JP3078410U - Lightweight ceramic plate - Google Patents

Abstract

(57) [Summary] [PROBLEMS] To reduce the load on a support (wall surface, etc.) by reducing the weight, to prevent the danger of falling, to facilitate handling, and to reduce shrinkage during firing. Provide a lightweight ceramic plate with almost no cracks. SOLUTION: Porcelain powder is used as a main raw material, carbon fiber powder is mixed with 10 to 40% (volume), an appropriate amount of water is added thereto, and the mixture is kneaded to form a base material. It is characterized by being formed by drying, glazing and firing by a conventional method.

Description

[Detailed description of the invention]

[0001]

[Technical field to which the invention belongs]

 The present invention relates to a porcelain plate used for an interior building material, an exterior building material, a furniture material, a flooring material, a ceiling material, an art porcelain plate, and more particularly to a lightweight porcelain plate.

[0002]

[Prior art]

 Conventionally, porcelain plates are made of porcelain clay, to which a predetermined amount of water is added, kneaded, shaped, dried, unglazed, glazed and fired (baked). It is manufactured by. Porcelain clay is prepared by using kaolin, clay, feldspar, quartzite, porcelain stone and wax stone as main raw materials. An example of a conventional porcelain clay formulation (composition example) is shown in Table 1 below.

[0003]

[Table 1]

[0004]

[Problems to be solved by the invention]

 Ceramic plates are excellent in hardness, durability, fire resistance, washability, workability, dimensional stability, and have a unique aesthetic, so they are widely used for interior building materials, exterior building materials, furniture materials, flooring materials, ceiling materials, art ceramic plates, etc. Have been. However, the conventional porcelain plate is made of porcelain clay, and as shown in Table 1 above, porcelain clay is prepared by using kaolin, clay, feldspar, quartzite, porcelain stone, wax stone and the like as main raw materials. For this reason, the conventional porcelain plates are very heavy and have difficulties in handling, and when used on old walls, there is a problem that the porcelain plates are too heavy to support and may fall. In particular, a large porcelain plate becomes heavier and more difficult to handle. For example, it becomes very difficult to mount the porcelain plate on a wall or the like, and a heavy load is applied to the support.

[0005] Porcelain plates are often adhered (adhered) to, for example, the wall surfaces of buildings via mortar or an adhesive, but when the weight becomes heavy, attaching to the wall surfaces with mortar or an adhesive cannot support the concrete. It is difficult to create a problem with the contact force) and it is necessary to fix it with some kind of mounting brackets (nails, bolts, etc.). However, since the ceramic plate is hard and cannot be nailed, and it is difficult to provide bolt holes later, it is necessary to provide holes for the ceramic plate in the manufacturing process in advance, and the manufacturing process is time-consuming. In other words, the use of the mounting bracket requires additional steps such as providing a supporting column on the wall surface, and also causes problems such as an increase in the number of parts.

[0006] Further, conventional large-sized porcelain plates made of porcelain clay have a high shrinkage rate during drying and firing, and therefore, when they are rapidly dried, cracks are generated. Therefore, drying takes a number of days, and cracks are easily formed during firing. There is a problem that requires technology for manufacturing.

The present invention has been proposed to solve such a problem. The purpose of the present invention is to reduce the load on a support (wall surface, etc.) by reducing the weight, and to prevent danger such as dropping. Another object of the present invention is to provide a lightweight porcelain plate that is easy to handle, reduces shrinkage during firing, and has almost no cracks.

[0008]

[Means for Solving the Problems]

 In order to solve the above problems, the lightweight porcelain plate of the present invention is a kneaded material obtained by mixing porcelain clay powder as a main material, 10 to 40% (by volume) of carbon fiber powder, and adding an appropriate amount of water thereto. The substrate is formed by molding into a predetermined shape, followed by drying, glazing, and firing by a conventional method, and the carbon fiber powder is a bead powder.

[0009]

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. FIG. 1 is a perspective view showing an embodiment of the present invention, and FIG. 2 is a sectional view showing a use state.

