KR101891370B1 - Porous ceramic tile expressing the apperance of natural stone and the method of manufacturing the same - Google Patents

Abstract

Wherein the two or more ceramic tile particles each comprise a different decorative effect material.
Mixing a composition for two types of ceramic tiles including different decorative effect material to form a ceramic formed body; A step of dry-pressing the ceramic formed body to produce a porous ceramic tile; Drying the shaped porous ceramic tile; Dipping the dried porous ceramic tile into a glaze; And firing the sintered porous ceramic tile. The present invention also provides a method for manufacturing a porous ceramic tile.

Description

TECHNICAL FIELD [0001] The present invention relates to a porous ceramic tile and a method of manufacturing the same. More particularly,

The present invention relates to a porous ceramic tile for realizing a natural stone appearance and a manufacturing method thereof.

A tile is a flat, clay-plated product made to cover the surfaces of floors and walls. It is usually very thin compared to the surface area, and is used in manufacturing processes that are glazed or poured, Refers to those having special physical properties and characteristics by performing a heat treatment which causes a substantial change in the mechanical properties of the ceramic body by reaction, calendering and melting of the components. The tile includes a built-in tile, an exterior tile, a mosaic tile, an acid-resistant tile, a floor tile, a salt tile, and a query tile.

Tiles have various performances, and they are relatively easy to install, they do not cause cracking or discoloration after construction, they are the best materials to protect the surface of the structure because they have excellent durability, , Toilets, bathrooms, restrooms, etc.

In general, tiles are used as surface finishing materials such as exterior or interior finishing materials, and they are used to enhance the aesthetic effect of the building. Therefore, the color and shape of the surface should be beautiful. Therefore, the development of tiles having excellent decorative properties is increasing.

One embodiment of the present invention provides a porous ceramic tile that implements the appearance of gemstones by incorporating different decorative effect material into each composition.

Another embodiment of the present invention provides a method of making the porous ceramic tile.

In one embodiment of the present invention, the porous ceramic tile includes particles for two or more ceramic tiles, each of the particles for the two or more ceramic tiles being different from one another.

The two or more ceramic tile particles each include pigments of different colors, so that the colors imparted to the two or more ceramic tile particles together can realize a complex color feeling.

The decorative effect-realizing material may include at least one selected from the group consisting of a pigment, a metal flake, a metal powder, a glitter powder and a combination thereof.

The two or more ceramic tile particles may be in the form of a plurality of small particles and may include a structure in which the small particles are aggregated.

The particles for the at least two ceramic tiles may have an average diameter of about 50 탆 or more.

The particles for the at least two ceramic tiles may comprise a decorative effect material, gamma -alumina, and parent material.

The decorative effect material may be included in an amount of about 0.1 part by weight to about 20 parts by weight with respect to 100 parts by weight of the parent material.

The parent material may include at least one selected from the group consisting of clay, loess, clay and combinations thereof.

The gamma -alumina may comprise a mesopore having an average diameter of about 2 nm to about 50 nm.

The pore volume of the meso pores (mesopore) may be about 0.001cm ³ / g to about 0.1 cm ³ / g.

The porous ceramic tile may include pores having an average diameter of about 10 nm to about 10 um.

In another embodiment of the present invention, there is provided a method of manufacturing a ceramic molded body, comprising: forming a ceramic formed body by mixing two kinds of compositions for ceramic tiles including different decorative effect material; A step of dry-pressing the ceramic formed body to produce a porous ceramic tile; Drying the shaped porous ceramic tile; Dipping the dried porous ceramic tile into a glaze; And firing the sintered porous ceramic tile. The present invention also provides a method for manufacturing a porous ceramic tile.

The composition for the two types of ceramic tiles is formed by ball-milling, mixing and grinding a decorative effect-imparting material, an aluminum source which can be phase-changed into gamma -alumina, and a mother material, and then forming the mixture by a spray drying process .

The aluminum source which can be phase-transformed into? -Alumina may be at least one selected from the group consisting of aluminum hydroxide, aluminum nitride, aluminum carbonate, aluminum chloride, aluminum chloride dihydrate, and combinations thereof.

The firing step may be performed at a temperature of from about 800 [deg.] C to about 1000 [deg.] C for a time of from about 1 minute to about 15 minutes.

