tile

Abstract

To provide a tile having brilliant feeling.SOLUTION: A tile 1 is provided with an uneven structure on a surface 1A by a plurality of glaze particles 3. In the surface 1A, a plurality of mineral particle 7 having flat surfaces 8 are arranged in a manner that each flat surface 8 faces in two or more directions.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates to tiles. [Background technology]

[0002] For example, Patent Document 1 discloses a ceramic product having a lustrous property. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 2019-123655 Summary of the Invention [Problem to be solved by the invention]

[0004] However, this ceramic product has a problem of having a weak luster. The present disclosure has been made in consideration of the above-mentioned circumstances, and aims to provide a tile with a high luster. The present disclosure can be realized in the following forms. [Means for solving the problem]

[0005] The surface is made uneven by the multiple glaze particles. A tile having a surface on which a plurality of mineral particles having flat surfaces are arranged with each of the flat surfaces facing in two or more different directions. [Brief explanation of the drawings]

[0006] [Figure 1] FIG. [Figure 2] FIG. [Figure 3] 1 is a surface observation image of a tile of an example (Experimental Example 3) observed by SEM. [Figure 4] FIG. 4 is a diagram showing particle contours for explanation purposes in the surface observation image of FIG. 3. [Figure 5]1 is a surface observation image of a tile of a comparative example (Experimental Example 1) observed by SEM. DETAILED DESCRIPTION OF THE INVENTION

[0007] The present disclosure will be described in detail below. Note that when a numerical range is described using "-", it is intended to include both the lower limit and the upper limit unless otherwise specified. For example, the description "10-20" includes both the lower limit "10" and the upper limit "20". In other words, "10-20" has the same meaning as "10 or more and 20 or less". 1. Tile 1 The tile 1 has a surface 1A formed with a concave-convex structure by a plurality of glaze particles 3. On the surface 1A, a plurality of mineral particles 7 each having a flat surface 8 are arranged with each flat surface 8 facing in two or more different directions. The size and shape of the tile 1 are not particularly limited and can be changed as appropriate depending on the application. For example, the tile 1 can be in the shape of a plate.

[0008] There is no particular limitation on the use of the tile 1. For example, the tile 1 is used as a flooring material for living rooms, entrance rooms, bathrooms, kitchens, etc. in buildings such as houses. It is also used as a flooring material for buildings, stations, public facilities, and commercial facilities.

[0009] (1) Tile base 9 From the viewpoint of maintaining a beautiful appearance, the tile 1 preferably comprises a tile base 9 and a glaze layer 11 formed on the tile base 9. The tile 1 may also be one without the glaze layer 11. The raw material (tile raw material) of the tile base 9 is not particularly limited as long as it is a raw material that can be fired to produce the tile 1. Tile raw materials are generally made primarily of clay and feldspar. Here, the term "main raw material" refers to a raw material that accounts for 50 parts by mass or more of the total of the tile raw material, assuming that the tile raw material is 100 parts by mass, meaning that the total of the clay and feldspar is 50 parts by mass or more. The tile raw material may contain pottery stone, limestone, or talc as necessary. The tile raw material may also contain various additives such as pigments.

[0010] (2) Glaze layer 11 The glaze layer 11 is formed, for example, by firing a glaze applied to at least one surface of a molded body formed from a tile raw material.

[0011] (3) Glaze grains 3 The glaze particles 3 are made by crushing frit (glass frit) and are also called granular frit (glass particles). The glaze particles 3 are preferably scattered on the tile base 9. The chemical composition of the glaze particles 3 is not particularly limited. Examples of oxides contained in the glaze particles 3 include SiO2, Al2O3, BO3, PO5, CaO, MgO, BaO, ZnO, PbO, Na2O, KO, Li2O, and ZrO2. The glass transition temperature (Tg) of the material constituting the glaze particles 3 is not particularly limited. If the glaze particles 3 melt so much that they deform during firing and their height becomes too low, it becomes difficult to adjust the orientation of the flat surfaces 8 of the mineral particles 7 to various directions. In other words, if the glaze particles 3 deform and become too low, even if the mineral particles 7 lean against the glaze particles 3, the orientation of the flat surfaces 8 of multiple mineral particles 7 will be generally uniform, approximately parallel to the surface of the tile base 9 or the surface of the glaze layer 11. As a result, the lustrous properties of the tile 1 will not be fully exhibited. On the other hand, if the glaze particles 3 do not melt enough during firing, the mineral particles 7 will not be sufficiently fixed (anchored) to the surface of the glaze particles 3. Therefore, from these perspectives, the glass transition temperature (Tg) of the material constituting the glaze particles 3 is preferably 500°C or higher and 700°C or lower.

