JPH0699184B2 - Manufacturing method of artificial stone - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial field of application] The present invention relates to a method for producing an artificial stone material used for floor surfaces of inner and outer walls of a building.

[Prior art] For the inner and outer walls and floors of conventional structures, natural rocks such as granite, marble, and porphyry rocks are sliced and the surface is polished, and the surface is finished by tapping, etc., or granite or marble. After crushing the stone pieces of No. 1 with white cement and molding, the ones whose surface has been processed and the pigmented material which has been previously granulated or molded into granules of 1 to 5 m / m are mixed, pressure-molded and fired. There is a ceramic tile product that has a pattern and surface condition similar to that of natural stone.

[Problems to be Solved by the Invention] In the case of natural stone, marble is easy to process, but it is difficult and expensive to obtain the same pattern. Since granite is hard, the cost of finishing such as cutting and polishing is high. Also, stones such as marble that are hardened with white cement are difficult to process depending on the stones used, but like marble, they cannot be used for the exterior. Furthermore, the appearance of the ceramic tile, which is a mixture of agglomerates of pigmented material, pressure molding and firing, looks like a natural stone, but in essence, it contains a large amount of glass and fine crystals are scattered in it. For example, even if the surface is mirror-finished, it is essentially different from the surface of natural stone, and it looks like a polished multicolor mixed glass.

[Means for Solving the Problems] In the present invention, particles of a mineral having a developed crystal face such as feldspar, mica, orthopyroxene, silica gemstone, and garnet are mixed with a mixture of rhyolite fine powder and clay. After vibration pressure molding, 1100-1250
After firing at ℃, by finishing the surface, mixed minerals with developed crystal planes have the same effect as phenocrysts in natural rock, revealing a stone texture similar to natural rock unlike conventional tiles. In addition, the wear resistance is similar to that of natural rock due to the mineral particles having a developed crystal surface. Here, the size of the mineral particles having a developed crystal face is 0.5 m / m or more, preferably up to about 5 m / m from the standpoint of lithology. A mixture of fine rhyolitic powder and clay begins to soften when the natural glass, which is the main component of rhyolite, exceeds 800 ° C, and the clay mineral melts into it, forming a gap between the crystalline mineral particles and forming crystals. Change occurs. Therefore, the ratio of rhyolite to clay is preferably 6: 4 to 9: 1 rhyolite: clay. If the ratio of clay is higher than this, the clay will completely melt into the rhyolite and the temperature will be 12
The temperature exceeds 50 ° C., and crystalline minerals are thermally unfavorably subjected to crystal transition decomposition or reaction. If the clay ratio is less than this, the formability can be maintained by adding an organic binder such as CMC, but the handling of the molded product becomes difficult, and the crystallization of rhyolite becomes insufficient and foaming may occur. . Further, a coloring material may be appropriately mixed with the finely pulverized mixture of rhyolite and clay. In addition, vibration molding, which is vibration molding, is performed from the viewpoints of densification of molding, beauty of surface finish, and the like. The firing temperature is preferably in the range of 1100 ° C to 1250 ° C.
If the temperature is less than ℃, the reaction between rhyolite and clay is insufficient and sufficient strength cannot be obtained, and if it exceeds 1250 ℃, the crystallized rhyolite will once again become vitreous, which is close to a ceramic tile with a lot of glass. Becomes Also, in order to obtain a fine grain, it is necessary to consider the grain size of the mixed amount of crystalline minerals,
It is 40% or less, preferably 30% to 20%. Appropriate means such as polishing, sand blasting, and cutting are applied as the surface finish, as desired.

[Examples] (1) Red beryl (0.5-5 m / m) 30 parts (weight) Rhyolite 50 parts Fine powder 20 parts Kibushi Clay 20 parts was mixed well and the base material which added suitable water to this was plaster type. It was vibration-cast and molded into a 200 x 200 x 10 green substrate.
This was dried and baked at 1200 ° C. for 2 hours, and the surface was polished. Orchard stone appears as black phenocrysts on the polished surface,
Building materials similar to natural granite were obtained. With a water absorption rate of less than 1%, it can be fully used as an exterior building material. The gradual firing shrinkage was 4%.

(2) Feldspar (2 to 5 m / m) 15 parts Silica (2 to 5 m / m) 10 parts Rhyolite fine powder 55 parts Kaolin 20 parts Mix well and add proper water to the base material in a wooden pattern 20
Vibration press molding was performed to a size of 0 × 200 × 10. After drying 1150 ℃
After baking for 2 hours, the surface was polished. On the polished surface, feldspars were scattered as white spots and silica stones were cracked as transparent crystals, and a building material with an appearance similar to quartz porphyry was obtained. The water absorption rate was 1% or less. The shrinkage rate was 3%.

(3) Silica gneiss (1 to 3 m / m) 35 parts Rhyolite Fine powder 50 parts Kibushi Clay 15 parts CMC 0.2 parts Mix well and add the appropriate amount of water to the base material 200 × 200 Vibratory press molded to dimensions of × 10 1200 after drying
After firing at ℃ for 2 hours, the surface was sandblasted.
A building material with a finish similar to that of natural sandstone was obtained.

(4) Granite (3-10m / m) 30 parts Rhyolite 50 parts fine powder Koshibushi clay 20 parts Mix well and add the appropriate amount of water to the base material by vibration casting using a plaster mold to 200 × 200 Molded to x10. After drying, it was baked at 1150 ° C. and then the surface was polished. On the polished surface, red olivine was scattered and a gorgeous pattern was obtained. The water absorption was 1% or less and the absorption was 2%.

[Effects of the Invention] According to the present invention, since the crystalline mineral particles are mixed, the shrinkage rate of the product by drying and firing becomes small. Therefore, a large plate of 1 m square and a thickness of about 10 m / m can be relatively easily formed. Moreover, since the rhyolite crystallizes the clay by squeezing clay, it is possible to obtain a stone material with a small amount of glass and a natural strength close to that of natural rock. Moreover, it is possible to freely select the crystal minerals mixed as phenocrysts, and by freely coloring the stone base with a coloring material, it is possible to obtain a stone material having a desired stone texture.

 ─────────────────────────────────────────────────── ─── Continuation of the front page (56) References Japanese Patent Laid-Open No. 51-81809 (JP, A) Patent 157271 (JP, C1) Special Table 60-501555 (JP, A)

Claims (3)

[Claims] 1. Particles of a mineral having a developed crystal plane, such as feldspar, mica, ortholith, silica gemstone, garnet, and olivine, are mixed with a mixture of fine rhyolitic powder and clay, and then vibration-molded.
A method for manufacturing an artificial stone material, which comprises firing at 1100 to 1250 ° C and then finishing the surface. 2. The method for producing an artificial stone material according to claim 1, wherein an organic binder is added to the raw material. 3. The method for producing an artificial stone material according to claim (1) or (2), wherein the mineral having a developed crystal plane is a grain of 0.5 m / m or more.