drawback. It is an important object of the present invention to provide a method for producing a colored ceramic tile which can produce a beautifully glossy and high quality ceramic tile in large quantities at low cost.

[0007]

According to the colored manufacturing method of the present invention, ceramic tiles are not manufactured one by one by a stamping method. Ceramic tiles are efficiently produced in large quantities without using molds. The manufacturing method of the present invention without using a mold first manufactures a large transparent substrate. The transparent substrate is
It is manufactured in a size that can be divided into a plurality of ceramic tiles. A large transparent substrate is separated into a plurality of tile bodies cut into a square shape . The tile body has a shape equal to the outer shape of the ceramic tile. Apply a Yu medicine to the back of the separated tile base. The reason why the back medicine is applied is to provide a transparent layer with a tile base on the surface of the colored surface. The tile base coated with Yu medicine is
By firing with the application side down , the Yu medicine is sintered on the back side of the tile base.

[0008] Further, the tile base obtained by cutting the transparent substrate has a very sharp right-angled peripheral edge, and is like a cutting tool. This shape cannot be used as a ceramic tile. This is because a shape having a sharp outer periphery cannot be constructed with security, and even in a constructed state, if the outer periphery is exposed, it is extremely dangerous. For this reason, it is necessary to cut a large transparent substrate into small ceramic tiles and chamfer the tile base so that the outer periphery is safe. According to the manufacturing method of the present invention, a chamfering process of the tile base is omitted to process the tile base into a shape that can be used safely. This is because, in the step of sintering the yu medicine applied to the back surface to the tile base, the outer peripheral edge of the tile base is softened and flowed to be processed into a chamfered shape. Soda glass used as a tile base softens at about 700 ° C. and its viscosity decreases to about 10 ⁷ . Further, when heated, the viscosity decreases, and as shown in the cross-sectional view of FIG. 1, the sharp right-angled corner which is the outer peripheral edge 1A of the tile base 1 flows and is processed into a chamfered shape. The shape softened and flowed by heat and chamfered becomes an extremely smooth shape. The production method of the present invention sets the temperature at which the Yu medicine 2 is melted and sintered to the tile base 1 by the tile base 1.
Is set at a temperature at which chamfering is performed by softening and flowing the outer peripheral edge 1A of the tile base 1 in the baking step of the Yu medicine 2.
Chamfer A. The melting temperature of the Yu medicine varies depending on the kind of the Yu medicine, but is 700 to 1500 ° C. For example, in the step of sintering the Yu medicine on the back surface of the tile base using a pottery Yu medicine whose melting temperature is about 800 ° C., the outer periphery of the tile base is chamfered into a beautiful shape.

[0009]

Embodiments of the present invention will be described below with reference to the drawings. However, the following examples illustrate a method for manufacturing a ceramic tile for embodying the technical idea of the present invention, and the present invention does not specify a method for manufacturing a ceramic tile to the following method.

[0010] A colored ceramic tile is produced as follows. [Step of Mixing Glass Raw Materials] Cullet Glass crushed soda glass is added as cullet. The cullet reduces raw material costs and hastens the melting of the prepared glass raw material. 100% of this cullet
To produce a transparent substrate. Silicic acid The main component is SiO ₂ , which is the main component of the glass raw material. Natural silica sand and crushed silica sand obtained by crushing silica stone are used. If there is an impurity, it is colored. Many impurities contain iron oxide. Iron oxide
Wash with water or pickle to remove. Lime Naturally produced limestone is ground and added as calcium carbonate. Lime has an effect of generating carbon dioxide gas together with soda ash to homogenize the dough. Sodium ash, soda ash, sand glass, borax, dustpeter, etc. are ground and added. Flux Flux is added to lower the melting temperature and promote the melting of glass raw materials. An alkali nitrate such as sodium nitrate or potassium nitrate is added to the flux. Further, boric acid, borax or the like can also be used as a flux. Refining agent Added to remove bubbles contained in molten glass.
Alkali nitrate and boric acid can be used as fining agents because they lower the melting point and lower the viscosity. In addition, arsenous acid and antimony oxide have excellent clarifying action when used together with alkali nitrate. Colorant To color the tile substrate lightly and lightly, a small amount of colorant is added. As the coloring agent, the above-described metal oxides and metal powders can be used.

