JP3672598B2 - Plastic molding slurry composition, method for producing the plastic molding slurry composition, plastic molding clay obtained by subjecting the plastic molding slurry composition to dehydration and kneading, and use of the plastic molding clay Molding method of plastic molded body, plastic molded body molded by the molding method, and dried plastic molded body obtained by drying the plastic molded body - Google Patents
Plastic molding slurry composition, method for producing the plastic molding slurry composition, plastic molding clay obtained by subjecting the plastic molding slurry composition to dehydration and kneading, and use of the plastic molding clay Molding method of plastic molded body, plastic molded body molded by the molding method, and dried plastic molded body obtained by drying the plastic molded body Download PDFInfo
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- JP3672598B2 JP3672598B2 JP19774294A JP19774294A JP3672598B2 JP 3672598 B2 JP3672598 B2 JP 3672598B2 JP 19774294 A JP19774294 A JP 19774294A JP 19774294 A JP19774294 A JP 19774294A JP 3672598 B2 JP3672598 B2 JP 3672598B2
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- 229920003023 plastic Polymers 0.000 title claims description 43
- 239000004033 plastic Substances 0.000 title claims description 43
- 239000002002 slurry Substances 0.000 title claims description 34
- 239000004927 clay Substances 0.000 title claims description 22
- 238000000034 method Methods 0.000 title claims description 19
- 238000010137 moulding (plastic) Methods 0.000 title claims description 17
- 238000000465 moulding Methods 0.000 title claims description 16
- 239000000203 mixture Substances 0.000 title claims description 15
- 238000001035 drying Methods 0.000 title claims description 12
- 230000018044 dehydration Effects 0.000 title claims description 8
- 238000006297 dehydration reaction Methods 0.000 title claims description 8
- 238000004519 manufacturing process Methods 0.000 title claims description 7
- 238000004898 kneading Methods 0.000 title claims description 5
- 239000011347 resin Substances 0.000 claims description 37
- 229920005989 resin Polymers 0.000 claims description 37
- 239000002689 soil Substances 0.000 claims description 31
- 239000000919 ceramic Substances 0.000 claims description 27
- 239000000843 powder Substances 0.000 claims description 26
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 22
- 229920001577 copolymer Polymers 0.000 claims description 9
- 238000001125 extrusion Methods 0.000 claims description 9
- 238000002156 mixing Methods 0.000 claims description 5
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- 239000011118 polyvinyl acetate Substances 0.000 claims description 5
- 238000004382 potting Methods 0.000 claims 2
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- 239000004744 fabric Substances 0.000 description 8
- 239000000839 emulsion Substances 0.000 description 7
