JPH0347378B2 - - Google Patents

Description

[Detailed description of the invention] [Industrial application field]

The present invention relates to a method of manufacturing anti-slip tiles used for constructing bathroom floors and the like.

[Conventional technology]

Conventionally, as a method for manufacturing anti-slip tiles, there is a method disclosed in Japanese Patent Application No. 51-153929 (Japanese Patent Application Laid-Open No. 53-78629). That is, as shown in FIG. 1A, a glaze 3 is applied to the surface 2a of the tile base 2, and sintered alumina having a refractory temperature higher than the firing temperature is applied.
A single particle or several particle groups of fine particles 4 made of porcelain or the like are dispersed on the substrate surface 2a via an adhesive layer such as starch paste or a pressure-sensitive adhesive layer 5, and the first
As shown in Figure C, add glaze 6 if desired.
After that, the fine particles 4, 4, etc. are adhesively fixed to the surface of the tile body by firing, and the particle size of the fine particles 4 is set to 0.1 to 0.8 mm, and the firing temperature is set to 800°C. The above is a manufacturing method in which the temperature is set such that the fine particles 4 are not completely melted.

[Problem to be solved by the invention]

However, the conventional manufacturing method has the following drawbacks. (a) When the fine particles 4, 4... dispersed on the glaze 3 through the adhesive layer 5 are fired as shown in FIG. 1A, the fine particles are transferred into the glaze 3 as shown in FIG. 4, 4... was sinking. (b) When the glaze 6 is applied and fired as shown in Figure 1C, the glaze 6 may flow into the glaze 3 side with fine particles 4, 4, etc. as shown in Figure 1D. In some cases, it was not possible to form anti-slip protrusions on the tile body. (c) The phenomena a and b above are remarkable when the particle size of the fine particles 4 is particularly fine. Therefore, in the conventional method, it was impossible to use fine particles smaller than 0.1 mm due to the thinning limit of the glaze thickness, so it was necessary to use particles larger than 0.1 mm. Some tiles may cause damage to bare feet, and it has not been possible to manufacture anti-slip tiles that provide an appropriate level of anti-slip effect. The present invention has developed a 0.1 mm
The purpose of the present invention is to provide a method for manufacturing an anti-slip tile using fine particles of less than or equal to 100%.

[Means to solve the problem]

Method for manufacturing an anti-slip tile according to the present invention (hereinafter referred to as
The means adopted by the "manufacturing method of the present invention" are as follows:
In the manufacturing method of anti-slip tiles, the measurement value of the tilt button test is 2.0cm on the surface of the tile base.
A base glaze layer is formed with a base glaze having the following fluidity, and fine particles with a melting point higher than that of the adhesive glaze and a particle size of 0.06 mm or more and less than 0.1 mm are suspended in the adhesive glaze, which has a higher melting point than the base glaze. This is applied to the surface of the base glaze layer at a suitable location, and fired at a temperature that is higher than the eutectic temperature of the base glaze and the adhesive glaze and lower than the eutectic temperature of the adhesive glaze and the fine particles. Incidentally, the base glaze layer may be formed by forming a first layer on the entire surface of the tile base material, and then partially forming a second layer at an arbitrary location on the surface of the first layer.