Since the porous ceramic tile realizes the appearance of natural stone, it can exhibit a better natural beauty and can be used for interior decoration.

Porous ceramic tiles having an appearance similar to that of granite and excellent in humidity control function and durability can be manufactured through the production of the porous ceramic tiles.

1 is a diagrammatic representation of a porous ceramic tile and method of manufacture.
2 is a photograph of a porous ceramic tile according to an embodiment of the present invention.

Hereinafter, embodiments of the present invention will be described in detail. However, the present invention is not limited thereto, and the present invention is only defined by the scope of the following claims.

Porous ceramic tile

In one embodiment of the present invention, the porous ceramic tile includes particles for two or more ceramic tiles, each of the particles for the two or more ceramic tiles being different from one another.

In recent years, the public interest in interior decorations has been increasing, and tiles having a high visibility frequency have attracted attention for products with natural colors and patterns.

Because of this tendency, the interior decoration tiles are often used as the finishing materials of natural stone such as granite and marble. However, the finishing material of the natural stone material represents the natural beauty most, but it is difficult to process and the price competitiveness is not secured.

On the other hand, the ceramic tile is relatively inexpensive because it can be relatively mass-produced compared to the above-mentioned natural stone material, but the color of the surface of the tile is determined mainly by the glaze on the surface of the tile. Therefore, the color and the pattern are simple and limited to a relatively unnatural appearance .

Particularly, due to the process characteristic of glazing on the surface of tiles, it is difficult to apply various colors at the same time, and it is difficult to express natural and composite appearance of natural stone materials such as granite and marble.

The porous ceramic tile includes particles for two or more ceramic tiles, and the particles for the two or more ceramic tiles include different decorative effect material, so that the appearance of natural stone can be realized, Can be used for interior.

For example, the two or more ceramic tile particles may include particles for a first ceramic tile and particles for a second ceramic tile, and each of the particles for the first ceramic tile and the second ceramic tile .

The decorative effect-realizing material may include at least one selected from the group consisting of a pigment, a metal flake, a metal powder, a glitter powder and a combination thereof. A composite visual effect can be exhibited by the composition for the two or more ceramic tiles including the various decorative effect material.

For example, the particles for the first ceramic tile and the particles for the second ceramic tile include pigments of different colors, and the colors imparted to the particles for the first ceramic tile and the particles for the second ceramic tile are mixed together It is possible to realize coloring.

The pigment refers to a coloring agent having a unique color. Since the color of each pigment included in the particles for the first and second ceramic tiles realizes a complex color tone, the appearance of the natural stone, specifically, granite, marble, have.

The two or more ceramic tile particles may be in the form of a plurality of small particles and may include a structure in which the small particles are aggregated.

According to the porous ceramic manufacturing method to be described later, two or more compositions for ceramic tiles including different decorative effect-imparting materials are formed and then mixed to form a ceramic formed body. The ceramic formed body is subjected to a firing step to form two or more ceramic Particles for the tile may be formed, and the particles for the at least two ceramic tiles may be in the form of a small particle.

Specifically, the average diameter of the particles for the two or more ceramic tiles may be 50um or more, for example, 50um to 1,000um. The average diameter means an average value of diameters measured in an arbitrary region of the particle. By adjusting the average diameter of the particles within the range, the appearance of the tile can be modified, and the mixing effect of particles having different colors can be maximized, The effect can be improved.

Specifically, when the average diameter of the particles is less than about 50 袖 m, the visual effect is insufficient due to insufficient visibility. When the average diameter of the particles is more than about 1,000, the visibility is too strong and the boundary with other particles becomes clear, have.

The particles include different decorative effect material, and are in the form of a small particle having different color or texture. The tile may include a structure aggregated through molding, drying, sowing, firing and the like of the small particles have.

The aggregated structure can exhibit superior natural beauty compared to conventional porous ceramic tiles formed of particles for ceramic tiles that embody one color with two or more colors or materials of different texture.

The particles for the at least two ceramic tiles may comprise a first decorative effect material, gamma -alumina, and a parent material. Further additives such as frit, flux, peptizer, filler, thickener, antibacterial agent, antifungal agent, and numerical stabilizer may be further included as functional materials. Specifically, about 100 parts by weight of the mother material may contain about 0.1 to about 20 parts by weight of a decorative effect material. The porous ceramic tile is manufactured through various steps as described below, so that color or texture can be expressed in the final product by controlling the material content of the decorative effect material.

