JPS59111986A - Dressing material fusion-adhered foam lightweight body - Google Patents

Abstract

(57)【要約】本公報は電子出願前の出願データであるた
め要約のデータは記録されません。(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

【発明の詳細な説明】 本発明は無機質の化粧材融着発泡軽量体に関する。詳し
くは、無機系発泡体用材料の発泡化と同時に少くともそ
の一面に無機系化粧材を融着一体化した無機質化粧発泡
軽量体、およびその製法に関する。DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a lightweight inorganic decorative foamed body. Specifically, the present invention relates to a lightweight inorganic decorative foam in which an inorganic foam material is foamed and at least one surface of the inorganic decorative material is fused and integrated, and a method for producing the same.

従来、この種類の無機系化粧発泡体は、無機系発泡軽量
体を先ず製造し、次いで（ｉ　）該発泡体の表面に釉薬
等を塗布して燃焼又は溶射すること体の表面に接着剤を
用いてタイル等の化粧材を貼着して化粧仕上げすること
によって、製造されてぎた。上記の化粧発泡体（１ンは
焼成が二段階であるほかに、釉薬によって発泡体の粗表
面を充分に化粧するのはかなり困難であり、また、下塗
材を併用して溶射する場合には一般に剥離しやづ゛い恐
れ等があった。上記の化粧発泡体（ｉｉ）の場合、施工
の手数を要するほかに、無機接着剤（例えばセメント）
または有機接着剤のいずれを用いても耐熱接着性に限度
がある。これらの工程を簡略化した方法として、発泡材
料としてウレタン樹脂材料を用いて化粧材の裏面に硬質
ウレタン発泡層を発泡付着させた化粧プレートが開発提
案されている（特公昭４６〜３０１３８号）。しかしこ
の製品は、その有機材料に原因して高い温度での強度お
よび接着性に当然問題が存在する。更に、製造の際の有
毒性ガスの発生および連続気泡による吸水性の問題もあ
る。Conventionally, this type of inorganic decorative foam has been produced by first manufacturing a lightweight inorganic foam, and then (i) applying a glaze or the like to the surface of the foam and burning or spraying it; or applying an adhesive to the surface of the foam. It has been manufactured by using decorative materials such as tiles and applying a decorative finish. In addition to the above-mentioned decorative foam (1-N), which requires two stages of firing, it is quite difficult to sufficiently decorate the rough surface of the foam with glaze, and when thermal spraying is used in combination with a primer material, In general, there was a fear that it would be difficult to peel off.In the case of the above-mentioned decorative foam (ii), in addition to requiring a lot of work, inorganic adhesives (e.g. cement)
Or, no matter which organic adhesive is used, there is a limit to the heat-resistant adhesive properties. As a method to simplify these steps, a decorative plate has been developed and proposed in which a hard urethane foam layer is foam-adhered to the back surface of the decorative material using a urethane resin material as the foam material (Japanese Patent Publication No. 46-30138). However, this product naturally has problems with strength and adhesion at elevated temperatures due to its organic material. Furthermore, there are problems with the generation of toxic gases during production and water absorption due to open cells.

無機系材料の発泡化と同時にタイル等の化粧材を融着さ
せる本発明の態様に関して該化粧材を熱編成させずに無
機系材料を充分に発泡化する焼成条件では、両者間の充
分な強度のある融着一体化が達成不可能と従来考えられ
ていたようである。Regarding the aspect of the present invention in which a decorative material such as a tile is fused at the same time as the inorganic material is foamed, under firing conditions that sufficiently foam the inorganic material without thermally forming the decorative material, there is sufficient strength between the two. It appears that some fused integration was previously thought to be unattainable.

本発明者等は、珪酸塩系材料からなる裏面を有ターる化
粧材と溶化してガラス質を形成する珪酸塩系発泡体用材
料との組み合げによって、予想外にも、発泡化と同時に
両者間の満足な融着が達成できることを見出した。The present inventors have unexpectedly achieved foaming by combining a decorative material with a back surface made of a silicate material and a silicate foam material that dissolves to form a glassy material. At the same time, it was found that satisfactory fusion between the two could be achieved.

すなわち本発明によって、溶化ガラス質形成性珪酸塩系
発泡体の少くとも一表面に、珪酸塩系材料の裏面を有す
る化粧材をガラス質融着一体化してなることを特徴とす
る建材等として有用な無機質化粧材融着発泡軽量体が提
供される。That is, according to the present invention, a decorative material having a back surface of a silicate material is integrated with glassy fusion on at least one surface of a vitreous silicate foam, which is useful as a building material. A lightweight inorganic decorative material fused foam body is provided.