A glass material is weighed with a predetermined weight and mixed well.

[Glass Raw Material Melting Step] The glass raw material is heated to 1300 to 1500 ° C. to be melted and clarified. Full-cold type, in which the molten glass is pulled up directly with a roller, while being horizontally transferred by a bending roller, the upper and lower surfaces are sandwiched by a drawing roller to form a plate of a predetermined thickness A transparent substrate is manufactured by a pulling method such as the Colburn method. Furthermore, a plate-shaped transparent substrate can be manufactured by a roll method in which the molten glass is fed out in a horizontal direction, and the fed out molten glass is sandwiched between a mold roller and a rolling roller to be formed into a predetermined thickness. The transparent substrate manufactured by the roll method can be formed into an uneven surface by using a mold roll.

Although a transparent substrate can be manufactured by the above steps, commercially available plate glass or template glass can be used for the transparent substrate. The thickness of the transparent substrate is designed to an optimal value in consideration of the size of the tile base. The transparent substrate used for a large tile substrate is made thick, and the transparent substrate used for a small tile substrate is made thin.

[Step of Cutting Transparent Substrate into Tile Base] The transparent substrate is cut into a predetermined size to obtain a square tile base. To cut the transparent substrate, the surface of the glass is cut linearly with diamond, and the transparent substrate is broken and separated along the cut line.

[Step of Applying Yu-Yu on the Back of Tile Base] A yu-Yu is applied to the back of the tile base separated into a square shape. As the Yu-Yu, a material capable of chamfering by softening and flowing the outer peripheral edge of the tile base at the melting temperature is used. The soda glass used for the transparent substrate has a softening temperature of about 700.
° C and the melting temperature is about 1400 ° C. The tile base cannot be heated above the melting temperature to sinter the Yuchu. This is because in the step of sintering the Yu-Yu, the rectangular tile base material is melted and loses its original shape. Therefore, those having a melting temperature of 700 to 900 ° C. are used as the Yu medicine. The melting temperature of the drug can be adjusted by the components. In general, a Yu medicine has a property that the melting temperature decreases as the content of silica increases and the content of alumina decreases. Further, the Yu-Yu can lower the melting temperature by adding a flux such as alkali carbonate, borax and lead carbonate.
Low heat Yu, low heat Yu, and enamel Yu can be used as the Yu medicine that is melted at 700 to 900 ° C. Low heat Yu and low heat Yu can be produced by adding lead carbonate and borax to silica stone. An enamel can be produced by mixing feldspar, quartz, borax, soda ash, chile saltpeter, fluorite, quartz stone and the like.

The Yu-Drugs add a metal to them in the form of oxides or carbonates to develop a predetermined color. When a metal is baked in an oxidizing atmosphere and a reducing atmosphere, the coloration is different. For example, the following metals have the following colors in an oxidizing atmosphere and a reducing atmosphere. (1) Iron Oxidizing atmosphere …………… Red, brown, black Reducing atmosphere ……………… Blue and green (2) Copper Oxidizing atmosphere …………… Blue Blue reducing atmosphere ……………… (3) Chromium Oxidizing atmosphere ………………………………………………………………………………………………………………………………… .. (4) Cobalt Oxidizing atmosphere …………… .. Blue reducing atmosphere ……………. 5) Manganese Oxidizing atmosphere ………… Purple, reddish brown Reducing atmosphere ……………… Brown, dark brown (6) Nickel Oxidizing atmosphere ……………… Green Green reducing atmosphere ……………… Gray (7) Uranium Oxidizing atmosphere ………………………………………………………………………………………………………………………………………………………………………………………………………………………. Antimony Oxidizing atmosphere …………… Yellow Reducing atmosphere …………… Colorless (10) Iridium Oxidizing atmosphere ……… ...... black reducing atmosphere .................. gray