When the decorative effect material is contained in an amount of less than about 0.1 part by weight, the visibility may deteriorate. When the decorative effect material is contained in an amount exceeding about 20 parts by weight, the raw material cost may increase, Is advantageous in that it secures visual effects and physical stability.

For example, the first ceramic tile particles may contain 5 parts by weight to 10 parts by weight of the material for achieving a decorative effect, and the second ceramic tile particles may be 5 parts by weight with respect to 100 parts by weight of the mother material. To 10 parts by weight of decorative effect-imparting material.

The parent material may be at least one selected from the group consisting of clay, clay, loess, and combinations thereof. The parent material may be at least one selected from the group consisting of clay, clay, .

The content of the parent material is not particularly limited and may be varied depending on the application field and application of the porous ceramic tile. For example, the parent material may include the entire composition 100 for the ceramic tile About 10 parts by weight to about 70 parts by weight, based on the weight of the composition. By including the parent material in the above range, the porous ceramic tile can be appropriately shaped and sintered, and mechanical stability can be ensured.

The particles for the at least two ceramic tiles include? -Alumina, so that the humidity control function can be realized. Due to the decorative effect material, the particles can exhibit excellent appearance of natural stone and at the same time have excellent humidity control function and durability due to? -Alumina. Therefore, it is possible to manage indoor air quality when used for interior decoration .

The γ-alumina is a transition alumina and can impart a humidity control function. It has a wide specific surface area and fine pore holes and can exhibit excellent properties as a separator, a catalyst, a catalyst carrier and an adsorbent.

The? -Alumina may have pores on its surface and may have an excellent humidity control and deodorizing function. Accordingly, when the humidity is high, the γ-alumina absorbs moisture through the pores to lower the humidity of the room. On the contrary, when the humidity is low, the γ-alumina emits moisture stored in the pores to increase the room humidity.

The γ-alumina may be a commercially available γ-alumina, but in terms of cost reduction and efficiency, more specifically, γ-alumina which is phase-shifted by heat treatment at a low cost aluminum source can be used.

Specifically, the at least two ceramic tile particles have a hygroscopic property and a moisture-proof property by containing? -Alumina, so that they can exhibit a function of controlling indoor humidity, inhibiting condensation formation and inhibiting microbial growth such as fungi.

For example, the? -Alumina may comprise about 5 parts by weight to about 40 parts by weight, specifically about 10 parts by weight to about 35 parts by weight, based on 100 parts by weight of the parent material. When the? -Alumina is less than about 5 parts by weight based on 100 parts by weight of the parent material, it may be difficult to exhibit a sufficient humidity control function. When the? -Alumina exceeds about 40 parts by weight, the sintering strength of the porous ceramic tile is lowered The strength of the tile may be lowered.

The? -Alumina may comprise mesopores having an average diameter of 2 nm to 50 nm. When the moisture absorptive and desorptive amount of the tile exceeds 50 g / m ² , the effectiveness of the moisture absorption and moisture-proof effect increases, so that the y-alumina contains mesopores having an average diameter of about 2 nm to about 50 nm, Can be made to exceed 50 g / m ² . When the mesopore is out of the above range, the moisture absorptive and desorptive property of? -Alumina is insignificant, and there is little humidity control effect.

Conventional natural stone finishes are difficult to include mesopores having a uniform average diameter therein, and it is also technically impossible to artificially include mesopores in the finish. However, the porous ceramic tile may include a mesopore having a certain average diameter inside the tile by a manufacturing method described later.

The γ-alumina contains mesopore, so that the moisture absorptive and desorptive amount can exceed 50 g / m ^2, thereby exhibiting an excellent humidity control function and naturally expressing the natural stone appearance.

Specifically, the 'average diameter' means an average value of pore diameters measured in each mesopore region. When the average mesopore diameter is less than about 2 nm, moisture absorption is possible, but there is a limitation in controlling the humidity , And when it exceeds about 50 nm, moisture absorptive and desorptive property can not be exerted.