- 238000010304 firing Methods 0.000 description 4
- HEMHJVSKTPXQMS-UHFFFAOYSA-M Sodium hydroxide Chemical compound [OH-].[Na+] HEMHJVSKTPXQMS-UHFFFAOYSA-M 0.000 description 3
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- WRIDQFICGBMAFQ-UHFFFAOYSA-N (E)-8-Octadecenoic acid Natural products CCCCCCCCCC=CCCCCCCC(O)=O WRIDQFICGBMAFQ-UHFFFAOYSA-N 0.000 description 1
- TUSDEZXZIZRFGC-UHFFFAOYSA-N 1-O-galloyl-3,6-(R)-HHDP-beta-D-glucose Natural products OC1C(O2)COC(=O)C3=CC(O)=C(O)C(O)=C3C3=C(O)C(O)=C(O)C=C3C(=O)OC1C(O)C2OC(=O)C1=CC(O)=C(O)C(O)=C1 TUSDEZXZIZRFGC-UHFFFAOYSA-N 0.000 description 1
- LQJBNNIYVWPHFW-UHFFFAOYSA-N 20:1omega9c fatty acid Natural products CCCCCCCCCCC=CCCCCCCCC(O)=O LQJBNNIYVWPHFW-UHFFFAOYSA-N 0.000 description 1
- HNNQYHFROJDYHQ-UHFFFAOYSA-N 3-(4-ethylcyclohexyl)propanoic acid 3-(3-ethylcyclopentyl)propanoic acid Chemical compound CCC1CCC(CCC(O)=O)C1.CCC1CCC(CCC(O)=O)CC1 HNNQYHFROJDYHQ-UHFFFAOYSA-N 0.000 description 1
- QJZYHAIUNVAGQP-UHFFFAOYSA-N 3-nitrobicyclo[2.2.1]hept-5-ene-2,3-dicarboxylic acid Chemical compound C1C2C=CC1C(C(=O)O)C2(C(O)=O)[N+]([O-])=O QJZYHAIUNVAGQP-UHFFFAOYSA-N 0.000 description 1
- QSBYPNXLFMSGKH-UHFFFAOYSA-N 9-Heptadecensaeure Natural products CCCCCCCC=CCCCCCCCC(O)=O QSBYPNXLFMSGKH-UHFFFAOYSA-N 0.000 description 1
- 229920005789 ACRONAL® acrylic binder Polymers 0.000 description 1
- 229920000178 Acrylic resin Polymers 0.000 description 1
- 239000004925 Acrylic resin Substances 0.000 description 1
- 239000005995 Aluminium silicate Substances 0.000 description 1
- 239000001263 FEMA 3042 Substances 0.000 description 1
- 239000005642 Oleic acid Substances 0.000 description 1
- ZQPPMHVWECSIRJ-UHFFFAOYSA-N Oleic acid Natural products CCCCCCCCC=CCCCCCCCC(O)=O ZQPPMHVWECSIRJ-UHFFFAOYSA-N 0.000 description 1
- BPQQTUXANYXVAA-UHFFFAOYSA-N Orthosilicate Chemical compound [O-][Si]([O-])([O-])[O-] BPQQTUXANYXVAA-UHFFFAOYSA-N 0.000 description 1
- LRBQNJMCXXYXIU-PPKXGCFTSA-N Penta-digallate-beta-D-glucose Natural products OC1=C(O)C(O)=CC(C(=O)OC=2C(=C(O)C=C(C=2)C(=O)OC[C@@H]2[C@H]([C@H](OC(=O)C=3C=C(OC(=O)C=4C=C(O)C(O)=C(O)C=4)C(O)=C(O)C=3)[C@@H](OC(=O)C=3C=C(OC(=O)C=4C=C(O)C(O)=C(O)C=4)C(O)=C(O)C=3)[C@H](OC(=O)C=3C=C(OC(=O)C=4C=C(O)C(O)=C(O)C=4)C(O)=C(O)C=3)O2)OC(=O)C=2C=C(OC(=O)C=3C=C(O)C(O)=C(O)C=3)C(O)=C(O)C=2)O)=C1 LRBQNJMCXXYXIU-PPKXGCFTSA-N 0.000 description 1
- 229910052581 Si3N4 Inorganic materials 0.000 description 1
- CDBYLPFSWZWCQE-UHFFFAOYSA-L Sodium Carbonate Chemical compound [Na+].[Na+].[O-]C([O-])=O CDBYLPFSWZWCQE-UHFFFAOYSA-L 0.000 description 1
- 235000021355 Stearic acid Nutrition 0.000 description 1
- 238000010521 absorption reaction Methods 0.000 description 1
- 238000005054 agglomeration Methods 0.000 description 1
- 230000002776 aggregation Effects 0.000 description 1
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 1
- 235000012211 aluminium silicate Nutrition 0.000 description 1
