JP2012250899A - Method of forming abrasion-resistant layer - Google Patents
Method of forming abrasion-resistant layer Download PDFInfo
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- JP2012250899A JP2012250899A JP2011135730A JP2011135730A JP2012250899A JP 2012250899 A JP2012250899 A JP 2012250899A JP 2011135730 A JP2011135730 A JP 2011135730A JP 2011135730 A JP2011135730 A JP 2011135730A JP 2012250899 A JP2012250899 A JP 2012250899A
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本発明は床用セラミックスタイル(以下、タイル)の耐摩耗性に関する。詳しくは舗道や駅構内において用いられる、通行誘導や施設案内のためのデザイン画像を印刷したタイルに、ノンスリップ性の耐摩耗層を形成する技術に関する。 The present invention relates to the wear resistance of a ceramic style for floors (hereinafter, tile). More specifically, the present invention relates to a technique for forming a non-slip wear-resistant layer on a tile printed with a design image for traffic guidance and facility guidance used in a pavement or a station premises.
駅構内や舗道などの床面にはタイルを貼ることが一般的である。一方、その床面に通行誘導、避難誘導、施設案内、禁煙区域などの標識を表示するニーズが高まっている。この目的のためフイルムにデザイン画像を印刷した上に、ガラスビーズを埋め込んだ保護フイルムをオーバーラミネートしたものを貼付することが行なわれている。しかし、大都市の駅構内や駅近辺の舗道などにおいては、毎日の通行人数が膨大で、一日当たり数万以上に達するところもありフイルム製では耐久性がない。しかも汚れやすく、周辺部が剥がれやすいという問題もある。 It is common to place tiles on the floors of stations and pavements. On the other hand, there is a growing need to display signs such as traffic guidance, evacuation guidance, facility guidance, and non-smoking areas on the floor. For this purpose, a design image is printed on a film, and a protective film in which glass beads are embedded is over-laminated. However, the number of people passing by on the streets of large cities and in the vicinity of the station is enormous, and there are places where the number reaches more than tens of thousands per day. In addition, there is a problem that it is easily soiled and the peripheral portion is easily peeled off.
上記のような有機の材料ではなく、耐磨耗性に優れた焼成印刷を利用する方式も提案されている。タイルにデザイン画像を焼成印刷する方式としては大量生産用のスクリーン印刷以外に、印刷版を必要としないオンデマンド方式も実用化されている。例えば本発明者が開示した「接着記録方法」(特開2005−161828号公報)である。これはインクジェットプリンタを用いて、アルコールを溶媒とする接着性インクを噴射してタイルに接着性画像を印刷し、その上に焼成顔料を付着させ焼成する方法である。これらの方法で焼成印刷したタイル表面は硬度や耐光性に優れているが、床面に施工した場合の耐摩耗性という点では十分ではない。何故なら、その印刷層の厚みは10数μ程度に過ぎないからである。産官学で組織された床材料磨耗試験委員会の昭和43年の報告によれば、12万人の駅改札口通過により磁器タイル表面は3.4μ磨耗したとあり、施工場所にもよるが印刷層の上に、更にノンスリップ性の100μクラス以上の耐磨耗性の保護層を積層することが要請される。 Instead of the organic materials as described above, a method using baking printing having excellent wear resistance has been proposed. In addition to screen printing for mass production, an on-demand method that does not require a printing plate has been put to practical use as a method for baking and printing design images on tiles. For example, the “adhesion recording method” disclosed in the present inventor (Japanese Patent Laid-Open No. 2005-161828). This is a method in which an adhesive image using an alcohol as a solvent is ejected by using an ink jet printer to print an adhesive image on a tile, and a fired pigment is adhered thereon and fired. The tile surface fired and printed by these methods is excellent in hardness and light resistance, but is not sufficient in terms of wear resistance when applied to the floor surface. This is because the thickness of the printed layer is only about a few tens of microns. According to a report in 1968 of the Floor Material Abrasion Test Committee organized by industry, government, and academia, the surface of porcelain tiles was worn by 120,000 through the ticket gates of 120,000 people. It is required to further laminate a non-slip 100 μ class or more wear-resistant protective layer on the layer.
しかし、印刷層の上にこのような厚膜の平らなガラス質の保護層を形成することは容易ではない。スクリーン印刷による厚膜のベタ印刷でも積層出来る厚みはせいぜい数10μ程度である。また例え所望の厚みの平らなガラス質の保護層を積層出来たとしても、ガラス質自体は硬度は高くなく(モース硬度5程度)、また表面はスリップ性があり、未だ完全な解決ではない。 However, it is not easy to form such a thick flat glassy protective layer on the printed layer. The thickness that can be laminated even by solid printing of a thick film by screen printing is about several tens of microns at most. Further, even if a flat glassy protective layer having a desired thickness can be laminated, the glassy material itself does not have a high hardness (Mohs hardness of about 5), and the surface is slippery, which is not yet a complete solution.
