JPH03266639A - Ceramic sheet with moisture adjusting functionality - Google Patents

Abstract

PURPOSE:To obtain a ceramic plate having moisture adjusting functionality without dropping out of a moisture adjusting raw material from a cut part o peeling off of a decorative layer by melting and integrating specified base layer, ceramic sheet and decorative layer by calcination. CONSTITUTION:A closed-cell base layer 1 is a layer prepd. by making particles of a raw material wherein acid clay and fire-resistant stone are used as a main raw material and a melt medium material such as soda ash and glass powder and a foaming agent such as Dolomite are supplementarily compounded and the compounded mixture is ground and foaming the particles by heating. A network-like ceramic sheet 2 placed on the base layer 1 is a product prepd. by adhering a net made of an org. fiber with a slurry moisture adjusting raw material. As a raw material for a decorative layer 3 with an open-cell, a compounded raw material wherein feldspar, soda ash, sodium nitrate, zinc flower, lime stone and glass powder are properly combined. A ceramic plate is prepd. by placing lamellarly the granulate for the base layer on for example, a heat-resistant mesh belt and laminating thereon the ceramic sheet and the granulate for the decorative layer and carrying the obtd. laminated body into a calcinating oven and integrating it in a body by heat-calcination.

Description

DETAILED DESCRIPTION OF THE INVENTION [Field of Industrial Application] The present invention relates to a ceramic plate having a humidity control function. More specifically, the present invention relates to a ceramic plate that is a large, lightweight plate and has a humidity control function with improved strength in the humidity control portion. In the present invention, the term "humidity control function" refers to a moisture absorption function and a moisture release function. For example, when the ceramic board of the present invention is used as a wall material, when the indoor humidity is high, the wall material This refers to the function of the wall material to absorb moisture and, conversely, to release moisture into the room when the humidity is low.

[Prior art and problems to be solved by the invention] Traditional Japanese buildings were mainly constructed of wood, earth, and paper, and although they were easily affected by the outdoor climate, all of the structures had a breathing effect. When the humidity is high, it absorbs moisture, and when it is dry, it releases moisture to adjust indoor humidity.

However, many buildings these days are of a closed type, as typified by concrete structures, and have a structure that does not allow ventilation or breathing. Therefore, in regions with high humidity, condensation is particularly harmful, reducing the livability of buildings.

For this reason, in the past, livability was maintained by pasting decorative paper on gypsum board or moisture-absorbing sheets on concrete surfaces, but gypsum board is vulnerable to water and has poor decorative and strength properties. There is a problem that the moisture absorption sheet is inferior, and that the moisture absorbing sheet gets dirty easily and needs to be replaced. Therefore, there has long been a desire for a building material that is a ceramic plate like a tile and has a humidity control function.

Therefore, as a result of intensive research into such building materials,
The present inventors have discovered that a ceramic plate in which a humidity control layer containing a humidity control inorganic raw material is interposed between a base layer formed by heating and foaming a foamable inorganic raw material and a decorative layer has a humidity control function and an excellent heat insulation property. He discovered that it has fire resistance and fire resistance, and filed three patent applications (Japanese Patent Application No. 62-271407, Japanese Patent Application No. 62-271408, and Japanese Patent Application No. 62-27140).
No. 9).

However, a mixture of dry-pulverized humidity control raw materials and granules to a particle size of 1 to 2 ml and granules for the base layer or decorative layer is used as the raw material for the humidity control layer (Japanese Patent Application No. 62-271407). In the case where the humidity control layer is composed of a lattice-shaped foam and a humidity control raw material filled in the openings of the lattice (Japanese Patent Application No. 62-271408
The humidity control function of the obtained ceramic plate is sufficient, but when cutting a large plate, the granules that have a humidity control function may fall out from the cut, and the strength of the humidity control part that is formed on the cut may be reduced. The problem was that it was small. This is because the moisture control function granules are granules, and the bonding strength of the fine particles is weak.Also, the reason why the moisture control function granules break down is that even when fired, the moisture control function granules do not weld and the bond between the granules cannot be changed. It is from.

Furthermore, even if the humidity control raw material is made into a sheet by a paper-forming method and buried, it still has a moisture function, but in order to interpose this paper-made sheet between the substrate layer and the decorative layer and integrate them by welding, it is necessary to A hole with a diameter of 4 to 5 mm must be made, the cosmetic raw material and the substrate raw material must be contacted and welded through the hole, and the humidity control sheet that is not welded must be held. In this way, a step of punching holes in the sheet becomes necessary, and about 30% of raw material is lost in the holes, which causes an increase in manufacturing costs.

