JPH10169083A - Tile panel and manufacture thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide light weight and high durability by applying the constitution that the reverse side of a tile is buried in a substrate made of a cured inorganic setting composition mainly composed of SiO2 -Al2 O3 powder and an alkaline metal silicate aqueous solution, according to the prescribed pattern. SOLUTION: Tiles 2 are coupled to all of position restricting recesses arranged on a form so as to keep tile surface directed to the bottom of the form. Then, a slurry of an inorganic setting composition mainly composed of SiO2 -Al2 O3 powder and an alkaline metal silicate aqueous solution is supplied to the form, so as to conceal the tiles 2. In addition, the composition is hardened in the form and then taken out, thereby forming a tile panel 4 with the reverse sides of the tiles 2 buried in a substrate 3 as the hardened body of the composition, and joints 31 formed around the tiles. 2. As a result, adhesive strength between the tiles 2 and the substrate 3 becomes high, and the occurrence of efflorescence at the joints 31 can be prevented.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

[0001] The present invention relates to a tile panel and a method of manufacturing the same.

[0002]

2. Description of the Related Art Tiles are used as interior and exterior materials and flooring materials of buildings, and wet construction methods have been used as construction methods for tiles. However, in the wet method, mortar or the like is applied to the construction surface of the tile, and the tile is stuck to the construction surface via the mortar or the like.

In order to solve these problems, a tile panel is fixed by a glue at a factory or a tile panel by a dry method in which only a panel is firstly constructed at a site and the tile is fixed there with an adhesive or mortar. There is. Further, a tile panel by a pre-installation method in which a tile is fixed to a mold in advance and then concrete is cast into the mold is used. (References: Design and construction guidelines and explanations for preventing external wall spalling, edited by the Japan Society for Finishings, Technical Shoinsha, March 1994
Also, a method has been proposed in which after forming a panel, a tile is pressed and cured by a press to increase the adhesive strength (Japanese Patent Application Laid-Open No. Hei 8-25331).

However, each of the above-mentioned dry methods has the following problems. That is, when an adhesive is used, there is a problem that the tile may peel off when the adhesive changes over time or in a fire. When concrete is used, there is a problem that the weight of the base material is heavy and joints are whitened. Also in the case of the tile panel disclosed in Japanese Patent Application Laid-Open No. Hei 8-25331, there is a possibility that the joints may be whitened, or the base material may be cracked due to aging, and the tiles may fall off.

[0005]

SUMMARY OF THE INVENTION In view of such circumstances, the present invention provides a tile panel in which a tile and a panel are firmly integrated, have excellent durability, are light in weight, and do not cause joint whitening. An object of the present invention is to provide a manufacturing method thereof.

[0006]

[Summary of the present invention to such a tile panel (hereinafter, referred to as "panel of the present invention"), in order to achieve the above object, SiO ₂ -Al ₂ O ₃ system powder, The structure was such that the back side of the tile was embedded in a predetermined pattern in a base material obtained by curing an inorganic curable composition mainly composed of an aqueous solution of an alkali metal silicate.

A method of manufacturing a tile panel according to the present invention (hereinafter, referred to as "the manufacturing method of the present invention") is to arrange tiles in a predetermined pattern in a mold so that the surface side faces the bottom of the mold. An inorganic curable composition slurry containing SiO ₂ —Al ₂ O ₃ powder and an alkali metal silicate aqueous solution as main components was poured into a mold to cure the inorganic curable composition.

In the panel and the manufacturing method of the present invention, the tile is not particularly limited, and examples thereof include commercially available ceramic tiles, large ceramic plates, and ceramic tiles. The size and shape of the tile are not particularly limited as long as they are determined in consideration of the design, strength, and workability of the entire panel. For example, a tile having a back side and formed in a foot shape is preferable. .

In the above structure, SiO ₂ —Al ₂ O ₃
As the system powder, SiO ₂ : Al ₂ O ₃ = 1: 9 to 9:
1 (weight ratio) can be used, and it is desirable that the total powder contains at least 50% by weight of SiO ₂ and Al ₂ O ₃ in total. That is, if the content is less than 50% by weight, the reactivity with the aqueous alkali metal silicate solution is reduced, and the strength of the obtained cured product may be reduced.