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- HPNMFZURTQLUMO-UHFFFAOYSA-N diethylamine Chemical compound CCNCC HPNMFZURTQLUMO-UHFFFAOYSA-N 0.000 description 1
- WEHWNAOGRSTTBQ-UHFFFAOYSA-N dipropylamine Chemical compound CCCNCCC WEHWNAOGRSTTBQ-UHFFFAOYSA-N 0.000 description 1
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- 239000010433 feldspar Substances 0.000 description 1
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- LRBQNJMCXXYXIU-QWKBTXIPSA-N gallotannic acid Chemical compound OC1=C(O)C(O)=CC(C(=O)OC=2C(=C(O)C=C(C=2)C(=O)OC[C@H]2[C@@H]([C@@H](OC(=O)C=3C=C(OC(=O)C=4C=C(O)C(O)=C(O)C=4)C(O)=C(O)C=3)[C@H](OC(=O)C=3C=C(OC(=O)C=4C=C(O)C(O)=C(O)C=4)C(O)=C(O)C=3)[C@@H](OC(=O)C=3C=C(OC(=O)C=4C=C(O)C(O)=C(O)C=4)C(O)=C(O)C=3)O2)OC(=O)C=2C=C(OC(=O)C=3C=C(O)C(O)=C(O)C=3)C(O)=C(O)C=2)O)=C1 LRBQNJMCXXYXIU-QWKBTXIPSA-N 0.000 description 1
- 238000000227 grinding Methods 0.000 description 1
- 239000004021 humic acid Substances 0.000 description 1
- QXJSBBXBKPUZAA-UHFFFAOYSA-N isooleic acid Natural products CCCCCCCC=CCCCCCCCCC(O)=O QXJSBBXBKPUZAA-UHFFFAOYSA-N 0.000 description 1
- NLYAJNPCOHFWQQ-UHFFFAOYSA-N kaolin Chemical compound O.O.O=[Al]O[Si](=O)O[Si](=O)O[Al]=O NLYAJNPCOHFWQQ-UHFFFAOYSA-N 0.000 description 1
- 229920005610 lignin Polymers 0.000 description 1
- 230000003137 locomotive effect Effects 0.000 description 1
- QIQXTHQIDYTFRH-UHFFFAOYSA-N octadecanoic acid Chemical compound CCCCCCCCCCCCCCCCCC(O)=O QIQXTHQIDYTFRH-UHFFFAOYSA-N 0.000 description 1
- OQCDKBAXFALNLD-UHFFFAOYSA-N octadecanoic acid Natural products CCCCCCCC(C)CCCCCCCCC(O)=O OQCDKBAXFALNLD-UHFFFAOYSA-N 0.000 description 1
- ZQPPMHVWECSIRJ-KTKRTIGZSA-N oleic acid Chemical compound CCCCCCCC\C=C/CCCCCCCC(O)=O ZQPPMHVWECSIRJ-KTKRTIGZSA-N 0.000 description 1
- 239000002245 particle Substances 0.000 description 1
- 150000003014 phosphoric acid esters Chemical class 0.000 description 1
- 239000004014 plasticizer Substances 0.000 description 1
- 229920000058 polyacrylate Polymers 0.000 description 1
- 235000019353 potassium silicate Nutrition 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
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- UMJSCPRVCHMLSP-UHFFFAOYSA-N pyridine Natural products COC1=CC=CN=C1 UMJSCPRVCHMLSP-UHFFFAOYSA-N 0.000 description 1
- 239000010453 quartz Substances 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- HBMJWWWQQXIZIP-UHFFFAOYSA-N silicon carbide Chemical compound [Si+]#[C-] HBMJWWWQQXIZIP-UHFFFAOYSA-N 0.000 description 1
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- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 description 1
- 235000011121 sodium hydroxide Nutrition 0.000 description 1
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 238000001694 spray drying Methods 0.000 description 1
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Landscapes
- Emulsifying, Dispersing, Foam-Producing Or Wetting Agents (AREA)
- Compositions Of Oxide Ceramics (AREA)
- Press-Shaping Or Shaping Using Conveyers (AREA)