【Example】

The manufacturing method of the present invention will be explained below based on the embodiment shown in FIGS. 2A and 2B. In the first step, as shown in FIG. 2A, the first layer 13a of the base glaze layer 13 is coated with the base glaze 9 on the entire surface 8a of the tile base 8 or in appropriate places to a desired thickness A (for example, by firing as shown in FIG. Later thickness A′=0.02~0.03
The method is to form the glaze to a thickness A) of mm. The tile base 8 is obtained by a known dry pressure molding method, wet extrusion molding method, or the like. The base glaze 9 has a measured value L of the tilt button test described below.
(See Figure 4B) and have a fluidity of L = 2.0 cm or less. The reason for using the base glaze 9 having a fluidity of L = 2.0 cm or less as measured by the tilt button test is because the base glaze 9 in a molten state is used during firing in the fourth step to be described later. This is to prevent the adhesive glaze 11 from flowing into the base glaze layer 13 even if the adhesive glaze 11, which will be described later, melts on the layer 13. If a base glaze with good fluidity with a measured value L of the inclined button test exceeding L = 2.0 cm is used, the adhesive glaze 11 will flow into the base glaze layer made of this base glaze and cause the fine particles 14 to form. By immersing it in the base glaze layer, the number of microscopic protrusions protruding from the tile surface is extremely reduced, resulting in a tile with low slip resistance (see the comparison results shown in the graph in Figure 5), which exists in conventional technology. It becomes impossible to solve the problems that were being faced. The above-mentioned tilt button test means that, as shown in FIG. 4A, the surface 8'a of the unglazed tile base 8' obtained by bisque firing the tile base 8 is θ=25 with respect to the horizontal plane.
At the same time, a test glaze block 9' with D = 1.0 cmφ and H = 1.0 cm is glued on the surface 8'a with vinyl acetate resin (not shown).
The temperature is heated to a predetermined firing temperature _T1 , which will be described later, and the temperature is maintained at the temperature _T1 for 30 minutes, followed by gradual cooling, and the molten glaze 9'' on the surface 8''a of the tile base 8'' shown in FIG. 4B is heated. The flow length L of the glaze is measured, and the fluidity of the glaze is evaluated based on this measured value L.The test glaze block 9' has a diameter of 100
1.0 g of the dried glaze that has passed through a mesh sieve is press-molded into a short cylinder. In the second step, as shown in FIG. 2A, a second layer 13b of the base glaze layer 13 is applied to an arbitrary location on the first layer 13a with a base glaze 10 having a measured value of L = 2.0 cm or less in the inclined button test. to the desired thickness B (for example,
The glazing thickness B) is such that the thickness B' after firing as shown in FIG. 3 is 0.05 to 0.1 mm. The base glaze 10 is applied by a known glazing method such as a buttoning method using a buttoning machine or a printing method using a screen printing machine. In addition, in the second step, by partially providing the second layer 13b on the first layer 13a to form an uneven part, the anti-slip effect due to the uneven part is slightly improved and/or the uneven part pattern is improved. This is done as necessary for the purpose of improving the design effect, and it is of course possible to omit it. In the third step, as shown in FIG. 2B, a suspension 15 (not shown) in which fine particles 14 are suspended in the adhesive glaze 11 is applied to an appropriate place on the surface of the base glaze layer 13 in an amount of 0.5 to 2. g/10 cm square to obtain a substrate 16. As the adhesive glaze 11, a glaze having a higher melting point (for example, about 100° C. higher) than the base glazes 9 and 10 is used. This is to completely melt the base glazes 9 and 10 before the adhesive glaze 11 softens and melts. The fine particles 14 have a higher melting point than the adhesive glaze 11 (for example, 100° C. higher), and are made of fused alumina particles and/or zircon sand particles and have a particle diameter of 0.06 mm or more and less than 0.1 mm. What makes the melting point of the fine particles 14 higher than that of the adhesive glaze 11 is that the fine particles 1
This is to form microscopic protrusions for anti-slip without melting 4. The reason why the particle size of the fine particles 14 is limited to the above range is that if it is less than 0.06 mm, most of the height of the fine particles will be absorbed into the layer of the fired adhesive glaze 11, so the effectiveness of the fine particles contributing to the anti-slip effect will be reduced. This is because the number of protrusions will be reduced, and if the diameter is 0.1 mm or more, the particles will not be suspended in the adhesive glaze 11 but will precipitate. Applying the precipitated particles to the coating surface in a uniformly dispersed state is extremely difficult in terms of coating technology. On the other hand, applying the suspended fine particles 14 to the coating surface in a uniformly dispersed state is simple from a coating technique. The mixing ratio of the fine particles 14 and the adhesive glaze 11 constituting the suspension 15 is such that the value obtained by dividing the weight of the fine particles 14 by the dry weight of the adhesive glaze 11 is 0.2 to 0.4 (preferably 0.3). .
The suspension 15 having this blending ratio is adjusted to have a specific gravity of about 1.9 to 2.1. The suspension 15 can be applied by a known method such as a glazing method using a spraying machine or a centrifugal glazing machine, or a printing method using a screen printing machine. In the fourth step, the base 16 obtained in the third step is heated at a temperature T _{1 that is higher than the eutectic temperature T 2} of the base glazes 9 and 10 and the adhesive glaze 11 and lower than the eutectic temperature T ₃ of the adhesive glaze and the fine _particles . It is to be fired. The substrate 16
is the melting point of base glazes 9 and 10 as the temperature increases.
When the temperature T ₄ is reached, the base glaze layer 13 melts, and when the eutectic temperature T ₂ is reached as the temperature increases, the thin adhesive glaze 11 melts. However, even if the adhesive glaze 11 is melted on the base glaze layer 13 in a molten state, the base glazes 9 and 10 have very poor fluidity (L = 2.0 cm or less at the measurement site of the inclined button test), so there is no problem. It does not flow into the base glaze layer 13. Further, since the upper limit of the firing temperature is less than the temperature _T4 , the fine particles 14, 14, etc. are adhesively fixed on the base glaze layer 13 by the molten adhesive glaze 11 without being melted at all. Fine particles 14
Even if it is covered with the adhesive glaze 11 during application in the third step (see FIG. 2B), a part of it is exposed due to the flow accompanying the melting of the adhesive glaze 11 during firing (see FIG. 2B). (see figure). Said firing temperature T ₁
After being held in this state for a suitable period of time, it is gradually cooled to obtain the anti-slip tile 17 shown in FIG. Note that the base glaze 9 forming the first layer 13a of the base glaze layer 13 shown in FIG. 2B is bright glaze or semi-matte glaze, and the base glaze 1 forming the second layer 13b is used.
When 0 is a matte glaze and the adhesive glaze 11 is a matte glaze, it is possible to obtain an anti-slip tile with a mosaic pattern consisting of a glossy part and a matte part and excellent in design effect. The present inventors conducted experiments under the following conditions and obtained the following results. [Experimental conditions] (1) Conditions for base glaze 9 for the first layer Mixture length Stone 20% Silica sand 10% Calcium carbonate 20% Clay 5% Clay powder 10% Fritz 20% Talc 15% Type: Bright glaze alone Melting point: 1140℃ Measured value of inclined button test: 2.0cm (2) Conditions for base glaze 10 for second layer Composition Silica sand 15% Calcium carbonate 25% Clay 5% Fritz 20% Talc 25% Zircon 10% Seed Type: Pine glaze Individual melting point: 1140℃ (3) Conditions for adhesive glaze 11 Contents Clay 10% Fritz 20% Talc 30% Zircon 40% Type: Pine glaze Individual melting point: 1250℃ (4) Fine particles 14 Conditions Material: Fused alumina Average particle size: 0.075mm Single melting point: 1450℃ (5) Conditions for suspension 15 Mixing ratio: 30 parts by weight of fine particles to 100 parts by weight of dry adhesive glaze Specific gravity: 2.0 (6 ) Glazing or coating method 1st layer 13a: Curtain glazing method 2nd layer 13b: Bottle glazing method Suspension 15: Spray coating method (7) Glazing or coating amount 1st layer: 6.0g/10cm square 2nd layer : 1.0g/10cm square Suspension: 1.0g/10cm square (8) Firing temperature: 1190℃ [Experimental results] The number of microscopic protrusions formed on the tile surface by fine particles was approximately 160/1.0cm square. It was hot. Also,
The slip resistance obtained by the test specified in JISA1407 is
It was 0.9. Further, the present inventors conducted a comparative experiment to examine the influence of the fluidity of the base glazes 9 and 10 on the number of microprotrusions and the sliding resistance, and obtained the comparative results shown in the graph of FIG. As is clear from the results of this comparison, if the fluidity of the base glaze exceeds 2.0 cm as measured by the tilt button test, the number of fine protrusions and sliding resistance will be extremely reduced, resulting in a very slippery tile.

