JPH0859355A - Sheet-shaped ceramic and its production - Google Patents

Abstract

PURPOSE: To produce a sheet-shaped ceramic capable of being used for various purposes and to provide its production method. CONSTITUTION: Many clay members 3 arranged on a metallic net 2 are rolled by a rolling machine 9 to cover the front and rear of the net with the clay members in uniform thickness, and a sheet-shaped substrate 4 is formed. The substrate 4 is appropriately dried, placed in a kiln and fired, the fired sheet- shaped ceramic is coated with a water repellent agent and a reinforcing agent, hence the durability against tension, bending, etc., is improved, the ceramic is shaped into an optional shape, and the shaped ceramic is used far various purposes. Alternately, the fired sheet-shaped ceramic is coated with a glaze and again fired, hence the ceramic is lustered, colored and hardened while keeping its shape, and ceramic is used as one panel.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention is used, for example, for decoration such as outdoors or indoors, as an interior / exterior material for buildings, furniture, etc., for wall materials for the purpose of heat insulation, heat retention, etc. The present invention relates to a sheet-shaped ceramic that can be used for rugs or the like, or can be used for fire protection of walls and doors, and a method for manufacturing the same.

[0002]

2. Description of the Related Art Conventionally, in the case of producing a sheet-shaped ceramic (baked product) such as the above-mentioned example, for example, after generally commercially available clay members are kneaded and formed into an appropriate shape,
By putting the base material in a kiln and subjecting it to kiln firing at an appropriate temperature, it is possible to manufacture one ceramicized pottery.

[0003]

However, when the sheet-like pottery is manufactured as described above, if the thickness of the pottery is made thin, cracks and collapses easily occur in the entire ceramic due to the high heat during firing, It is very difficult to fire kiln in an appropriate shape. Since the green body is kiln-fired in a state where it is appropriately shaped, the baked product cannot be transformed into an arbitrary shape after the kiln-fired. Therefore, in consideration of the shrinkage rate and the deformation rate that occur during the kiln firing, it is necessary to form the base material in a size and shape according to the purpose of use,
High pottery skills are required. Moreover, since the pottery is cracked or chipped when it is used, it must be handled with care and cannot be used for purposes or purposes other than pottery.

In view of the above-mentioned problems, the present invention improves the durability against pulling and bending by forming a mesh-shaped metal net by kiln-baking with the clay member covered with the clay member, and improves the durability. It is an object of the present invention to provide a sheet-shaped ceramic that can be molded into various shapes and can be used for various purposes according to demand, and a manufacturing method thereof.

[0005]

According to the first aspect of the present invention,
It is characterized in that it is a sheet-shaped ceramic formed by coating a metal net formed in a mesh shape with a clay member, and performing a kiln firing treatment with the metal net covered with the clay member.

The invention according to claim 2 is, in addition to the structure according to claim 1, characterized in that it is a sheet-shaped ceramic obtained by applying a binder to the ceramic portion of the kiln-fired sheet-shaped ceramic.

According to a third aspect of the present invention, a clay member is arranged on one side surface of a metal net formed in a mesh shape, and the clay member arranged on one side surface of the metal net is rolled into a flat state by a clay rolling means. Then, a sheet-shaped substrate is formed by coating both sides of the metal net with a clay member to a uniform thickness. A method for producing a sheet-shaped ceramic is characterized in that the above-mentioned sheet-shaped substrate is dried in an appropriate state, and then the dried sheet-shaped substrate is put into a kiln and kiln-baked at an appropriate temperature.

The invention according to claim 4 is, in addition to the structure according to claim 3, a method for producing a sheet-shaped ceramic which is produced by applying a binder to the ceramic portion of the kiln-fired sheet-shaped ceramic. Is characterized by.

According to a fifth aspect of the present invention, in addition to the structure of the third aspect, after applying a glaze solution to the ceramic portion of the kiln-fired sheet-shaped ceramic, the sheet-shaped ceramic is placed in the kiln. It is characterized in that it is a method for manufacturing a sheet-shaped ceramic which is manufactured by performing a kiln firing again.

