JPH0489202A - Manufacture of ceramic material having laminate pattern - Google Patents

Abstract

PURPOSE:To enable the occurrence of gaps among crack layers to be prevented by successively casting two kinds or more different color chinaware slurry having fluidity into a predetermined gypsum mold for forming laminate patterns, and drying them integrally to be made a block body, and thereafter baking them, and then subjecting to a block severing process. CONSTITUTION:For example, each moisture of a brown material A, a yellow material B, and a light-brown material C consisting of the same laminate material is adjusted for manufacturing chinaware slurry, and it is poured into a gypsum mold 1 successively for forming laminate patterns wherein drying is effected by the water absorption of the gypsum mold 1 and the air drying in an opened part of the gypsum 1, and then they are pressed down by a gypsum block 2 for correcting the laminated state and thus a block body 3 is formed, following this mold releasing is effected therein. After burning the block body 3, it is cut into appropriate dimensions as a wall material 31. In this way, since it is comprised of the same chinaware composite and the evaporation of moisture is conducted integrally, contraction (thermal expansion coefficient) in each layer is made nearly the same degree, thereby preventing the occurrence of cracks during the period of baking. Inasmuch as slurry is poured into the gypsum mold 1 and then laminated, it becomes possible that air is prevented from coming into each layer.

Description

DETAILED DESCRIPTION OF THE INVENTION (Industrial Application Field) The present invention relates to a method for manufacturing a ceramic material having a multicolored laminated pattern for use as a decorative board for walls, floors, ceilings, road pavements, etc. for the interior and exterior of buildings.

(Prior art) Decorative boards with laminated patterns for walls, which have been conventionally used, are generally made of organic materials such as plastics, wood products such as metal plates and plywood, and materials such as plaster, cement, and tiles. It is being

Among these decorative laminates with a laminated pattern, for example, those made of plastic are made by forming thin sheets from the organic material to which coloring pigments have been added, laminating or winding the sheets, and heating each sheet. The laminate is formed by fusing them together, or by adhering each of the 7 pieces to each other using an adhesive resin during lamination, and cutting these laminates along a predetermined surface direction to form the laminate. It formed a decorative board with a pattern.

In the metal plates, plywood, plaster, cement, tiles, etc., a laminate is formed using an adhesive resin, and the laminate pattern is formed from this laminate.

In addition to the method of forming a laminated pattern from these laminates, there is also a method of forming a pattern that at first glance appears to be laminated by printing, transferring, drawing, or the like on the surface of each material.

In view of whether the decorative board having a woodgrain laminated pattern manufactured by these manufacturing methods has an excellent texture, the inventors have developed a laminated board as shown in Japanese Patent Application Laid-Open No. 1-239050. We have invented a new ceramic product with a laminated pattern that combines the decorative qualities of wood, especially the wood grain pattern, and the stone feel of ceramic. forming a ceramic flat plate consisting of a non-coloring material part and a coloring material-containing thin layer part formed by scattering and coating a pigment as a coloring agent on the non-coloring material part, and laminating the two types of ceramic flat plates, or The laminate was wound up to form a laminate, dried and fired, and then cut to form a decorative board having a laminate pattern with woodgrain pattern content.

(Problems to be Solved by the Invention) However, according to this invention, the pigment in the colorant-containing thin layer portion reacts with the colorant-free portion during firing and fuses with the colorant-free portion. According to this invention, the shrinkage rate (coefficient of thermal expansion) during firing is different because the material of the pigment in the coloring material-containing thin layer portion and the earthenware, semi-earthenware, etc. material of the ceramic raw material in the non-coloring material portion are different. There remained the problem of cracks occurring between each layer during firing.

Furthermore, according to the manufacturing method of forming a ceramic flat plate laminate made by scattering or coating a coloring agent, since the water-containing batting rate of the coloring material-containing thin layer portion and the coloring material-free portion are different, the above-mentioned When the laminate is completely dried after being formed, there is also the problem that cracks occur between the layers due to differences in drying shrinkage rates due to evaporation of water.

In addition, during the molding process, air may enter during lamination or be rolled up during winding, resulting in air bubbles, and even if re-pressurized with a press, etc. It is impossible to remove the bubbles, and the bubbles create gaps between the layers, resulting in insufficient strength and causing damage to the ceramic material when cutting the laminate.

The present invention was made in view of the above-mentioned problems, and its purpose is to process a ceramic material having a laminated pattern such as a wood grain pattern without causing cracks and without creating gaps between the laminated layers due to air bubbles. , which also allows production in a convenient manner.