上記の化粧材融着発泡軽量体は、焼成用の枠（例えば匣
鉢）の枠面の少くとも一面（すなわち−面ないし複数面
）に上記の化粧材の裏面を内側にして配置し、該化粧材
の裏面に接して上記の発泡軽量体の発泡体用材料を充填
し、この系を該化粧材の熱変性未満の湿度そして該発泡
体用材料の溶化発泡温度以上にて焼成して該材料を溶化
発泡せしめると同時に両者を融着づ−ることを特徴とす
る製法によって効果的に製造できる。The above lightweight decorative material fused foam is placed on at least one side (i.e. - side or multiple sides) of the frame surface of a baking frame (for example, a sagger) with the back side of the above decorative material inside. The foam material for the lightweight foamed material described above is filled in contact with the back side of the decorative material, and this system is fired at a humidity lower than the thermal denaturation temperature of the decorative material and at a temperature higher than the melting and foaming temperature of the foam material. It can be effectively manufactured by a manufacturing method characterized by melting and foaming the materials and simultaneously fusing them together.

この製法において、該化粧材の少くとも裏面および該発
泡体用材料は珪酸塩系材料であり、焼成によって該発泡
体用材料が溶化して両者の接触面を漏らし、両者が珪酸
塩系の同化をするため、溶化した該材料が冷却するに従
って固化して両者間に強固な融着が達成される。なお、
上記の製法において、一般にその必要はないが該化粧材
と該発泡体用材料との接触界面に、発泡剤を含有しない
該発泡体用材料と実質的に同じガラス質形成性材料また
は融着性の大きいガラス系材料を小量存在させると、両
者間の融着性が更に増強される。In this manufacturing method, at least the back surface of the decorative material and the foam material are silicate-based materials, and upon firing, the foam material is dissolved and leaks through the contact surface between the two, and both are assimilated as silicate-based materials. Therefore, as the melted material cools, it solidifies and a strong fusion is achieved between the two. In addition,
In the above manufacturing method, although it is generally not necessary, at the contact interface between the decorative material and the foam material, a vitreous forming material or a fusion material that does not contain a blowing agent and is substantially the same as the foam material. When a small amount of a glass-based material with a large .

前記のカラス質形成性珪酸塩系発泡体用材料は、溶化し
てカラス質を形成する珪酸塩系材料の粉末および加熱焼
成時に気体を放出する有効量の粉末状発泡剤を含む粉状
ないし粒状の珪酸塩系材料である。The glass-forming silicate-based foam material described above is a powder or granular material containing a powder of a silicate-based material that dissolves to form a glass and an effective amount of a powdered blowing agent that releases gas when heated and fired. It is a silicate-based material.

該ガラス質形成性珪酸塩としては、抗火石（学名：波璃
雲母石英粗面岩）、火山灰（例えばシラス）、ガラス系
廃物材料、膨張頁岩、真珠岩、スラグおよびこれらの混
合物が例示される。該発泡剤には、例えば、炭化珪素、
窒化珪素、炭素、水力ラス、石こう、炭酸塩等、および
これらの氾合物が含まれる。該発泡剤は、希望する断熱
性能、高比重等の要求性能また発泡成分によって変化す
るが、本発明では重量％にて該発泡体用材料の約０．１
〜約２％、好ましくは約０．３〜約１．５％そして典型
的には約０．５〜約１％前後が使用できる。Examples of the glass-forming silicates include anti-pyrosite (scientific name: quartz trachyte), volcanic ash (e.g., shirasu), glassy waste materials, expanded shale, perlite, slag, and mixtures thereof. . The blowing agent includes, for example, silicon carbide,
Includes silicon nitride, carbon, hydraulic lath, gypsum, carbonates, etc., and their mixtures. The foaming agent varies depending on the required performance such as desired insulation performance and high specific gravity, and the foaming components, but in the present invention, it is used in an amount of about 0.1% by weight of the foam material.
Up to about 2%, preferably about 0.3 to about 1.5% and typically around about 0.5 to about 1% can be used.