[0010]

In the sheet-shaped ceramic according to claim 1, the net-shaped metal net is kiln-baked while being covered with the clay member, so that the durability against pulling or bending is improved, For example, it can be formed into various shapes as desired by deforming it into an arbitrary shape, perforating it at an arbitrary position, or making a crack in a mesh shape.

In the sheet-like ceramic according to the second aspect, in addition to the action according to the first aspect, since the binder is applied to the ceramic portion of the sheet-like ceramic subjected to the kiln firing, the metal net and the ceramic portion are applied. The bond strength between the metal net and the ceramic part can be prevented from being separated when the metal net and the ceramic part are deformed into an arbitrary shape.

According to a third aspect of the present invention, in the method for producing a sheet-shaped ceramic, the clay member arranged on one side surface of the metal net is rolled into a flat state by the clay rolling means, and both side surfaces of the metal net are uniformly thickened by the clay member. By forming a sheet-shaped substrate formed by coating the shavings into a kiln and putting the dried sheet-shaped substrate in an appropriate state in a kiln to perform a kiln-baking treatment, similar to the invention according to claim 1, a variety of demands can be obtained. In addition to being capable of being shaped into a shape, the work of manufacturing a sheet-shaped ceramic can be performed mechanically.

In the method for producing a sheet-shaped ceramic according to a fourth aspect of the invention, in addition to the action of the third aspect, a ceramic portion of the kiln-fired sheet-shaped ceramic is bonded to a binder such as a water repellent or a reinforcing agent. By applying, the bonding strength between the metal net and the ceramic portion is increased, and the ceramic portion is prevented from coming off the metal net when deformed into an arbitrary shape.

In the sheet-shaped ceramic manufacturing method according to the fifth aspect, in addition to the operation of the third aspect, the ceramic portion of the kiln-fired sheet-shaped ceramic is coated with glaze liquid and fired again. The surface of the ceramic part is colored and glossy, and it hardens in a state of being molded into a preset appropriate shape, so it can be attached to appropriate parts such as buildings and furniture 1
It can be used as a panel of sheets.

[0015]

EFFECT OF THE INVENTION According to the present invention, since a sheet-shaped ceramic is formed by kiln-baking a net-shaped metal net covered with a clay member, it is excellent in durability against pulling, bending, etc. For example, it can be formed into an arbitrary shape by being deformed into an arbitrary shape, perforated at an arbitrary position, or having a crack in a mesh shape, and can be used for various purposes according to demand. The ceramic part does not fade or discolor even after long-term use, and it has a characteristic that it does not easily change over time. Therefore, the hue during manufacturing can be maintained for a long time.

Moreover, by applying a binder such as a water repellent or a reinforcing agent to the ceramic portion, the bonding strength between the metal net and the ceramic portion is increased, and the ceramic portion collapses when deformed into an arbitrary shape. Can be positively prevented.
In addition, by selecting the type of clay used during molding and the type of glaze applied during glaze, it is possible to set the color of the ceramic portion to various hues according to the selection.

Further, far infrared rays radiated from the ceramic portion can provide various effects such as a heating effect and blood circulation promotion, and can be used as a rug such as a sheet or a mat. Moreover, since it is fired at an appropriate temperature in advance, it has excellent heat resistance and fire resistance. For example, by using a sheet-shaped ceramic for a building, furniture, etc., a high effect as a fireproof material can be obtained.

[0018]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS One embodiment of the present invention will be described below in detail with reference to the drawings. The drawings show a sheet-shaped ceramic and a manufacturing method thereof in which a metal net formed in a mesh shape is embedded in a clay member and subjected to a kiln firing process, and in FIGS. 4 and 7, the sheet-shaped ceramic 1 is The entire front and back surfaces of the metal net 2 formed of a suitable metal, for example, collected clay,
Clay member 3 used for baked goods such as compounded clay and commercially available clay
(For example, Shigaraki special red clay) to form a sheet-shaped substrate 4, and the sheet-shaped substrate 4 obtained by coating the metal net 2 with a clay member 3 is dried to an appropriate state, and then the sheet-shaped substrate 4 It is a sheet-like baked product obtained by putting 4 into a kiln 6 and kiln-baking it.

A manufacturing method for manufacturing the above-mentioned sheet-shaped ceramic 1 will be described below with reference to the drawings.

First, as shown in FIGS. 1 and 2, for example, a large number of metal wires 2a ... Which are formed of a suitable metal material such as stainless steel and copper that can withstand the high temperature during kiln firing are entangled in a mesh shape. While the metal net 2 is knitted, the mesh portions 2b ... Of the metal net 2 are formed in a hexagonal shape (honeycomb shape). Alternatively, the mesh portions 2b ... May be formed in a circle, a rhombus, an ellipse, a triangle, a quadrangle, or the like.

Next, as shown in FIGS. 3 and 4, for example, Shigaraki special red clay, Shino clay, Koshinraku clay, Kasama clay,
Clay component 3 used for pottery such as Echizen clay and Karatsu clay
Is selected or adjusted to be formed into an appropriate thickness and an appropriate shape, and the metal net 2 is laid on the feeding-side transfer surface of the rolling conveyor 8 constituting the roller-type rolling mill 7, and then laid on the rolling conveyor 8. A large number of clay members 3 are arranged on the front surface side of the metal net 2 at appropriate intervals. After that, the rolling conveyor 8 is rotated in the feeding direction by the driving force of a motor with a speed reducer (not shown), and the metal net 2 laid on the rolling conveyor 8 is moved in the feeding direction. At the same time, as shown in FIG. 5, the clay members 3 disposed on the front surface side of the metal net 2 are flattened by a rolling roller 9 (for example, a Cera roller) which is axially mounted in the width direction of the conveying surface of the rolling conveyor 8. Roll in order.

That is, each clay member 3 disposed on the surface side of the metal net 2 is rolled into a flat state by the rolling roller 9, and each clay member 3 is attached to each mesh portion 2b of the metal net 2.
... are forcibly press-fitted to cover the outer peripheral surfaces of the metal wires 2a forming the same metal net 2 with the clay members 3. At the same time, the clay members 3 are rolled in all directions to be in close contact with each other, and the entire front and back surfaces of the metal net 2 are covered with the clay members 3 to have a uniform thickness to form one sheet-shaped substrate 4. To do. In addition, each clay member 3 arranged on the surface side of the metal net 2 is rolled by an artificial operation,
The entire front and back surfaces of the metal net 2 may be evenly covered with the clay members 3.

Next, as shown in FIG. 6, the metal net 2
Sheet-shaped substrate 4 which is obtained by coating the entire surface of the
Is dried to an appropriate state. That is, when the sheet-shaped substrate 4 is rapidly dried, many cracks, cracks and the like are generated. For example, after drying in the shade in a poorly ventilated place and slowly drying it until the sheet-shaped substrate 4 is appropriately dried, The sheet-shaped substrate 4 is completely dried by an appropriate drying means such as sun-drying or mechanical drying. When dried to an appropriate state, the clay member 3 coated on the metal wires 2a of the metal net 2 is quickly dried because the thickness of the clay member 3 is thin, and the thin portion is discolored to white. The drying process is completed when the sheet-shaped base material 4 is discolored into a white mesh along the lines 2a.

Next, as shown in FIG. 7, the sheet-shaped base material 4 that has been appropriately dried is put into a kiln 6 such as a wood furnace, a gas kiln, a kerosene kiln, an electric kiln, or the like. About 80
The kiln is baked at 0 ° C to about 1000 ° C. That is, an appropriate number of sheet-shaped bases 4 ... Are placed on a plurality of shelves 6a that are built inside the kiln 6, and after the sheet-shaped bases 4 ... are kilned at appropriate vertical intervals, For example, heating is performed for about 5 hours until the quenching temperature in the kiln 6 reaches about 800 ° C., and each sheet-shaped substrate 4 placed on each shelf 6 a in the kiln 6 is kiln-fired. , The clay member 3 coated on the metal net 2 is made into ceramic. After this, each sheet-shaped substrate 4 that has been kiln-baked in the kiln-inserted kiln 6
... is left for about one day, and each sheet-shaped base material 4 is slowly cooled over a period of time until it cools to an appropriate temperature, thereby producing one sheet-shaped ceramic 1 as shown in FIG. . When fired in an appropriate state, cracks are left on the ceramic layer 5 along the metal wires 2a ... Of the metal net 2.

Next, when a pattern or pattern is drawn on the entire front surface or back surface or one side surface of the kiln-fired sheet-shaped ceramic 1 by any one coating method such as spraying, coating, pouring, dipping, etc. The water-repellent agent A used and the reinforcing agent B made of synthetic resin used for preventing collapse of the baked product are uniformly applied. That is, as shown in FIGS. 8 and 9, the water repellent A and the reinforcing agent B stored in the containers 10 and 11 are applied twice by the above-described application method.

When the water repellent A and the reinforcing agent B are sprayed, the water repellent A and the reinforcing agent B are uniformly applied to the sheet-shaped ceramic 1 by a spray 12 connected to a compressor or the like, as shown in FIG. Spray on. In addition, when applying, as shown in FIG. 11, the water-repellent agent A and the reinforcing agent B are uniformly applied to the sheet-shaped ceramic 1 by the brush 13.
In addition, in the case of pouring or dipping, as shown in FIG. 12, the water repellent A or the reinforcing agent B stored in the liquid storage tank 14 is sprinkled or dipped into the sheet-shaped ceramic 1 and uniformly applied. To do. As described above, kiln-fired sheet-shaped ceramic 1
By applying the water-repellent agent A and the reinforcing agent B to the entire front and back surfaces or one side surface twice, the bonding strength between the metal net 2 and the ceramic layer 5 is increased, and when the ceramic layer is deformed into an arbitrary shape. It is possible to positively prevent 5 from collapsing. If desired, for example, as shown in FIG. 14, it is possible to perforate the ceramic layer 5 at an arbitrary position corresponding to each mesh portion 2b ... Of the metal net 2, or to make a crack in the mesh shape. However, in this case, the entire ceramic layer 5 does not collapse, and the ceramic layer 5 can be shaped as desired.

Next, as shown in FIG. 13, the entire front and back surfaces or one side surface of the kiln-fired sheet-shaped ceramic 1 is, for example,
The glaze liquid C (for example, natural glaze liquid, mixed glaze liquid, commercially available glaze liquid) is glazed by any one of the glaze methods such as coating, spraying, dipping, and pouring, and the kiln is baked again.

When the above-mentioned glaze C is glazed, for example,
Celadon glaze, straw ash glaze, iron red glaze, transparent glaze, Oribe glaze, black Tenme glaze,
Container 1 by selecting or blending glaze liquid C such as Kiseto glaze and glaze
5, the glaze liquid C is uniformly applied to the kiln-fired sheet-shaped ceramic 1 by the spray 12 or the brush 13 described above, or the glaze liquid C stored in the liquid storage tank 14 is used.
By pouring or immersing the sheet-shaped ceramic 1 evenly on the sheet-shaped ceramic 1 and then kilning the sheet-shaped ceramic 1 that has been glazed into a kiln 6 and then kiln-baking it again at an appropriate temperature,
The surface of the ceramic layer 5 is colored and glossy, and high design value is obtained. In addition, since it is cured in a state of being formed into an appropriate shape, it can be used as, for example, one panel attached to a flat surface portion of a building or furniture.

As described above, the mesh-shaped metal net 2
Since the sheet-shaped ceramic 1 is formed by performing the kiln firing with the clay member 3 being covered with the clay member 3, it is excellent in durability against pulling, bending, etc. It can be molded into an arbitrary shape by applying a crack or a crack in the mesh shape, and can be used for various purposes according to demand. Since the ceramic layer 5 does not fade or discolor even after long-term use, and has a characteristic that it does not easily change over time, the hue during manufacturing can be maintained for a long period of time.

Furthermore, by coating the ceramic layer 5 with the water repellent A and the reinforcing agent B, the bonding strength between the metal net 2 and the ceramic layer 5 is increased, and the ceramic layer 5 collapses when deformed into an arbitrary shape. It is possible to prevent positively. Moreover, by selecting the type of the clay member 3 used at the time of molding and the glaze liquid C applied at the time of glaze, it is possible to set the color of the ceramic layer 5 to various hues corresponding to the selection.

Further, far infrared rays emitted from the ceramic layer 5 have various effects such as a heating effect and blood circulation promotion, and can be used as a rug such as a sheet or a mat. Moreover, since it is fired at an appropriate temperature in advance, it is excellent in heat resistance and fire resistance. For example, by using the sheet-shaped ceramic 1 in a building, furniture, etc., a high effect as a fireproof material can be obtained.

