JP3015001U - Foam ceramic tiles - Google Patents

Abstract

(57) [Summary] [Purpose] To provide a foamed ceramic tile that is lightweight, has impact resistance, is excellent in appearance and weather resistance, and is not likely to come off. is there. [Structure] A ceramic composition component of a glass-like substance containing ceramic fine hollow particles having a compressive strength of 600 kgf / cm ² or more, a bulk specific gravity of 0.3 to 0.5 g / cm ³ , and a melting point of 1500 ° C. or more and a material serving as a flux. After kneading the composition, it is pressure-molded into a tile-shaped plate material having an arbitrary size and baked at 700 to 1300 ° C. to obtain a tile base material, and the surface side is coated with a decorative material,
A foam ceramic tile is formed by forming a mounting thin locking protrusion or a thin engaging groove on the back surface side.

Description

[Detailed description of the device]

[0001]

[Industrial applications]

 The present invention relates to a lightweight, impact-resistant, and easy-to-install foam ceramic tile for use as a decorative material for columns, inner and outer walls of buildings, gates, fences, etc.

[0002]

[Prior art]

 Conventional tiles are porcelain-heavy, and on-site construction requires a skilled technician to put in horizontal lines with water thread and stick them one by one with cement mortar or adhesive, which is troublesome and can only be done by skilled workers. It was a thing.

There is a dry method of tiles that has become popular in recent years in which a ceramic or metal-based mounting base material is provided with engaging protrusions and the like, and heavy ceramic tiles are attached thereto with an adhesive or cement mortar. However, since the tiles are made of heavy ceramics, it is not possible to easily perform on-site work and only skilled workers can install them. The mounting base on top of it is also heavy and the structural material must bear a large load.

The biggest drawback of the tile construction method is that there is a high risk that the tiles that have fallen off due to peeling off may damage the human body. Since the adhesive or cement mortar deteriorates and the tile is heavy, it easily falls off, and none of the conventional improved stacking method, improved compression method, adhesion method, dry method etc. can completely prevent the exfoliation.

[0005]

[Problems to be solved by the device]

 In view of such circumstances, an object of the present invention is to provide a foamed ceramic tile that is lightweight, has impact resistance, is excellent in appearance and weather resistance, is not likely to come off, and can be installed by an unskilled person very easily. .

[0006]

Means for Solving the Problems The present invention includes ceramic fine hollow particles having a compressive strength of 600 kgf / cm ² or more, a bulk specific gravity of 0.3 to 0.5 g / cm ³ , and a melting point of 1500 ° C. or more and a material serving as a flux. After kneading the composition consisting of the ceramic composition of the glass-like substance, press-molding it into a tile-shaped plate of arbitrary size and firing at 700 to 1300 ° C to melt the ceramic composition of the glass-like substance containing the material to be the flux. The fine ceramic hollow particles are spot-bonded to each other to form a lightweight tile base material.

[0007] The surface side of this lightweight tile base material is coated with a decorative coating material, and the finished surface is exposed to a light-luminance tile-like pattern, a stone pattern, a sand wall pattern, a brick-like pattern, etc., and is attached to the back surface side of the base material. A thin width locking protrusion or a thin width locking groove is formed. This is to facilitate the construction of the foamed ceramic tile according to the present invention easily and accurately.

[0008]

[Action]

The foamed ceramic tile according to the present invention is a tile-shaped plate material having a kneading composition composed of ceramic fine hollow particles having a hydrostatic strength of 600 kgf / cm ² or more and a glass-like substance containing a material serving as a flux. Pressure molding is performed and firing is performed at 700 to 1300 ° C., which is used as a base material. The thickness of the base material is more preferably in the range of 2 to 15 mm.

The foamed ceramic tile substrate is a plate obtained by kneading a composition in which ceramic fine hollow particles are 100 to 300 parts by weight and a ceramic composition of a glassy substance containing a material serving as a flux is in a range of 10 to 300 parts by weight. The pressure-forming method is such that the pressure is 50 to 500 kgf / m ^{2 with} a press or a roller. If it is 50 kgf / m ² or less, excess air bubbles are mixed in the base material to deteriorate the underlying physical properties. Also, even if a pressure of 500 kgf / m ² or more is applied, no significant change in physical properties is observed.

The base material of the foamed ceramic tile is made up of a myriad of perfectly spherical ceramic fine hollow particles, and the ceramic fine hollow particles are connected to each other at points so that each ceramic fine hollow particle constitutes a strong base material. You can do it.