[Step of melting and sintering the Yu medicine into the tile base] After sufficiently drying the Yu medicine, the tile base coated with the Yu medicine is put into a firing furnace and fired. The baking furnace melts the Yu-Yu medicine and softens and flows the corners of the outer peripheral edge of the tile base to process it into a chamfered shape. Heating temperature is 750
To 950 ° C, preferably 800 to 900 ° C. The tile base coated with Yu medicine is heated, for example, by placing it upward on a belt conveyor of a continuous furnace, melting the bottom medicine, sintering it on the back side of the tile base, and softening and flowing the outer peripheral edge of the top surface. As a state, it is made to flow down by gravity and processed into a chamfered shape.

[Step of Slowly Cooling and Taking Out of Firing Furnace] As the Yu medicine is sintered, the ceramic tile whose outer peripheral edge of the tile base material is chamfered is cooled slowly so as not to be cracked. It is discharged from the firing furnace. The tile substrate continuously fired in the firing furnace is gradually cooled at the discharge side of the firing furnace and discharged slowly.

In the above-described method for manufacturing a ceramic tile, a transparent substrate is cut into a tile base, and then a wax is applied. In the method for producing a ceramic tile according to the present invention, it is not always necessary to apply a separating agent to the tile base. For example, it is also possible to apply a Yu medicine to the back surface of the transparent substrate, dry the Yu medicine, and then separate the transparent substrate to obtain a tile base. This manufacturing method has a feature that the application of the Yu-Yu can be performed efficiently because the Yu-Yu is applied to a large transparent substrate.

[0020]

EXAMPLES [Example 1] "Raw material preparation process" Even if the raw materials used are the same, the content of components varies depending on the raw materials produced in nature. Therefore,
Even if the amount of raw materials used is specified, the components of the manufactured glass are not constant. Therefore, a glass raw material is prepared so that the components of the glass have the following values. Silicon oxide ... 70 to 72% by weight Alumina ... 1 to 2% by weight Sodium oxide ... 10 to 20% by weight Calcium oxide ... ... 5 to 15% by weight Iron oxide ... 0.03 to 2.5% by weight Magnesium oxide 0.5 to 1% by weight Potassium oxide ... ……… 6% by weight or less Lead oxide ……………………… 1% by weight or less

[Transparent Substrate Manufacturing Process] The prepared raw material is heated to 1400 ° C. and melted, and the molten glass is clarified.
It is formed into an m-thick plate. The plate-shaped glass is gradually cooled so as not to be broken to form a transparent substrate.

Although a transparent substrate can be manufactured as described above, commercially available plate glass or template glass can be used as it is as the transparent substrate.

[Step of Cutting Transparent Substrate into Tile Base] The transparent substrate is cut into a square of 5 cm square to obtain a tile base. The transparent substrate can be easily separated into tile bases by making a linear scratch on the surface with diamond and passing along this line. As shown in FIG. 1A, the outer peripheral surface 1B of the separated tile base 1 is not a smooth surface. The outer peripheral edge 1A of the tile base 1 has a sharp right-angled corner.
In the tile base 1, the outer peripheral portion of the tile base 1 is softened and fluidized in the step of firing the Yu medicine, so that the cut outer peripheral surface 1B becomes a smooth surface as shown in FIG. The peripheral edge 1A has a chamfered shape.

“Step of Applying Yu-Yu Medicine to Bottom Surface of Tile Base” As the Yu-Yu, for example, an iron oxide using iron oxide as a coloring agent is used. As the Yu medicine, a mixture of 60 parts by weight of silica sand, 20 parts by weight of lead carbonate, and 3 parts by weight of borax mixed with 3 parts by weight of bengara and kneaded with water is used. . This Yu medicine color the back of the tile base red. The color to be colored can be adjusted with the added metal. After the Yu medicine is applied to the back of the tile base, the Yu medicine is sufficiently dried.