[0010] As the SiO ₂ -Al ₂ O ₃ -based powder, for example, include those as-follows, or used these alone, in combination. Fly ash containing 80% by weight or more of particles having a particle size of 10 μm or less Decolorizing fly ash containing 80% by weight or more of particles having a particle size of 10 μm or less

[0011] Inorganic powder obtained by melting fly ash or clay and spraying it into a gas. The inorganic powder obtained by applying mechanical energy of 0.1 to 30 kwh / kg to the clay is further added to the powder. Inorganic powder obtained by heating at ~ 750 ° C

[0012] 0.1 to 30 kwh /
Inorganic powder obtained by applying kg of mechanical energy Ash of an electric precipitator during the production of corundum or mullite Pulverized calcined bauxite Metakaolin

Incidentally, ordinary fly ash is defined in JIS.
A The fine ash particles collected by a dust collector from a pulverized coal combustion boiler specified in A6201 have a SiO ₂ content of 40% or more, a moisture content of 1% or less, a specific gravity of 1.95 or more, and a specific surface area of 270.
It passes through a standard sieve of 0 cm ² / g or more and 44 μm or more by 75% or more. Then, fly ash is a method of classifying this normal fly ash using a commonly used classifier such as wet sedimentation classification, air classification, specific gravity separation, and fine milling such as a jet mill, a roll mill, and a ball mill. It can be obtained by processing by a conventionally known method such as a method of pulverizing also using a mill, a method of using a continuous system of a classifier and a pulverizer, and the like.

The reason why the particles having a particle size of 10 μm or less must be contained in an amount of 80% by weight or more, such as fly ash, is that if the amount of the fly ash having a particle size of 10 μm or less is less than 80% by weight, the alkali metal silicate This is because the reactivity with the salt aqueous solution is reduced, and there is a possibility that the strength is reduced or curing failure is caused.

The above-mentioned bleached fly ash is obtained by baking fly ash at 400 to 1000 ° C. or baking ordinary fly ash at 400 to 1000 ° C.
Can be obtained in the same manner as fly ash.
That is, fly ash is generally black, and if this black fly ash is fired at a temperature of 400 ° C. or higher as described above, it can be decolorized. However, when firing at a temperature exceeding 1000 ° C., the reactivity with the aqueous solution of the alkali metal silicate decreases, so firing at the above temperature range is desirable.

The inorganic powder is obtained by melting fly ash or clay and spraying it into a gas.
As a method of melting and spraying in a gas, a spraying technique applied to a ceramic coating, preferably a spraying technique in which the fly ash and clay are melted at a temperature of 2000 to 16000 ° C and sprayed at a speed of 30 to 80 m / s. ,
Specifically, a plasma spraying method, a high energy gas spraying method, an arc spraying method, and the like can be given.

In general, the specific surface area of the inorganic powder obtained by the above thermal spraying technique is controlled to 0.1 to 60 m ² / g.

The above-mentioned inorganic powder and the clay used as a raw material of the inorganic powder include SiO ₂ as a chemical composition;
Clay containing 5 to 85% by weight, Al ₂ O ₃ ; 90 to 10% by weight, for example, kaolinite, dickite, nacrite, kaolin minerals such as halloysite, muscovite, illite, fengite, sea chlorite, celadonite, Mica clay minerals such as paragonite and branmarite, montmorillonite, beidellite, nontronite, sabonite,
Examples include smectites such as saconite, chlorite, pyrophyllite, talc, and sand shale.

The mechanical energy used in the production of the inorganic powder refers to a compressive force, a shearing force and an impact force, which may be used alone or in combination of two or more. . Examples of the equipment for making these act specifically include a ball mill, a vibration mill, a planetary mill, a medium stirring type mill, a roller mill, a mortar, and a jet powder crusher.

The particle diameters of the clay and metakaolin used in the production of the above inorganic powders are not particularly limited.
The average particle diameter is preferably from 0.01 to 500 μm, more preferably from 0.1 to 500 μm, in order to effectively exert mechanical energy.
It is preferably from 1 to 500 μm, particularly preferably from 0.1 to 1 μm.
00 μm.

When the mechanical energy applied during the production of the inorganic powder is less than 0.1 kwh / kg, the reactivity of the obtained inorganic powder with the aqueous alkali metal silicate solution is reduced, and If it exceeds, the load on the above-mentioned crushing device increases, and the wear and damage of the device increase,
Since problems such as impurities to the above-mentioned clay occur, 0.1 to
Limited to 30 kwh / kg, preferably 1.0 to 26
Act at kwh / kg.

The reason why the mechanical energy applied to metakaolin is limited to 0.1 to 30 kwh / kg is the same as in the above cases. When applying mechanical energy, a grinding aid may be added as necessary.

The pulverizing aid is for preventing the powder of clay or metakaolin from adhering or remarkably aggregating inside the apparatus when applying mechanical energy. For example, alcohols such as methyl alcohol and ethyl alcohol, Examples thereof include alcohol amines such as triethanolamine, metal soaps such as sodium stearate and calcium stearate, and acetone vapor. These may be used alone or in combination of two or more.

The inorganic powder of (1) is obtained by applying steam mechanical energy to the clay and then heating the clay to 100 to 750 ° C., because the mechanical strength is improved by heating. If the heating temperature is lower than 100 ° C., no improvement in strength is observed. If the heating temperature is higher than 750 ° C., crystallization of the inorganic powder occurs, and the reactivity with respect to the alkali metal silicate aqueous solution decreases. Limited, preferably limited to 200-600 ° C. Further, when the heating time is short, the improvement in mechanical strength of the obtained cured product is small, and when the heating time is long, the energy cost increases, so 1 minute to 5 hours is desirable.

The inorganic powders described in JP-B-3-9
060 and Japanese Patent Publication No. 4-45471. The commercially available metakaolin can be used.

The alkali metal silica used in the present invention
The aqueous acid salt solution is M_TwoOn SiOn _Two(M = K, Na,
Silicate water represented by at least one metal selected from Li)
A solution with a good appearance when the value of n is small
I can't get my body
Therefore, 0.05 to 8 is desirable, more preferably 0.5 to 8.
２．５2.5.

When the concentration of the aqueous alkali metal silicate solution decreases, the reactivity with the SiO ₂ —Al ₂ O ₃ powder decreases, and when the concentration increases, the alkali metal salt easily forms. It is desirably set to 〜60% by weight. Alkali metal silicate solution is an alkali metal silicate as it is pressurized, may be dissolved in water with heating, but quartz sand in an aqueous alkali metal hydroxide solution, the SiO ₂ component, such as silica powder n is a predetermined amount It may be dissolved under pressure and heat so that it may be used, or a commercially available aqueous solution of an alkali metal silicate may be used after being adjusted to a predetermined composition with a metal hydroxide and water.

The amount of the aqueous alkali metal silicate solution is 1 to 100 parts by weight of the SiO ₂ —Al ₂ O ₃ powder.
0 to 1300 parts by weight, preferably 10 to 1
000 parts by weight. That is, if the amount is less than 10 parts by weight, mixing is difficult, and if the amount is too large, cracks or the like may occur in the cured product.

In addition to the above, the inorganic composition of the present invention further comprises:
If necessary, fillers, reinforcing fibers, lightweight aggregates, pigments, foaming agents, foaming assistants, foaming agents, and the like can be added. Mineral composition SiO ₂ -Al ₂ O ₃ -based powder, optionally not limited to aqueous alkali metal silicate, the inorganic filler, reinforcing fibers, lightweight aggregate, pigments can be used. Further, an inorganic foamed cured product using a foaming agent or a foaming agent may be used. In this case, a foaming aid can be used.

As the inorganic filler, silica sand, rock powder,
Volcanic ash (silver, anti-firestone, etc.), wollastonite, calcium carbonate, silica stone, diatomaceous earth, mica, mica, silica fume and the like can be used. The compounding amount is SiO ₂ -Al ₂
900 parts by weight or less is desirable for 100 parts by weight of the O ₃ -based powder. If the amount exceeds 900 parts by weight, the mechanical strength may be reduced.

As the reinforcing fibers, those used in ordinary cement products can be used, such as polypropylene, vinylon, rayon, alkali-resistant glass, carbon, acrylic,
Fibers such as aramid and acrylonitrile can be used alone or in combination. Fiber diameter is 1 ~ 500μ
m and a fiber length of 1 to 15 mm are desirable. That is, if the fiber diameter is less than 1 μm, a fiber ball is formed during mixing,
When the strength exceeds 500 μm or the fiber length is less than 1 mm, a reinforcing effect such as improvement in tensile strength cannot be expected. On the other hand, if the fiber length exceeds 15 mm, the dispersibility decreases, and a cured product having uniform strength cannot be obtained.

As the amount of the reinforcing fiber, SiO ₂ -A
It is desirable that the content be 10 parts by weight or less based on 100 parts by weight of the l ₂ O ₃ powder. If it exceeds 10 parts by weight, the dispersibility of the fiber may be reduced. Lightweight aggregates include perlite, glass balloons, silica balloons, fly ash balloons,
Inorganic foams such as shirasu foam and organic foams such as phenolic resin, urethane resin, polyethylene and polystyrene can be used.

The amount of the lightweight aggregate added is SiO ₂ -A
The amount is desirably 150 parts by weight or less based on 100 parts by weight of the composition comprising l ₂ O ₃ -based powder, alkali metal silicate and water.
If the amount exceeds 150 parts by weight, there is a possibility that the strength, surface smoothness or molding workability may be reduced.

As the pigment, metal oxide pigments such as iron oxide, titanium oxide and cobalt oxide, and carbon black are desirable. The addition amount of the pigment with _respect to SiO 2 -Al ₂ O ₃ -based powder 100 parts by weight, preferably not more than 50 parts by weight.
That is, even if it exceeds 50 parts by weight, the hiding power is not improved and it is uneconomical.

As the foaming agent, Mg, Ca, Cr, M
n, Fe, Co, Ni, Cu, Zn, Al, Ga, S
n, Si, metal powders such as ferrosilicon, hydrogen peroxide water or sodium peroxide, potassium peroxide, peroxide powders such as sodium perborate, and the like, cost, safety,
Considering availability and ease of mixing, Al and hydrogen peroxide are preferred.

The powder of the foaming agent preferably has a particle diameter of 1 to 200 μm. That is, if the particle diameter is smaller than 1 μm, the dispersibility is reduced, and rapid foaming is caused. If the particle diameter is larger than 200 μm, the reactivity may be reduced. The addition amount of the foaming agent (solution 100% basis), compared SiO ₂ -Al ₂ O ₃ -based powder 100 parts by weight or less is preferable 5 parts by weight. That is, if the amount exceeds 5 parts by weight, the strength is remarkably reduced, and the molded article cannot be handled.

Examples of the foaming aid include porous powders such as silica gel, zeolite, activated carbon and alumina gel, and metal soaps such as metal stearate and metal palmitate. As the addition amount of the foaming aid, SiO ₂ —Al
_It is desirable that the amount be 10 parts by weight or less based on 100 parts by weight of the ₂ O ₃ powder. If the amount is more than 10 parts by weight, there is a possibility that bubbles may be broken.

As foaming agents, higher alcohol sulfates, alkyl ether sulfates, sulfonates of aromatic derivatives, imidazoline derivatives, fatty acid amides,
Animal protein systems can be used. The addition amount of the foaming agent is S
It is desirable that the content be 10 parts by weight or less based on 100 parts by weight of the iO ₂ -Al ₂ O ₃ powder. If the amount is more than 10 parts by weight, poor curing tends to occur.