上記の発泡材は珪酸塩材料および発泡体の物性等の観点
から当業者が容易に選定し得る。例えば、抗火石および
／または火山灰を主成分とする材料では、独立気泡の形
成並びに焼結性、熔融粘度、気体発生量等の制御の観点
から炭化珪素が好ましい。The above-mentioned foam material can be easily selected by those skilled in the art from the viewpoint of the silicate material and the physical properties of the foam. For example, in a material whose main component is anti-flinder and/or volcanic ash, silicon carbide is preferred from the viewpoint of forming closed cells and controlling sinterability, melt viscosity, amount of gas generated, and the like.

該珪酸塩系発泡体用材料には、前記のカラス質形成性珪
酸塩材料Ｊ５よび発泡剤のほかに、発泡状態を制御調節
するために、該材料の約４０％重量未満の量の泥岩（頁
岩、粘土岩、シルト岩等）そして代表的には頁岩、カオ
リン−１珪砂等が有利に使用できる。In addition to the glass-forming silicate material J5 and a blowing agent, the silicate foam material includes an amount of mudstone (less than about 40% by weight of the material) to control and adjust the foaming conditions. shale, claystone, siltstone, etc.) and typically shale, kaolin-1 silica sand, etc. can be advantageously used.

該化粧材は、少くもその裏面が珪酸塩系材料である無機
系化粧材から選ばれ、代表的には施釉セラミックタイル
および石材等が例示される。施釉タイルの場合は釉薬が
高温度熔融性のものが好ましい。The decorative material is selected from inorganic decorative materials whose back surface is made of a silicate material, and typical examples include glazed ceramic tiles and stone. In the case of glazed tiles, it is preferable that the glaze be one that melts at high temperatures.

前記の発泡融着の焼成条件は、材料に応じて変化し得る
が、一般的に約り００℃〜約１３００℃の焼成温度そし
て約０．５時間以上（例えば約１〜約８時間）の焼成時
間の範囲である。すなわち、上記の焼成条件は、使用材
料のほかに、所望の発泡性（気泡形、断熱性等）によっ
ても変化し得るが、例えば約９００°Ｃ〜約１２００℃
で約２時間以上の典型的な条件を基準として当業者が容
易に設定できる。The firing conditions for the foam fusion described above may vary depending on the material, but generally include a firing temperature of about 00°C to about 1300°C and a duration of about 0.5 hours or more (for example, about 1 to about 8 hours). Baking time range. That is, the above firing conditions can vary depending on the desired foaming properties (cell shape, heat insulation, etc.) in addition to the materials used, but for example, from about 900°C to about 1200°C.
Those skilled in the art can easily set the conditions based on typical conditions of about 2 hours or more.

前記のように匣鉢等の枠内に化粧材を配置し発泡体用材
料を充填する態様は、水平型の枠の底面に化粧側を裏面
を上にして並べ、その上に該発泡体用材料を充填しく必
要に応じて充填した材料の上に更に化粧材を裏面を下に
して配置して）、そして適当な重さの蓋をして焼成する
のが普通である。また、縦型の枠を採用し、その−側面
または両側面に化粧材を同様に貼付し、発泡体用材料を
充填しそして蓋をして焼成することも当然可能である。As described above, the decorative material is arranged in a frame such as a sagger and filled with the foam material. It is common to fill the container with the materials (if necessary, place a decorative material on top of the filled materials with the back side facing down), then cover with a lid of an appropriate weight and bake. Naturally, it is also possible to employ a vertical frame, affix a decorative material to one or both sides thereof, fill it with a foam material, cover it, and fire it.

該粋の化粧材を配置する面にアルミナ等の耐火性粉末を
散布し若しくは付着させて、溶着および一時的な過熱等
を防止するのが好ましい。なお、枠の上下両面または両
側面に化粧材を配置する態様によって、発泡体の両面に
融着しＩｃ化粧材を有する製品が得られる。これはそれ
自体で有用であるが、該化粧材の面に平行に該発泡体を
切断して、片面に化粧材が融着した発泡体を得ることも
できる。It is preferable to sprinkle or adhere a refractory powder such as alumina on the surface on which the decorative material is placed to prevent welding and temporary overheating. In addition, by placing the decorative material on both the upper and lower surfaces or both sides of the frame, a product having the Ic decorative material fused to both surfaces of the foam can be obtained. Although this is useful in itself, it is also possible to cut the foam parallel to the face of the decorative material to obtain a foam with the decorative material fused to one side.