このような事情から焼成印刷を利用する場合、以下のような方法が一部で実用化されているに過ぎない。即ち、表面に砂粒大の骨材が多数突出している特製の粗面タイルにスクリーン印刷を行ない焼成する方法である。この場合突出した骨材が保護して、谷間の印刷層が直接に靴底で摩擦されることが少ないので多少の耐磨耗性を有するが未だ十分ではない。しかも製版印刷のため高コストで小ロット対応が出来ないとともに、突起部周りの印刷画像がすぐに摩滅してしまうという問題もある。 Under these circumstances, when using baked printing, the following methods are only partly put into practical use. That is, it is a method in which screen printing is performed on a special rough surface tile having a large number of aggregates of sand grains protruding on the surface, followed by firing. In this case, the protruding aggregate protects and the printed layer between the valleys is less likely to be directly rubbed by the shoe sole, so it has some wear resistance, but it is still not sufficient. In addition, because of plate-making printing, there is a problem that it is not possible to deal with a small lot at a high cost, and the printed image around the protruding portion is quickly worn out.
故に本発明の課題は、デザイン画像が印刷されたタイル上に、耐摩耗性に優れたノンスリップ性の保護層を積層することにある。 Therefore, the subject of this invention is laminating | stacking the non-slip-proof protective layer excellent in abrasion resistance on the tile on which the design image was printed.
本発明者は鋭意検討の結果、デザイン画像が印刷されたタイル表面の全面に、まず微細な接着性ドットを疎らに印刷し、その上に細かく分級されていて、かつ焼成温度では熔融しないセラミックス骨材(以下、骨材)を付着させ、しかるのち骨材間の空隙にガラス体を積層したあと焼成することにより、印刷された接着性ドットに対し、ほぼ1対1の比率で骨材を付着出来るとともに、これが一定の散在密度以内であれば、下部に位置するデザイン画像の透視性をほとんど阻害しないこと、および、所定の厚みのガラス層を平らに積層出来るとともに、タイルベースからガラス層を貫通し表面に突出した構造で骨材を強固に固着出来ること、を見出し本発明に到達したものである。 As a result of diligent study, the inventor has first printed fine adhesive dots on the entire surface of the tile surface on which the design image has been printed. Adhesive material (hereinafter referred to as “aggregate”) is adhered, and then the glass body is laminated in the gaps between the aggregates and then fired, so that the aggregate is adhered to the printed adhesive dots at a ratio of about 1: 1. As long as it is within a certain density, it hardly disturbs the transparency of the design image located at the bottom, and a glass layer with a predetermined thickness can be laminated flat and penetrated from the tile base to the glass layer. The inventors have found that the aggregate can be firmly fixed with a structure protruding from the surface, and the present invention has been achieved.
微細な接着性ドットを印刷するには、粘着性物質を微細にドット状に印刷出来る方法であれば、インクジェット印刷、スクリーン印刷など何れの方法でもよい。インクジェット印刷の場合は、骨材を付着させるに足る粘着性のインクであれば、水性、溶剤、油性、UVなど何れでもよい。またスクリーン印刷の場合はクリアワニスなどを使用すればよい。印刷される接着性ドットの大きさは、粒径0.1〜0.5mm、好ましくは0.15〜0.3mm程度である。本発明においては、これらの接着性ドットにほぼ1個の骨材が付着することを特徴とする。このため骨材の大きさは接着性ドットの大きさに対応する必要がある。上記サイズに対応する骨材の大きさは、おおよそ平均粒径100〜200μで、しかも細かい範囲に分級されているものである。200μ以上のサイズの骨材が付着すると、それが如何に疎らに散在していても、下部のデザイン画像の良好な透視性は阻害される。 In order to print fine adhesive dots, any method such as ink jet printing or screen printing may be used as long as the adhesive substance can be printed in a fine dot shape. In the case of inkjet printing, any ink such as water, solvent, oil, and UV may be used as long as it is a sticky ink sufficient to adhere aggregate. In the case of screen printing, a clear varnish may be used. The size of the adhesive dots to be printed is about 0.1 to 0.5 mm, preferably about 0.15 to 0.3 mm. In the present invention, approximately one aggregate adheres to these adhesive dots. For this reason, the size of the aggregate needs to correspond to the size of the adhesive dots. The size of the aggregate corresponding to the above size is approximately an average particle size of 100 to 200 μm and is classified into a fine range. When aggregates having a size of 200 μm or more are attached, good transparency of the lower design image is hindered no matter how loosely scattered the aggregate is.
