JP3187974B2 - Method for manufacturing ceramic molded body - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates, about the method of producing a ceramic molded body formed by inserting the mounting member.

[0002]

Conventionally, the molded body according to tile such as ceramics, the case also for housing for construction as an exterior material for the building,
Since the mortar was used as a dumpling, it took a lot of time and construction costs were high. To solve such a problem,
Japanese Patent Application Laid-Open No. 2-194249 and the like have made it possible to perform dry-type simple construction by making a ceramic molded body such as a tile and a frame at the time of construction fit. However, in order to realize this, the ceramic molded body such as a tile needs to have a complicated irregular cross section, and a molding method for enabling this is limited to extrusion molding. In addition, since it is limited to extrusion molding, its shape is also limited, and its construction method is also limited.

On the other hand, if a ceramic molded body such as a tile and a mounting member can be integrally formed, the degree of freedom of the construction method is greatly increased. However, the molded body before simply firing, during the manufacturing process, when performing the insertion of ceramic or metal member, cracks due to the difference in thermal expansion during systole and firing during drying of the green body There was a problem that it was impossible to produce a good molded body. In addition, during firing, conventional ceramics have a high firing temperature, for example, when simultaneously mounting members such as stainless steel,
There has been a problem that the mounting member is significantly damaged, and even if molding and firing are possible, the mounting member is likely to be embrittled after cooling.

[0004]

SUMMARY OF THE INVENTION An object of the present invention is to solve the above-mentioned problems of the prior art and to provide a method of manufacturing a ceramic molded body having a high degree of freedom in a molding method and an application method. .

[0005]

According to the present invention, a mixture containing 30 to 79 % by weight of glass powder , 20 to 60% of ceramic aggregate , and 1 to 20% of microsilica in weight% as an inorganic component is formed into a predetermined shape. A method for producing a ceramic molded body by obtaining an intermediate molded body and firing the intermediate molded body, wherein a method for producing a ceramic molded body comprising inserting a metal mounting member into the intermediate molded body is provided. You.

In the present invention, the content of the glass powder is 3
If it is less than 0%, sintering does not proceed sufficiently at a low temperature of about 700 to 1000 ° C., and the water absorption is hardly reduced. Also,
The content of the glass powder shrinkage increases during the firing exceeds 79%, not easy deteriorated dimensional accuracy. As the glass powder used in the present invention, glass cullet if example embodiment, frit, what is called a natural glass are used. Among them, SiO ₂ : 71 to 73 because they are easily available.
_{%, Al 2 O 3: 1~2} %, CaO: 6~7%, Na 2
_{O + K 2 O: 14~15%} , MgO: preferably cullet 3-4% of the glass sheet.

[0007] The ceramic aggregate used in the present invention is used as a reinforcing material. When the content of the ceramic aggregate is less than 20%, the firing shrinkage becomes large and the ceramic aggregate becomes large.
%, The sintering becomes insufficient and the water absorption increases.
As the ceramic aggregate, one having a melting point higher than the softening temperature of the glass used, for example, silica sand, alumina or the like is used.

As a molding aid, it is preferable to add an organic substance such as methylcellulose or polyvinyl alcohol. In the case of molding by extrusion molding, it is preferable to add 1 to 2% of methylcellulose. Moreover, it added microsilica 1-20% as a molding aid. As the microsilica, silicic dust produced at the time of production of ferrosilicon and desiliconized zirconia, having a SiO ₂ content of 80% or more and a specific surface area of 10 m ² / g or more, preferably 20 m ² / g or more is reactive. It is preferable because it is rich.

[0009] As the microsilica is not particularly problem moldability and exceeds 20% in the range, tend to exhibit a foaming phenomenon at the time of firing, the water absorption after firing greater ing. When forming by extrusion, the particle size of the glass powder and the ceramic aggregate is preferably 50 μm or less. If the particle size of the glass powder and ceramic aggregate is 50μm greater, it increases the internal friction angle of the entire raw materials, because the extrusion is lowered. An intermediate molded body is formed using the above mixture. As the molding method, but any method can be used, extrusion or preferably press forming. The shape is not particularly limited.

As a method of inserting the mounting member into the intermediate molded body, the mounting member may be inserted at the same time as the molding of the intermediate molded body. A preformed body is formed in advance, and the mounting member is inserted into the preformed body. It may be an intermediate molded body. The metal used for the mounting member has a coefficient of thermal expansion of 10 to 2
It is preferably 0 × 10 ⁻⁶ / ° C., and the firing temperature
( Usually in the range of about 700 to 1000 ° C. ) , it is preferable to maintain the shape and strength.