[0012] There is no particular limitation on the particle size of the glaze particles 3. The average particle size of the glaze particles 3 is preferably 10 μm or more and 250 μm or less, more preferably 10 μm or more and 200 μm or less, and even more preferably 10 μm or more and 150 μm or less. The average particle diameter of the glaze particles 3 is determined by observation using a scanning electron microscope. Specifically, the surface of the glaze particles 3 is observed using a scanning electron microscope (SEM), and the maximum diameter of each glaze particle 3 is taken as the particle diameter of the glaze particle 3. The maximum diameter of the glaze particles 3 may be determined automatically using image analysis software, or by measuring the maximum diameter from the obtained SEM image. When measuring the maximum diameter from the obtained SEM image, a straight line is drawn connecting any two points on the periphery of the glaze particle 3 in the SEM image, and the point where the length of that line is greatest is identified. The length of the line at that point is then measured, and this is taken as the maximum diameter of the glaze particle 3. Some of the glaze grains 3 are partially buried in the glaze layer 11 (see reference numerals 3C, 3D, 3E, 3F, and 3G in FIG. 4). Some of the glaze grains 3 are partially covered and hidden by the mineral particles 7 (see reference numerals 3A, 3E, and 3F in FIG. 3). Some of the glaze grains 3 are bonded together (see reference numeral 3G in FIG. 3). To measure the maximum diameter of the glaze grains 3, ten glaze grains 3 whose overall size can be grasped are selected and measured, for example, ten individual particles whose outer peripheries can be roughly grasped, such as those shown by reference numerals 3B and 3H in FIG. 3. The average particle diameter of the ten glaze grains 3 is then used as the average particle diameter.

[0013] (4) Mineral particles 7 The mineral particles 7 are not particularly limited as long as they have flat surfaces 8. From the viewpoint of enhancing the brilliance, the mineral particles 7 are preferably at least one type selected from the group consisting of mica and hematite. It is preferable that at least a portion of the flat surfaces 8 of the mineral particles 7 is exposed without being covered with glass or the like. There are no particular limitations on the average particle size of the mineral particles 7. The average particle size of the mineral particles 7 is preferably 10 μm or more and 400 μm or less, more preferably 10 μm or more and 300 μm or less, and even more preferably 10 μm or more and 250 μm or less. The average particle diameter of the mineral particles 7 is determined by observation with a scanning electron microscope. Specifically, the surface of the mineral particles 7 is observed with a scanning electron microscope (SEM), and the maximum diameter of each mineral particle 7 is taken as the particle diameter of the mineral particles 7. The maximum diameter of the mineral particles 7 may be determined automatically using image analysis software, or may be determined by measuring the maximum diameter from an obtained SEM image. When measuring the maximum diameter from an obtained SEM image, a line is drawn connecting any two points on the periphery of the mineral particle 7 in the SEM image, and the point where the length of the line is greatest is identified. The length of the line at that point is then measured, and this is taken as the maximum diameter of the mineral particles 7. Some mineral particles 7 are partially buried in the glaze layer 11 (see 7A, 7B, and 7C in Figure 4). Other mineral particles 7 are partially covered and hidden by the glaze grains 3 (see 7D in Figure 4). To measure the maximum diameter of mineral particles 7, ten mineral particles 7 whose overall size can be grasped—for example, ten particles whose entire peripheries can be grasped, such as those shown by 7D in Figure 4—are selected and measured. The mineral particle 7 designated by 7D is barely buried in the glaze layer 11, and only a small portion is hidden by the glaze grains 3. It is believed that the exposed area is 90% or more. The maximum diameter of the mineral particle 7 designated by 7D can be determined using the observable periphery. The average particle diameter of the ten mineral particles 7 is then used as the average particle diameter.

[0014] (5) Amount of glaze particles 3 and mineral particles 7 (5.1) Ratio of glaze particles (3) to mineral particles (7) The ratio (mass ratio) of the glaze particles 3 to the mineral particles 7 is not particularly limited. From the viewpoint of obtaining a sufficient brilliance while suppressing the detachment of the mineral particles 7 from the tile 1, the mass ratio of the glaze particles 3 to the mineral particles 7 is preferably in the range of 100:3 to 100:15, more preferably 100:3 to 100:6.

[0015] (5.2) Amount of glaze particles 3 The mass of the glaze particles 3 per unit area of ​​the surface 1A (hereinafter also simply referred to as "mass of the glaze particles 3 per unit area") is not particularly limited. In order to form a sufficient uneven structure, the mass of the glaze particles 3 per unit area is 5 g / m 2 More than 10g / m is preferable. 2 More preferably, 40 g / m 2 The upper limit of the mass of the glaze particles 3 per unit area is not particularly limited, but is preferably 100 g / m 2 The following is preferred: Therefore, the mass of glaze grain 3 per unit area is 5 g / m 2 More than 100g / m 2 Less than 10 g / m 2 More than 100g / m 2 Less than 40 g / m is more preferable. 2 More than 100g / m 2 The following is even more preferred:

[0016] (5.3) Amount of mineral particles 7 The mass of the mineral particles 7 per unit area of ​​the surface 1A (hereinafter also simply referred to as "mass of the mineral particles 7 per unit area") is not particularly limited. The mass of the mineral particles 7 per unit area is set to 0.1 g / m from the viewpoint of enhancing the brilliance and suppressing the mineral particles 7 from overlapping with each other and not being sufficiently fixed to the glaze particles 3 and falling off. 2 More than 1.5g / m 2 Less than 0.2 g / m is preferred 2 More than 1.0g / m 2 Less than 0.4 g / m is more preferable. 2 More than 0.8g / m 2 The following is even more preferred:

[0017] (6) The state of glaze particles 3 and mineral particles 7 In the case of a tile 1 having a glaze layer 11, the glaze particles 3 are preferably scattered on the glaze layer 11. In the case of a tile 1 without a glaze layer 11, the glaze particles 3 are preferably scattered on the tile substrate 9. The mineral particles 7 are arranged on the surface 1A with their respective flat surfaces 8 facing in two or more different directions. This requirement is met if a pair (two) of mineral particles 7 having flat surfaces 8 facing in different directions are observed on the surface 1A. To confirm that the mineral particles 7 are arranged in this manner, for example, the surface 1A can be observed using a microscope, two mineral particles 7 are selected, and the two contrasting flat surfaces 8 of the two mineral particles 7 are observed. Specifically, the fact that the two flat surfaces 8 face in different directions can be confirmed as follows: Two mineral particles 7 are selected using a microscope, and the normal vectors V of the two contrasting flat surfaces 8 of the two mineral particles 7 are determined. When the angle between the two normal vectors V is greater than 0° (preferably greater than 10°), it can be confirmed that the two flat surfaces 8 face in different directions. Note that the angle between the two normal vectors V is usually less than 180°. An example will be described in which two mineral particles 7 are observed, as shown in Figure 2. The two mineral particles 7 each have a flat surface 8A, 8B. Both flat surfaces 8A, 8B face the front side of the tile 1. The normal vectors V of the flat surfaces 8A, 8B are defined as normal vectors V1, V2, respectively. In this case, if the angle between normal vector V1 and normal vector V2 is greater than 0°, it is determined that the two flat surfaces 8A, 8B face in different directions.

[0018] The mineral particles 7 are present around the glaze particles 3, and the mineral particles 7 are preferably fixed to the glaze particles 3. With this configuration, the mineral particles 7 are less likely to detach from the tile 1. The mineral particles 7 are preferably fixed to the glaze grains 3 in a manner that they lean against the glaze grains 3. By leaning against the glaze grains 3, the mineral particles 7 are stably fixed to the glaze grains 3. The directions in which the flat surfaces 8 face differ among the multiple mineral particles 7 because they lean against the glaze grains 3 differently. For example, Figure 2 shows that the mineral particles 7 on the left and the mineral particles 7 on the right lean against the glaze grains 3 in different ways, resulting in different directions in which the flat surfaces 8 face. It is preferable that at least a portion of the flat surface 8 of the mineral particles 7 is exposed on the surface 1A of the tile 1. This eliminates the need for incident light to pass through the glaze layer 11, etc. before reaching the flat surface 8, and also eliminates the need for reflected light to pass through the glaze layer 11, etc., resulting in an increased sense of brilliance.

