JPH0637046B2 - Method for producing inorganic decorative board having uneven pattern - Google Patents

Description

TECHNICAL FIELD The present invention relates to a method for producing an inorganic decorative board having an uneven pattern.

(Problems to be solved by the prior art and invention) Conventionally, as a method for producing an inorganic decorative board, for example, a silicate material and a foaming agent are kneaded, and the obtained kneaded product is molded into a plate shape, and There is a method of obtaining an inorganic decorative board having a concavo-convex pattern on the surface by subjecting the surface of the fired body to a fired body and subjecting the surface of the fired body to impact processing such as shot peening.

However, in this method, among the shells forming the cells exposed on the surface of the fired body, only the thin portion is crushed and removed, so that the surface of the fired body is only roughened gently, There is a problem that an inorganic decorative board having a surface shape with a rich three-dimensional effect cannot be obtained.

(Means for Solving the Problems) In view of the above problems, the present inventor has, in order to obtain an inorganic decorative board having a surface shape with a rich three-dimensional effect, in the fired body, an impact force higher than that of a shell forming a cell. In the coexistence of a fragile inorganic foam material, paying attention to the difference in fragility that the inorganic foam material is more likely to be crushed than the shell part and is easily scraped off, and manufacture of an inorganic decorative board having a three-dimensional rich surface shape I came to complete the method.

That is, the gist of the present invention is to knead a granular inorganic foaming material which has been subjected to rapid thermal expansion in advance, a silicic acid raw material and a foaming agent,
The obtained kneaded product is fired and foamed at a temperature equal to or lower than the melting point of the inorganic foam material to obtain a fired body having a predetermined shape having a large number of pores smaller than the particle diameter of the inorganic foam material, and the surface of the fired body. A method for producing an inorganic decorative board, which comprises subjecting a sheet to impact processing.

As the granular inorganic foaming material, an inorganic powder or granular material such as pearlite, pinelite, obsidian, or shirasu is about 900 to 1200 ° C.
Spherical body obtained by rapidly heating within several minutes and expanding several times to several tens of times, for example, commercially available perlite,
Shirasu foam, fuyolite expanded obsidian, etc. are used. Generally, as an inorganic foam material, the diameter is from 1 mm
The one having a diameter of several mm is used, but the one having a diameter of 2 mm to 5 mm, which is larger than a cell (hole portion) described later formed by the foaming agent, is preferable. Since this inorganic foam material has a large number of fine cells with a wall thickness of several tens of microns or less,
It has the property that it is more fragile than the shell of the glassy cell formed by slowly firing the silicate-based raw material described later.

The siliceous raw material is one containing 60% or more of SiO _2, and, for example, siliceous clay such as acid clay and frog clay is used.

As the foaming agent, soda ash, sodium nitrate, calcium carbonate, zinc oxide, sodium silicate, dolomite, etc. are used.

The kneaded product is basically the above-mentioned granular inorganic foaming material of several% by weight to
It is composed of several tens wt%, silicate raw material 50 wt% to 80 wt%, and blowing agent 5 wt% to 30 wt%. Also, kneadability,
In order to improve dispersibility and affinity, a flocculant, if necessary,
You may add 0.1 weight% -10 weight% of a thickener. And, the above components are usually added to the mixture in an amount of 5% by weight to 1% by weight of water.
5% by weight is added and kneaded.

As the coagulant, for example, aluminum phosphate is used, and as the thickener, for example, polyvinyl alcohol (PVA), carboxymethyl cellulose (CMC) and the like are used.

As a kneading method, the above components are mixed in an appropriate order and kneaded.

The firing and foaming is performed by heating the kneaded product at a temperature (700 to 1000 ° C.) below the melting point of the inorganic foam material for several tens of minutes to several hours. By this operation, a fired body having a glass cell (hole portion 1) with a diameter of 0.1 to several millimeters is obtained, and its specific gravity is about 0.2 to 0.5.