- Preparation Of Clay, And Manufacture Of Mixtures Containing Clay Or Cement (AREA)
Description
【０００１】
【産業上の利用分野】
本発明は、塑性成形用スラリー組成物、該塑性成形用スラリー組成物の製造法、該塑性成形用スラリー組成物をロ過脱水及び土練して得た塑性成形用坏土、該塑性成形用坏土を用いた塑性成形体の成形方法、該成形方法により成形された塑性成形体、該塑性成形体を乾燥させて得た乾燥した塑性成形体に関する。
【０００２】
【従来の技術】
従来、陶磁器やセラミックスの成形における塑性成形では、陶磁器用素地土やセラミックス素地土など所要の素地土に水などを適量添加して流動性を与え（通常含水率４０〜７０％）、ボ−ルミル等で混合粉砕し、スラリ−を調整せしめたのち、フィルタ−プレス機等にかけて脱水することにより含水率１０〜３０％のプレスケ−キを生成せしめている。そして、このプレスケ−キを真空土練機を用いて塑性成形用坏土に調製し、塑性成形、即ち、押出し成形やろくろ成形することにより所要の成形体を成形するものとされている。かかる成形体は乾燥、素焼、施釉、焼成、切削等の工程を経て最終製品とされるものであるが、かかる方法による場合、スラリ−の脱水が問題なく出来ること、坏土に気泡が混入しないこと、成形体の乾燥が速く、仕上げ加工、運搬等の取扱いが可能な程度の機械的強度を有することが必要である。
【０００３】
このため、従来より陶磁器を製造する場合、その坏土中に蛙目粘土、木節粘土などを含有させることにより塑性成形上必要とされる可塑性を付与せしめ、かつ、機械的強度を得ている。しかしながら、かかる従来の陶磁器用坏土では、大型、薄型部材成形においては成形体の機械的強度が充分でなく、製造が困難であった。
【０００４】
また、セラミックス製造時の塑性成形においては、セラミックス用坏土だけでは成形に必要とされる可塑性が不充分であり、充分な強度の塑性成形体を得ることが出来ないという問題があった。
【０００５】
かかる従来の問題点を解決するものとして、水溶性樹脂や水性樹脂エマルジョン等をスラリー調製時、又は土練時に添加する方法が提案されている（特公平３−６４４６５号公報、特開平５−１０４５０９号公報参照）。
【０００６】
【発明が解決しようとする課題】
上記の解決策は、水溶性樹脂や水性樹脂エマルジョンの添加により成形体の強度を向上せしめることが出来る反面、以下の欠点を有する。
▲１▼まず第１に、陶磁器用素地土やセラミックス用素地土と、水性樹脂エマルジョンなどとの密度差が大きい為に分離しやすく、均一分散したスラリ−を調製しづらく、ひいては、そのスラリ−から得た塑性成形体にソリやワレを発生しや
すいものである。特に、高粘度スラリ−の場合には均一混合が難しい。
▲２▼第２に、脱水時において、水溶性樹脂や水性樹脂エマルジョンは脱水される水とともに移動するため、ロ布への付着、目詰りや系外への流出、ロ布面での乾燥固化、プレスケ−キのロ布への付着等を生じ、ロ過濃縮が出来ない状態にな
る。
▲３▼第３に、もし脱水されたプレスケ−キが得られ、また、土練時にうまく添加出来ても、成形体を乾燥処理するさいには樹脂の表面乾燥により皮膜化を起し、
内部乾燥の遅れやソリ、ワレ、フクレ等を生じせしめやすいものである。
【０００７】
本発明者等は、上記従来の問題点を解決するために鋭意研究を行なった結果、再分散性樹脂粉末を素地土と水に加えてスラリ−化せしめることにより、均一分散化やプレス機による脱水濃縮作業を極めて効率よく行うことが出来る共に、乾燥性、機械的強度などに優れた特徴を持つ塑性成形体を成形せしめ得ることを見出し、本発明を完成するに至ったものである。
【０００８】
【課題を解決するための手段】
この出願の第１の発明は、陶磁器用素地土、および又はセラミックス用素地土１００重量部に対して、ポリ酢酸ビニル、酢酸ビニル共重合体、あるいはアクリル酸エステル共重合体からなる再分散性樹脂粉末０．５〜２０重量部、および水を添加し、その際、素地土に再分散性樹脂粉末を添加してから水を添加し、これらを混合せしめてなることを特徴とする、押出し成形用、ろくろ成形用の塑性成形用スラリー組成物である。この出願の第２の発明は、陶磁器用素地土、および又はセラミックス用素地土１００重量部に対して、ポリ酢酸ビニル、酢酸ビニル共重合体、あるいはアクリル酸エステル共重合体からなる再分散性樹脂粉末０．５〜２０重量部、および水を添加し、その際、素地土に再分散性樹脂粉末を添加してから水を添加し、これらを混合せしめることを特徴とする、押出し成形用、ろくろ成形用の塑性成形用スラリー組成物を製造する方法である。この出願の第３の発明は、請求項１記載の塑性成形用スラリー組成物をロ過脱水した後、土練することにより生成せしめることを特徴とする塑性成形用坏土である。この出願の第４の発明は、請求項３記載の塑性成形用坏土を押出し成形することを特徴とする塑性成形体の成形方法である。この出願の第５の発明は、請求項３記載の塑性成形用坏土をろくろ成形することを特徴とする塑性成形体の成形方法である。この出願の第６の発明は、請求項４又は５記載の成形方法により成形した塑性成形体である。この出願の第７の発明は、請求項６記載の塑性成形体を乾燥せしめてなることを特徴とする乾燥した塑性成形体である。
【０００９】
本発明における陶磁器用素地土としては、長石、珪石、陶石、カオリン、あるいは粘土など公知の陶磁器用原料を使用することができ、また、セラミックス用素地土としては、アルミナ、ジルコニア、シリカ、フェライト、炭化珪素、窒化珪素、あるいはサイアロンなど公知のセラミックス用原料を使用することが出来る。そして、これら陶磁器用素地土およびセラミックス用素地土は、各々単独で、あるいは必要に応じて適宜配合して使用することが出来る。以下、陶磁器用素地土やセラミックス用素地土など所要の素地土を単に素地土と略称する。
【００１０】
また、再分散性樹脂粉末としては、ポリ酢酸ビニル、酢酸ビニル共重合体、あるいはアクリル樹脂系のエマルジョンを噴霧乾燥することによって得られる、所謂再分散性樹脂粉末を使用する。そして、かかる再分散性樹脂粉末のガラス転移温度は、好適な造膜形成の面から−５℃以上が好ましく、−５℃未満の場合には凝集して付着しやすく、また、逆にガラス転移温度が高くなりすぎると造膜形成が不充分となりやすいため、好ましくは０〜２０℃である。なお、高めのガラス転移温度を有する再分散性樹脂を用いる場合には、乾燥温度を高くして時間をかけたり、あるいは可塑剤や造膜助剤を加えるとよい。また、素地土に対する再分散性樹脂粉末の添加量は、素地土の種類、再分散性樹脂粉末の種類、製造されるべき焼結体の特性等によって異なるが、通常は０．５〜２０重量部、好ましくは１．０〜１５重量部である。かかる再分散性樹脂粉末の添加量が素地土に対して０．５重量部未満の場合には、成形体の機械的強度が不充分となり、また、２０重量部をこえる場合には、後述する脱水後のロ布からのプレスケーキの取出し性が低下すると共に、焼成前の機械的強度には問題ないが焼成収縮が大きくて焼結体の強度低下が大きくなるのみならず、素地土の特性を減殺せしめやすいものである。これら再分散性樹脂粉末は、住友化学工業株式会社製のスミカフレックス（登録商標）ＲＰ−１００Ｓ、ＲＰ−１１０、三菱油化バーディッシェ株式会社製のアクロナール（登録商標）ＤＳ−６０２９、ＤＳ−６０３１、ヘキスト合成株式会社製のモビニル（登録商標）ＤＭ２００、ＤＭ２８９、８４３、ＳＡ、Ｅ４５等の商品名で市販されている。なお、かかる再分散製樹脂粉末の製造方法については、特開昭５９−１９９７０３号公報、特開平６−２４８２０号公報等に開示されている。
