JP5479197B2 - Design material - Google Patents

Description

The present invention relates to a novel design material.

Conventionally, a gypsum molded body such as a gypsum board has been widely used as a building material. This gypsum molded body can be obtained by filling a gypsum slurry in which gypsum is dispersed in water into a mold or the like, or applying the gypsum slurry to a surface of a base material to form a desired shape and solidifying it by hydration. Thus, the gypsum molded article is excellent in moldability but has a problem that it is inferior in water resistance. As a technique for improving water resistance, Patent Document 1 describes mixing a water resistant agent for gypsum. Patent Document 2 describes that a specific acrylic emulsion is added to a mixture containing gypsum and cement as main components. However, Patent Documents 1 and 2 may not have sufficient water resistance.

  On the other hand, decorative building materials such as glass tiles in which a substrate is coated with glass as in Patent Document 3 are often used as inorganic building materials other than gypsum moldings.

Japanese Patent Laid-Open No. 2001-39752 JP 11-49551 A Japanese Patent Laid-Open No. 10-25177

However, the molded body obtained by mixing and firing ceramic stone, feldspar, clay material, etc. used as a substrate such as glass tile has excellent water resistance, but the firing temperature at the time of production is high, There is a risk of shrinkage, warping and cracking of the molded plate.

  This invention is made | formed in view of such a point, and provides the design material excellent in water resistance and a moldability.

As a result of intensive studies to achieve the above-mentioned object, the present inventor made a molded body of an inorganic composition containing glass particles, gypsum and water glass as essential components as a base layer, and a glass layer as a design layer thereon. As a result, the present invention was completed.
That is, the design material of the present invention has the following characteristics.

1. A design material in which a design layer is laminated on a base material layer,
The base material layer is a molded body of an inorganic composition,
The inorganic composition contains 10 to 200 parts by weight of gypsum and 5 to 150 parts by weight of water glass as a solid content with respect to 100 parts by weight of glass particles having an average particle diameter of 0.01 to 5 mm, and the weight of gypsum and water glass. The ratio is 90:10 to 40:60,
1. The design material, wherein the design layer is a glass layer. The base material layer and the design layer are fused. 2. Design material described in 3. The design layer is a sintered body of glass powder particles. ~ 2. The design material according to any one of
4). The glass powder is a glass particle having an average particle diameter of 0.01 to 5 mm. ~ 3. The design material according to any one of
5). The base material layer has a thermal expansion coefficient of 2 to 15 × 10 ⁻⁶ K ⁻¹ ;
The thermal expansion coefficient of the glass layer is in the range of ± 1 × 10 ⁻⁶ K ⁻¹ with respect to the base material layer . ~ 4. The design material according to any one of

  The present invention uses glass particles, gypsum, and water glass as essential components, a molded body of an inorganic composition containing gypsum and water glass at a specific weight as a base material layer, and a design layer is laminated on the base material layer. By this, the design material excellent in design property, water resistance, intensity | strength, etc. can be obtained.

  Hereinafter, the best mode for carrying out the present invention will be described.

The design material of the present invention is obtained by laminating a design layer on a base material layer.
(Base material layer)
The base material layer of the present invention comprises (A) glass particles, (B) gypsum, and (C) water glass as essential components, and an inorganic composition (B) gypsum and (C) water glass in a specific weight ratio ( In the following, it is also referred to as “inorganic composition”), the inorganic composition has excellent moldability, and the molded product obtained from the inorganic composition has excellent water resistance and strength.
The inorganic composition of the present invention will be described.
It does not specifically limit as glass particle (A) (henceforth "(A) component") of this invention, For example, glass particles, such as soda-lime glass, lead glass, borosilicate glass, an alkali free glass, are mentioned. It is done. As the component (A), one having an average particle diameter of 0.01 to 5 mm, preferably 0.02 to 3 mm is used. When the particle diameter is in such a range, an inorganic composition having excellent moldability can be obtained. Moreover, the base material layer excellent in water resistance, intensity | strength, etc. can be obtained by shape | molding and baking an inorganic composition. Furthermore, a pattern can also be provided to the base material layer by using glass particles having a large average particle diameter within the above range.
The average particle diameter referred to here is a value obtained by performing sieving using a metal mesh sieve defined in JIS Z8801-1: 2000 and calculating an average value of the weight distribution.

The component (A) may be prepared by pulverizing a pre-formed glass so as to be adjusted to the above particle diameter range, or by directly forming glass particles having a predetermined particle diameter from a molten glass material. it can. Moreover, what grind | pulverized the waste glass collect | recovered from the waste of glass products, such as a glass bottle, can also be used.

In addition, the component (A) may be transparent, opaque, or colored, and can be appropriately mixed to impart design properties. For example, when colored glass particles are used, the base material layer can be arbitrarily colored. Moreover, when a plurality of colored glass particles are mixed, various design properties can be imparted. In particular, when two or more colored glasses having a large average particle diameter (1 mm or more) are used, a design such as a natural stone tone is expressed. You can also

  In the present invention, the component (A) has a melting point of preferably 1000 ° C. or lower, more preferably 950 ° C. or lower. In the case of such a melting point, even when an inorganic composition mixed with gypsum and water glass described later is fired at a relatively low temperature, a substrate layer having excellent strength can be obtained.

As the gypsum (B) of the present invention (hereinafter also referred to as “(B)” component), a known gypsum material can be used. For example, various hemihydrate gypsums such as natural gypsum and chemical gypsum and anhydrous gypsum can be mentioned. Chemical gypsum includes phosphate gypsum, titanium gypsum, and drainage gypsum. There are two types of hemihydrate gypsum, α and β types, which can be used. In the inorganic composition of the present invention, the component (B) is 10 to 200 parts by weight, preferably 20 to 150 parts by weight with respect to 100 parts by weight of the component (A). In such a range, an inorganic composition excellent in moldability can be obtained.
In this invention, (B) component has the effect which suppresses the shrinkage | contraction at the time of drying and baking, after giving the moldability excellent to the inorganic composition and shape | molding an inorganic composition. In the present invention, the component (B) hardly shrinks at the time of drying (hydration curing), and in the firing temperature range described later, since decomposition and the like at the time of firing are relatively small, the shrinkage of the molded body can be suppressed. it can. In the present invention, a base material layer having a desired shape can be obtained by the action of the component (B).

The water glass (C) of the present invention (hereinafter also referred to as “component (C)”) has a general formula Na ₂ O.nSiO ₂ (n = 2 to 4) (in some cases, K ₂ O and / or Li ₂ O). a powder or an aqueous solution of an alkali silicate represented by containing), the difference in the content of SiO ₂ and Na ₂ O, are distinguished in No. 1 No. to 4. Although any of them can be used in the present invention, No. 3, No. 4, etc. with relatively little alkali component are particularly advantageous in terms of water resistance.

In the inorganic composition of the present invention, the component (C) acts as a binder for the component (A) and the component (B). In addition, since the melting point of the component (A) can be lowered at the time of firing the inorganic composition, it is possible to form a base material layer having excellent strength even when fired at a low temperature. (C) component is 5-150 weight part as solid content with respect to 100 weight part of (A) component, Preferably it is 10-100 weight part. In such a range, an inorganic composition excellent in moldability can be obtained. Moreover, at the time of baking of an inorganic composition, shrinkage | contraction of a molded object can be suppressed by (C) component foaming, and the base material layer which has a desired shape can be obtained.

  In the inorganic composition of the present invention, the weight ratio of the component (B) and the component (C) is 90:10 to 40:60, preferably 80:20 to 50:50. In such a range, an inorganic composition excellent in moldability can be obtained. Further, warpage, shrinkage, etc. can be suppressed during drying of the molded body, and further, shrinkage, cracks, etc. can be suppressed during firing. For example, when there is too much (B) component, there exists a possibility that the intensity | strength of a base material layer may fall. Moreover, when there are too many (C) components, it is easy to produce a curvature at the time of shaping | molding, and there exists a possibility that dimensional stability may worsen.

  The inorganic composition of the present invention is obtained by adding water to a mixture of the above component (A), component (B), and component (C) (hereinafter also referred to as “(A), (B), (C) mixture”) and a slurry. It is a thing. The amount of water added may be appropriately set, but it is preferably about 10 to 100 parts by weight with respect to 100 parts by weight (solid content) of the mixture (A), (B) and (C). In such a range, an inorganic composition excellent in moldability can be obtained. In addition, warping and shrinkage can be suppressed when the inorganic composition is molded and then dried, and further shrinkage, cracking, and the like can be suppressed during firing.

  The inorganic composition of the present invention includes one or more inorganic materials selected from quartz sand, molten slag, fly ash, kaolin, talc, mica, bentonite, feldspar, porcelain stone, wollastonite, ceramic pulverized material, fibers and the like ( D) (hereinafter also referred to as “component (D)”) can be added. However, when the component (D) is added, the amount is preferably 400 parts by weight or less, more preferably 300 parts by weight or less, and more preferably 200 parts by weight or less with respect to 100 parts by weight of the component (A). Most preferred. The average particle diameter is preferably 1 mm or less, more preferably 0.5 mm or less. If it is such a range, the inorganic composition excellent in the moldability can be obtained. Further, warping, shrinkage, and the like during drying after molding the inorganic composition can be suppressed. Furthermore, shrinkage, cracks, and the like can be suppressed during firing, and a base material layer having excellent strength can be obtained.

Furthermore, a metal salt and / or a metal oxide (E) (hereinafter also referred to as “component (E)”) can be added to the inorganic composition of the present invention. (E) A component mixes with the said (A) component etc., and colors a base material layer by baking simultaneously.
Furthermore, as long as the effects of the present invention are not impaired, a dispersant, an antifoaming agent, a water reducing agent, a curing retarder, a reinforcing material, a flux, and the like may be added to the inorganic composition of the present invention.

The thickness of the base material layer is preferably 1 to 20 mm, more preferably 2 to 15 mm. Moreover, it is preferable that the thermal expansion coefficient of a base material layer is 2-15 * 10 <^-6> K < ^-1 >. In such a range, a substrate layer excellent in water resistance and strength can be obtained, and when laminated with a design layer described later, cracks and peeling between layers can be prevented, and excellent design properties Can be expressed.

(Design layer)
If the design layer of this invention is a glass layer, it will not specifically limit, For example, glass layers, such as soda-lime glass, lead glass, borosilicate glass, an alkali free glass, are mentioned. The glass layer may be transparent, opaque, or colored, and various designs can be imparted by mixing them. Furthermore, when the glass layer has transparency, a variety of colors can be expressed in combination with the above-described base material layer, and a design material excellent in design properties can be obtained.

Examples of the glass layer include, for example, a preformed glass plate, a glaze layer, a layer formed of glass powder, and the like, and particularly in the present invention, a layer formed of glass powder is preferable. A sintered body of glass powder is preferable. By being a sintered body of glass powder particles, various colors and patterns can be expressed, and the design is excellent.
As said glass granular material, the thing similar to the glass particle (A) used for the said base material layer can be used. Further, the average particle diameter of the glass particles is usually preferably 0.01 mm to 10 mm (preferably 0.05 mm to 5 mm), and the shape thereof is, for example, spherical, elliptical, flake-like, plate-like, or hemispherical. Any shape such as an indefinite shape, a polygonal plate shape, an elliptical plate shape, a rod shape, or a needle shape may be used. Furthermore, it is preferable that the design layer of the present invention is used by mixing at least two glass powder bodies having different particle diameters. By using a plurality of glass powder particles having different particle diameters, a uniform glass layer can be easily formed.

The glass powder particles may be transparent, opaque, or colored, and can be appropriately mixed to impart design properties. Moreover, when a plurality of colored glass particles are mixed, various design properties can be imparted. In particular, when two or more colored glasses having a large average particle diameter (1 mm or more) are used, a design such as a natural stone tone is expressed. You can also
The average particle diameter referred to here is a value obtained by performing sieving using a metal mesh sieve defined in JIS Z8801-1: 2000 and calculating an average value of the weight distribution.

Moreover, as a glass powder body, a melting | fusing point has a preferable thing of 800 degrees C or less, Furthermore, it is preferable to use a thing of 750 degrees C or less. In the case of such a melting point, the glass layer can be formed at a relatively low temperature.

The thickness of the glass layer formed by the sintered body of the glass powder is preferably 0.01 to 10 mm, more preferably 0.05 to 5 mm. In the present invention, it is preferable that the thermal expansion coefficients of the base material layer and the glass layer are approximate, and in particular, the thermal expansion coefficient of the glass layer is within a range of ± 1 × 10 ⁻⁶ K ⁻¹ with respect to the base material layer. It is preferable that it is in the range of ± 0.5 × 10 ⁻⁶ K ⁻¹ . Thereby, when the base material layer and the glass layer are fused by firing, cracks and peeling between the layers can be prevented. When the glass layer is formed of a sintered product of glass particles, the thermal expansion coefficient of the glass particles is preferably in the range of ± 1 × 10 ⁻⁶ K ⁻¹ with respect to the base material layer, Further, it is preferably in the range of ± 0.5 × 10 ⁻⁶ K ⁻¹ .

The design material of the present invention is
(1) First step of forming an inorganic composition and drying to obtain a molded body (2) Second step (3) of obtaining a laminate by laminating a glass layer on the molded body obtained in the first step In the second step The obtained laminate can be fired, and can be produced by a method including a third step of obtaining a design material by fusing the base material layer and the design layer.

In the above (1), the method for molding the inorganic composition is not particularly limited, and examples thereof include molding using a mold or the like. As a formwork to be used, for example, a formwork made of silicone resin, urethane resin, metal, or the like, or a formwork provided with release paper can be used. As a method of filling the formwork with the inorganic composition, for example, a method using means such as spray, roller, trowel, brush coating, reciprocating, coater, pouring, etc. can be employed.

  Further, in the above (1) first step, the molded body can be dried at room temperature, but in the present invention, it is particularly desirable to heat. The heating temperature is preferably set not to exceed 100 ° C. When it exceeds 100 ° C., the molded article may be warped. Demolding may be performed after curing and drying to such an extent that the shape of the molded body is maintained.

In the above (2) second step, the method for laminating the glass layer on the molded body obtained in the first step is not particularly limited. For example, when laminating glass powder particles,
(A) A method of laying glass powder particles on a molded body,
(A) A method of placing glass powder particles on a mold and placing a molded product thereon,
Etc. When the glass powder particles are spread in (a) and (b) above, a known paste material such as carboxymethyl cellulose, carboxyethyl cellulose, polyvinyl alcohol or the like may be used. Moreover, as a formwork used for said (a), for example, the formwork made from silicone resin, the product made from urethane resin, metal, gypsum, etc., or the formwork provided with the release paper etc. can be used. In particular, when a metal or plaster mold is used, the next step (3) can be performed without demolding. In addition, the same mold frame as in the above (A) can be used for the above (A).

  In said (3), the calcination temperature of a laminated body is about 900 degrees C or less normally, Preferably it is about 600-850 degreeC, More preferably, it is about 700-850 degreeC. When it sets to such temperature, in the base material layer, the surface of a glass particle (A) can be fuse | melted and it can be combined with gypsum (B) and water glass (C). For this reason, the heat shrink at the time of shaping | molding can be suppressed. In the design layer, the surface of the glass particles is melted and the particles are sintered. Furthermore, each component is fused at the interface between the base material layer and the design layer. Since firing is possible at a relatively low temperature in this way, the energy load is small when compared with ceramic building materials obtained by firing clay minerals or the like.

In addition, for example, a reinforcing material (ceramic paper, glass cloth, mesh, etc.) can be laminated in the inorganic molded body before and after firing as long as the effects of the present invention are not impaired.
Furthermore, if it is in the range which does not inhibit the effect of this invention remarkably, an overcoat layer can also be laminated | stacked in order to improve surface protection, surface water repellency, design property, etc. after baking. Such an overcoat layer can be formed by applying a known water-based or solvent-type paint. These coatings may be performed by a known coating method, and a coating tool such as a spray, a roller, or a brush can be used.

Examples are given below to clarify the features of the present invention.

The following were used as raw materials.
(A-1) Alkali-free glass (colorless)
Melting point: 900 ° C., average particle size 0.22 mm
Thermal expansion coefficient: 3.83 × 10 ⁻⁶ K ⁻¹
(A-2) Alkali-free glass (colorless)
Melting point: 900 ° C., average particle size 0.085 mm
Thermal expansion coefficient: 3.83 × 10 ⁻⁶ K ⁻¹
(A-3) Soda lime glass (colorless)
Melting point: 800 ° C., average particle size 0.085 mm
Thermal expansion coefficient: 8.71 × 10 ⁻⁶ K ⁻¹
(A-4) Soda lime glass (brown)
Melting point: 800 ° C., average particle size 0.085 mm
Thermal expansion coefficient: 8.69 × 10 ⁻⁶ K ⁻¹
(A-5) Potassium lime glass (colorless)
Melting point: 750 ° C., average particle size 0.2 mm
Thermal expansion coefficient: 8.60 × 10 ⁻⁶ K ⁻¹
(A-6) Potassium lime glass (blue)
Melting point: 750 ° C., average particle size 3.5 mm
Thermal expansion coefficient: 8.56 × 10 ⁻⁶ K ⁻¹
(A-7) Potassium lime glass (green)
Melting point: 750 ° C., average particle size 2 mm
Thermal expansion coefficient: 8.56 × 10 ⁻⁶ K ⁻¹
(A-8) Glaze (white)
Melting point: 750 ° C., average particle size 0.2 mm
Thermal expansion coefficient: 4.10 × 10 ⁻⁶ K ⁻¹
(B): Hemihydrate gypsum α-type (C): Sodium silicate No. 3 standard, powder (D): Silica sand Average particle size 0.16 mm