Further, in the production method of the present invention, the shape of the mold is the same as that of the intended product, the slurry can be poured, and the moisture does not evaporate during the curing of the inorganic composition. It is preferable to have a closed structure. Further, when the tiles are arranged in the formwork in advance, it is preferable that a concave portion corresponding to the shape of the tile and a convex portion corresponding to the joint are provided at the bottom of the formwork, and the tile is fitted into the form.

Although the material of the mold is not particularly limited, rubber such as silicon, urethane and NBR is preferred. Moreover, you may reinforce with iron, aluminum, etc. as needed. Injection of the inorganic curable composition slurry into the mold may be performed by a natural fall method, or may be forcibly injected by a pump or the like. Vibration may be applied to the mold or the slurry for leveling or defoaming during or after the injection of the inorganic curable composition slurry into the mold.

[0041]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments of the present invention will be described below.
This will be described in detail with reference to the drawings. FIG. 1 shows an embodiment of the manufacturing method of the present invention.

As shown in FIG. 1, in this manufacturing method, first, all the position regulating recesses provided in the mold 1 with the surface side of the tile 2 facing the bottom of the mold 1 are formed. 11, 11,... Next, a slurry of an inorganic curable composition mainly composed of an SiO ₂ —Al ₂ O ₃ powder and an aqueous solution of an alkali metal silicate is poured into the mold 2 so as to cover the tile 2.

After the inorganic curable composition is cured in the mold 2 and taken out of the mold, the composition shown in FIG.
As shown in the figure, the tile panel 4 in which the back side of the tile 2 is embedded in the base material 3 which is a cured body of the inorganic curable composition and joints 31 are formed around the tile 2 can be obtained. And
In the obtained tile panel 4, the base material 3 is made of SiO ₂ —Al ₂
Since it is formed of a cured product of an inorganic curable composition mainly composed of an O ₃ -based powder and an aqueous solution of an alkali metal silicate, it is superior in strength to concrete and can be made thinner.

Accordingly, the weight can be reduced, and the joint portion does not cause the whitening phenomenon unlike the concrete. Moreover, there is no occurrence of cracking or the like over time, and no peeling of the tile 2 or the like occurs.

[0045]

Embodiments of the present invention will be described below in more detail.

(Example) Tile, formwork, S
iO ₂ -Al ₂ O ₃ system powder, was prepared alkali metal silicate solution.

[Tile] Pottery tile HAL-355 manufactured by INAX <backing shape = dovetail shape 145 x 45 mm 7.5 mm thickness>

[Mold] Material: Urethane <Inner dimensions 640 × 640 × 20 mm 14
48 5 x 45 mm recesses Joints 4 mm wide
Height 3mm>

[SiO ₂ -Al ₂ O ₃ -based powder] Metakaolin (manufactured by Engelhardt, trade name: SATENTON)
E SP33, average particle size 3.3 μm, BET specific surface area:
5.8 m ² / g) 100 parts by weight of a mixed solution of 25% by weight of triethanolamine and 75% by weight of ethanol 0.5
Parts by weight are ultra fine mills (Mitsubishi Heavy Industries, zirconia balls 10 mm used, ball filling rate 85% by volume)
It is supplied to obtain a SiO ₂ -Al ₂ O ₃ -based powder C by the action of mechanical energy of 10 kWh / kg. The applied mechanical energy was expressed by dividing the electric power supplied to the ultrafine mill by the unit weight of the treated powder.

[Alkali metal silicate aqueous solution] Nippon Chemical Industrial Co., Ltd. <SiO ₂ 20% K ₂ O 25% Water 55%>

Next, mica (M-10 manufactured by Repco Corp.)
0) 20 parts by weight, talc (Talc S manufactured by Nippon Talc)
30 parts by weight, 57.5 parts by weight of wollastonite (Kemorit A-60 manufactured by Tsuchiya Kaolin), 0.5 parts by weight of vinylon (RM182-3 manufactured by Kuraray), and the above SiO ₂ −
100 parts by weight of the Al ₂ O ₃ -based powder was supplied to an Erich mixer and dry-mixed for 5 minutes to obtain an inorganic powder.