【００１１】
その他、分散媒としての水は、スラリ−の含水率がおよそ４０〜７０重量％となるように添加されるのが好ましい。なお、かかる水のほか、苛性ソ−ダ、珪酸ソ−ダ、水ガラス、リン酸エステル等の無機解膠剤、ジエチルアミン、ジ−ｎ−プロピルアミン、ピリジン、ポリアクリル酸塩などの有機解膠剤、フミン酸、タンニン酸、リグニンなどの保護コロイド剤、ステアリン酸、オレイン酸、ナフテン酸等の粉砕助剤、その他、分散剤、湿潤剤、減水剤、流動化剤、高性能流動化剤、乳化剤等を必要に応じて添加せしめることが出来る。
【００１２】
スラリーは、素地土に所要量の再分散性樹脂粉末を加え、水および必要に応じて解膠剤などを添加しつつ、ボールミルやチューブミルなど公知の粉砕機により素地土の粒径が０．１〜１０μｍになるように調製する。このさい、再分散性樹脂粉末は、粉末状であるため、従来の水性樹脂エマルジョンに比して気泡を発生することなく、また、素地土との密度差に伴う分離や再凝集を生じることなく、非常に安定的に均一分散して適性粘度のスラリーを好適に調製せしめる。このため、調製スラリー中には、常に再分散性樹脂粉末が安定的に均一分散している。
【００１３】
得られたスラリ−は、公知の方法により加圧式ロ過機、例えばフィルタ−プレス機等により脱水濃縮して含水率が１０〜３０重量％、好ましくは１５〜２５重量％のプレスケ−キに生成せしめる。この工程は、ロ布を通してスラリ−を脱水するもので、再分散性樹脂粉末が非常に安定的に均一分散しているために水分のみがロ布を通って除かれ、ロ布の目詰り、凝集付着、皮膜化等がなく、ロ過作業を極めて容易に行うことが出来ると共に、ロ布へのプレスケ−キの付着もなくプレスケ−キを容易に除去せしめることが出来る。
【００１４】
得られたプレスケ−キは、公知の土練機により土練りして塑性坏土に調製する。その後、かかる塑性坏土を用い、押出し成形や動力ろくろ成形等の塑性成形を行ない、所望の塑性成形体を成形せしめる。得られた塑性成形体は適宜乾燥処理せしめるが、２０℃以上で乾燥するのがよい。なお、本発明では再分散性樹脂粉末が安定的に均一分散した形態を呈するため、乾燥処理や焼成処理時にフクレ、ハガレ、ワレ等を生じるおそれがなく、焼成前の強度が強いために所望の形状を薄く生成することが出来るものである。また、本発明は、スラリ−の粉砕混合を最も理想的な状態で調製し、そのスラリ−を脱水濃縮することで塑性成形用坏土を調製するものであるが、その塑性坏土に再び水や分散剤等を加えて塑性成形用スラリ−を調製し、使用に供することも可能である。
得られた塑性成形体は、適宜乾燥処理せしめた後、公知の方法により焼成して焼結体を生成せしめる。
【００１５】
【実施例】
以下に、本発明の一実施例を示すが、本発明はこれに限定されるものではない。
【００１６】
実施例１〜６、および比較例１〜６
表１に示す配合割合に基づき、素地土に再分散性樹脂粉末、水溶性樹脂及び水性樹脂エマルジョン（固形分で表示）を加え、水を添加してボ−ルミルにより粉砕混合し、含水率約６０％のスラリ−を調製した。
上記スラリ−を株式会社マキノ製のフィルタ−プレスＭ１４−Ｓ型を使用し、１４Ｋｇ／ｃｍ2までプレス圧を上げ、そのまま３０分間保持し、減圧してプレスケ−キを得た。この操作を最高２０回繰り返し、その結果を表２に示す。次に、生成したプレスケ−キを石川時鐡工所株式会社製のＳＹ−１１型真空土練機に投入し、ＮＧＫクレイハ−ドネステスタ−で硬度１１になるように塑性成形用坏土を調製した。その後、下記記載の方法により押出し成形、及び動力ロクロ成形を行った。
【００１７】
押出し成形：上記の真空土練成形機を用い、縦１０ｍｍ×横３０ｍｍの連続押出し成形を行い、長さ５０ｍｍ毎に切り出した。
動力ロクロ成形：動力ろくろ成形機を用い、縦５０ｍｍ×横３０ｍｍ×厚１０ｍｍの成形体が得た。
上記の２方法で得られた成形体をそれぞれ２０℃下で２４時間風乾し、次に１１０℃下で２４時間乾燥させた。さらに、１２３０℃まで５時間かけて昇温し、そのまま１時間保持せしめたのち、４時間で冷却して焼結体を得た。そして、焼成前の２０℃下で乾燥後、１１０℃下で乾燥後、及び焼成後の曲げ強度、また、焼成時の収縮率、及び吸水率を以下の方法により測定した。その結果を表２に示す。
【００１８】
【発明の効果】
本発明によれば以上の次第で、素地土に再分散性樹脂粉末と水とを添加して混合せしめるため、再分散性樹脂粉末を非常に安定的に均一分散せしめ、このスラリ−をロ過脱水により含水率を大きく下げ、塑性成形用坏土を調製して所要形状に塑性成形することで、機械的強度を大幅に向上せしめた成形体を得、それにより、従来形状の製品に比して、薄く、軽く、しかも大型状の焼結体を製造せしめることが出来るものである。
【００２２】
【表１】
【表２】
[Industrial application fields]
The present invention relates to a slurry composition for plastic molding , a method for producing the slurry composition for plastic molding, a clay for plastic molding obtained by subjecting the slurry composition for plastic molding to dehydration and soiling, and the plastic molding slurry. The present invention relates to a molding method of a plastic molded body using clay, a plastic molded body molded by the molding method, and a dried plastic molded body obtained by drying the plastic molded body .
[0002]
[Prior art]
Conventionally, in plastic molding of ceramic and ceramic molding, an appropriate amount of water or the like is added to a required base soil such as a ceramic base soil or ceramic base soil to give fluidity (usually moisture content of 40 to 70%), and a ball mill. After the mixture is pulverized and the slurry is adjusted, a press cake having a water content of 10 to 30% is produced by dehydration by a filter press or the like. Then, this press cake is prepared into a plastic forming clay using a vacuum kneader, and a required formed body is formed by plastic forming, that is, extrusion forming or potter's wheel forming. Such a molded body is made into a final product through processes such as drying, unglazed, glazed, fired, and cut. However, according to such a method, slurry can be dehydrated without any problem, and bubbles are not mixed into the clay. In addition, it is necessary for the molded body to dry quickly and to have mechanical strength that allows handling such as finishing and transportation.
[0003]
For this reason, when producing ceramics from the past, the plasticity required for plastic forming is imparted and mechanical strength is obtained by including glazed clay, Kibushi clay, etc. in the clay. . However, in such a conventional clay for ceramics, the mechanical strength of the molded body is not sufficient in the molding of large and thin members, and it is difficult to manufacture.
[0004]
Further, in the plastic forming at the time of manufacturing ceramics, there is a problem that the plasticity required for forming is insufficient only with the ceramic clay, and a plastic formed body having sufficient strength cannot be obtained.
[0005]
In order to solve such a conventional problem, a method of adding a water-soluble resin, an aqueous resin emulsion or the like at the time of slurry preparation or at the time of soil mixing has been proposed ( Japanese Patent Publication No. 3-64465 , Japanese Patent Laid-Open No. 5-104509). No. publication).
[0006]
[Problems to be solved by the invention]
The above solution can improve the strength of the molded body by adding a water-soluble resin or an aqueous resin emulsion, but has the following drawbacks.
(1) First of all, it is difficult to prepare a uniformly dispersed slurry because there is a large density difference between the ceramic soil or ceramic ground and the aqueous resin emulsion. It is easy to generate warpage and cracking in the plastic molded body obtained from 1. In particular, in the case of a high viscosity slurry, uniform mixing is difficult.
(2) Secondly, during dehydration, the water-soluble resin and aqueous resin emulsion move together with the dehydrated water, so that they adhere to the cloth, clog or flow out of the system, and dry and solidify on the cloth surface. This causes the press cake to adhere to the cloth and prevents the excessive concentration.
(3) Thirdly, if a dehydrated press cake is obtained, and even if it can be successfully added at the time of kneading, a film is formed by drying the surface of the resin when the molded body is dried,
It is easy to cause delays in internal drying, warping, cracking and swelling.
[0007]
As a result of diligent research to solve the above-mentioned conventional problems, the present inventors have added a redispersible resin powder to the base soil and water to form a slurry, which enables uniform dispersion and pressing. The inventors have found that it is possible to perform a dehydrating and concentrating operation extremely efficiently, and that a plastic molded body having excellent characteristics such as drying property and mechanical strength can be formed, and the present invention has been completed.
[0008]
[Means for Solving the Problems]
The first invention of this application is a redispersible resin comprising a polyvinyl acetate, a vinyl acetate copolymer, or an acrylate copolymer with respect to 100 parts by weight of a ceramic base soil and / or a ceramic base soil. Extrusion molding characterized in that 0.5 to 20 parts by weight of powder and water are added, and then water is added after mixing the redispersible resin powder to the base soil, and these are mixed. And plastic forming slurry composition for potter's wheel forming . The second invention of this application is a redispersible resin comprising a polyvinyl acetate, a vinyl acetate copolymer, or an acrylate copolymer with respect to 100 parts by weight of a ceramic base soil and / or a ceramic base soil. 0.5 to 20 parts by weight of powder and water are added. At that time, after adding the redispersible resin powder to the base soil, water is added, and these are mixed, for extrusion molding, This is a method for producing a plastic molding slurry composition for potter's wheel molding. A third invention of this application is a clay for plastic forming characterized in that the slurry is formed by subjecting the slurry composition for plastic forming according to claim 1 to dry dehydration and then kneading. A fourth invention of this application is a method for forming a plastic molded body, wherein the clay for plastic molding according to claim 3 is extruded. According to a fifth aspect of the present invention, there is provided a method for forming a plastic molded body, characterized in that the plastic forming clay according to claim 3 is formed in a potter's wheel. A sixth invention of this application is a plastic molded body molded by the molding method according to claim 4 or 5. A seventh invention of this application is a dried plastic molded body obtained by drying the plastic molded body according to claim 6.
[0009]
As the ceramic base soil in the present invention, known ceramic raw materials such as feldspar, quartz stone, ceramic stone, kaolin, or clay can be used, and as the ceramic base soil, alumina, zirconia, silica, ferrite Known ceramic raw materials such as silicon carbide, silicon nitride, or sialon can be used. And these ceramic base soils and ceramic base soils can be used alone or in combination as needed. Hereinafter, a required base soil such as a ceramic base soil and a ceramic base soil is simply referred to as a base soil.
[0010]
As the redispersible resin powder, a so-called redispersible resin powder obtained by spray-drying polyvinyl acetate, a vinyl acetate copolymer, or an acrylic resin emulsion is used. The glass transition temperature of the redispersible resin powder is preferably −5 ° C. or more from the viewpoint of suitable film formation, and when it is less than −5 ° C., it tends to aggregate and adhere, and conversely, the glass transition temperature. If the temperature is too high, film formation tends to be insufficient. When a redispersible resin having a high glass transition temperature is used, it is preferable to increase the drying temperature and take time, or add a plasticizer or a film-forming aid. The amount of the redispersible resin powder added to the base soil varies depending on the type of the base soil, the type of the redispersible resin powder, the characteristics of the sintered body to be manufactured, etc., but usually 0.5 to 20 weights. Parts, preferably 1.0 to 15 parts by weight. When the amount of the redispersible resin powder added is less than 0.5 parts by weight with respect to the base soil, the mechanical strength of the molded body becomes insufficient, and when it exceeds 20 parts by weight, it will be described later. The press cake removal from the cloth after dehydration is reduced and there is no problem in mechanical strength before firing, but not only the shrinkage of the sintered body is increased due to the large shrinkage of firing, but also the characteristics of the base soil It is easy to kill. These redispersible resin powders are Sumikaflex (registered trademark) RP-100S, RP-110 manufactured by Sumitomo Chemical Co., Ltd., Acronal (registered trademark) DS-6029, DS-6031 manufactured by Mitsubishi Yuka Birdishe Co., Ltd. It is commercially available under the trade names such as Movinyl (registered trademark) DM200, DM289, 843, SA, E45 manufactured by Hoechst Chemical Co., Ltd. Incidentally, such a method for producing the redispersible resin powder, Japanese HirakiAkira 59-199703 and JP disclosed in JP-A 6-24820 Patent Publication.
[0011]
In addition, water as a dispersion medium is preferably added so that the water content of the slurry is about 40 to 70% by weight. In addition to such water, inorganic peptizers such as caustic soda, silicate soda, water glass and phosphate esters, organic peptizers such as diethylamine, di-n-propylamine, pyridine and polyacrylate Agents, protective colloids such as humic acid, tannic acid, lignin, grinding aids such as stearic acid, oleic acid, naphthenic acid, other dispersants, wetting agents, water reducing agents, fluidizing agents, high-performance fluidizing agents, An emulsifier etc. can be added as needed.
[0012]
The slurry is prepared by adding a required amount of redispersible resin powder to the base soil, adding water and a peptizer as necessary, and using a known pulverizer such as a ball mill or a tube mill to reduce the particle size of the base soil to 0. Prepare to be 1-10 μm. At this time, since the redispersible resin powder is in the form of a powder, it does not generate bubbles as compared with the conventional aqueous resin emulsion, and does not cause separation or reagglomeration due to a density difference from the base soil. A slurry having an appropriate viscosity can be suitably prepared by uniformly dispersing in a very stable manner. For this reason, the redispersible resin powder is always stably and uniformly dispersed in the prepared slurry .
[0013]
The resulting slurry is dehydrated and concentrated by a known method using a pressure filter, such as a filter press, to produce a press cake having a water content of 10 to 30% by weight, preferably 15 to 25% by weight. Let me. In this process, the slurry is dehydrated through the cloth, and since the redispersible resin powder is very stably and uniformly dispersed, only the moisture is removed through the cloth, and the cloth is clogged. There is no agglomeration adhesion, film formation, etc., and it is possible to carry out the low-pass work very easily, and the press cake can be easily removed without adhesion of the press cake to the cloth.
