JPH07115966B2 - Manufacturing method of colored foam ceramic building materials - Google Patents

Description

TECHNICAL FIELD The present invention relates to a method for producing a colored foam ceramic building material colored with a pigment.

[Prior Art] As a method for manufacturing ceramic building materials such as tiles, flooring materials, and roofing materials, various natural or artificial mineral materials are wet pulverized, then this slurry is dehydrated and dried, and the dried product is pulverized. , Dry press molding and firing.

As another manufacturing method, there is a method in which dehydration of the above-mentioned raw material slurry is extruded, and this is dried and fired.

In any method, if a pigment is added to the above raw material,
A colored ceramic building material is produced. Further, when the above-mentioned raw material is foamable (for example, expanded shale or one containing expanded viscosity or a foam material such as silicon carbide added thereto), a foamed ceramic building material is produced.

[Problems to be Solved by the Invention] In the colored foam ceramic building material manufactured by the above-mentioned conventional method, there is a problem that the coloring is uniform and is of a monotone, and thus the appearance is flat and hardly changed.

[Means for Solving the Problems] In the method for producing a colored foam ceramic building material of the present invention, a dried product of a dehydrated cake of a slurry containing a foamable ceramic raw material and a pigment is crushed, and the crushed product is subjected to dry press molding. It is characterized by being fired.

[Action] The crushed product of the dried product of the dehydrated cake has an extremely wide particle size distribution including large-sized agglomerates to small-sized agglomerates or powders. When a press-molded product of this crushed material is fired, a gas generated from a foaming component (for example, carbon dioxide gas derived from water or combustible substances in expanded shale or expanded clay) is generated from small-sized agglomerates or powders. When a material is added, the gas generated by the oxidation or decomposition of the added material, etc.) is volatilized early. For this reason, foaming hardly occurs once again in the small-diameter agglomerate or the portion where the powder is collected. On the other hand, large-sized agglomerates foam by firing.

Then, in the surface portion of the obtained sintered body, the portion where the large-sized agglomerates were present is expanded and stretched, and the pigment concentration (content ratio) becomes relatively low, resulting in a light color. .
On the other hand, since foaming does not occur in a portion where small-sized agglomerates or powders are gathered, the concentration (content ratio) of the pigment becomes relatively high and the color becomes dark.

As a result, the surface of the obtained sintered body becomes a colored surface with shades appearing in a plaque shape, and a colored surface with a unique depth not seen in natural stone or existing artificial stone is obtained.

In addition, on the surface of the sintered body, the expanded portion bulges outward to bulge, and the unexpanded portion tries to sink from the surface due to baking. As a result, the surface of the obtained sintered body becomes a unique surface in which minute irregularities are mixed. Moreover, since the convex portions are light-colored and the concave portions are dark-colored, the unevenness on the surface is strongly visible.

In the present invention, clay, feldspar, and silicon carbide as a foaming component are suitable as the expandable ceramic raw material.

That is, when the present invention has conducted various studies,
By mixing and molding 1 part by weight or less of feldspar, 60 to 90 parts by weight of feldspar, and 1 part by weight or less of silicon carbide, and firing at 1200 to 1300 ° C., there is almost no absorbency with closed pores (independent pores, closed pores). It was found to be a lightweight body. In this case, non-foaming clay is used as the clay. The feldspar is not particularly limited, and various types can be used. As the silicon carbide, for example, fine powder having a particle size of 10 μm or less is used.

The blending amount of clay and feldspar is 40 to 10 parts by weight of clay and feldspar.
60 to 90 parts by weight is suitable. If the ratio of feldspar is less than this, the density of the portion other than the pores of the sintered body is insufficient, and the water absorption rate of the sintered body increases. On the other hand, if the amount of feldspar is more than the above range, the sintering temperature becomes low, and the dimensional accuracy of the sintered body deteriorates.

That is, silicon carbide decomposes at about 1200 to 1300 ° C. to generate gas, and the gas forms pores in the sintered body.
If the firing temperature is lower than 1200 ° C, pores cannot be formed because the matrix does not have sufficient viscosity. On the other hand, if the firing temperature is higher than 1300 ° C, the firing matrix becomes low in viscosity, the formed pores are associated with each other to form coarse air holes, and the strength of the sintered body is reduced.

With the above composition and firing temperature, the diameter is about 20-200 μm.
It is possible to obtain a lightweight body having a degree of independent pores and substantially zero boiling water absorption as well as 24-hour water absorption.

Of course, the present invention may use raw materials other than the above, such as blast furnace slag, slag, volcanic glass, expanded shale, expanded clay, and shirasu.

As the pigment, a commercially available kneading pigment containing cobalt oxide, chromium oxide, iron oxide or nickel oxide as a component is preferable, but other pigments may be used.

When crushing the dried product of the dehydrated cake, the maximum diameter of the agglomerate is 0.
It is suitable to crush it to about 8 mm.

[Example] Example 1 The following composition was pulverized and mixed with a wet ball mill to form a slurry, and the slurry was dehydrated and then dried. This was crushed by a crusher to produce a crushed product having a maximum agglomerate diameter of about 0.8 mm.

A small amount of water was added to this crushed material by spraying, and then dry press molding was performed to obtain a molded body of 5 × 10 × 0.8 cm. After this molded body was dried, it was baked at 1250 ° C. for 1 hour to produce the building material of the present invention.

Compounded clay (Kawamoto Kibushi) 30 parts by weight Feldspar (Ayama feldspar) 70 parts by weight Silicon carbide (average particle size 0.5 μm) 0.3 parts by weight Pigment (chromium oxide type) 1.0 parts by weight The surface of the obtained building material is mottled gray. It has a unique aesthetic appearance with a light and shade pattern and an uneven pattern.

Example 2 A building material of the present invention was produced in the same manner as in Example 1 except that the composition and pigment were as follows. The surface of the building material had a peculiar aesthetic appearance with a mottled green color shade pattern and an uneven pattern.

Clay (Onada Kibushi) 20 parts by weight Feldspar (Kumoi feldspar) 80 parts by weight Silicon carbide (average particle size 0.5 μm) 0.2 parts by weight Pigment (nickel oxide type) 1.0 parts by weight [Effect] According to the method for producing a colored foam ceramic building material, it is possible to produce a beautiful foam ceramic building material having a peculiar mottled shading pattern and an uneven pattern.

Claims (1)

[Claims] 1. A method for producing a colored foam ceramic building material, which comprises crushing a dried product of a dehydrated cake of a slurry containing a foamable ceramic raw material and a pigment, dry crushing the crushed product, and firing.