SUMMARY OF THE INVENTION In view of the above-mentioned problem, the present invention aims to provide a ceramic plate that eliminates the drawbacks of the prior art. That is, an object of the present invention is to provide a ceramic plate having a humidity control function that prevents humidity control raw materials from spilling from the cut portions and prevents the decorative layer from peeling off.

[Means for Solving the Problems] The ceramic plate having a humidity control function of the present invention includes a closed pore base layer formed by heating and foaming an expandable inorganic granule, and a humidity control raw material formed on the base layer. The base layer, the ceramic sheet, and the decorative layer are solvated by firing. It is characterized by being integrated.

[Example] Hereinafter, the ceramic plate of the present invention will be explained based on the attached drawings.

The independent porosity base layer (1) is mainly made of acid clay, anti-firestone, shirasu, perlite, etc., and contains solvents such as soda ash, glass powder, sodium nitrate, boric acid, borax, water glass, etc., and dolomite. ,S]C.

The raw material is dry-pulverized to about 96% or more of 325 mesh bath with supplementary foaming agents such as potassium carbonate and soda carbonate, and is then reduced to a particle size of 1 to 2 using a pan-type granulator, for example.
．． This layer is made by heating and foaming granules that have been granulated to about 51 mm. The granulated product is used after being granulated and then dried.

It is preferable to embed a reinforcing material such as a lath net inside the base layer (1) in order to maintain the strength of the ceramic plate.

The thickness of the base layer (1) is not particularly limited in the present invention, but is approximately 15 to 25 sv.

(2) is a reticulated ceramic sheet placed on the base layer (1). The sheet (2) has a wire diameter of 0, for example.
．． Organic fiber net (3
) to which a slurry-like humidity control material, which will be described later, is attached. The sheet (2) is made by first soaking the fiber net (3) in a 7% solution of magnesium chloride or a 10% solution of potash water glass containing a sizing agent such as PVA or CMC, and then drying it. It can be obtained by immersing (3) in a wet-pulverized slurry of activated alumina with the addition of sepiolite or zeolite as a binder, or by pouring the slurry over a fiber net (3). Fiber net (3
) is immersed in the slurry, the slurry becomes entangled with and adheres to the fibers constituting the net (3). Although the openings of the fiber net (3) become smaller due to the adhesion of the slurry, it is necessary to select the fiber net so that the expandable inorganic granules can pass through the openings in this state. Humidity control raw materials containing activated alumina solidify and retain their shape through firing, but
Since it is not dissolved and integrated with the base layer or decorative layer, the granules for the decorative layer charged on the ceramic sheet or the granules for the base layer on the sheet pass through the mesh of the fiber net and become the granules for the base layer. Alternatively, it is solubilized and integrated with the granules for the decorative layer to wrap and hold the net containing activated alumina. Therefore, the size of the mesh needs to be selected so that the granulated granules for the decorative layer or the base layer can come into contact with the granules for the base layer or the decorative layer as much as possible. Specifically, when using granules for the decorative layer with a particle size of about 1 to 2.511 m, a fiber net with openings of about 5 to IOam is used, taking into account the adhesion of slurry to the fiber net. Is it necessary to select

Although the thickness of the ceramic sheet (2) is not particularly limited in the present invention, it is generally 2 to 4 mm.

As raw materials for the open-pored decorative layer (4), blended raw materials in which feldspar, soda ash, sodium nitrate, dolomite, zirconite, zinc white, limestone, glass powder, zircon frit, etc. are appropriately combined can be used. Examples of such combinations include combinations of feldspar, soda ash, zirconite, zinc white, limestone, and zircon frit, and combinations of feldspar, soda ash, zirconite, zircon frit, and glass powder. The raw materials are dry-pulverized and then used in a pan-type granulator to give a powder of 0.5 to 1
．． Particles granulated to about 5 ms can be used.

Granules for the decorative layer need to be formulated in such a way that they do not melt and bond or vitrify at the point of contact between grains, filling the grain boundaries, or foaming too much to fill all the grain boundaries. There is. Specifically, by reducing the foaming rate, continuous pores can be left after foaming. That is, when the foaming rate is small, the particles melted and foamed by heating form a layer by point adhesion, leaving pores at the grain boundaries between the grains. When the foaming rate is high, the grain boundaries are crushed by the increased grain volume and pressure, and continuous pores disappear, but when the foaming rate is low, continuous pores remain after foaming. Moisture or moisture passes through the communication holes left in this decorative layer and is adsorbed by the humidity control material in the ceramic sheet, and when the indoor humidity decreases, the moisture discharged from the humidity control material passes through the communication holes. and is discharged indoors. In this way, the indoor humidity is always controlled to a comfortable level.

The basic composition of the decorative layer is preferably adjusted so that it is white so that it can be colored freely, and it is also preferably softened so that a relief pattern can be applied by rolling.

The design of the surface of the makeup layer (4) can be freely colored with pigments, and various expressions can be given by mixing the colored particles, adjusting the gloss, and the degree of solubilization, but in any case, it is always It is important to maintain continuous pores without filling grain boundaries.

The thickness of the decorative layer is not particularly limited to the thickness of other interlayers such as the base layer, but it is generally 3 to 5 II 1 m as a guide.

In the ceramic plate of the present invention, a wet-pulverized humidity control raw material in the form of a slurry is attached to a continuous net-like ceramic sheet, so that the humidity control raw material particles are strongly bonded to each other. Therefore, the humidity control raw material does not spill out when the ceramic plate is cut, and the strength of the cut humidity control layer (ceramic sheet) can be increased.

The ceramic plate of the present invention is produced by placing the above-mentioned base layer granules in a layered manner on a heat-resistant mesh belt or the like, and then laminating the ceramic sheet and the decorative layer granules in this order. It is manufactured by transporting the body into a firing furnace such as a tunnel kiln or roller hearth kiln, and heating and firing it to make it into one piece.

Next, the ceramic plate of the present invention will be explained based on Examples, but the present invention is not limited to these Examples.

Example 1 Preparation of granules for base layer Oya stone 6445% (weight %, same hereinafter), water glass powder 5
%, soda ash 18%, royal talc 12% and SiC0
, 5% was placed in a ball mill with 10 mm steel balls and dry ground for 5 hours.

The resulting powder had a size greater than 96% of the 325 mesh pass.

This powder was granulated using a pan-type granulator while spraying a binder liquid (molasses 15% aqueous solution) to obtain granules having a particle size of 1 to 2.5 square meters. 20 The granulated product was dried in a viblift transfer hot air dryer so that the moisture content of the granules was 3% or less.

Preparation of ceramic sheet A square sheet (100cm x 100C!) of fiber net (Jumbo Net (trade name) manufactured by Kanayama Lace) with an opening of 10m x 6mm and a wire diameter of 0.5cm is added to 3g of water and 8 pieces of bittern.
90 and GL-05 (product name. Nippon Gosei PV^)
It was soaked in a solution containing 49ii and dried.

On the other hand, 60 parts by weight of C-303 (trade name, dried aluminum hydroxide manufactured by Sumitomo Chemical ■) and C-31 (trade name).

80 parts by weight of aluminum hydroxide, 20 parts by weight of dried aluminum hydroxide manufactured by Sumitomo Chemical ■, and 20 parts by weight of sepiolite.
Parts by weight, 0.7 parts by weight of defrosting agent (Poise 530), 6 parts by weight of water
A blended raw material containing 0 parts by weight was placed in a pot mill together with porcelain balls and wet-pulverized for 2 hours to obtain a slurry-like humidity control raw material.

The fiber net is immersed in this slurry-like humidity control raw material,
A humidity control raw material was attached to the net.

Preparation of granules for decorative layer 54% feldspar powder, 20% glass, 14% soda ash, 296% sodium nitrate, 3% dolomite and 796 zirconite
The mixed raw material consisting of the following was put into a pot mill together with 1 Dmm steel balls and dry-milled for 3 hours. The powder obtained had a size of more than 325 mesh baths and 9696 mesh baths.

Add binder liquid (monard gum 0.5% solution) to this powder.
is granulated using a pan-type granulator while spraying to obtain a particle size of 0.5 to 1.
, 0+++ll1O granules were obtained. The moisture content of the granules was 15%. 20 The granulated material was dried in a pipe lift rotating hot air dryer so that the moisture content of the granulated material was 3% or less.

Alumina was applied as a mold release material onto a medium 1m heat-resistant mesh belt for conveyance built in a tunnel furnace with a total length of 89m, and the base layer granules prepared in advance were coated on top of it to a thickness of 8G.
It was charged to form a layer of I11. At that time, a lath mesh synchronized with the speed of the mesh belt was inserted and buried at the position of the mesh belt L51II11.

