JP3059156U - Lightweight unfired tile - Google Patents

Abstract

(57) [Summary] [Problem] Lightweight non-fired tile with stone-grain light brightness and depth that can be easily formed into any shape and size, lightweight, resource saving, energy saving, easy workability and weatherability It is to provide. SOLUTION: A lightweight non-fired tile is formed by pressing a composition obtained by adding a fine core hollow particle and a crushed ceramic waste particle to cement and water into a thin plate-shaped core material, and cementing the same into water.

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]

 From the viewpoint of energy saving and resource saving, the present invention reuses scraps such as defective ceramic tiles generated during the production process as pulverized particles, and has excellent appearance and high strength without firing. Provide tiles.

[0004]

[Means for Solving the Problems]

 The present invention has been made in view of the above circumstances, and a composition composed of cement and water is added to fine hollow particles of ceramic and ground particles of ceramic waste, and a thin plate-shaped core material is put therein and pressed into a tile shape. It is a lightweight non-fired tile.

[0005]

[Embodiment of the invention]

 When a composition consisting of fine ceramic hollow particles and crushed ceramic waste particles is pressure-formed into a tile using cement as a binder, a high strength is obtained by putting a thin plate-shaped core material inside this tile-like molded body, and the surface becomes It has a stone-like pattern composed of ground ceramic waste particles. Furthermore, the ceramic fine hollow particles can reduce the weight, and the ceramic fine hollow particles can reflect light and exhibit excellent gloss and light brightness on the surface of the lightweight stone-grained tile. The stone-grain pattern can be changed arbitrarily by combining various types.

In the present invention, in addition to the above, various surfactants, thickeners, anti-sagging agents, anti-settling agents, anti-freezing agents and the like are added as dispersants in order to improve the properties of tiles as necessary. May be added. Further, for the purpose of improving the performance of the tile, a plasticizer, a stabilizer for preventing deterioration due to heat or light, a fungicide for preventing the occurrence of mold, and the like may be added.

[0007] The cement used in the present invention is not particularly limited. Mixed cements such as blast furnace cement, silica cement, fly ash cement, etc., special cements such as white Portland cement, cement-based solidifying material, and alumina cement are exemplified. Of these, ordinary Portland cement is preferably used in terms of price and quality.

[0008] The lightweight unfired tile uses ceramic fine hollow particles having a water pressure resistance of 600 kgf / cm ² or more. Hydraulic strength is synonymous with the compressive strength of fine hollow ceramic particles. When measuring the compressive strength of the ceramic fine hollow particles, the particles are put into water and pressure is applied to the water, and the pressure applied to the water is transmitted to the ceramic fine hollow particles to measure the compressive strength. If the water pressure resistance of the ceramic fine hollow particles is low, most of them are destroyed during kneading of raw materials and molding of tiles, and it is not possible to form a stone-grain surface having light brightness.

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. In other words, 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 exhibit a stone-like texture color. .

[0010] The ceramic fine hollow particles are used in the range of 20 to 350 µm, and are mixed and used by adjusting the particle size as fine 20 to 75 µm, medium 75 to 150 µm, and coarse 150 to 350 µm. 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, the stone-gloss gloss and light brightness cannot be said to be sufficient, and if it is more than 25% by weight, the physical properties of the tiles deteriorate.

Conventional inorganic fine hollow foams include shirasu balloons, glass balloons, silica balloons and the like, but the water pressure resistance of shirasu balloons is only 80 kgf / cm ² , and that of glass balloons and silica balloons is 150 to 200 kgf. / Cm ^2, it cannot satisfy the purpose of the present invention.

Since the present invention uses fine ceramic hollow particles having a water pressure resistance of not less than 600 kgf / cm ² , the fine hollow particles are not broken 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.

The crushed ceramic waste particles used in the present invention are obtained by crushing defective products generated in the porcelain production process. The pottery here includes earthenware, pottery, stoneware, and porcelain.Specific products include black clay tiles, bricks, clay pipes, earthen pipes, pottery with interior and exterior tiles, sanitary ware, etc. Porcelain includes interior and exterior tiles, floor tiles, mosaic tiles, sanitary ware, etc., and crushes defective products, waste, etc. use.

The crushed ceramic waste particles are fine, medium, and coarse, and the fine particle diameter is 0.1 to 0.5 mm, fine is 0.5 to 1.5 mm, and coarse is 1.5 to 3 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 necessary.

[0015] 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.

When a composition composed of fine ceramic hollow particles having a water pressure resistance of not less than 600 kgf / cm ² and crushed ceramic waste particles is pressure-formed into a tile and a cement, the inside of the tile-shaped molded body is formed. By adding a thin core material to the tile, the strength as a tile was increased, and the surface was able to exhibit excellent lightweight stone-like luster and light brightness.