“Step of firing tile base coated with Yu medicine” The tile base is placed in a firing furnace and heated to 850 ° C. for firing. The tile base is baked on a flat ceramic plate with the surface of the Yu-Yu medicine applied downward. The Yu medicine is heated and melted. The molten yu medicine adheres to the back surface of the tile base material as a clean smooth surface. The tile substrate is heated to soften and flow. However, since the temperature of the tile base does not increase until it is in a molten state, the tile base has a square shape and the entire shape does not change. In particular, as shown in FIG. 1 (1), since the outer peripheral edge 1A of the tile base 1 protrudes, it is heated to a high temperature, softened, flows, and deforms as if a corner flowed. As shown in (2), it is processed into a chamfered shape.

The yu medicine is sintered on the back of the tile base,
The ceramic tile processed into a shape in which the tile base is chamfered is gradually cooled so as not to be broken, and is taken out of the firing furnace.

Example 2 A ceramic tile was prepared in the same manner as in Example 1, except that the step of applying the Yu-Yu medicine was changed from the step of separating the tile base to the back of the transparent substrate before separation into the tile base. To manufacture.

[0028]

The method for manufacturing a ceramic tile according to the present invention is characterized in that ceramic tiles of high quality colored with beautiful luster can be mass-produced at low cost. The reason is that the manufacturing method of the present invention does not cast the molten glass into a mold as in the related art, and manufactures the glass one by one. Instead, it is cut into a predetermined shape as a large transparent substrate to form a tile base. Separate and
Further, the tile base is processed into a beveled and beautiful shape in the sintering process of the Yuyaku. That is, the method for manufacturing a ceramic tile of the present invention can efficiently produce a large amount of tile base without using a large number of molds, and can omit the chamfering of the separated tile base. Has the feature of mass production.

Further, the ceramic tile manufactured by the method of the present invention has a feature that the colored surface is on the back surface and the surface is a transparent glass layer, so that the transparent glass layer can make the colored surface beautiful shine. is there. That is, the conventional ceramic tile, when wet with water, the surface will shine beautifully, but when the surface is dry, the shine will be less, but the ceramic tile of the present invention, even when the surface is dry, will always be wet with water There is a feature that shines neatly. For this reason, the manufacturing method of the present invention has an extremely excellent feature that a high-quality ceramic tile can be manufactured at low cost.

Further, in the ceramic tile of the present invention, in the step of sintering the Yuchu, the corners of the outer peripheral edge of the tile base material are softened and flowed to chamfer a smooth shape. The ceramic tile that is chamfered by flowing the tile base is
The chamfered part can be made a beautiful smooth surface. For this reason, for example, there is a feature that the chamfered portion can be processed into a beautiful shape that flows naturally as compared with polishing and chamfering. Further, since the outer peripheral surface of the cut tile base is processed into a smooth surface, the ceramic tile obtained by sintering the Yu-Yu has an advantage that the outer peripheral surface is also processed into a smooth surface.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view showing a step of firing a tile substrate by a manufacturing method of the present invention.

[Explanation of symbols]

1 ... tile base 1A ... outer edge 1B
… Outer surface 2… Yu medicine

Claims (2)

(57) [Claims] 1. A a process for manufacturing a plurality of transparent substrates linked ceramic tiles, and separating the plurality of tiles green body by cutting the transparent substrates in a square shape, minute <br/> in a square shape A step of applying a yu medicine to the back surface of the separated tile base,
The tile base coated with Yu medicine is placed with the Yu medicine applied side down.
And baking to sinter the Yu-Yu medicine on the back surface of the tile base, and softening, flowing and chamfering the outer peripheral edge of the tile base. 2. A step of manufacturing a transparent substrate in which a plurality of ceramic tiles are connected, a step of applying a wax to the back surface of the transparent substrate, and a step of applying the wax to form the transparent substrate into a square shape. and separating the plurality of tiles green body was cut into, a rectangular shape
The coated surface of Yuukusuri bisection isolated tile matrix baked <br/> form facing downward, together to sinter the Yuukusuri on the back surface of the tile base material, the outer peripheral edge of the tile base material softened by flowing A method for producing a colored ceramic tile, comprising the step of chamfering.