以下に本発明の代表的な実施態様を例示して、本発明を
更に説明する。しかし本発明はこれらの例に限定される
ものではなく、本発明の技術思想内の変形および修正は
当然可能であることが理解される。The present invention will be further explained below by illustrating typical embodiments of the present invention. However, it is understood that the present invention is not limited to these examples, and that variations and modifications within the technical idea of the present invention are naturally possible.

例１ 発泡体用材料として、造粒した粉状抗火石１００重量部
、炭化珪素粉末１重量部および頁岩粉末１０重量部から
なる均質混合物粉末を使用した。内部寸法が２００ｘ　
２００ｍｍの匣鉢の底面にアルミナ粉末を散布し、施釉
セラミックタイルく合計重量６００グラム）をタイルの
裏面を上向きにして配置し、その上に上記の混合粉末を
２５＋ｎｎ＋の厚さに充填した。Example 1 As a material for a foam, a homogeneous mixture powder consisting of 100 parts by weight of granulated powdered firestone, 1 part by weight of silicon carbide powder and 10 parts by weight of shale powder was used. Internal dimensions are 200x
Alumina powder was sprinkled on the bottom of a 200 mm sagger pot, glazed ceramic tiles (total weight 600 grams) were placed with the back side of the tiles facing upward, and the above mixed powder was filled on top to a thickness of 25+nn+.

これを１１５０°Ｃにて２４時間焼成しそして放置して
冷却した。このようにして、化粧タイルと融着一体化さ
れた発泡軽量体が、発泡ｄ３よび融着を同時に達成して
得られた。該発泡層の厚さは５５ｍｍでこの重量は５５
０グラムであり、従って比重は０．４２であった。更に
得られた発泡体は実質的に非吸水性であり、実質的に独
立気泡から構成されていた。This was fired at 1150°C for 24 hours and left to cool. In this way, a foamed lightweight body integrally fused with the decorative tile was obtained by achieving foaming d3 and fusion at the same time. The foam layer has a thickness of 55 mm and a weight of 55 mm.
0 grams, so the specific gravity was 0.42. Furthermore, the resulting foam was substantially non-water-absorbing and consisted essentially of closed cells.

例２ 発泡体用材料として、抗火石１００重量部、炭化珪素１
重量部、Ｐ　Ｖ　Ａ　７５重量部からなる混合粉末を水
を用いて小粒化したものを使用した。例１の場合と同寸
法の匣鉢に、例１と同様に、平板状に切断した玄部岩片
、を配置しそして上記の発泡体用材料を充填し、１２０
０℃にて４時間焼成した。放置冷却して、玄武岩化粧材
と融着一体化己ＩＣガラス質発泡体が得られた。Example 2 As materials for foam, 100 parts by weight of anti-flame stone, 1 part by weight of silicon carbide
A mixed powder consisting of 75 parts by weight of PVA and 75 parts by weight was made into small particles using water. In the same way as in Example 1, pieces of basal rock cut into flat plates were placed in a sagger pot of the same size as in Example 1, and the above-mentioned foam material was filled.
It was baked at 0°C for 4 hours. After cooling, a self-IC vitreous foam fused and integrated with the basalt decorative material was obtained.

例３ 化粧タイルと発泡体用材料との間に、抗火石１００重量
部と頁岩１０重量部との発泡材を含有しない混合粉末を
薄く散布したほかは、例１と同様に実施した。得られた
化粧タイル融着発泡軽量体の融着部分を検査すると、該
タイルと該発泡体との融着状態が緻密であった。Example 3 The same procedure as in Example 1 was carried out, except that a foam-free mixed powder of 100 parts by weight of firestone and 10 parts by weight of shale was thinly sprinkled between the decorative tile and the foam material. When the fused portion of the obtained lightweight decorative tile fused foam was inspected, it was found that the tile and the foam were tightly fused.