[0019] (7) Arithmetic mean height Sa There is no particular limitation on the arithmetic mean height Sa in the portion of the tile 1 where the concave-convex structure is formed. The arithmetic mean height Sa is defined in JIS B0681-2:2018. From the viewpoint of obtaining a sufficient sense of brilliance, the arithmetic mean height Sa is preferably 9 μm or more, more preferably 12 μm or more, and even more preferably 15 μm or more. On the other hand, from the viewpoint of improving the cleanability of the tile 1 and / or the feel of the tile 1 to the touch, the arithmetic mean height Sa is preferably 35 μm or less, more preferably 25 μm or less, and even more preferably 15 μm or less. From these viewpoints, the arithmetic mean height Sa is preferably 9 μm or more and 35 μm or less, more preferably 12 μm or more and 25 μm or less, and even more preferably 12 μm or more and 15 μm or less.

[0020] 2. Manufacturing method of tile 1 An example of a manufacturing method for the tile 1 will be described. The tile 1 of the present disclosure can be suitably manufactured by the following manufacturing method. First, a base material is obtained from ceramic raw materials. Next, a glaze is applied (glazed) to the surface of the base material to obtain a glazed product. The glaze can be applied (glazed) using methods commonly used in tile production, such as curtain glazing, spray glazing, and centrifugal glazing. The glazed product may also be decorated. For decoration, for example, glaze (ink) may be sprayed onto the surface of the glazed product from the tip (head) of a nozzle without contact, thereby reproducing the data that forms the basis of the design. This type of decoration is also called digital decoration (inkjet decoration).

[0021] The glazed product is then coated (glazed) with a mixed liquid containing granular frit and mineral particles 7. The mixed liquid is a liquid in which the granular frit and mineral particles 7 are dispersed in a predetermined aqueous solution. For coating (glazing) the dispersion liquid, methods such as curtain coating, spray glazing, and centrifugal glazing, which are commonly used for glazing in tile production, can be used. Other methods that can be used include spin coating, roll coating, and brush coating. The coated product with the dispersion liquid coated is fired at a predetermined temperature.

[0022] The firing temperature is preferably 850°C or higher and 1300°C or lower from the viewpoint of adequately adhering the mineral particles 7 to the surfaces of the glaze particles 3. On the other hand, the firing temperature is preferably 1200°C or lower from the viewpoint of the following: If the glaze particles 3 are deformed and become too low, it becomes difficult to adjust the orientation of the flat surfaces 8 of the mineral particles 7 to various directions. In other words, if the glaze particles 3 are deformed and become too low, even if the mineral particles 7 lean against the glaze particles 3, the orientation of the flat surfaces 8 of multiple mineral particles 7 will be generally uniform, approximately parallel to the surface of the tile base 9 or the surface of the glaze layer 11. As a result, the lustrous properties of the tile 1 will not be fully exhibited. Therefore, to prevent this phenomenon and fully ensure the lustrous properties of the tile 1, the upper limit of the firing temperature during firing is preferably the value described above. From these viewpoints, the firing temperature is preferably 850°C or higher and 1200°C or lower. [Example]

[0023] The present invention will be explained in more detail below with reference to examples. Experimental Examples 2, 3, 5, and 6 correspond to examples, and Experimental Examples 1 and 4 are comparative examples.

[0024] 1. Making tiles (1) Experimental example The ceramic base was prepared, and then glazed with a layer of glaze. Next, it was digitally decorated using an inkjet printer. Next, a mixture containing hematite and glaze particles was applied by draping or spraying. The amount of glaze particles applied was determined so that the amount of glaze particles on the tile surface was as shown in Table 1. The amount of hematite applied was determined so that the amount of hematite on the tile surface was 0.6 g / m 2 It was made to be like this. The coated product with the mixed liquid was fired at a maximum temperature of 1200°C using a roller hearth kiln (firing furnace).