The pore volume of the meso pores (mesopore) may be 0.001cm ³ / g to 0.1 cm ³ / g. The 'average diameter' can be measured by BET (Brunauer-Emmet-Teller) and can be calculated by measuring the volume of mesopore contained per unit weight of the γ-alumina. The mesopore is advantageous in retaining the fuctional site capable of controlling the humidity by maintaining the pore volume, so that sufficient humidity control can be exhibited.

The porous ceramic tile may include pores having an average diameter of about 10 nm to about 10 um. If the pore size is less than about 10 nm, the air can not easily enter and exit the interior of the porous ceramic tile. Therefore, the humidity control function may be restricted due to hygroscopicity and moisture resistance. If the pore size exceeds 10 μm, And the strength is weakened, so that breakage can easily occur.

Porous ceramic tile manufacturing method

Another embodiment of the present invention is a method for manufacturing a ceramic tile, comprising: forming a ceramic formed body by mixing a composition for a second type of ceramic tile including different decorative effect material; A step of dry-pressing the ceramic formed body to produce a porous ceramic tile; Drying the shaped porous ceramic tile; Dipping the dried porous ceramic tile into a glaze; And firing the sintered porous ceramic tile. The present invention also provides a method for manufacturing a porous ceramic tile.

2 is a photographic view of a porous ceramic tile according to an embodiment of the present invention.

First, the ceramic molded body may be formed by mixing two kinds of compositions for ceramic tile including different decorative effect material.

In order to allow the porous ceramic tile, which is the final product, to have a natural color and pattern of natural stone appearance, it is possible to mix the above two ceramic tile compositions including different effect material.

Specifically, the two kinds of ceramic tile compositions are prepared by ball milling, mixing and pulverizing a decorative effect material, an aluminum source which can be phase-transformed with γ-alumina, and a mother material, followed by a spray drying process As shown in FIG.

For example, about 5 parts by weight to about 10 parts by weight of an inorganic pigment which emits different colors to 100 parts by weight of the parent material, about 5 to 40 parts by weight of an aluminum source which can be phase-changed into? -Alumina So that the raw materials can be mixed.

The mixture can be homogeneously mixed and pulverized to an appropriate size by using a ball mill, and water, an organic binder, a dispersing agent and an antifoaming agent can be added in an appropriate amount during pulverization.

When the pulverized mixture becomes a slurry having an appropriate viscosity, two types of granular powder-like ceramic tile compositions having spherical particles can be prepared through a spray drying process.

By controlling the content of the inorganic pigment, it is possible to control the color and texture desired to be realized by the composition, and by controlling the aluminum source content which can be phase-changed into the? -Alumina, two kinds of ceramic tiles The durability and the humidity control function can be exhibited by controlling the y-alumina content in the particles.

The aluminum source which can be phase-transformed into? -Alumina may be at least one selected from the group consisting of aluminum hydroxide, aluminum nitride, aluminum carbonate, aluminum chloride, aluminum chloride dihydrate, and combinations thereof. Specifically, aluminum trihydroxide, aluminum chloride, or the like can be used.

The porous ceramic tile can be manufactured through the steps of dry-pressing the ceramic formed body. The prepared ceramic formed body, that is, the composition mixture for the first and second ceramic tiles in granular powder form can be put into a dry press mold to produce a ceramic molded body having a desired shape.

And then drying the shaped porous ceramic tile. In the drying step, although the drying temperature is not particularly limited, the drying may be performed at a temperature of about 200 ° C to about 250 ° C. In this case, during a short time passing through the hot gas- It is possible to suppress the defects such as the substrate explosion.

The dried porous ceramic tile may include souring as a glaze. The above step is for applying a glaze to the surface of the porous ceramic tile, and there is no particular limitation on the method of tilting, and wet method using glaze slurry, dried powder or granule of glaze, and dry method using calt of frit can be used.

For example, by decreasing the content of the inorganic pigment and the color additive in the slurry of the glaze, it is possible to make the color feeling realized by the composition for the first and second ceramic tiles visible and minimize the occurrence of the coloring.

Finally, the sintered porous ceramic tile may be sintered. The firing is an operation for making a curable material by heating a combined raw material. The porous ceramic tile is heated and fired to form two kinds of ceramic tile compositions including the porous ceramic tile, It can be transformed into soluble particles and fired. Specifically, it may be a γ-alumina containing a mesopore having an average diameter of about 2 nm to about 5 nm which is phase-changed in an aluminum source which can be phase-changed into the γ-alumina through a sintering step, Humidity can be controlled by.