If the coefficient of thermal expansion of the ceramic or metal used for the mounting member is larger or smaller than the above range, it is not preferable because it is difficult to follow the change in expansion and contraction. Stainless steel, nickel steel, and the like are materials that meet this condition and are inexpensive. Considering the possibility of being used outdoors, an attachment member made of stainless steel having excellent corrosion resistance is particularly preferable. As the shape of the attachment member, a rail, a nut, a bolt, and a hook are preferable. In addition, it is preferable that the attachment member has a shape that expands in the ceramic molding and is hard to be detached.

[0012] The intermediate molded body thus formed is 700
It is fired at a temperature of about 1000 ° C. to produce a ceramic molded body. This firing time of the atmosphere is arbitrary, the mounting member is oxidized at a high temperature is used, if the material there is a risk of embrittlement, a reducing atmosphere is preferable.

[0013]

In the present invention, the reason why the metal to be inserted as the mounting member and the matrix adhere to each other is not quantitatively clear, but it can be qualitatively explained as follows. The use of glass powder , which is a material completely different from conventional ceramic materials, makes it possible to increase the coefficient of thermal expansion by a factor of two to three compared with ceramics using clay.
As a result, although it is a very practical material, the thermal expansion coefficient of the material is almost equal to that of iron, stainless steel or the like, and the materials can be combined. Further, the molded body using the above-mentioned glass powder has shrinkage at the time of firing less than half that of ceramics using other clays, and is fixed to the metal jig even after cooling.

[0014]

EXAMPLES Table 1 shows two examples and one comparative example. Material (comparative example each formulation shown in Table 1 Micro Siri
Contains no mosquitoes. Also, methyl cellulose, pulp, water
Including Yuryou is, Der% of outer percentage relative to the solid content of 100% of
You. ) Is extruded and 300mm wide x 450mm long x
A preformed body having a thickness of 20 mm was obtained. Next, a rail or nut having a C-shaped cross section is placed at a predetermined position on the preformed body, pressed with a pressure of ²⁰ to 30 kg / cm ² , and the rail or nut is inserted into the preformed body. And an intermediate molded body was obtained. Next, the intermediate molded body was dried and fired under the following conditions. That is, 40 in a hot air dryer.
C. for 16 hours, and further dried at 110.degree. C. for 3 hours.
Then, the temperature was raised at 100 ° C./Hr by an electric furnace, and 900
After sintering at 1 ° C. for 1 hour, the mixture was cooled.

Table 1 also shows the results of observing the ceramic molded body thus obtained with the naked eye and the results of measuring the coefficient of thermal expansion and the rate of shrinkage of firing of the ceramic molded body. The symbol ◎ in Table 1 indicates that no microcracks were observed, and the symbol × in the table indicates that cracks including microcracks were generated. As is clear from the table, according to the present invention, a ceramic molded body having a mounting member can be manufactured without cracking or deformation.

[0016]

[Table 1]

[0017]

According to the present invention, Ru <br/> can a ceramic body having a metal mounting member having an arbitrary shape in manufacturing. Since such a molded article has the above-described characteristics, when it is used for a building material such as a wall material, the degree of freedom of a construction method is increased, and the workability is further improved.

──────────────────────────────────────────────────続 き Continuation of the front page (72) Inventor Asahi Hirano 1150 Hazawacho, Kanagawa-ku, Yokohama-shi, Kanagawa Prefecture Asahi Glass Co., Ltd. Examiner at Central Research Laboratory Mitsuo Teramoto (56) References JP-A-4-112005 (JP, A) JP-A-61-96121 (JP, A) JP-A-4-241906 (JP, A) JP-A-2-194249 (JP, A) (58) Fields investigated (Int. Cl. ⁷ , DB name) B28B 11/00-23/22 C04B 35/00-35/22 C04B 37/00-37/04

Claims (1)

(57) [Claims] 1. A glass powder 3 expressed as a percentage by weight as an inorganic component.
0-79%, ceramic aggregate 20% to 60%, micro
A method of molding a mixture containing 1 to 20% of silica into a predetermined shape to obtain an intermediate molded body, and firing the intermediate molded body to produce a ceramic molded body, wherein a metal mounting member is attached to the intermediate molded body. A method for producing a ceramic molded body, comprising: