JPH01320272A - Pottery and production thereof - Google Patents

Abstract

PURPOSE:To enhance holding power for the shape of a molded body by molding the compound of both plastic matter powder of pottery incorporating a raw material for crystallized glass containing a raw material having fluororichterite composition and thermoplastic resin fiber into paperlike sheet and heat-pressing this sheet and thereafter calcining it. CONSTITUTION:Powdery or fibrous amorphous glass is obtained by blending a raw material having fluororichterite composition with one or more kinds selected from among Al2O3, PbO, ZrO2 and P2O5 and melting this compound. Then a raw material for crystallized glass having fluororichterite crystal as a main component is obtained by heat-treating this amorphous glass at 900-1,000 deg.C. Then plastic matter powder of pottery is obtained by blending 0-50wt.% raw material for crystallized glass with the raw material for pottery having known composition. 100wt.% plastic matter powder of pottery is blended with 5-30wt.% thermoplastic resin fiber such as PE and thereafter this compound is molded into paperlike sheet. This paperlike sheet is heat-pressed to produce the molded body of pottery base material and thereafter this molded body is calcinec.

Description

[Detailed Description of the Invention] (Industrial Application Field) This invention relates to ceramics made by hot press-molding a paper-like sheet made from ceramic clay mixed with resin and then firing, and a method for manufacturing the same. .

(Prior Art) Forming methods used in the ceramic manufacturing process have traditionally been called plastic forming methods such as casting, potter's wheel forming, and press forming, which depend on the rheological properties of plastic raw materials such as kaolin, pottery stone, and clay. The blending of plastic raw materials is recognized to have the effect of imparting green strength to the molded product, facilitating finishing processing, and reducing shape deformation during firing, and the blending of organic materials, such as in the molding method of fine ceramics, is effective. The imparting of plasticity by this method was not common.

In recent years, ceramic paper, which is made by blending pulp with ceramic clay and forming it into a paper-like paper using a paper-making method, has been developed and used as a handicraft material.

In addition, a method for obtaining ceramic green sheets by adding surfactants and organic binders to ceramic clay powder has also been devised.

(Problems to be Solved by the Invention) This invention proposes that the conventional plastic molding method for ceramics relies heavily on the rheological properties of the plastic raw material, in order to obtain good moldability and prevent deformation during firing. There was a problem in that it was essential to mix a certain amount.

Furthermore, ceramic paper containing a large amount of pulp has problems such as being damaged when the temperature is raised depending on the firing conditions, or having a low density after firing and not having sufficient strength.

On the other hand, in the molding method in which ceramic clay is blended with surfactants, organic binders, etc., the slurry properties and mold releasability are poor due to the adhesiveness of the organic binder, and the molding shape is limited, making it practical. There were problems such as not being accurate.

Therefore, an object of the present invention is to present a practical ceramic and a method for manufacturing the same that solves the above-mentioned problems.

(Means for Solving the Problems) In order to achieve the above-mentioned object, in the ceramics and manufacturing method thereof of the present invention, 100% by weight of ceramic clay powder is blended with 5 to 30% by weight of thermoplastic resin fibers, A paper-like sheet is formed by impregnating a paper-like material formed by the method with a liquid thermosetting resin. Next, the basic method of producing ceramics is to continuously mold them using a hot press that can be molded into a predetermined shape to form a ceramic base, and then fire it under predetermined firing conditions. In this case, the PJJ porcelain clay used is a mixture of 0 to 50% by weight of a crystallized glass raw material in a known ceramic composition raw material, and the crystallized glass raw material is a fluorinated richterite composition raw material containing Al103, PbO, Z.
Powdered or fibrous amorphous glass made by blending at least one kind of rO2 and P2O5 composition raw materials.900
By heat-treating at ~1000°C, crystallized glass containing fluorinated richterite crystals as a soil component is entangled with a porcelain base to obtain ceramics with a microstructural structure of high density and strong bending strength.

The details of the present invention will be explained below.

In this specification, % indicates weight % unless otherwise specified.

To manufacture the ceramics of the present invention, feldspar, silica stone, pottery stone, and kaolin are used. Ceramic clay of known composition prepared from clay, bone ash, dolomite, talc, frit, etc., or the ceramic clay prepared with sodium carbonate, cryolite, dolomite,
A mixture of raw materials such as talc, magnesium carbonate, alumina, zirconium silicate, lead white, and bone ash is mixed and melted. When heat-treated at 900 to 1000°C, it becomes a crystallized glass containing fluorinated richterite crystals as an earth component.
Alternatively, 5 to 30 parts by weight of thermoplastic resin fibers such as polyethylene or polypropylene are blended with 100 parts by weight of clay powder, which is a ceramic raw material made by blending fibrous amorphous glass, and various chemicals required for paper-making operations are added. The added slurry is machined to a desired thickness using a paper machine to form a paper-like body.

Next, this paper-like material is impregnated with a solution of thermosetting resins such as glyoxal, melamine-based resin, and urea-based resin to create a paper-like sheet, which is formed into a material of a predetermined thickness as a material before ceramic molding. It is also possible to save it. 1. Next, to mold a predetermined ceramic base, it is heated and pressed using a mold of the desired shape using a press machine used for molding plastics, paper, etc. Finally, a firing operation is performed under firing conditions that suit the clay composition of each pottery to complete the pottery.

The molding method of the present invention consists of molding a paper-like body by a papermaking method and molding a ceramic base by hot pressing. However, if the amount of fiber blended is less than 5 parts by weight, paper making becomes difficult, and if it exceeds 30 parts by weight, the compacted density becomes small (and the firing shrinkage becomes excessive). This may cause problems such as

On the other hand, the reason why thermoplastic resin fibers are used instead of bulbs is that the firing density increases compared to using bulbs, and the reason why the paper-like material is impregnated with liquid thermosetting resin is to improve the strength of the molded product after hot pressing. It is for the purpose of granting.

(Function) As explained in the above-mentioned technical means, the ceramic clay of the present invention and its manufacturing method are made of known raw materials, and the crystallized glass is also relatively easily obtained by conventional methods. This is a known product that can reduce deformation during firing by adding crystallized glass, and has the effect of increasing the strength of the fired product. Since thermoplastic resin fibers are used in place of valves in papermaking, the fibers are melted and diffused between the ceramic clay powder particles during the hot press process, and are incorporated like organic binders in fine ceramic molding methods. , the firing density is higher than in the case of bulb compounding, and it is impregnated with thermosetting resin, so it is able to firmly maintain the shape of the ceramic base after hot press molding, and at the same time it helps shape retention in the low temperature range during firing. You can obtain the effect of Further, the resin-impregnated paper sheet has the effect of being able to withstand long-term storage as a so-called raw sheet or as a raw press-molded product.

Therefore, the ceramics produced by this manufacturing method are similar to ordinary ceramics.
In addition to having practical physical properties such as having strength comparable to that of 23, it is possible to exceptionally increase the productivity of sheets that are made by mixing resin, making it possible to manufacture highly competitive ceramics of high quality and mass production. is large.

(Example) Embodiments of the invention are shown below and will be described in detail.

Note that this invention is not limited to these.

Table 1 shows examples A, B, C, and D of ceramic clay powders prepared as raw materials used in the examples of the ceramics and manufacturing method thereof of the present invention.
The compositions of five types of E are shown. Next, the raw material formulations of crystallized glass raw materials as shown in Table 2 are shown as blending compositions for two types of cases a and b.

As shown in Table 3, thermoplastic synthetic resin fibers were added to Example 1 of the above-mentioned ceramic clay powder composition raw material blending examples A, B, C, D, and E and the crystallized glass raw material blending examples a and b. After adjusting the formulation as shown in Example 9, a slurry made by adding an appropriate amount of water and an agent such as a flocculant used in paper making is applied to a paper machine, made to an arbitrary thickness, and dried to form a paper-like material. Examples of liquid thermosetting resins consisting of the raw material formulations shown in Table 4.Those consisting of the two types of formulations A and B are impregnated by spray coating, brush coating, and dipping to maintain the appropriate amount of moisture required to maintain flexibility. After manufacturing a paper-like sheet to which
It is molded into a predetermined shape using a heated press machine.

In addition, Table 3 shows Comparative Example 10.1) in which valves were added instead of synthetic resin fibers as a blending composition for Examples 1 to 9.
An example of the formulation is shown below.

Next, Table 5 shows Example 1 based on the combination of the above manufacturing conditions.
The measurement results of the degree of deformation, density, and bending strength of samples molded and fired for Examples ~9 and Comparative Example 1O1)1 are displayed.

The firing temperature in the table indicates the maximum temperature, which was maintained at that temperature for 1 hour and then naturally cooled, and the temperature increase rate was 3°C.
/min.

Comparative Example 1O1) 1 does not have a water absorption rate of O.

The method for preparing and measuring the data is as follows.

(1) Sample The Examples and Comparative Examples shown in Table 5 were made into sheets of 150 mm x 20 m5 x 5 am each by the above-mentioned operations.

(2) Firing deformation The sample sheet is calcined to remove the binder and placed on supports 2 with 100 fin spacing as shown in Figure 1 at a temperature suitable for each sample l (temperature at which water absorption becomes 0). The sagging size dam of the deformed sample 1a shown in FIG. 2 was measured.

(3) Density Sample sheets were fired on a refractory flat plate at a temperature appropriate for each sample, the weight and dimensions of the fired samples were measured, and the volume was calculated using equation (1).

Density = weight particle volume... (1) (4) Bending strength The fired sample used for density measurement was placed in a three-point loading type bending tester with an edge spacing a = 100 fins, and the weight was approximately 10 kg. /min
The load at the a/2 position was increased at a speed of , the load P at which breakage occurred was measured, and the bending strength was determined using equation (2).

5=3aP/2bh... (2) However, b
is the width and h is the thickness of the fired sample.

(The following is a blank space) (Effects of the Invention) Since the present invention has the above-described configuration, it has the following effects.

(1) The method for manufacturing ceramics according to claim (1) facilitates the molding of a paper-like body by a papermaking method by replacing the valve with thermoplastic resin fibers, and furthermore, the fibers are used in the molding process by a hot press to form a ceramic body. It melts and diffuses into the soil powder and does not hinder the densification of the Mi weave during firing, and at the same time has the effect of increasing the shape retention of the molded object by impregnating it with liquid hardening resin, so it is possible to press high quality ceramics. The great advantage is that it can be semi-automated and manufactured with high productivity.

(2) Among the raw materials for crystallized glass according to claims (2) and (3), deformation during firing can be suppressed by using ceramic clay blended with fluorinated richterite crystallized glass as a raw material. , have the effect of increasing the strength of fired products.

(3) Since the ceramic according to claim (4) has a high-density structure in which crystallized glass is entangled with a magnetic base material, it has high bending strength and is durable. It is expected to be widely used in building materials such as trays, tableware, refractories, tiles for wall decoration, etc.

(4) Furthermore, in the manufacturing method described in claim (1),
Because it is molded using the paper-making method, it is possible to reduce the amount of plastic raw materials used, and because it is formed into paper-like sheets, it is suitable for mass production, and compared to traditional ceramic manufacturing methods, it is cleaner to handle and easier to transport and store. Therefore, the intermediate product in the form of a paper-like sheet can be used as a material for handicrafts, for example, in the pottery field, where it can be cut to desired dimensions and shaped freely for hobby crafts. In addition, since it absorbs water in that state, it is possible to adhere objects made using paper-making slip, making it possible to form a wide range of objects.

[Brief explanation of the drawing]

FIG. 1 is a schematic diagram illustrating a method of mounting a sample in a firing deformation test of an embodiment of the ceramics of the present invention and its manufacturing method, and FIG. 2 is a schematic diagram illustrating a method for measuring the deformation state during firing. Figure 2

Claims (4)

[Claims] (1) A paper-like sheet made by blending 100% by weight of ceramic clay powder with 5 to 30% by weight of thermoplastic resin fibers, forming a paper-like body by a papermaking method, and then impregnating it with liquefied thermosetting resin. A method for manufacturing ceramics, which is characterized by heating and pressing to shape a ceramic base and firing it. (2) The method for manufacturing ceramics according to claim (1), wherein the ceramic clay powder is obtained by blending 0 to 50% by weight of a crystallized glass raw material into a composition raw material for ceramics. (3) The raw material for crystallized glass is Al_2O_3, PbO, ZrO_2 and P_2O_ in the fluorinated richterite composition raw material.
Powdered or fibrous amorphous glass made by blending at least one or more 5 composition raw materials and melting the powdered or fibrous amorphous glass.
2. The method of manufacturing ceramics according to claim 1, wherein the method comprises heat-treating at a temperature of 0.degree. (4) Claims (1) and (2) that the crystallized glass has high bending strength due to its high-density structure entangled with the ceramic base.
) and (3) Ceramicware characterized by being molded and fired by the manufacturing method described.