<Manufacture of base material layer (molded body)>
According to the composition shown in Table 1, each raw material is mixed and stirred by a conventional method to produce an inorganic composition, and a mold having a releasability of 100 × 70 mm (depth 13 mm) (hereinafter referred to as “form”). ) And dried at room temperature (25 ° C.) for 6 hours, and then dried at 50 ° C. for 12 hours to obtain a molded body 1.

(Evaluation 1: Warpage)
About the molded object 1, the molded article was set | placed on the flat surface, 1 side was pressed on the smooth surface, and curvature was measured by the presence or absence of the diagonal side floating from the smooth surface. As a result, the molded body 1 had no warpage and was not warped. Table 1 shows the results.
○: No warping ×: Warping

(Evaluation 2: Drying shrinkage)
As for the molded body 1, the length of each side was measured and compared with the size of the mold. As a result, the size of the mold was maintained and no shrinkage due to drying was observed. Table 1 shows the results.
A: No contraction B: Slight contraction (less than 1%)
×: Shrinkage

(Evaluation 3: Thermal expansion coefficient of base material layer)
After firing the molded body 1 at 850 ° C. for 30 minutes, a sample cut into a L50 mm × φ5 mm rod shape was used as a sample, and a thermal expansion measurement device (DLY7000RH, manufactured by Vacuum Riko Co., Ltd.) was used. The thermal expansion coefficient of the range was measured. Table 1 shows the results.

  According to the formulation shown in Table 1, molded bodies 2 to 13 were produced and evaluated in the same manner as the molded body 1 described above. Table 1 shows the results.

<Manufacture of design materials>
(Test Example 1)
As a base material layer, a mixture of design material raw materials in a weight ratio shown in Table 2 was spread on the above-described molded body 1 and fired at the temperature shown in Table 2 for 30 minutes to obtain a design material 1.
(Evaluation 4: Shrinkage by heating)
As for the design material 1, the length of each side was measured and compared with the size of the mold. As a result, the size of the mold was maintained, and shrinkage due to firing was not observed. Table 2 shows the results.
A: No contraction B: Slight contraction (less than 1%)
×: Shrinkage

(Evaluation 5: Designability)
About the design material 1, the lamination | stacking state of a base material layer and a design layer, and the designability (presence of the crack of a glass layer) were evaluated. The evaluation criteria are a four-level evaluation (excellent: ◎>○> △) where each layer is uniformly laminated, “◎” when there is no crack, and “×” when each layer is unevenly laminated or has a crack. > ×: inferior). Table 2 shows the results.

(Evaluation 6: Water resistance)
About the design material 1, it immersed in water for 24 hours, and evaluated the state of the molded object. Table 2 shows the results.
◎: No change ○: Almost no change △: Brittle after water immersion ×: Gradually collapsed during water immersion

(Test Examples 2 to 16)
Design materials 2 to 16 were produced in the same manner as in Test Example 1 by the combination of the molded body and the design layer shown in Table 2, and the same evaluation as that of the design material 1 was performed. The results are shown in Table 2.

Claims (5)

A design material in which a design layer is laminated on a base material layer,
The base material layer is a molded body of an inorganic composition,
The inorganic composition contains 10 to 200 parts by weight of gypsum and 5 to 150 parts by weight of water glass as a solid content with respect to 100 parts by weight of glass particles having an average particle diameter of 0.01 to 5 mm, and the weight of gypsum and water glass. The ratio is 90:10 to 40:60,
The design material is a glass layer, the design material The design material according to claim 1, wherein the base material layer and the design layer are fused. The said design layer is a sintered compact of a glass granular material, The design material in any one of Claims 1-2 characterized by the above-mentioned. The said glass powder body is a glass particle with an average particle diameter of 0.01-5 mm, The design material in any one of Claims 1-3 characterized by the above-mentioned. The base material layer has a thermal expansion coefficient of 2 to 15 × 10 ^-6 K ^-1 And
The thermal expansion coefficient of the glass layer is ± 1 × 10 with respect to the base material layer. ^-6 K ^-1 The design material according to any one of claims 1 to 4, wherein the design material is