JP3054808U - Lightweight unfired tile - Google Patents

Abstract

(57) [Summary] [PROBLEMS] To provide a stone-grain or brick-like light brightness and depth that can be easily formed into an arbitrary shape and dimensions, to save resources by reducing weight.
An object of the present invention is to provide an energy-saving, easy-to-install, and weather-resistant lightweight non-fired tile. SOLUTION: A composition obtained by adding fine ceramic hollow particles and crushed ceramic waste particles to a synthetic resin emulsion is pressure-formed into a tile shape to obtain a lightweight non-fired tile.

Description

[Detailed description of the invention]

[0001]

[Technical field to which the invention belongs]

 The present invention is a lightweight, non-fired tile that exhibits excellent aesthetics and is easy to construct and used for decorative finishing materials such as pillars, inner and outer walls, flooring materials, gates, and walls of buildings.

[0002]

[Prior art]

 Conventionally, tiles must be fired with common sense that they are made of porcelain and energy was required. In addition, defective ceramic tiles generated during the production process had to be disposed of as industrial waste.

[0003]

[Problems to be solved by the invention]

 In this invention, from the viewpoint of energy saving and resource saving, scraps such as defective ceramic tiles generated during the production process are reused as pulverized particles and used as tiles with excellent appearance without firing Is provided.

[0004]

[Means for Solving the Problems]

 The present invention has been made in view of such circumstances, and produces a composition comprising ceramic fine hollow particles, crushed ceramic waste particles, and a synthetic resin emulsion, and press-molds the composition into a tile shape.

[0005]

[Embodiment of the invention]

 By pressing a composition consisting of fine ceramic hollow particles and ground ceramic waste particles into a tile shape using a synthetic resin emulsion as a binder, the surface exhibits a stone-like or brick pattern consisting of ground ceramic waste particles. In addition, the ceramic fine hollow particles can reduce the weight, and the ceramic fine hollow particles reflect light, thereby exhibiting excellent gloss and light brightness on the surface of the lightweight stone-grain or brick-like tile. By mixing various types of ground ceramic waste particles, it is possible to arbitrarily change the stone tone or brick pattern.

The synthetic resin emulsions used in the present invention include acrylic resin emulsions, vinyl acetate resin emulsions, vinyl chloride resin emulsions, vinylidene chloride resin emulsions, styrene / butadiene resin emulsions, epoxy resin emulsions and acrylic resin emulsions. Examples include acid esters, styrene, ethylene, vinyl esters, vinyl acetate, and copolymers with synthetic rubber.

For example, copolymers of these include acrylic / vinyl acetate copolymers, vinylidene chloride / butyl acrylate copolymers, ethylene / vinyl acetate copolymers, and the like. The amount of the synthetic resin emulsion composition used is in the range of 5 to 8% by weight in terms of solids. If it is less than 5% by weight, the physical properties of the tile will not be improved, and if it is more than 8% by weight, the nonflammability of the tile will be reduced.

In the present invention, in addition to the above, various surfactants as a dispersant, an emulsifier for stabilizing an emulsion, an antifoaming agent for an emulsion, a thickener, Anti-sagging agents, anti-settling agents, anti-freezing agents and the like may be added. Further, for the purpose of improving the performance of the tile, a plasticizer, a stabilizer for preventing deterioration due to heat and light, and a fungicide for preventing the occurrence of mold may be added.

The ceramic fine hollow particles of the lightweight unfired tile have a water pressure resistance of 600 kgf / cm ² or more. Hydraulic strength is synonymous with the compressive strength of ceramic fine hollow particles. When measuring the compressive strength of the ceramic fine hollow particles, the particles are put into water, pressure is applied to the water, and the pressure applied to the water is transmitted to the ceramic fine hollow particles, so that the compressive strength can be measured. If the water pressure resistance of the ceramic fine hollow particles is low, most of them are broken at the time of kneading the raw materials and forming the tiles, so that the stone-like tone or the brick having the light brightness cannot be made the surface.

The ceramic fine hollow particles used have a water pressure resistance 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. Therefore, under any kneading conditions in the tile manufacturing process. It is not destroyed at all and is not destroyed at all during molding. In addition, the hardness and impact strength of the tile surface can be increased, and the ceramic fine hollow particles are uniformly dispersed on the tile surface, exhibiting excellent gloss and light brightness. That is, the ceramic fine hollow particles have a small particle size and are transparent or translucent in appearance, reflect when irradiated with light, exhibit an extremely high gloss and luminance surface, and can express a stone-like or brick-like texture color. You can.

The ceramic fine hollow particles are used in a range of 20 to 350 μm, and are mixed and used as fine particles of 20 to 75 μm, medium particles of 75 to 150 μm, and coarse particles of 150 to 350 μm by adjusting the particle size. Since the bulk specific gravity is heavy for fine particles and light for rough ones, the range of the bulk specific gravity is 0.3 to 0.5 g / cm ³ . The amount of the ceramic fine hollow particles used is in the range of 3 to 25% by weight. If it is less than 3% by weight, it cannot be said that the lightness and brightness of the stone tone or brick tone are sufficient, and if it is more than 25% by weight, the physical properties of the tile deteriorate.

[0012] Shirasu is a conventional inorganic microporous foam balloons, glass balloons, Shirikaba but are bulb pressure strength and the like rune shirasu balloon only 80 kgf / cm ² only rather name, glass balloon, also silica balloons 150~200kgf / Cm ^2, it cannot satisfy the purpose of the present invention.