Next, the prepared ceramic sheet was placed on top of the granules for the base layer, and then the opening of the hopper containing the granules for the decorative layer was opened on top of the sheet, and a layer of 4 cm thick was placed on top of the sheet. It was automatically charged to form. The obtained laminate is 20cm/
The sample was transferred to a preheating zone at a speed of 1 minute, and passed through a firing zone with a maximum temperature of 870°C, a rapid cooling zone, a gradual cooling zone, and a cooling zone to complete firing. The time required from loading to unloading was approximately 200 minutes.

The obtained ceramic plate is r190cm, length 100CO
The base layer was a foam with closed pores, and there was a white humidity control layer on top of the foam.

The humidity control layer was hard and hardened, did not break even when poked with a nail, and was firmly held by the base layer and decorative layer.

The decorative layer was made of white foamed grains, and each foamed grain was slightly foamed and welded at the contact points of the grains, but the grain boundaries remained and continuous pores were maintained.

When water is dropped from above the makeup layer, it does not absorb water instantly, but it absorbs water within a few seconds. The surface of the decorative layer was a flat surface with small irregularities, and the concave portions had the ends of communicating holes, allowing the glossy decorative ceramic plate to be scaled.

Example 2 Preparation of Granulated Material for Decorative Layer A white brick was coarsely crushed using a crusher and further finely crushed using a roll crusher to obtain crushed granules having a particle size of 0.5 to 11 Il. To 100 parts by weight of the obtained crushed grains, 30 parts of C-3 frit (trade name: Frit manufactured by Kasai Glaze Co., Ltd.) was added using a pan-type granulator while spraying a binder (3% isopane solution). Coated.

A ceramic plate was produced in the same manner as in Example 1 except that the thus coated granules were used as the granules for the decorative layer.

The decorative layer of the resulting ceramic plate had a shiny ``Juraku wall''-like surface. The crushed grains of white brick were encased in a glassy skin and had a weak luster. Each layer was fused by the glass skin, but there were more grain boundaries than in the decorative layer in Example 1, and when water was dropped from above, it was instantly absorbed. In the example, the coating is transparent, but if the frit to be coated is colored, any color tone can be obtained.

Next, the ceramic plate obtained in Example 1 was heated to 301 il.
A test piece was prepared by cutting into a size of ×301III and sealing the end and back side with silicone resin. Each test piece was placed in constant temperature and humidity layer A (25℃,
40%R11) and constant temperature and humidity layer B (25℃, 80%R
11), and after the weight became constant, the test piece of the constant temperature and humidity layer ASB was replaced, and the amount of moisture absorption and desorption of the test piece over time was measured. The results are shown in Figure 3. For comparison, similar tests were conducted on cedar (thickness: 7.4 mm) and inorganic cloth gypsum board (thickness: 9 am).

The moisture absorbing and desorbing ceramic board had a much greater humidity control speed and capacity than cedar and inorganic cloth gypsum boards, and showed better humidity control ability than conventional products.

[Effects of the Invention] As explained above, according to the ceramic plate of the present invention,
Since we do not use granular humidity control raw materials and instead use a sheet of fiber net coated with slurry humidity control raw materials as the humidity control layer, when the ceramic board is cut, the humidity control raw materials will spill out from the cut surface. This has the effect of improving the strength of the humidity control layer.

FIG. 1 is a schematic explanatory diagram of an embodiment of the ceramic plate of the present invention, FIG. 2a is a schematic explanatory diagram of a fiber net before slurry is attached, FIG. 2b is a schematic explanatory diagram of a fiber net after slurry is attached, and FIG. The figure is a graph showing the results of measuring the amount of moisture absorption and release of the ceramic board, cedar board, and gypsum board according to Example 1.

(Main symbols on drawings) (1) Two layers (2) Ceramic sheet (3): Makeup layer

Claims (1)

[Scope of Claims] 1. A closed-pore base layer formed by heating and foaming an expandable inorganic granule, a reticulated ceramic sheet containing a humidity control raw material formed on the base layer, and a reticulated ceramic sheet containing a humidity control raw material formed on the base layer; and a decorative layer with open pores formed by heating and foaming foamable inorganic granules, the base layer, the ceramic sheet, and the decorative layer being melted and integrated by firing. Ceramic plate with. 2. The ceramic plate according to claim 1, wherein the humidity control raw material contains activated alumina as a main component and at least one of zeolite and sepiolite. 3. Claim 1, wherein the ceramic sheet is a net made of organic fibers to which a humidity control raw material in a slurry state is adhered.
Ceramic plate as described. 4. The ceramic plate according to claim 3, wherein the pore size of the mesh of the ceramic sheet to which the humidity control raw material is attached is larger than the particle size of the expandable inorganic granules constituting the base layer or the decorative layer.