The size of the pores 1 needs to be smaller than that of the inorganic foam material. This is because if the pores 1 are larger than the inorganic foam material, it becomes difficult to secure a predetermined strength. Further, if the pores 1 have the same size as the inorganic foam material, the impact This is because the dents formed by processing become uniform and a complicated and varied planar shape cannot be obtained.

Next, the impact processing of the fired body is performed to form an uneven pattern on the surface of the fired body, and a predetermined thickness is obtained by cutting or polishing to expose the pores 1 and the inorganic foam material 2 (first (Fig. 1). In addition, 3 is a non-foaming melted portion of the siliceous material, which appears in a crack shape.

Then, mainly by crushing and scraping the inorganic foam material 2 with shot peening, sand blasting, brushing, hammer crusher, pin roller, etc.
There is a method of forming an uneven pattern on the surface of the fired body by combining a plurality of impact processes (Fig. 2).

In particular, it is preferable to perform shot peening, sand blasting, hammer crusher, etc., and then brushing, because sand and steel balls sandwiched in the cells are removed, and dust and chips after processing are reduced.

The impact processing does not have to be performed on the entire surface of the fired body, and may be partially performed by masking.Also, the impact-treated portion is strengthened and dust that cannot be completely removed is fixed. Further, in order to improve the stain resistance, it is preferable to appropriately apply a coating material such as acrylic, urethane, aminoalkyd or the like on the surface of the fired body.

(Example) 10 parts by weight of perlite having a diameter of 2 to 5 mm as a granular inorganic foaming material, 68 parts by weight of acid clay as a siliceous raw material,
1 blowing agent of sodium carbonate and sodium nitrate
3.5 parts by weight, 0.5 parts by weight of PVA as a thickening agent, and 8 parts by weight of water were mixed and kneaded, and the obtained kneaded product was rolled with a roller to form a plate. Was fired and foamed at a maximum temperature of 850 ° C for 120 minutes including preheating and gradual cooling to obtain a fired body, and the surface of the fired body was ground to expose the inorganic foam and the vitreous cell, and then shot peening was performed. Then, a concavo-convex pattern was formed on the surface thereof, and a portion that was easily chipped and dust were removed by brushing, and acrylic urethane paint was spray-coated to obtain a sample.

When the surface shape of the sample was visually observed, the inorganic foam located on the surface of the fired body was crushed by impact processing and scraped off, and the vitreous cell made of the siliceous raw material exposed on the surface. The thin-walled part of the shell that was formed was crushed and scraped off to form a deep, uneven pattern with sharp angles, so a decorative plate with a complex and varied three-dimensional appearance was obtained on the surface of the fired body. I found out that

(Operation and Effect of the Invention) As is apparent from the above description, according to the present invention, when the surface of the fired body is subjected to impact processing such as shot peening after firing and foaming, the minute wall exposed on the surface has a small wall thickness. Inorganic foam material with thin and fragile cells is roughly crushed and scraped off, and the thin part of the shell that forms the glassy cells (holes) is crushed and scraped off. Only the meat remains and is exposed. For this reason, there is an effect that, in combination with the cracks in the non-foamed molten portion, a deep concave and convex pattern is formed on the surface of the fired body, and a decorative plate having a complicated and varied three-dimensional surface shape can be obtained.

[Brief description of drawings]

1 and 2 are partially enlarged sectional views showing a decorative plate according to the present invention before and after impact processing. 1 ... Vitreous cell (void), 2 ... Inorganic foam material.

Claims (1)

[Claims] 1. A granular inorganic foam material, a siliceous raw material and a foaming agent are kneaded, and the resulting kneaded product is fired and foamed at a temperature not higher than the melting point of the inorganic foam material to obtain a particle size of the inorganic foam material. Obtain a fired body of a predetermined shape having a large number of pores smaller than
A method for producing an inorganic decorative board having a concavo-convex pattern, characterized by subjecting the surface of this fired body to impact processing.