付着させる骨材の平均粒径を100〜200μと前提したとき、下部のデザイン画像の明瞭透視性を許容する骨材の散在密度は、平方cm当たり80〜400個程度である。より好ましくは120〜250個程度である。これより少ないと透視性は一層増すが、耐磨耗性を発揮する中心材料であるべきアルミナが不足するからである。これより大きいと耐磨耗性は増すが透視性は格段に劣ってくる。この範囲において明瞭透視性とJIS規格で定める耐磨耗性がほぼ両立する。なお耐スリップ性はアルミナの表面突出の構造から、これらの全範囲で良好である。ここにおいては骨材が狭い範囲に分級されていることが重要である。骨材に分級範囲外の細かな骨材が混じっていると、それが優先して先に接着性ドットに付着してしまい、意図した大きさの骨材が付着出来ないからである。骨材が一定の範囲の大きさであれば、付着した骨材の上面レベルもほぼ一定化する。その骨材間の空隙をガラス体で埋めることにより、容易に所定の厚みのガラス層を平らに積層出来る。骨材は焼成時に熔融しない白色もしくは透明なセラミックスである。このような骨材として好ましいのは硬度が極めて高いアルミナやジルコニアである。特にアルミナは品番ごとに粒径を細かく分級して市販されており、本発明に極めて好都合である。本発明においては品番100(105〜125μ)から品番80(150〜180μ)くらいまでの範囲が対象となる。もし品番80のアルミナを付着させたとすれば、平均的にみてアルミナのトップを結ぶ仮想平面はタイルベースから150〜180μの範囲の高さに位置しているとみて差し支えない。 Assuming that the average particle size of the aggregate to be adhered is 100 to 200 μm, the scattered density of the aggregate that allows clear transparency of the lower design image is about 80 to 400 per square centimeter. More preferably, it is about 120-250 pieces. If the amount is less than this, the transparency is further increased, but there is a shortage of alumina which should be the central material exhibiting wear resistance. If it is larger than this, the wear resistance is increased, but the transparency is significantly inferior. In this range, clear transparency and wear resistance defined by JIS standards are almost compatible. Note that the slip resistance is good in the entire range because of the surface protrusion structure of alumina. Here, it is important that the aggregate is classified into a narrow range. This is because if fine aggregate outside the classification range is mixed in the aggregate, it will preferentially adhere to the adhesive dots first, and the aggregate of the intended size cannot be adhered. If the aggregate size is within a certain range, the upper surface level of the adhered aggregate is also almost constant. By filling the gaps between the aggregates with a glass body, a glass layer having a predetermined thickness can be easily laminated flatly. Aggregates are white or transparent ceramics that do not melt during firing. Preferred as such an aggregate is alumina or zirconia having extremely high hardness. In particular, alumina is commercially available after finely classifying the particle size for each product number, which is very convenient for the present invention. In the present invention, the range from the product number 100 (105 to 125 μ) to the product number 80 (150 to 180 μ) is an object. If alumina of product number 80 is attached, it can be assumed that on average, the imaginary plane connecting the tops of alumina is located at a height in the range of 150 to 180 μm from the tile base.
ガラス体としては長石、珪石、石灰、硼砂などを調合・粉砕したガラス粉末が好ましい。これを熔融して球状化したビーズであってもよい。本発明においてはガラス層が厚膜になりタイルとの膨張率の差でクラックが入りやすくなるので、ガラス体はタイルに合わせて熱膨張率の小さい処方にする。ガラス体を積層するには、ガラス粉末をタイルに盛り骨材の上面レベルでレベラーを水平に引き余剰粉を除去する方法や、オイルなどでペースト状に練ってレベラーで引き方法に依ればよい。粉末で使用する場合ガラス粉末は流動性がいいように、平均粒径20〜100μ程度、好ましくは40〜80μ程度の範囲のものが好ましい。このようにして積層されたガラス体は焼成段階で熔融したとき上面位置が20%程度沈下する。粉末の場合は空隙が充填されるからであり、ペーストの場合はオイル等が滅失するからである。この結果、ほぼ全部の骨材の上部がガラス層の上に突出する。突出した部分の高さはガラス体の積層具合で自由に加減可能である。焼成温度は一般にガラス体が熔融する850℃程度でよいが、高温用ガラス体の場合であれば1100℃程度である。 As the glass body, glass powder prepared by mixing and pulverizing feldspar, silica, lime, borax and the like is preferable. It may be a bead obtained by melting this into a spheroid. In the present invention, since the glass layer becomes thick and cracks easily occur due to the difference in expansion coefficient from the tile, the glass body is formulated to have a low thermal expansion coefficient in accordance with the tile. To laminate the glass body, glass powder is tiled and the leveler is pulled horizontally at the upper surface level of the aggregate, or the excess powder is removed, or the powder is kneaded into a paste with oil or the like and pulled by the leveler. . When used as a powder, the glass powder preferably has an average particle size of about 20 to 100 μm, and preferably about 40 to 80 μm so that the fluidity is good. When the glass bodies laminated in this way are melted in the firing stage, the upper surface position sinks by about 20%. This is because voids are filled in the case of powder, and oil and the like are lost in the case of paste. As a result, almost the entire upper part of the aggregate protrudes above the glass layer. The height of the protruding portion can be freely adjusted depending on the degree of lamination of the glass bodies. The firing temperature may generally be about 850 ° C. at which the glass body melts, but in the case of a high-temperature glass body, it is about 1100 ° C.