Since the present invention uses ceramic fine hollow particles having a water pressure resistance of 600 kgf / cm ² or more, the fine hollow particles are not destroyed at all during the kneading process of the tile raw material and the tile molding. Therefore, there is no reduction in volume due to the destruction, and no change in the composition due to the destructed particles. The finished tile can achieve its intended purpose completely as designed.

[0014] The crushed ceramic waste particles used in the present invention are defective in the ceramic production process. Porcelain, such as tiles, floor tiles, and ceramic pipes, includes interior and exterior tiles, floor tiles, mosaic tiles, and sanitary ware. These products are used to crush defective products and waste.

The crushed ceramic waste particles are fine, medium, and coarse, and the fine particles have a particle diameter of 0.1 to 0.5 mm, a medium of 0.5 to 1.5 mm, and a coarse of 1.5 to 3 mm, respectively. Adjust to 4 mm before use. In addition to crushed ceramic waste particles, silica powder, fly ash, silica fume, clay, talc, kaolin, slow-cooled blast furnace slag slag, and siliceous dust may be added as required.

The color of the ground ceramic waste particles differs depending on the original ceramic product, and a unique texture can be obtained by blending them in various ways. For example, the addition of a moderate amount of white sanitary garbage waste ground particles to the coarse and fine ground brick ground particles makes it possible to express a completely new tile pattern that did not exist before.

By pressing a composition composed of a synthetic resin emulsion, ceramic fine hollow particles, and ground ceramic waste particles into a tile shape, the tile surface is excellent in lightweight, light-grained or brick-like luster and brightness. Was able to appear.

The shape and dimensions of the lightweight non-fired tile can be arbitrarily designed, and the dimensions are freely variable, and square, rectangular, triangular, round, and other special shapes are possible. . The size can be any size and shape from small mosaic tiles to large tiles of 1 m or more. The form includes a flat plate and one with an end part that is partially joined.

[0019]

【Example】

 An embodiment of the present invention will be specifically described.

Example As a synthetic resin emulsion, 12% by weight of a synthetic rubber-modified acrylic copolymer emulsion (6% by weight in terms of solid content), 8.0% by weight of ceramic fine hollow particles, 66.5% by weight of ground ceramic waste particles, organic matter A composition containing 4.0% by weight of additives (dispersant, etc.), 4.0% by weight of inorganic extender, and 5.5% by weight or more was sufficiently mixed and stirred by a vacuum degassing kneader.

The ceramic fine hollow particles having a composition of 43.0 to 44.0% alumina, 54.5 to 55.5% silica, and 1.5 to 2.5% other than silica are used. It has a compressive strength of 700 kgf / cm ² , a bulk specific gravity of 0.4 g / cm ³ , a melting point of 1600 ° C., and is composed of only completely hollow particles. The particle size of the fine ceramic hollow particles was adjusted to 20 parts by weight, 20 parts by weight, and 30 parts by weight. The crushed particles of ceramic waste used were crushed particles of Sanshu tiles, and the particle size was adjusted to 10 parts by weight and 70 parts by weight. To this, 20 parts by weight of a medium size of ground white sanitary ware waste ground particles were added and blended.

The composition was pressure-molded into a two-piece tile shape having a thickness of 12 mm, cured at room temperature for 24 hours, and then buffed on the surface. The pressure of the pressure molding is 50 kgf / cm ² , and FIG. 1 shows this lightweight unfired tile. It was proved that this lightweight non-burning tile had the same weather resistance and abrasion resistance as the physical strength of ceramic tiles or higher.

[0023]

[Effect of the invention]

The lightweight non-fired tile according to the present invention is obtained by pressing ceramic fine hollow particles having a water pressure resistance of 600 kgf / cm ² or more and a melting point of 1500 ° C. or more and crushed ceramic waste particles into a tile shape with a synthetic resin emulsion. The following effects, which could not be achieved with, were achieved.

[0024] Despite the fact that non-firing is achieved by using defective resin pulverized particles generated during the production process of ceramics and using a synthetic resin emulsion as a binder, performance comparable to that of fired ceramic tiles is achieved. I was able to make a tile.

By changing the composition of the crushed ceramic waste particles, it was possible to arbitrarily express various stone tones and brick tones of natural stone style.

[0026] The ceramic waste discarded as industrial waste can be effectively used, and can be formed by non-firing, so that the energy saving effect can be made extremely high.

On the surface of the lightweight unfired tile, ceramic fine hollow particles are uniformly arranged, and the ceramic fine hollow particles are transparent or translucent fine hollow, and are reflected by light irradiation to achieve extremely high gloss and light brightness. It was possible to exhibit a better texture by buffing.

By using lightweight ceramic fine hollow particles, lightweight tiles are formed and construction is facilitated, and a body having high heat insulating properties and lightweight unfired tiles can prevent temperature rise due to solar heat in summer. In addition, the surface of the lightweight unfired tile is high in hardness and hard to be scratched, and can express the same smoothness as natural stone. In addition, since it is strong against acid, it is not contaminated by acid rain.

[Brief description of the drawings]

FIG. 1 is an example of a lightweight non-fired tile.

[Explanation of symbols]

 1. Example light-weight unfired tile

Claims (1)

[Utility model registration claims] 1. A lightweight non-fired tile, which is formed by pressing a composition comprising fine ceramic hollow particles, ground ceramic waste particles and a synthetic resin emulsion into a tile shape.