The above two types of ceramic tile particles in which the compositions for the two types of ceramic tiles are deformed by the firing step are as described above.

The firing step may be performed at a temperature of from about 800 [deg.] C to about 1000 [deg.] C for a time of from about 1 minute to about 15 minutes. By firing at the above temperature, the aluminum source which can be phase-changed into gamma -alumina is changed into gamma -alumina, so that the moisture absorptive and desorptive properties can be improved. Specifically, the two kinds of ceramic tile compositions are the two kinds of ceramic tiles It can be transformed into a soluble particle. In addition, when the tile is installed at the temperature in the above-mentioned range, since the tile secures an appropriate strength, breakage during construction can be minimized.

The calcination may be carried out for a time of from about 1 minute to about 15 minutes. If the firing time is exceeded, the firing may not be performed sufficiently.

FIG. 2 is a photograph of a porous ceramic tile formed by the method of manufacturing the porous ceramic tile. The tile may have a similar appearance to granite and marble.

Hereinafter, specific embodiments of the present invention will be described. However, the embodiments described below are only intended to illustrate or explain the present invention, and thus the present invention should not be limited thereto.

< Example  And Comparative Example >

Example

40 parts by weight of clay, 0.2 parts by weight of blue inorganic pigment (CP-201B, Zr (Sio ₄ ) 70%, SiO ₂ 20%, ZrO ₂ 10% , Cr ₂ O ₃ 75%, SiO ₂ 25%), 13 parts by weight of aluminum trihydroxide to be phase-changed into γ-alumina, 13 parts by weight of calcium carbonate and 4 parts by weight of water are added to 4 parts by weight of glass frit and pulverized and mixed by a ball mill process The slurry thus obtained was spray dried to prepare a composition for a first ceramic tile, which was spherical granular powder.

Clay 38 parts by weight of inorganic pigment _{(FCS-33735, Cr 1x Fe} 1 .66 for black implemented _x O4 _x About 99%), 13 parts by weight of aluminum trihydroxide to be phase-changed into γ-alumina, 13 parts by weight of calcium carbonate and 4 parts by weight of water are added to 4 parts by weight of glass frit and pulverized and mixed by ball milling The obtained slurry was spray-dried to prepare a composition for a second ceramic tile which was spherical granular powder.

Next, the ceramic compositions were formed by mixing the compositions for the first and second ceramic tiles at a ratio of 3: 7, and then the ceramic formed bodies were dry-pressed to form porous bodies having dimensions of 5 cm, 5 cm, Ceramic tiles were prepared. Then, the ceramic tiles were put into an electric furnace and fired at a temperature of 850 ° C. for 5 minutes to prepare porous ceramic tiles including the particles for the first and second ceramic tiles.

Comparative Example  One

Porous ceramic tiles were prepared in the same manner as in the above example, except that porous ceramics tiles were prepared after forming a formed body with the composition for the first ceramic tile.

Comparative Example  2

forming a mixture except for the aluminum trihydroxide to be phase-changed into? -alumina, preparing a composition for the first ceramic tile, forming a formed body with the composition for the first ceramic tile, Porous ceramic tiles were prepared in the same manner as in the above example.

< Experimental Example 1 > - Effect of porous ceramic tile color implementation

The colors of the porous ceramic tiles of the examples and comparative examples were visually observed to evaluate the appearance of the natural stone.

Example Comparative Example 1 Comparative Example 2 Excellent appearance of natural stone appearance Bad appearance of natural stone appearance Bad appearance of natural stone appearance

Referring to Table 1, the examples were formed using the compositions for the first and second ceramic tiles, and the natural stone appearance was superior to the first and second comparative examples formed by using only the composition for the first ceramic tile.

< Experimental Example 2 > - Porous ceramic tile Absorption and desorption  And Flexural strength  Measure

The moisture absorptive and desorptive amount and the bending strength of the porous ceramic tiles of the examples and comparative examples were measured and the results are shown in Table 2 below.