本発明により、焼成印刷されたデザイン画像上に厚み100μクラス以上のガラス質と大粒のアルミナよりなる耐磨耗層が積層されるので、磨耗がデザイン画像層に達するまで膨大な人数の通行に耐えることが出来る。またアルミナがベースから表面までガラス層を貫通して固着している構造なので、最後まで剥落することがなく、かつ透視性も良好である。経時的にガラス層が磨耗していっても、硬度の数段高いアルミナ(モース硬度9)は磨耗しながらも依然表面に突出する仕組みになるので、耐磨耗性に大いに寄与するとともに、ノンスリップ性を最後まで発揮し続けることが出来る。 According to the present invention, a wear-resistant layer made of a glass material having a thickness of 100 μm or more and large alumina is laminated on a fire-printed design image, so that it can withstand a large number of people until the wear reaches the design image layer. I can do it. In addition, since alumina has a structure in which the glass layer penetrates and adheres from the base to the surface, it does not peel off to the end and has good transparency. Even if the glass layer wears over time, alumina (Mohs hardness 9), which is several steps higher in hardness, still protrudes to the surface while being worn, thus contributing greatly to wear resistance and non-slip You can continue to show your sex.
前記した如く本発明は多様な実施形態を有するが、本実施例においては特許請求の範囲に記す耐磨耗層の形成方法に絞って本発明のエッセンスを示す。使用したインクジェットプリンタはピエゾ方式のエプソンヘッドを搭載したフラットベッド型のGP−604(商標、ミマキエンジニアリング社製)である。 As described above, the present invention has various embodiments. In this example, the essence of the present invention is shown by focusing on the method for forming the wear-resistant layer described in the claims. The ink jet printer used is a flat bed type GP-604 (trademark, manufactured by Mimaki Engineering Co., Ltd.) equipped with a piezo type Epson head.
以下の組成の接着性インクを調製しGP−604の黒インクカートリッジにセットした。
アルコール可溶アクリル樹脂
「エルバサイト」(商標、Dupont社製) 4%
ロジンエステル 3%
フタル酸ジメチル 3%
イソプロピルアルコール 40%
2−エトキシエタノール 50%
次にデザイン画像が焼成印刷された40cm角で厚さ13mmのタイルに、GP−604の黒インク単独印刷モードで、噴射量を最大にして接着性ドットを均一に疎らに印刷した。このときの平方cm当たりの印刷ドット数は平均160個であった。An adhesive ink having the following composition was prepared and set in a black ink cartridge of GP-604.
Alcohol soluble acrylic resin
"Elbasite" (trademark, manufactured by Dupont) 4%
Rosin ester 3%
Dimethyl phthalate 3%
Isopropyl alcohol 40%
2-Ethoxyethanol 50%
Next, adhesive dots were uniformly and sparsely printed on a 40 cm square tile having a thickness of 13 mm on which the design image was baked and printed, using the GP-604 black ink single print mode with the maximum ejection amount. At this time, the average number of printed dots per square centimeter was 160.
この上に品番80のアルミナを散布して付着させ余剰粉をブラシで除去した。そのあと平均粒径50μのガラス粉末を盛り、付着したアルミナの上面レベルでレベラーを水平に引き余剰粉を除去した。この一体物を850℃で焼成した結果、130μ程度の厚さのガラス層が積層されており、かつ表面にアルミナが突出したタイルを得た。このときデザイン画像は加工前の原タイルと較べて同等レベルに明瞭に透視できた。 The alumina of the product number 80 was sprinkled and adhered on this, and the excess powder was removed with the brush. Thereafter, glass powder having an average particle size of 50 μm was piled up, and a leveler was horizontally drawn at the upper surface level of the adhered alumina to remove excess powder. As a result of firing this monolith at 850 ° C., a tile having a glass layer with a thickness of about 130 μm and alumina protruding on the surface was obtained. At this time, the design image could be clearly seen on the same level as the original tile before processing.