(Means for Solving the Problems) In order to achieve the above object, the present invention provides two or more types of ceramic compositions with different fluidities each containing one or more types of ceramic pigments or metal oxides. The resulting ceramic slurry is successively cast into a predetermined plaster mold to form a laminated pattern, and the ceramic slurry is dried and integrated within the plaster mold to form a block, which is then fired. The cutting process is performed along a predetermined surface direction.

In addition, two or more types of fluid ceramic slurries of different colors made of ceramic compositions containing one or more types of ceramic pigments or metal oxides are successively cast in a predetermined plaster mold so as to form a layered pattern. After drying and integrating the ceramic slurry in a plaster mold to form a block body,
The block body may be cut along a predetermined surface direction and then fired.

It is also preferable that the ceramic slurry contains one or more organic binders or inorganic binders.

It is also preferable that the ceramic slurry contains one or more types of glass fibers or inorganic mineral fibers.

(Function) One or more ceramic pigments or metal oxides are added to the base ceramic composition to create two or more fluid ceramic slurries that have the same composition as the ceramic composition but differ only in color. These ceramic slurries are sequentially poured into a predetermined plaster mold to form a laminated pattern, and the water content of the ceramic slurry is poured into the plaster mold within the plaster mold using the water absorption properties of the plaster mold. After absorbing water and at the same time air-drying it in the opening of the plaster mold to dry the ceramic slurry and forming a block body, it is fired at a predetermined temperature, and then the block body is cut along a predetermined surface direction. By processing, a ceramic material with a laminated pattern is manufactured. By composing all the ceramic materials with a laminated pattern from the same ceramic composition, the evaporation of water in the ceramic slurry does not occur separately for each layer. The whole is made as one piece, and cracks between the layers due to shrinkage of the ceramic slurry during drying are prevented, and
When firing the block body formed by this drying, the entire block body is made of the same ceramic composition, and the shrinkage rate (thermal expansion coefficient) of each layer during firing is made approximately the same, so that each layer that occurs during firing is This prevents the occurrence of cracks due to differences in shrinkage between layers. In addition, since the fluid ceramic slurry is poured into the plaster mold and layered,
It becomes possible to prevent air from entering between each layer.

Further, after drying the ceramic slurry to form a block body, the block body is cut along a predetermined surface direction, and then fired at a predetermined temperature to produce a ceramic material having a laminated pattern. You can also do that.

Further, by including one or more kinds of organic binders or inorganic binders in the ceramic slurry, generation of cracks during drying due to entanglement of the fibers or binders can be more effectively prevented.

Furthermore, by including one or more types of glass fibers or inorganic mineral fibers in each of the ceramic slurries, the glass fibers or inorganic mineral fibers can be melted or welded during firing, and cracks that occur during firing can be more effectively prevented. It will be done.

(Example) The present invention will be specifically described below based on examples.

Example 1 An example of manufacturing a wall material embodying a wood grain-like layered pattern will be shown.

The composition of the ceramic composition, which is the basis of the laminated material, is 41% by weight of Amakusa pottery stone, 18% by weight of elbow feldspar, 37% by weight of clay, and 4% by weight of silica, in order to create brown material A1 yellow material B1 light brown material C Then, a coloring agent as shown in Table 1 is added to this composition.

When adding the colorant, the total amount that can be added is up to 20% by weight based on the total amount.

Table 1 Each material A, B, and C was adjusted to a water/material ratio of 1:2 (weight ratio) to create a ceramic slurry, which was then ground for 30 hours using an industrial grinding machine (trommel). Mix and
The particle size shall be as shown in Table-1.

Furthermore, inorganic fibers and a suitable binder as shown in Table 1 are added to each of the ceramic slurries after pulverization and mixing, and the mixture is mixed with a stirrer to adjust the viscosity to 6 to 15 poise. At this time,
When glass fiber is used as the inorganic fiber, its vitreous nature lowers the overall softening temperature, so the amount added is limited to 5% by weight based on the total amount. The addition of the inorganic fibers and organic binder more effectively prevents the generation of cracks during drying by entangling the fibers or binder, and the addition of the inorganic glass fibers allows the fibers or the binder to become entangled, thereby preventing cracks from occurring during drying. By melting the inorganic fibers, cracks that occur during firing are more effectively prevented.