In FIG. 1, reference numeral 1 denotes a ceramic plate as an exterior building material. The porcelain plate 1 is composed of porcelain clay powder as a main raw material, 10 to 40% (capacity) carbon fiber (hereinafter, referred to as CF) powder mixed with the powder, kneaded by adding an appropriate amount of water thereto, and kneading. I do. The CF powder is preferably blended as a bead powder. The porcelain clay powder is prepared by using kaolin, clay, feldspar, quartzite, porcelain stone, rosacea and the like as main raw materials, and may be a conventionally known one. Porcelain clay is necessary for sintering integration and performance as a porcelain plate, similarly to pottery, and CF powder is necessary for weight reduction.

The compounding ratio of the porcelain clay powder and the CF bead powder is preferably in the range of 10 to 40% (volume) of the CF bead powder with respect to the porcelain clay powder, and particularly preferably in the range of 15 to 20% (volume). . Since CF bead powder is blended for weight reduction, if CF bead powder is less than 10% (capacity), the contribution of weight reduction is small, and if it exceeds 40% (capacity), there is a problem in performance as integrated sintering. . Therefore, the content of the CF bead powder is preferably in the range of 10 to 40% (by volume).

A kneaded material obtained by mixing the above-mentioned porcelain clay powder as a main raw material, adding a proper amount of water to a raw material obtained by blending the CF bead powder with the raw material, and molding the mixture into a predetermined shape is formed as a porcelain plate 1 by an ordinary method. For example, a porcelain body formed into a predetermined shape is first dried, and then dried and then sintered. This sintering is usually performed at 800 to 900 ° C. The main purpose of unglazing is to bake to the necessary strength to paint or glaze the porcelain plate base, and in some cases, it may be directly baked without unglaring.

[0013] When the unglazing is completed, the mixture is gradually cooled and then glazed. Glazing (glaze) is used for decorative purposes such as covering the surface of the substrate and giving it a gloss, for providing waterproofness and smoothing the surface to prevent dirt, and for further increasing the mechanical strength. . Finally, bake it. Usually, the main firing is performed at a temperature of 1100 to 1150 ° C., and the main firing is integrated by sintering to further improve the strength.

However, since the ceramic plate 1 contains CF as a lightweight material, not only is it very light, but also its strength is improved. Although it depends on the mixing ratio of the clay powder and the CF bead powder, a ceramic plate containing 15% (volume) of CF bead powder with respect to the clay powder is about one third lighter than the conventional one. In addition, shrinkage during firing was about 3% with this compounding ratio, which was less than the conventional 8% to 15%, and there was almost no cracking during firing.

FIG. 2 is a sectional view showing a use state of the embodiment, in which a porcelain plate 1 is adhered to a wall surface 2 of a building using mortar 3. Even when the porcelain plate 1 is used for the wall surface 2 as described above, the porcelain plate 1 is lightweight and can be sufficiently adhered to the mortar 3 and the load applied to the wall surface is reduced. Absent.

[0016]

[Effect of the invention]

 As described in detail above, the lightweight porcelain plate according to the present invention is a kneaded mixture obtained by mixing porcelain powder as a main material, 10 to 40% (volume) of CF powder, and adding an appropriate amount of water to the mixture. Is formed into a predetermined shape, and then formed by drying, glazing, and firing by a conventional method, so that the following effects are obtained.

(1) The weight of the porcelain plate becomes very light, which is about one third of the conventional one. Since the weight of the porcelain plate is reduced, handling becomes easier and workability is improved. (2) Since the weight of the porcelain plate is reduced, the load on the support such as the wall surface is reduced, and there is no danger of collapsing the wall surface and dropping it. Also, since it is lightweight, it can be held sufficiently by mounting with mortar or adhesive. (3) Since the shrinkage during firing is as small as about 3%, there is almost no cracking during firing. (4) The blending of CF not only reduces the weight but also improves the strength.

[Brief description of the drawings]

FIG. 1 is a perspective view showing an embodiment of the present invention.

FIG. 2 is a cross-sectional view illustrating a use state of the embodiment of the present invention.

[Explanation of symbols]

 1 porcelain plate 2 wall 3 mortar

Claims (2)

[Utility model registration claims] 1. A kneaded material obtained by mixing 10 to 40% (volume) of carbon fiber powder with a ceramic clay powder as a main raw material, adding an appropriate amount of water to the mixture, and molding the mixture into a predetermined shape. After that, it is dried, glazed and fired in a conventional manner to form a lightweight ceramic plate. 2. The lightweight ceramic plate according to claim 1, wherein the carbon fiber powder is a bead powder.