After setting 48 tiles in a mold, 100 parts by weight of the inorganic powder and 75 parts by weight of an aqueous alkali metal solution were mixed with an omni mixer (Chiyoda Giken Kogyo Co., Ltd.).
For 2 minutes to obtain an inorganic curable composition slurry. This slurry was cast into a mold in which 48 tiles were set in advance.

This was put together with a mold in an oven at 85 ° C. for 3 hours to cure the inorganic curable composition.
The cured product was taken out of the mold to obtain a tile panel. In the tile panel obtained in the above example, the initial adhesive strength between the tile and the base material, the specific gravity of the base material alone, the presence or absence of the white spot phenomenon at the joint after the accelerated test, and the adhesive strength after the accelerated test are as follows. And the results are shown in Table 1.

[Adhesive Strength Evaluation Method] As shown in FIG.
After fixing the T-shaped jigs 6 and 6 made of steel on both surfaces of the test piece 5 obtained by cutting the tile panel into a 3 cm square with epoxy adhesives 7 and 7, this T-shaped jig is not shown. The tensile strength of each of Nos. 6 and 6 was measured with an autograph (AGS-1000B manufactured by Shimadzu Corporation) to determine the adhesive strength.

[Method of Measuring Specific Gravity] A test piece consisting only of a base material (cured inorganic material) was left in an oven at 105 ° C. for 24 hours, and the weight was measured. This was divided by the volume of the test piece to obtain the specific gravity.

[Accelerated test method] A tile panel was cut into a 10 cm square, and a shower ring (6
00 cc / min) for 10 minutes, 100 minutes for drying (80 ° C.) for 20 minutes
Cycle. After being taken out, the presence or absence of occurrence of efflorescence was observed, and the adhesive strength was measured by the same method as the above-mentioned adhesive strength evaluation method.

[0057]

[Table 1]

From Table 1, it can be clearly seen that the tile panel of the present invention can be reduced in weight as compared with the conventional tile panel, and has excellent strength over time without causing a white spot phenomenon.

[0059]

As described above, the tile panel according to the present invention has excellent adhesive strength between the tile and the base material, is light in weight, and does not cause joint white spots. Therefore, it is excellent in handleability, and when used as an interior / exterior material, the wall surface can be kept clean forever.

Further, the method of manufacturing a tile panel according to the present invention can easily manufacture the tile panel.

[Brief description of the drawings]

FIG. 1 is a perspective view illustrating an embodiment of a method for manufacturing a tile panel according to the present invention.

FIG. 2 is a sectional view of a tile panel according to the present invention.

FIG. 3 is an explanatory diagram illustrating a method for measuring the adhesive strength of a tile panel obtained in an example.

[Explanation of symbols]

 Reference Signs List 1 formwork 2 tile 3 base material 31 joint 4 tile panel

────────────────────────────────────────────────── ───

[Procedure amendment]

[Submission date] March 13, 1997

[Procedure amendment 1]

[Document name to be amended] Statement

[Correction target item name] 0029

[Correction method] Change

[Correction contents]

The inorganic composition of the present invention contains SiO ₂ -A
l ₂ O ₃ powder, not only alkali metal silicate aqueous solution but also inorganic filler, reinforcing fiber, lightweight aggregate,
Pigments and the like can be added. Further, when the base material is an inorganic foamed cured product, a foaming agent or a foaming agent can be used. In this case, a foaming aid may be used in addition to the foaming agent and the foaming agent.

Claims (2)

[Claims] 1. A back surface side of a tile is embedded in a predetermined pattern in a base material obtained by curing an inorganic curable composition mainly composed of an SiO ₂ —Al ₂ O ₃ powder and an aqueous solution of an alkali metal silicate. Tile panel. 2. Tiles are arranged in a mold in a predetermined pattern such that the surface side faces the bottom of the mold, and then the SiO ₂ -A
l ₂ O ₃ system powder, pouring the inorganic curable composition slurry mainly composed of an alkali metal silicate solution into a mold, a manufacturing method of a tile panel for curing an inorganic hardenable composition.