Further, the thermal expansion coefficients of the materials A, B, and C are as shown in Table-1. Each ceramic slurry after stirring is subjected to vacuum deaeration to remove air mixed in during the stirring.

Each of the ceramic slurries prepared as described above is poured into a plaster mold (1) shown in FIG. 1 so as to form a laminated pattern. That is, as shown in FIG. 2, the brown material A is poured, then the yellow material B is poured, and after this yellow material B is poured, the light brown material C is poured, and so on. After pouring it close to the opening of the plaster mold (1), it is dried by the water absorption action of the plaster mold and air drying at the opening of the plaster mold (1). Fit the gypsum block (2) that fits into the opening of 1), press the ceramic slurry with the gypsum block (2) at a press pressure of I kg/cJ to adjust the laminated state, and continue drying. Then, water in the ceramic slurry is evaporated to form a block body (3) as shown in FIG. 3, and the block body (3) is released from the plaster mold (1). Further, although the press pressure was set to 1 kg/cJ, the press pressure can be set within the range of 0.5 to 30 kg/cJ according to manufacturing conditions. Then, this block body (3) was heated to 60℃, 80℃, and 100℃.
Raise the drying temperature one after another and dry completely. This dried block body (3) is fired at a temperature of 1250°C,
After firing, the professional body (3) is cut (31) into a size suitable for wall material so as to have a laminated pattern, and the surface of the cut surface is further polished by sanding.
This makes it possible to produce wall materials with a layered pattern of wood-grained cane. The above manufacturing method is an example, and does not limit the drying method or polishing method.
Forced drying may be performed using a drying chamber, and boring, lapping, or the like may be used as a polishing method, and by doing so, a similar wall material can be obtained.

By manufacturing as described above, the present invention prevents cracks from forming not only between the layers of the block body (3) but also throughout the block body (3), and allows air bubbles to enter between the layers. Ceramic materials with a laminated pattern can be manufactured by a simple method without any problems.

In addition, in order to form unevenness in a fossil pattern on a wall material with a geological pattern, it is best to release it from the plaster mold (1) at the time when the block body (3) has not completely dried and has become plastic. The resulting block body (3) is cut to have a laminated pattern with a thickness that allows for wall material, and a fossil mold is buried in this cut surface, and after this burial treatment, as described above. Then, the material is dried with hot air and then fired, and after this firing, the material is cut into a size suitable for use as a wall material, and the cut surface is finished by sanding.

In addition, when it is desired to form a wall material with a rough surface, in the same manner as in the embedding process, the block body (3) at the point where it has plasticity is cut thinly and an uneven pattern is engraved with a press. It can be dried with warm air and fired as described above, and then cut into appropriate dimensions for wall material.

Example 2 A method for producing wall material with a wood grain pattern is shown.

The ceramic plastic material used as the base is the same as in Example 1 above.

To prepare dark brown material D1 and light brown material E, colorants are added to this composition as shown in Table 2.

Then, prepare a ceramic slurry by adjusting the moisture content of each of the above materials and E to a water:material ratio of 1:2 (weight ratio), and grind and mix for 30 hours using an industrial grinding machine (trommel).
The particle size shall be as shown in Table-2.

Furthermore, inorganic fibers and an organic binder as shown in Table 2 are added to each of the ceramic slurries after pulverization and mixing, and the mixture is mixed with a stirrer to mix the ceramic slurry made of the dark brown material with about 6 poise and the light brown A ceramic slurry made of material E is adjusted to a viscosity of around 10 poise. The coefficient of thermal expansion of the material E is as shown in Table 2.

Each ceramic slurry after stirring is subjected to vacuum deaeration to remove air mixed in during the stirring.

As in Example 1, each of the ceramic slurries prepared as described above is poured into a plaster mold (1) so as to form a laminated pattern. To explain in detail, a dark brown material is poured into the plaster mold (1), and the plaster mold (1) is vibrated to make the pouring surface smooth. Next, light brown material E is poured, the plaster mold (1) is similarly vibrated to smooth the pouring surface, and this operation is repeated to successively pass the mold. Then, after pouring it close to the opening of the plaster mold (1), drying is performed by the water absorption action of the plaster mold and air drying at the opening of the plaster mold (1),
During this drying, a gypsum block (2) that fits into the opening of the gypsum mold (1) is fitted, and the ceramic slurry is pressed by the gypsum block (2) with a press pressure of IKg/cJ. , adjust the laminated state, continue drying,
The moisture in the ceramic slurry is evaporated to form a block body (32) as shown in FIG. 4, and the block body (32) is released from the plaster mold (1). Then, this block body (32) was heated at 60°C and 80°C.
, 100° C. and then increase the drying temperature to complete drying.

