Plastic and nonmetallic article shaping or treating: processes – Disparate treatment of article subsequent to working,... – Effecting temperature change
Reexamination Certificate
1999-03-30
2001-02-13
Fiorilla, Christopher A. (Department: 1731)
Plastic and nonmetallic article shaping or treating: processes
Disparate treatment of article subsequent to working,...
Effecting temperature change
C264S234000
Reexamination Certificate
active
06187239
ABSTRACT:
INDUSTRIAL FIELD OF THE INVENTION
The present invention relates to a method of manufacturing an article, which is similar to an unglazed ceramic plate and is made of mainly clayey materials such as sericite and kaolin, without requiring a process that consumes a large amount of energy.
DESCRIPTION OF THE PRIOR ART
To manufacture molded articles using clayey materials, a method of kneading the clayey material with water thoroughly and then sintering a mixture, or methods of employing liquid glass, portland cement and a thermosetting resin have been proposed and practiced heretofore.
The sintering method can provide a sintered product having high strength, but needs a large amount of energy and consumes fuel, electric power, etc. considerably because of requiring high temperatures on the order of several hundreds to several thousands degrees. This method also requires a large-scale installation. The methods of employing liquid glass, portland cement, etc. (disclosed in JP, 57-88062, A and JP, 58-2255,A) accompany such problems that the use of liquid glass needs a long time for developing water resistance, and the use of cement causes a whitening phenomenon, i.e., produces a whitish precipitate when immersed in water. Also, the products manufactured by those methods are remarkably deteriorated in strength. An artificial stone using a thermosetting resin as a main component has a limit in refractoriness and always has a polished glossy appearance because the main component is a resin, i.e., an organic substance.
PROBLEM TO BE SOLVED BY THE INVENTION
An object of the present invention is to provide an interior or exterior finishing material, which is made of a clayey material as a main ingredient and is superior in water resistance and refractoriness, without consuming a large amount of energy as required in the sintering method.
MEANS FOR SOLVING THE PROBLEM
The present invention provides a manufacture method of an article similar to an unglazed ceramic plate, which is featured in using, as molding materials, a mixture of a clayey main ingredient of sericite or/and kaolin, a resin liquid as an agent for developing strength earlier, and a disperse solution of aluminum silicate as a weight reducing agent, and in producing a light-weight molded article, which is superior in water resistance and refractoriness and is free from a whitening phenomenon, by molding, drying and heating the mixture for hardening.
The above mixture preferably contains a pentaerythritol aqueous solution as an agent for improving fluidity in a mixing step. In this connection, the present invention provides a manufacture method of an article similar to an unglazed ceramic plate, which is featured in using, as molding materials, a mixture of a clayey main ingredient of sericite or/and kaolin, a resin liquid as an agent for developing strength earlier, a disperse solution of aluminum silicate as a weight reducing agent, and a pentaerythritol aqueous solution as an agent for improving fluidity in a mixing step, and in producing a light-weight molded article, which is superior in water resistance and refractoriness and is free from a whitening phenomenon, by molding, drying and heating the mixture for hardening.
The above mixture is specifically prepared by adding 40-60 weight parts of the clayey main ingredient to a liquid having a composition of 14-17 weight parts of a solution prepared by dispersing 4-9% of aluminum silicate in a 4% polyethylene glycol aqueous solution, 5-6 weight parts of a 2% pentaerythritol aqueous solution, and 11-29 weight parts of a resin disperse liquid. In this connection, the present invention provides a manufacture method of an article similar to an unglazed ceramic plate, which is featured in using, as molding materials, a mixture of a clayey main ingredient of sericite or/and kaolin, a resin liquid as an agent for developing strength earlier, and a disperse solution of aluminum silicate as a weight reducing agent, and in producing a light-weight molded article, which is superior in water resistance and refractoriness and is free from a whitening phenomenon, by molding, drying and heating the mixture for hardening.
The hardening under heating is specifically performed in the range of 110° C. to 150° C. In this connection, the present invention provides a manufacture method of an article similar to an unglazed ceramic plate, which is featured in using, as molding materials, a mixture of a clayey main ingredient of sericite or/and kaolin, a resin liquid as an agent for developing strength earlier, and a disperse solution of aluminum silicate as a weight reducing agent, and in producing a lightweight molded article, which is superior in water resistance and refractoriness and is free from a whitening phenomenon, by molding, drying and heating the mixture for hardening in the range of 110° C. to 150° C.
MODE FOR CARRYING OUT THE INVENTION
The clayey main ingredient is given by, for example, a clayey material containing a mica clay mineral or a kaolin mineral as a main component. Clayey materials called sericite and kaolin are used in an embodiment of the present invention.
The resin liquid used in the present invention has an effect of developing strength earlier. For example, a resin liquid having a composition of a 7.8% 2-propanol - water disperse solution that contains 60-63% of an acrylic styrene emulsion (solid part: 47.5%) and 5.0-6.0% of methylated melamine resin. An appropriate amount of water is added to the resin liquid if necessary for easier mixing and kneading.
The disperse solution of aluminum silicate contributes to reducing weight of the final product.
According to the method of the present invention, 40-60 weight parts of clayey materials such as called sericite and kaolin are mixed solely or in a combined fashion to a liquid having a composition of 14-17 weight parts of a solution prepared by dispersing 4-9% of aluminum silicate in a 4% polyethylene glycol (PEG) #200 aqueous solution, 5-6 weight parts of a 2% pentaerythritol aqueous solution, and 11-29 weight parts of the resin liquid. After kneading the mixture thoroughly, the mixture is, by way of example, filled in a mold for forming into a desired shape, followed by drying. After the drying, a molded product is heated to temperatures of 110° C. to 150° C. for hardening.
The manufacture process is summarized below. First, 14-17 weight parts of a 4% PEG #200 gelated water-disperse solution containing 4-9% of aluminum silicate, 5-6 weight parts of a 2% pentaerythritol aqueous solution, and 10-29 weight parts of a resin liquid having a composition described later are mixed together. Then, 40-60 weight parts of clayey materials such as called sericite and kaolin are put into the above mixed liquid solely or in a combined fashion, followed by kneading the mixture thoroughly. The mixture ratio of the clayey materials has no limitations and is adjusted depending on the tone and specific gravity required. The apparent specific gravity is larger when kaolin is used solely, and reduces as the mixing ratio of sericite increases. Though depending on effects of the other composition ingredients, the apparent specific gravity of the mixture is in the range of 1.77 to 1.06.
The effects of the other composition ingredients upon the apparent specific gravity have such a tendency that a larger amount of the resin liquid increases the apparent specific gravity, and a larger amount of the disperse solution of aluminum silicate reduces the apparent specific gravity.
The resin liquid used in the present invention is a composition prepared by dispersing, in water, 60-64%, preferably 62.5%, of an acryl styrene emulsion (solid part: 27.5%), 5.0-6.0%, preferably 5.9%, of methylated melamine resin, and 7.0-8.0%, preferably 7.8%, 2-propanol.
The amount of water added to facilitate kneading of the mixture is preferably as small as possible for shortening a period of time required for the subsequent drying step. However, the amount of water added must be increased as the mixing ratio of sericite increases. When sericite is used solely, th
Igari Makoto
Taira Tetsusaburo
Armstrong, Westerman Hattori, McLeland & Naughton
Fiorilla Christopher A.
Tokyo Seihinkaihatsu Kenkyusho
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