The base material of the foamed ceramic tile of the present invention has a myriad of micron-sized capillary air circulation holes, and high-strength ceramic fine hollow particles are welded to each other by a glass composition ceramic composition. Let them do it.

The ceramic fine hollow particles used in the present invention have particularly high compressive strength as compared with the conventional fine hollow foams, and the high stress and shearing force generated during the kneading and forming process of the foam ceramic tile base material. Can withstand. For this reason, it is possible to form a dense foam ceramic tile while reducing the weight even when pressure-molded.

The compressive strength of the ceramic micro hollow particles is synonymous with the hydrostatic strength, and the compressive strength is measured by pressurizing the ceramic micro hollow particles in water and transmitting the pressure applied to the water to the ceramic micro hollow particles. The pressure at which the ceramic micro hollow particles break is defined as the compressive strength.

A foamed ceramic tile substrate capable of exhibiting excellent physical properties must have a sufficient kneading step, and is particularly important for a foamed ceramic tile of uniform quality and good quality. When sufficient kneading is performed, the stress and shearing force applied to the ceramic fine hollow particles during the kneading are about 400 kgf / cm ^2, and therefore, considering the safety factor, the compressive strength needs to be 600 kgf / cm ² or more. In the past, since there were no such hollow microfoams that could withstand such high pressures, most of them were destroyed and the desired performance could not be secured.

For example, the conventional shirasu balloon, glass balloon, silica balloon, fly ash balloon and the like have a compressive strength of 80 to 300 kgf / cm ² .

The base material of the foamed ceramic tile is annealed at a temperature of 700 to 1300 ° C. for 10 to 40 minutes, which is a kind of glass composition containing a material serving as a flux to be used. It depends on the melting point. The fine ceramic hollow particles are joined together at points to firmly bond them. The ceramic composition component of the glassy substance containing the material serving as the flux used as the binder is melted, and the ceramic fine hollow particles are fixed by this melt. However, the ceramic fine hollow particles should not melt during this firing, and the strength should not be reduced by heating. Therefore, the melting point of the ceramic fine hollow particles is required to be 1500 ° C. or higher.

The fine ceramic hollow particles used in the present invention are formed by foaming a ceramic composition consisting of 38 to 40% alumina, 58 to 60% silica, and 1.5 to 2.0%. As for physical properties, it has a compressive strength of 700 kgf / cm ² , a melting point of 1600 ° C., a bulk specific gravity of 0.3 to 0.5 g / cm ³ , and is composed only of completely hollow particles.

The fine ceramic hollow particles having a crying diameter in the range of 20 to 350 μm are used by mixing them by adjusting the particle size so as to have fine 20 to 75 μm, medium 75 to 150 μm, and coarse 150 to 350 μm. The bulk specific gravity is heavy for finer particles and lighter for coarse ones. Therefore, the range of bulk specific gravity is 0.3 to 0.5 g / cm ³ .

The flux of the present invention is added with one or more of feldspar, limestone, magnesium carbonate, lime phosphate, lead oxide, borax, sodium carbonate, zinc oxide and the like. Further, the ceramic composition of the glassy substance means B ₂ O ₃ , SiO ₂ , GeO ₂ , ZrO ₂ , P ₂ O ₅ , As ₂ O ₅ , Sb ₂ O ₃ , Bi ₂ O ₃ , P ₂ O _3, etc. The acidic oxides include basic oxides such as Na ₂ O, K ₂ O, CaO and MgO, and Al ₂ O ₃ , ZnO, PbO and TiO ₂ added. For example _{SiO 2 -Na 2 O -B 2 O} 3, SiO 2 -Na 2 O-CaO, SiO 2 -K 2 O-CaO, Al 2 O 3 -SiO 2 -Na 2 O-CaO-B 2 O 3, such as _{al 2 O 3 -SiO 2 -TiO 2} -CaO-B 2 O 3 is used.

The blending amount of the ceramic composition of the glassy substance containing the material serving as the flux is 5 to 40 parts by weight with respect to 100 parts by weight by adjusting the particle size of fine, medium and coarse particles of the ceramic hollow particles. Add some. If the amount is 5 parts by weight or less, the foamed ceramic plates cannot be firmly bonded to each other to exhibit sufficient strength, and if the amount is 40 parts by weight or more, the amount of the melt in the foamed ceramic tile base material is too large, which makes it difficult to reduce the weight.

The decorative coating material to be applied to the surface side of the foamed ceramic tile base material can be selected from general commercial products having excellent water resistance and weather resistance, and the constitution thereof can be a binder, a synthetic resin solution, an emulsion, or a reaction material. A curable synthetic resin solution is used and various aggregates are added to it. A top coat may be applied on top of the decorative coating material to protect it and improve its durability.

The foam ceramic plate has a tile-like arbitrary size, and its shape and size can be freely designed, and various shapes such as a square shape, a rectangular shape, a triangular shape, a round shape, and other special shapes are possible. The size of the tile can be from a small size such as a mosaic tile to a large size tile of 1 m or more. Of course, you can also make things such as two-piece, three-piece, four-piece, small edge, and border sizes that are commonly called. The shape can be a flat plate or one in which both ends are jointed jointly.

The thin locking protrusions or the narrow locking grooves formed on the back surface side of the foam ceramic tile base material facilitate the installation work of the foam ceramic tile and allow even an unskilled person to easily attach the work. It was made possible.

[0024] A plurality of thin width locking grooves or thin width locking protrusions are formed in the horizontal direction of the structural base or the base panel, which is the mounting structure, at predetermined vertical intervals to form a thin ceramic ceramic tile. It engages with the width-shaped locking projection piece or the thin width-shaped locking groove, and is attached using an adhesive. The structural base or base panel, which is the mounting structure, can be easily and accurately attached to any material such as metal-based materials, inorganic-based materials, wood-based materials, and synthetic resin-based materials.

The thin locking protrusions formed on the back surface side of the foamed ceramic tile base material have a length of 5 to 15 mm, and a thickness of 2 to 7 mm. Further, the depth and width of the thin width locking groove may be the same as the length and width of the thin width locking projection piece to be engaged, but the adhesive can be increased by increasing the width by about 0.5 to 1.0 mm. It is possible to facilitate construction when using and sticking. These dimensions depend on the size and shape of the tile. The dimensions of the thin locking projections or the thin locking grooves formed on the mounting frame side are also the same.

When the foam ceramic tile has a thin width locking projection piece, this thin width locking projection piece becomes an obstacle during transportation. The protruding piece is put in the groove of the other party to eliminate the inconvenience of handling. When the back sides of the foam ceramic tiles are put together, the thin width locking protrusions are placed in the mating grooves to facilitate handling and prevent damage to the thin width locking protrusions.

[0027]

[Example of actual rotation]

 An embodiment of the present invention will be specifically described with reference to the drawings.

Embodiment 1 FIG. 1 is a cross-sectional view of a foam ceramic tile 1 according to the present invention, in which a narrow locking projection piece 4 is formed on the back surface side. Both ends of the tile were used as indirect joints 6 and 7.

Embodiment 2 FIG. 2 is a cross-sectional view of a foam ceramic tile having a thin width locking groove 9 formed on the back surface side. As in Example 1, both ends of the tile were made into the splicing joints 6 and 7.

The foamed ceramic tile substrate of this example has a hydrostatic strength of 700 kgf / cm ² , a bulk specific gravity of 0.3 to 0.5 g / cm ³ , and a melting point of 1600 ° C. An admixture (20 parts by weight of a ceramic composition of a glassy substance containing 100 parts by weight of finely divided particles, 10 parts by weight of fine particles, 30 parts by weight of coarse particles and 30 parts by weight of coarse particles and a material to be a flux) 1.2 parts by weight of stabilizer, dispersant, etc. and 2 parts by weight of water-based binder diluted with 25 parts by weight of water are sufficiently kneaded to form a plate, which is then pressed into a plate at a pressure of 300 kgf / m ^2. did. After pressure molding, the material was aged at room temperature for 30 minutes and fired at 800 ° C. for 30 minutes to prepare a foamed ceramic tile substrate.

The ceramic composition of the glassy substance containing the material serving as the flux is obtained by adding 15 parts by weight of borax as a flux to 100 parts by weight of glass powder composed of Si ₂ O—Na ₂ O—CaO. Polyethylene glycol was used.

The coating material applied to the surface of the foamed ceramic tile substrate shown in FIGS. 1 and 2 is a general commercial product, a natural stone tone special finish coating material manufactured by Company K, and the coating thickness is 4 mm.

The foamed ceramic tile substrate of this example has a thickness of 12 mm and a specific gravity of 0.43. The thin locking protrusion has a length of 6 mm and a thickness of 3 mm. The depth of the thin width locking groove is 6 mm and its width is 3.5 mm. The impact strength of this substrate is 500 g, and it can pass the test from the height of the falling weight of 1.5 m, which is about 3 times the height of the falling weight of the ceramic tile.

FIG. 4 shows a front view of the foamed ceramic tile of Example 1 formed into various shapes and dimensions and mounted on a concrete surface. It is a random layer of masonry. As described above, the foam ceramic tile according to the present invention can be formed in any shape and size.

FIG. 7 shows a state in which the foam ceramic tile of Example 1 is mounted on the concrete block surface. In FIG. 7, a plurality of thin locking grooves are horizontally provided on the concrete block surface at predetermined vertical intervals. Adhesive is applied to the back side of the foamed ceramic tile in this groove, and a thin width locking protrusion piece is engaged and attached.

FIG. 8 shows a state in which the foam ceramic tile of the actual rotation example 2 is attached and installed to the hard foam plastic hollow block. The material of the rigid foam plastic hollow block is polystyrene. The hollow part of the hollow block is reinforced with reinforcement and is filled with concrete. In addition, a plurality of thin width locking protrusions are formed horizontally at a predetermined interval in the vertical direction on the hollow block surface, and the thin width locking groove on the back surface of the foam ceramic tile is engaged with this and attached with an adhesive. There is.

[0037]

[Effect of device]

 The foamed ceramic tile according to the present invention has a specific gravity of about 0.40, is extremely lightweight, and is a completely noncombustible material, and has excellent physical properties such as bending strength and impact strength that surpass those of ceramic tiles. In addition, the thermal conductivity is 0.1 kcal / mhr ° C., which exhibits an excellent heat insulating effect against the heat fluctuation of the outside air, and protects the skeleton to improve weather resistance and durability.

Since the foamed ceramic tile is lightweight, it can be easily attached by simply applying an adhesive to the structural base or the base panel that serves as a mounting frame. Forming a narrow width locking protrusion or a thin width locking groove on the back side of the foam ceramic tile, and forming a narrow width locking groove or thin width locking groove on the structural base or bottom panel, which is the reverse of the foam ceramic tile. By forming a stop projection piece, even unskilled persons can easily perform the installation work without the need to use a water thread to bring out the horizontal line during the attachment work.

The foamed ceramic tile according to the present invention is completely incombustible by a method of combining forms with arbitrary shapes and dimensions, and can display various patterns having a three-dimensional depth without applying a heavy load to the body. Can be done.

[Brief description of drawings]

FIG. 1 is a sectional view of a foam ceramic tile of Example 1.

FIG. 2 is a sectional view of a foam ceramic tile of Example 2.

FIG. 3 is a front view showing a state of the actual rotation example 1 during conveyance.

FIG. 4 is a front view of stacking using Example 1.

FIG. 5 is a front view of piled up stone cuttings according to the first embodiment.

FIG. 6 is a front view of a layered stone masonry using Example 1.

FIG. 7 is a cross-sectional view of the mounting work of the first embodiment.

FIG. 8 is a cross-sectional view of the mounting construction of the second embodiment.

[Explanation of symbols]

 1. Foam ceramic tile 2. Decorative coating material 3. Foam ceramic substrate 4. Thin width locking protrusion 5. Cut groove 6. Indirect jointing 7. Indirect jointing 8. Foam ceramic tile 9. Narrow width locking groove 10. Laying 11. Crushed stone pile 12. Turbulent masonry 13. Concrete block 14. Thin width locking groove 15. Concrete 16. Reinforcing bar 17. Adhesive 18. Hard foam plastic hollow block 19. Thin width locking protrusion

Claims (2)

[Scope of utility model registration request] 1. A ceramic composition component of a glass-like substance containing ceramic fine hollow particles having a compressive strength of 600 kgf / cm ² or more, a bulk specific gravity of 0.3 to 0.5 g / cm ³ , and a melting point of 1500 ° C. or more and a material serving as a flux. A foamed ceramic plate obtained by kneading the following composition under pressure into a plate shape and then using the foamed ceramic plate fired at 700 to 1300 ° C. as a base material and applying the surface side of the base material with a decorative coating material. tile. 2. The foamed ceramic tile according to claim 1, wherein the foamed ceramic plate has a tile-like arbitrary size, and a mounting thin width locking protrusion or a thin width locking groove is formed on the back surface side.