This dried block body (32) is fired at a temperature of 1250°C, the fired block body (32) is cut into a size suitable for wall material so as to have a laminated pattern, and the cut surface By sanding the surface, it is possible to produce wall materials with a wood grain pattern.

Similar to Example 1, the above manufacturing method is an example, and does not limit the drying method or polishing method. As a drying method, forced drying using a drying chamber may be used.
Further, as a polishing method, polysong, lapping, etc. may be used, and similar wall materials can be obtained by such methods.

By manufacturing as described above, the present invention provides not only the space between each layer of the block body (31) but also the space between each layer of the block body (31).
) It is possible to produce a ceramic material with a laminated pattern by a simple method without cracks occurring in the entire structure and without air bubbles entering between the layers.

In addition, when it is desired to express tree rings, the block body (31) having plasticity, that is, the block body (31) immediately after being released from the plaster mold (1), is placed in a saddle-shaped press mold as shown in FIG. (4) Using (5), the saddle-shaped block body (32) shown in FIG. All you have to do is cut it to a size suitable for the wall material so that a board-grained or straight-grained annual ring pattern appears, and then polish this cut surface by sanding.

(Effects of the Invention) According to the method for producing a ceramic material having a laminated pattern of the present invention, all the ceramic materials having a laminated pattern can be composed of the same ceramic composition, so that the water content of the ceramic slurry evaporates. This can be done not only for each layer but also for the entire block, thereby preventing the occurrence of cracks due to differences in shrinkage between the layers that occur when the ceramic slurry dries. When firing, since the entire block can be made of the same ceramic composition, the shrinkage rate (coefficient of thermal expansion) of each layer during firing can be made almost the same, and the At the same time, it is possible to prevent cracks from occurring due to differences in shrinkage. Furthermore, since the fluid ceramic slurry is poured into the plaster mold and layered, it is possible to prevent air from entering between the layers.

Further, after drying the ceramic slurry to form a block body, the block body is cut along a predetermined surface direction, and then fired at a predetermined temperature to produce a ceramic material having a laminated pattern. It is also possible to obtain the above-mentioned effects in this case as well.

Further, by including one or more types of existing binders or inorganic binders in the ceramic slurry, the binders can be entangled with each other to more effectively prevent the occurrence of cracks during drying.

Furthermore, by including one or more types of glass fibers or inorganic mineral fibers in each of the ceramic slurries, the glass fibers or inorganic mineral fibers can be melted during firing, and cracks that occur during firing can be more effectively prevented. This is possible.

[Brief explanation of the drawing]

Figure 1 is a plaster mold used in manufacturing the ceramic material of the present invention, Figure 2 is a diagram showing the state of ceramic slurry being poured into the plaster mold, and Figure 3 is a block taken out from the plaster mold in Example 1. Figure 4 is a diagram showing the block body taken out from the plaster mold in Example 2, Figure 5 is Example 2.
FIG. 6 is a diagram showing a block body pressed by a saddle-shaped press die, and FIG. 6 is a diagram showing a block body after pressing in Example 2. (1)...Gypsum mold (3) (31) (32)...Block body Figure 1

Claims (1)

[Claims] 1) Forming a laminated pattern in a predetermined plaster mold with two or more fluid ceramic slurries of different colors made of a ceramic composition containing one or more ceramic pigments or metal oxides. The ceramic slurry is successively poured into the mold, dried in the plaster mold to form a block body, and then fired.
A method for manufacturing a ceramic material having a laminated pattern, characterized in that the block body is then cut along a predetermined surface direction. 2) Two or more types of fluid ceramic slurries of different colors made of ceramic compositions containing one or more types of ceramic pigments or metal oxides are successively cast in a predetermined plaster mold to form a laminated pattern; Production of a ceramic material having a laminated pattern, characterized in that the ceramic slurry is dried in a plaster mold to form a block body, the block body is cut along a predetermined surface direction, and then fired. Method. 3) The method for producing a ceramic material having a laminated pattern according to claim 1 or 2, wherein the ceramic slurry contains one or more types of organic binder or inorganic binder. 4) The method for producing a ceramic material having a laminated pattern according to claim 1 or 2, wherein the ceramic slurry contains one or more types of glass fibers or inorganic mineral fibers.