[Effects of the Invention] As detailed above, the manufacturing method of the present invention uses a base glaze that has a fluidity of 2.0 cm or less as measured by the tilt button test, so fine particles are absorbed into the base glaze layer. Furthermore, since a suspension of fine particles suspended in the adhesive glaze is applied to the surface of the base glaze layer, the fine particles and the adhesive glaze blend well, and the fine particles are firmly adhesively fixed to the surface of the base glaze layer. I can do it. As a result, the manufacturing method of the present invention has the excellent effect of manufacturing an anti-slip tile that can sufficiently exhibit an anti-slip effect without causing damage to bare feet.

[Brief explanation of drawings]

FIGS. 1A and 1C are cross-sectional views showing a conventional method of manufacturing an anti-slip tile, and FIGS. 1B and D are enlarged sectional views of essential parts of the conventional anti-slip tile. 2A and 2B are enlarged sectional views of main parts showing an embodiment of the manufacturing method of the present invention;
The figure is an enlarged sectional view of the main part showing the anti-slip tile obtained by the manufacturing method of the present invention, and FIGS. 4A and 4B are explanatory views of the tilt button test. FIG. 5 is a graph showing the results of a comparative experiment. 8...Tile base, 9,10...Base glaze, 1
1... Adhesive glaze, 13... Base glaze layer, 14...
Fine particles, 15...suspension.

Claims (1)

[Claims] 1. In a method for manufacturing an anti-slip tile, a method for manufacturing an anti-slip tile is provided in which a measurement value of an inclined button test is applied to a suitable place on the surface of a tile base.
An underground glaze layer is formed with a base glaze that has a fluidity of 2.0 cm or less, and the adhesive glaze has a melting point higher than that of the base glaze.
A suspension of fine particles of 0.06 mm or more and less than 0.1 mm is applied to the surface of the base glaze layer at a suitable location, and the temperature is higher than the eutectic temperature of the base glaze and the adhesive glaze and lower than the eutectic temperature of the adhesive glaze and the fine particles. A method for producing an anti-slip tile characterized by firing it. 2. Manufacturing the anti-slip tile according to claim 1, wherein the base glaze layer is formed by forming a first layer on the entire surface of the tile base material, and then partially forming a second layer at an arbitrary location on the surface of the first layer. Method.