In the correspondence between the structure of the present invention and the above-described embodiment, the ceramic portion of the sheet-shaped ceramic of the present invention corresponds to the ceramic layer 5 of the sheet-shaped ceramic 1 of the embodiment, and the same applies to the binder. Corresponds to the water repellent A and the reinforcing agent B, and the clay rolling means corresponds to the roller-type rolling mill 7 and the rolling conveyor 8 and the rolling roller 9. The configuration is not limited to the example configuration.

In the above-mentioned embodiment, the mesh portions 2b ... Of the metal net 2 are formed in a hexagonal shape (honeycomb shape). However, for example, a circle, a rhombus, an ellipse, a triangle, a quadrangle, a hexagon, etc. The metal net 2 may be formed by punching a metal plate (not shown) into an appropriate shape.
A plurality of (for example, two, three, four) rolling rollers 9 are provided on a rolling conveyor 8 that constitutes the roller type rolling mill 7.
Alternatively, the clay members 3 arranged on the metal net 2 may be continuously rolled by the rolling rollers 9 ...

[Brief description of drawings]

FIG. 1 is a perspective view showing a metal net knitted into a sheet shape.

FIG. 2 is a plan view showing a metal net knitted into a honeycomb shape.

FIG. 3 is a perspective view showing a clay member formed into a rectangle.

FIG. 4 is a perspective view showing a rolling operation of a roller-type rolling mill.

FIG. 5 is a vertical sectional side view showing a rolling portion of a roller type rolling mill.

FIG. 6 is a plan view showing a dry state of the sheet-shaped substrate.

FIG. 7 is a vertical cross-sectional front view showing a kiln-inserted state of the sheet-shaped substrate.

FIG. 8 is a perspective view showing a water repellent stored in a container.

FIG. 9 is a perspective view showing a reinforcing agent stored in a container.

FIG. 10 is a perspective view showing a method of spraying a solvent and a glaze.

FIG. 11 is a perspective view showing a method for applying a solvent and a glaze.

FIG. 12 is a perspective view showing a method of dipping a solvent and a glaze.

FIG. 13 is a perspective view showing a glaze solution stored in a container.

FIG. 14 is a plan view showing a state in which a large number of holes are formed in a sheet-shaped ceramic.

[Explanation of symbols]

 A ... Water repellent B ... Reinforcing agent C ... Glaze 1 ... Sheet-shaped ceramic 2 ... Metal net 2a ... Metal wire 2b ... Mesh part 3 ... Clay member 4 ... Sheet-shaped base 5 ... Ceramic layer 6 ... Baking kiln 6a ... Shelf 7 ... Roller type rolling machine 8 ... Rolling conveyor 9 ... Rolling roller 12 ... Spray 13 ... Brush 14 ... Liquid storage tank

Claims (5)

[Claims] 1. A sheet-shaped ceramic formed by coating a metal net formed in a mesh shape with a clay member and performing a kiln firing treatment in a state where the metal net is covered with the clay member. 2. The sheet-shaped ceramic according to claim 1, wherein a binder is applied to the ceramic portion of the kiln-fired sheet-shaped ceramic. 3. A clay member is arranged on one side surface of a metal net formed in a mesh shape, and the clay member arranged on one side surface of the metal net is rolled into a flat state by a clay rolling means,
A sheet-shaped substrate is formed by coating both sides of the metal net with a clay member to a uniform thickness. A method for producing a sheet-shaped ceramic, which is produced by drying the above-mentioned sheet-shaped base material to an appropriate state, and then placing the dried sheet-shaped base material in a kiln and kiln-baking it at an appropriate temperature. 4. The method for producing a sheet-shaped ceramic according to claim 3, wherein a binder is applied to the ceramic portion of the kiln-fired sheet-shaped ceramic. 5. The sheet according to claim 3, which is produced by applying a glaze solution to the ceramic portion of the kiln-fired sheet-shaped ceramic, then placing the sheet-shaped ceramic in a kiln and kiln-baking it again at an appropriate temperature. Of manufacturing ceramics.