The shape and dimensions of the lightweight non-fired tile having the light stone texture are generally rectangular as tiles, but can be arbitrarily set, and the dimensions are free and varied. In addition to rectangular shapes, square, triangular, round, and other special shapes are also possible. It can be of any size and shape, from small mosaic tiles to large tiles of 1 m or more. It is also possible to use a form in which the other end of the flat plate has a spliced joint.

The core material to be put into the tile-shaped molded body is a thin metal plate, for example, a thin plate made of an inorganic material such as iron, aluminum, copper, stainless steel, titanium, an aluminum-zinc alloy-plated steel plate, or a galvalume steel plate, for example, a flexible plate or an asbestos slate. , Alfaltic single, wood wool cement board, wood chip cement board, pulp cement board, gypsum board, rock wool board, calcium silicate board, slag cement board, etc., as well as vinyl chloride resin, polycarbonate, FRP, etc. A plastic sheet, a rigid foamed plastic sheet, a plywood, a fiber board, a particle board, a glass, etc. can be used.

The thickness of the core material must be determined according to the dimensions of the tile-shaped molded product. A range of 5 to 15.0 mm is used, with 2.0 to 10.0 mm being preferred for a four-clad tile.

The core material may be completely inserted into the tile-shaped molded body, or one side of the core material may be exposed on the back surface of the tile-shaped molded body. By exposing one surface of the core material to the back surface of the tile-shaped molded product, an adhesive can be applied to this surface during application and easily adhered. In this case, the effect of the adhesive can be enhanced by digging a groove on one side of the exposed core material.

[0021]

【Example】

 An embodiment of the present invention will be specifically described.

Example 25.0 parts by weight of ordinary Portland cement, 10.0 parts by weight of ceramic fine hollow particles, 64.5 parts by weight of ground ceramic waste particles, 4.0 parts by weight of organic additives (dispersants and the like), inorganic substance The pigment 4.0 parts by weight, a little water, 5.5 parts by weight, and the above composition were sufficiently mixed and stirred by a vacuum degassing kneader.

The ceramic fine hollow particles used are composed of 43.0 to 44.0% of alumina, 54.5 to 55.5% of silica, and 1.5 to 2.5% of other materials. 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. Crushed particles of ceramic waste The crushed particles obtained by crushing bricks were used, and the particle size was adjusted to 10 parts by weight for fine particles and 70 parts by weight for coarse particles. To this, 20 parts by weight of a medium size of ground white sanitary ware waste ground particles were added and blended.

When the above composition is formed into a two-piece (227 × 60 mm) tile shape having a thickness of 12 mm, a flexible plate having a thickness of 207 × 50 mm and a thickness of 207 × 50 mm is used as a core material, and one side is formed on the back side of the tile. It was arranged on a mold of a tile-shaped molded body so as to be exposed, and the composition was poured on it and pressed and molded. After curing at room temperature for 24 hours, the surface was buffed. The pressure for the pressure molding is 50 kgf / cm ² , and FIG. 1 shows this lightweight non-fired tile. This lightweight non-fired tile was proved to have weather resistance and abrasion resistance equivalent to the physical strength of ceramic tiles and higher.

[0025]

[Effect of the invention]

 The lightweight non-fired tile according to the present invention can not be achieved by the prior art by inserting a thin core material into ceramic fine hollow particles and crushed ceramic waste particles and pressing them into a tile shape with cement and water. The following effects could be achieved.

By adding a thin plate-shaped core material, a lightweight non-fired tile having high strength, high rigidity and excellent workability with bending strength and impact strength was obtained.

[0027] Tiles having performance comparable to fired ceramic tiles, despite being unfired by using ground particles of defective products generated during the ceramic production process and using cement as a binder, Could be produced.

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

[0029] 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 non-fired tile, ceramic fine hollow particles are uniformly arranged, and these ceramic fine hollow particles are transparent or translucent fine hollow, and are reflected by light irradiation to achieve extremely high gloss and light brightness. By buffing, it was possible to express a more excellent texture of light stone texture.

The use of the lightweight ceramic fine hollow particles enables the formation of lightweight tiles and facilitates construction, and the frame with the high heat insulation and the lightweight non-fired 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 a partial cross-sectional perspective view of an example lightweight non-fired tile.

FIG. 2 is a partial cross-sectional perspective view of another example.

[Explanation of symbols]

 1. 1. Lightweight non-fired tile composition Flexible board core material

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁶ Identification code FI E04F 13/14 102 B09B 3/00 301S

Claims (1)

[Utility model registration claims] 1. A lightweight non-sintering method characterized in that a composition composed of cement and water is put into ceramic thin hollow particles and crushed ceramic waste particles, and a thin plate-shaped core material is put therein and pressure-formed into a tile shape. tile.