[0025] [Table 1]

[0026] 2. Evaluation Method (1) Evaluation of brilliance (1.1) Evaluation by evaluation machine The Si / Sa value was determined using the following evaluation equipment. Separate experiments confirmed that the Si / Sa value correlates with the tile's brilliance. Specifically, when the correlation between the Si / Sa value and the sensory evaluation values ​​(described below) by five monitors was checked for several types of tiles with various brilliance, a correlation between the two was confirmed. It was found that the brilliance increases as the Si / Sa value increases. Therefore, it was confirmed that the Si / Sa value can be used as a substitute characteristic value for the brilliance (sparkle) of a tile surface. [Evaluation machine overview] Machine name: BYK-mac i 23mm (multi-angle colorimeter) Manufacturer: BYK-Gardner Product code: 7030 Measurement method: The measurement was performed once, and the average Si / Sa values ​​obtained at 15°, 45°, and 75° were used.

[0027] (1.2) Sensory evaluation Each of the five monitors evaluated the brilliance of the tile surface on a 5-point scale. The brilliance was evaluated on the following 5-point scale. The greater the brilliance (sparkle), the higher the score. The evaluation scores of the five people were then averaged to evaluate the brilliance. [Evaluation criteria] Score 1: Slightly shiny. Score 2: Shiny. Score 3: Very shiny. Score 4: Very bright Score 5: Very bright.

[0028] (2) Adhesion evaluation After the adhesive tape was adhered to the tile surface, the adhesive tape was peeled off. The hematite that had peeled off from the tile surface and adhered to the adhesive tape was visually observed and evaluated according to the following criteria. [Evaluation criteria] A: No hematite adheres to the adhesive tape. The hematite adheres very well to the tile surface. B: Almost no hematite adheres to the adhesive tape side. The hematite adheres well to the tile surface. C: A large amount of hematite adheres to the adhesive tape. The adhesion of hematite to the tile surface is poor.

[0029] (3) Evaluation by SEM The surface of each tile was observed by SEM.

[0030] 2. Evaluation Results The evaluation results of the glaze quality are also shown in Table 1. Experimental Examples 2, 3, 5, and 6, which used glaze particles, had a high glaze quality. SEM observation of the surfaces of Experimental Examples 2, 3, 5, and 6, which used glaze particles (see Figures 3 and 4), revealed that the surface had an uneven structure formed by multiple glaze particles, and that hematite particles were arranged with their flat surfaces facing in two or more different directions. The SEM images also revealed that hematite particles were present around the glaze particles and adhered to them. Furthermore, in Experimental Examples 2, 3, 5, and 6, the average particle diameter of the glaze particles was observed to be between 50 μm and 150 μm, as measured by the previously described method. Furthermore, in Experimental Examples 2, 3, 5, and 6, the average particle diameter of the hematite particles was observed to be between 10 μm and 250 μm, as measured by the previously described method.

[0031] Experimental Examples 3 and 6, in which the arithmetic mean height Sa was 9 μm or more and 35 μm or less, had a very high sense of brilliance.

[0032] Experimental Examples 1 and 4, which did not use glaze particles, had a low brilliance. When the surfaces of Experimental Examples 1 and 4, which did not use glaze particles, were observed using an SEM (see Figure 5), it was observed that the flat surfaces of the hematite particles on the surface were arranged facing the same direction.

[0033] The present invention is not limited to the above-described embodiments and examples, and various modifications and variations are possible. [Explanation of symbols]

[0034] 1...tile, 1A...surface, 3...glaze grain, 7...mineral particle, 8...surface, 8A...surface, 8B...surface, 9...tile substrate, 11...glaze layer, Sa...arithmetic mean height, V...normal vector, V1...normal vector, V2...normal vector

Claims

1. A plurality of glaze particles are scattered on the surface to form an uneven structure on the surface, A tile having a surface on which a plurality of mineral particles having flat surfaces are arranged with each of the flat surfaces facing in two or more different directions.

2. The mineral particles are present around the glaze grains, The tile of claim 1 , wherein the mineral particles are adhered to the glaze grains.

3. 3. The tile according to claim 1, wherein the mass ratio of the glaze particles to the mineral particles is in the range of 100:3 to 100:

15.

4. In the area where the concave-convex structure is formed, The mass per unit area of ​​the glaze particles is 5 g / m ２ The tile according to any one of claims 1 to 3, wherein:

5. The tile according to any one of claims 1 to 4, wherein the mineral particles have an average particle size of 10 µm or more and 250 µm or less.

6. In the area where the concave-convex structure is formed, The tile according to any one of claims 1 to 5, wherein an arithmetic mean height Sa is 9 µm or more and 35 µm or less.

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