1) Absorbing and desorbing amount: Porous ceramic tiles of the above examples and comparative examples were left for 24 hours under the conditions of a temperature of 25 ° C and a relative humidity (RH) of 50% , And the weight difference was measured. Then, the weight difference was measured again after maintaining the temperature at 25 ° C and RH 50% for 12 hours, and the weight difference was measured. The average value was divided by the surface area to obtain g / m ² value Respectively.

2) Flexural strength: The three-point bending strength method was used to measure the flexural strength, and three rectangular parallelepiped tiles each having a length of 5 cm and a length of 5 cm and a height of 0.5 cm were prepared, and then a force was applied to the bending strength Were measured.

The bending strength is calculated by (3PL) / (2wt ^ 2), where P is the maximum load when the tile is broken, L is the external spacing, w is the width of the tile, and t is the thickness of the tile.

Moisture absorptive and desorptive amount (g / m ² ) Strength (MPa) Example 77.5 5.5 Comparative Example 1 75.2 5.1 Comparative Example 2 2.7 5.3

Referring to Table 2, it can be seen that Example 1 formed by using the composition for the first and second ceramic tiles is superior in the moisture absorptive and desorptive amount and strength compared to Comparative Examples 1 and 2 formed by using the composition for the first ceramic tile there was.

In addition, the composition for the first ceramic tile of Comparative Example 2 does not contain? -Alumina, so that the moisture absorptive and desorptive amount is remarkably low, so that it does not possess the effective moisture absorptive and desorptive property.

Claims (15)

And at least two ceramic tile particles,
Wherein the at least two particles for ceramic tiles each comprise different decorative effect material,
Wherein the particles for the at least two ceramic tiles comprise a decorating effect material, gamma -alumina, and parent material,
Wherein 0.1 to 20 parts by weight of a decorative effect material is contained in 100 parts by weight of the parent material
Porous ceramic tiles.
The method according to claim 1,
Wherein the two or more ceramic tile particles include pigments of different colors from each other so that the colors imparted to the two or more ceramic tile particles together form a composite color tone
Porous ceramic tiles.
The method according to claim 1,
Wherein the decorating effect material comprises at least one selected from the group consisting of pigments, metal flakes, metal powders, glitter powders, and combinations thereof
Porous ceramic tiles.
The method according to claim 1,
Wherein the particles for the at least two ceramic tiles are in the form of a plurality of small particles,
Porous ceramic tiles.
The method according to claim 1,
Wherein the average diameter of the particles for the two or more ceramic tiles is 50um or more
Porous ceramic tiles.
delete delete The method according to claim 1,
Wherein the parent material comprises at least one selected from the group consisting of clay, loess, clay and combinations thereof
Porous ceramic tiles.
The method according to claim 1,
Wherein said gamma -alumina comprises mesopores having an average diameter of 2 nm to 50 nm
Porous ceramic tiles.
10. The method of claim 9,
The meso pore has a pore volume (mesopore) 0.001cm ³ / g to 0.1 cm ³ / g of
Porous ceramic tiles.
The method according to claim 1,
Wherein the porous ceramic tile includes pores having an average diameter of 10 nm to 10 [mu] m
Porous ceramic tiles.
Mixing a composition for two types of ceramic tiles including different decorative effect material to form a ceramic formed body;
A step of dry-pressing the ceramic formed body to produce a porous ceramic tile;
Drying the shaped porous ceramic tile;
Dipping the dried porous ceramic tile into a glaze; And
And firing the sintered porous ceramic tile,
The composition for the two types of ceramic tiles is formed by ball-milling, mixing and grinding a decorative effect-imparting material, an aluminum source which can be phase-changed into gamma -alumina, and a mother material, and then forming the mixture by a spray drying process And,
Wherein 0.1 to 20 parts by weight of the decorative effect-imparting material is added to 100 parts by weight of the parent material
A method for manufacturing a porous ceramic tile.
delete 13. The method of claim 12,
The aluminum source which can be phase-transformed into? -Alumina may be at least one selected from the group consisting of aluminum hydroxide, aluminum nitride, aluminum carbonate, aluminum chloride, aluminum chloride dihydrate and combinations thereof
A method for manufacturing a porous ceramic tile.
13. The method of claim 12,
The firing step is performed at a temperature of 800 ° C to 1000 ° C for a time of 1 minute to 15 minutes
A method for manufacturing a porous ceramic tile.

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