[0014]
The obtained press cake is kneaded with a known kneader to prepare a plastic clay. Thereafter, using the plastic clay, plastic molding such as extrusion molding or power wheel molding is performed to form a desired plastic molded body. The obtained plastic molded body is appropriately dried, but is preferably dried at 20 ° C. or higher. In the present invention, since the redispersible resin powder has a stably and uniformly dispersed form, there is no risk of swelling, peeling, cracking, etc. during the drying treatment or firing treatment, and the strength before firing is strong, so that it is desirable. The shape can be made thin. In the present invention, the slurry for pulverization is prepared in the most ideal state, and the slurry for plastic forming is prepared by dehydrating and concentrating the slurry. It is also possible to prepare a slurry for plastic forming by adding a dispersant or the like and use it.
The obtained plastic molded body is appropriately dried and then fired by a known method to form a sintered body.
[0015]
【Example】
Examples of the present invention will be shown below, but the present invention is not limited thereto.
[0016]
Examples 1-6 and Comparative Examples 1-6
Based on the blending ratio shown in Table 1, add redispersible resin powder, water-soluble resin and aqueous resin emulsion (indicated by solid content) to the base soil, add water, pulverize and mix with a ball mill. A 60% slurry was prepared.
A filter press M14-S type manufactured by Makino Co., Ltd. was used as the slurry, the press pressure was increased to 14 Kg / cm 2 , held for 30 minutes, and the pressure was reduced to obtain a press cake. This operation was repeated up to 20 times, and the results are shown in Table 2. Next, the produced press cake was put into a SY-11 type vacuum kneader manufactured by Ishikawa Tokiko Co., Ltd., and a clay for plastic forming was prepared so as to have a hardness of 11 with an NGK clay hard tester. . Thereafter, extrusion molding and power roll molding were performed by the methods described below.
[0017]
Extrusion molding: Continuous extrusion molding of 10 mm in length and 30 mm in width was performed using the above vacuum kneading machine, and cut out every 50 mm in length.
Power locomotive molding: Using a power wheel molding machine, a molded body having a length of 50 mm × width of 30 mm × thickness of 10 mm was obtained.
The compacts obtained by the above two methods were each air-dried at 20 ° C. for 24 hours, and then dried at 110 ° C. for 24 hours. Further, the temperature was raised to 1230 ° C. over 5 hours, held for 1 hour as it was, and then cooled in 4 hours to obtain a sintered body. And the bending strength after drying under 20 degreeC before baking, drying under 110 degreeC, and baking, the shrinkage rate at the time of baking, and the water absorption were measured with the following method. The results are shown in Table 2.
[0018]
【The invention's effect】
According to the present invention, depending on the above, the redispersible resin powder and water are added to the base soil and mixed together. Therefore, the redispersible resin powder is dispersed very stably and uniformly, and the slurry is filtered. The water content is greatly reduced by dehydration, and a plastic body for plastic forming is prepared and plastic molded into the required shape, resulting in a molded body with significantly improved mechanical strength, thereby comparing to products with conventional shapes. Thus, a thin, light and large-sized sintered body can be produced.
[0022]
[Table 1]
[Table 2]
Claims (7)
Priority Applications (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP19774294A JP3672598B2 (en) | 1994-07-29 | 1994-07-29 | Plastic molding slurry composition, method for producing the plastic molding slurry composition, plastic molding clay obtained by subjecting the plastic molding slurry composition to dehydration and kneading, and use of the plastic molding clay Molding method of plastic molded body, plastic molded body molded by the molding method, and dried plastic molded body obtained by drying the plastic molded body |
| US08/398,649 US5573982A (en) | 1994-03-05 | 1995-03-03 | Slurry composition, shaping method using the same, and fired body |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP19774294A JP3672598B2 (en) | 1994-07-29 | 1994-07-29 | Plastic molding slurry composition, method for producing the plastic molding slurry composition, plastic molding clay obtained by subjecting the plastic molding slurry composition to dehydration and kneading, and use of the plastic molding clay Molding method of plastic molded body, plastic molded body molded by the molding method, and dried plastic molded body obtained by drying the plastic molded body |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| JPH0840777A JPH0840777A (en) | 1996-02-13 |
| JP3672598B2 true JP3672598B2 (en) | 2005-07-20 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP19774294A Expired - Lifetime JP3672598B2 (en) | 1994-03-05 | 1994-07-29 | Plastic molding slurry composition, method for producing the plastic molding slurry composition, plastic molding clay obtained by subjecting the plastic molding slurry composition to dehydration and kneading, and use of the plastic molding clay Molding method of plastic molded body, plastic molded body molded by the molding method, and dried plastic molded body obtained by drying the plastic molded body |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JP3672598B2 (en) |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| JP4612146B2 (en) * | 2000-04-21 | 2011-01-12 | ガンツ化成株式会社 | Dry molded product that becomes a grindstone by firing and method for producing the same |
-
1994
- 1994-07-29 JP JP19774294A patent/JP3672598B2/en not_active Expired - Lifetime
Also Published As
| Publication number | Publication date |
|---|---|
| JPH0840777A (en) | 1996-02-13 |
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