Claims (1)

【特許請求の範囲】 １、溶化ガラス質形成性珪酸塩系の発泡軽量体の少くと
も一表面に、珪酸塩系材料の裏面を有する無機系化ｔａ
材を融着一体化してなることを特徴とする無機質化粧材
融着発泡軽量体。 ２、該発泡軽量体の材料の主成分が、抗火石。 火山灰、ガラス系材料、膨張頁岩、真珠岩、スラグおよ
びこれらの混合物から選ばれる特許請求の範囲第１項の
化粧発泡軽量体。 ３、該発泡軽量体が更に泥岩系成分を含む特許請求の範
囲第２項の化粧発泡軽量体。 ４、該発泡軽量体が少くとも抗火石を含む特許請求の範
囲第１、第２または第３項の化粧発泡軽量体。 ５、該発泡軽量体が実質的に独立気泡から構成されてい
る、特′ｆ＋請求の範囲第１〜４項のいずれかの化粧発
泡軽量体。 ６、該化粧材が施釉セラミックタイルおよび石材から選
ばれる、特許請求の範囲第１〜５項のいずれかの化粧発
泡軽量体。 ７、焼成用の枠の枠面の少くとも一面に、珪酸塩系材料
の裏面を有する無機系化粧材を裏面を内側にして配置し
、溶化カラス貝形成性珪酸塩系の発泡体用材料を該化粧
材の裏面に接して充填し、該化粧材の熱変性未満の温度
そして該発泡体用材料の溶化発泡温度以上の温度にて焼
成して、発泡化と共に両材料を融着せしめることを特徴
とする無機質化粧材融着発泡軽量体の製法。 ８、該発泡体用材料が焼成時に気体を放出する有効量の
発泡剤を含有する特許請求の範囲第７項の製法。 ９、該発泡剤が炭化珪素、窒化珪素、炭素。 水ガラス、石こう、炭酸塩およびこれらの混合物から選
ばれる特許請求の範囲第８項の製法。 １０、該発泡体用材料の主成分が、抗火石。 火山灰、ガラス系材料、膨張頁岩、真珠岩、スラグおよ
びこれらの混合物から選ばれる特許請求の範囲第７〜９
項のいずれかの製法。 １１、該発泡体用材料が更に泥岩系成分を含む特許請求
の範囲第１０項の製法。 １２、該発泡体用材料が少くとも抗火石を含む特許請求
の範囲第７〜１１項のいずれかの製法。 １３、該発泡剤が少くとも炭化珪素を含む特許請求の範
囲第７〜１２項のいずれかの製法。 １４、該化粧材が施釉セラミックタイルＪ３よび石材か
ら選ばれる特許請求の範囲第７〜１３項のいずれかの製
法。[Scope of Claims] 1. An inorganic ta having a back surface of a silicate material on at least one surface of a fused vitreous silicate foam lightweight body.
A lightweight inorganic decorative material fusion-bonded foam body characterized by being made by integrating materials by fusion bonding. 2. The main component of the lightweight foam material is anti-firestone. The decorative foam lightweight body of claim 1 selected from volcanic ash, glass-based materials, expanded shale, perlite, slag and mixtures thereof. 3. The decorative foam lightweight body according to claim 2, wherein the foamed lightweight body further contains a mudstone-based component. 4. The decorative foam lightweight body according to claim 1, 2 or 3, wherein the foamed lightweight body contains at least a flint-retardant. 5. The decorative foam lightweight body according to any one of claims 1 to 4, wherein the foamed lightweight body is substantially composed of closed cells. 6. The decorative foam lightweight body according to any one of claims 1 to 5, wherein the decorative material is selected from glazed ceramic tiles and stone. 7. On at least one side of the frame surface of the firing frame, place an inorganic decorative material having a back side of a silicate material with the back side facing inside, and apply a solubilized crayfish-forming silicate foam material. The material is filled in contact with the back surface of the decorative material and fired at a temperature lower than the thermal denaturation temperature of the decorative material and higher than the melting and foaming temperature of the foam material to foam and fuse the two materials together. A manufacturing method for lightweight foamed materials fused with inorganic decorative materials. 8. The method of claim 7, wherein the foam material contains an effective amount of a blowing agent that releases gas upon firing. 9. The foaming agent is silicon carbide, silicon nitride, or carbon. The method according to claim 8, which is selected from water glass, gypsum, carbonates and mixtures thereof. 10. The main component of the foam material is anti-firestone. Claims 7 to 9 selected from volcanic ash, glass-based materials, expanded shale, perlite, slag, and mixtures thereof
The manufacturing method in any of the paragraphs. 11. The manufacturing method according to claim 10, wherein the foam material further contains a mudstone component. 12. The manufacturing method according to any one of claims 7 to 11, wherein the foam material contains at least a flint-retardant stone. 13. The manufacturing method according to any one of claims 7 to 12, wherein the blowing agent contains at least silicon carbide. 14. The manufacturing method according to any one of claims 7 to 13, wherein the decorative material is selected from glazed ceramic tile J3 and stone.