このタイルを用いて、まずJIS A 1509−12「陶磁器タイル試験方法−第12部 耐滑り性試験方法」に則って滑り抵抗値(CSR値)の測定をおこなった。この試験は路上粉塵を想定して関東ロームの火山灰土を焼成・分級して標準化したものなどと、水を一定比率で混合して試験タイル上に敷き、耐滑り性を評価する試験である。その結果、滑り抵抗値は平均7.1という極めて良好な数値であった。 Using this tile, the sliding resistance value (CSR value) was first measured according to JIS A 1509-12 “Ceramic Tile Test Method—Part 12 Slip Resistance Test Method”. This test is a test to evaluate slip resistance by mixing water at a certain ratio with standardized by burning and classifying volcanic ash soil of Kanto Loam assuming road dust and spreading it on a test tile. As a result, the slip resistance value was an extremely good value of 7.1 on average.
次にJIS A 1509−6「施釉床タイルの耐磨耗試験」に準じて試験をおこなった。この試験は水中に試験タイルを配置し、その上に直径5mm、3mm、2mm、1mmの所定量の鋼球、およびごく少量のアルミナよりなる摩擦材料を置き、全体を回転させ表面を磨耗させる試験である。回転数は100回転、150回転、600回転、750回転、1500回転、2100回転、6000回転、12000回転と8段階を規定し、各段階で劣化状況により合否判定する。最高の12000回転において変化が認められなければ、施釉床タイルとして一番ハードな場所に施工してよいとされる。 Next, a test was conducted according to JIS A 1509-6 “Abrasion resistance test of glazed floor tile”. In this test, a test tile is placed in water, a predetermined amount of steel balls with a diameter of 5 mm, 3 mm, 2 mm, 1 mm and a friction material made of a very small amount of alumina are placed on it, and the entire surface is rotated to wear the surface. It is. The number of rotations is defined as eight stages: 100 revolutions, 150 revolutions, 600 revolutions, 750 revolutions, 1500 revolutions, 2100 revolutions, 6000 revolutions, and 12,000 revolutions, and pass / fail judgment is made at each stage according to the deterioration state. If no change is observed at the maximum 12,000 revolutions, it is said that the glazed floor tile may be constructed in the hardest place.
この試験を準用と述べたのは、同一色の釉薬がベースから表面まで熔着している施釉タイルと異なり、試験タイルがベースにデザイン画像があり、その上を透明な厚膜のガラス質が覆っているという2層構造のため、ガラス質表面が磨耗で傷付くと光が表面で乱反射して白みを帯び、初期の段階から多少変化が見られるという事情があるからである。しかし、ベースのデザイン画像が露出するまでの磨耗プロセスにより、施釉タイルと同一基準で耐摩耗性を判定することには妥当性がある。本試験では6000回転、12000回転、30000回転、50000回転の4ケースを行い、原タイルと比較した。この結果、6000回転、12000回転、更に30000回転でも磨耗はデザイン画像にまでは達しておらず、最高回転数の4倍以上の50000回転でも結果は同様であった。 This test is said to be applied mutatis mutandis, unlike glazed tiles in which the same color of glaze is welded from the base to the surface. This is because, due to the two-layer structure of covering, when the glassy surface is damaged due to wear, the light is irregularly reflected on the surface and becomes white, and a slight change can be seen from the initial stage. However, it is reasonable to determine the wear resistance on the same basis as the glazed tile by the wear process until the base design image is exposed. In this test, 4 cases of 6000 rpm, 12000 rpm, 30000 rpm, and 50000 rpm were performed and compared with the original tile. As a result, the wear did not reach the design image even at 6000 rpm, 12000 rpm, and even 30000 rpm, and the result was the same at 50000 rpm, which is four times or more the maximum number of revolutions.
本発明により、毎日の人の通行が膨大な駅構内や舗道用に、耐摩耗性およびノンスリップ性に極めて優れたデザイン画像付きタイルを安価に提供することが可能となる。According to the present invention, a tile with a design image that is extremely excellent in wear resistance and non-slip property can be provided at low cost for a station yard or a pavement where daily traffic is huge.
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JPS5378629A (en) * | 1976-12-20 | 1978-07-12 | Ina Seito Kk | Antiskid interior finish tile and method of producing same |
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