Ceramic material

Abstract

Provided is a ceramic material with improved design. The ceramic material includes a base material and a design material. At least a part of the design material is exposed on the surface and has a particle diameter and / or a color tone different from that of the base material. With the ceramic material, a more natural-looking design can be obtained. The ceramic material preferably has at least a color tone different from that of the design material, and in such a case, preferably, ΔL * is more than 0 and 70 or less, Δa * is more than 0 and 20 or less, Δb * is more than 0 and 45 or less, and ΔE * ab is more than 0 and 73.8 or less.

Description

Ceramic materials

[0001] The present disclosure relates to ceramic materials.

[0002] Ceramic materials have been known for use in the exterior and interior walls, roofs, etc. of buildings. In conventional ceramic materials, designs have been formed by molding a pattern using a mold or by painting with paint. However, in recent years, there has been a need for designs with a natural texture, and ceramic materials with designs closer to a natural texture have been proposed (see, for example, Patent Document 1).

[0003] Japanese Patent Application Laid-Open No. 2002-020157

[0004] The technology disclosed in Patent Document 1 involves impact processing the surface layer of a molded body, removing all or part of the surface layer to expose the interior, thereby obtaining an exterior material with excellent design. However, the technology disclosed in Patent Document 1 requires the skill, effort, and cost of impact processing, as the material that forms the design does not appear on the surface in its natural state. Meanwhile, there has been a demand for the development of ceramic materials with better design that make use of the material's original texture.

[0005] The present disclosure has been made in view of the above, and aims to provide a ceramic material with better designability.

[0006] The present disclosure relates to a ceramic material including a substrate and a decorative material, at least a portion of which is exposed on the surface and which has a particle size and / or a color tone different from that of the substrate.

[0007] <Ceramic Material> The ceramic material according to this embodiment includes a base material and a decorative material. A portion of the decorative material is exposed on the surface of the ceramic material, and the color and shape of the material itself used as the decorative material constitute the design. The decorative material differs from the base material in particle size and / or color tone. This allows for a design with a natural feel. The uses of the ceramic material are not particularly limited, but it can be used, for example, as decorative panels for the exterior or interior walls of buildings, exterior structural components such as gate sleeves and fences, roofing materials, partitions, etc.

[0008] (Substrate) As the substrate, any material used for ceramic materials can be used without any particular limitation, including, for example, cement, aggregate, pulp, silica sand, coloring material, waste material, etc.

[0009] Examples of cement include, but are not limited to, ordinary Portland cement, high-early-strength cement, alumina cement, magnesia cement, etc. Examples of aggregate include lightweight aggregate and silica stone. Examples of lightweight aggregate include perlite, pumice, and shirasu balloons. Examples of pulp include, but are not limited to, various pulp materials such as wood pulp (N-wood pulp, L-wood pulp, etc.), waste paper pulp, mechanical pulp, and chemical pulp. Examples of silica sand include, but are not limited to, artificial silica sand produced by crushing and classifying quartz, and natural silica sand collected and classified in the form of quartz sand from land, estuaries, coasts, etc. Examples of waste materials include fly ash, blast furnace slag, silica fume, and recycled materials (crushed scraps generated during the hardened body manufacturing process).

[0010] [Coloring material] The substrate may contain a coloring material as needed. The coloring material is used for the purpose of coloring the substrate. Therefore, in the concept of the color tone difference between the design material and the substrate described later, the color tone of the substrate containing a coloring material means the color tone of the substrate colored by the coloring material. The coloring material is not particularly limited, but it is preferable that it contains a carbonized material obtained by carbonizing waste material or biomass material. This allows the CO ２ The coloring agent can be fixed to the ceramic material. A specific example of the coloring agent is bamboo charcoal. The coloring agent may be used alone or in combination of two or more.

[0011] [Water Repellent] The substrate preferably contains a water repellent. Because the ceramic material according to this embodiment contains a decorative material, depending on the quality of the decorative material, it is expected that the water absorption rate of the ceramic material will be higher than that of ceramic materials that do not contain a decorative material. If the water absorption rate of a ceramic material is high, there is a risk of frost damage or changes in the design after thawing. By incorporating a water repellent into the ceramic material, the above-mentioned situations can be prevented. The content of the water repellent is preferably 0.01 to 5 mass% solids mass ratio based on the total weight of the solids of the ceramic material. The content of the water repellent is more preferably 0.1 to 2.5 mass%, and even more preferably 0.2 to 1.2 mass%.

[0012] In addition to the above components, the base material may contain known components that can be contained in ceramic building materials, within the scope that does not impair the effects of the present disclosure. For example, aggregates such as fine aggregate and coarse aggregate other than those described above, mica, reinforcing fibers (such as polypropylene), wood fibers, water-reducing agents, retarders, foaming agents, antifoaming agents, etc.

[0013] (Design Material) At least a part of the design material is exposed on the surface of the ceramic material. The design material is added for the purpose of imparting design to the ceramic material. The design material preferably contains a carbonized material obtained by carbonizing waste material or biomass material. This allows CO ２ can be fixed to ceramic materials. Specific examples of carbonizable materials (materials that can be carbonized) used as design materials include smoked charcoal, coconut shells, peanut shells, pine cones, edamame shells, flower petals, cedar, chestnuts, resin, fruit peels, cow and pig manure, mushroom tips and stubs, and plum seeds. Of the above design materials, materials other than those already carbonized do not need to be carbonized. Design materials other than carbonizable materials may also be used, such as vermiculite, eggshells, and seashells. One type of design material may be used, or two or more types may be combined. It is preferable to use at least two types of design materials, a first design material and a second design material, in combination. This allows for a more natural-looking design. In the following description, the first design material may be described as smoked charcoal, and the second design material as vermiculite. In addition to the above, decorative materials having a moisture-regulating function or a function of imparting a fragrance may also be used.

[0014] <Color Tone of Each Component in Ceramic Material> In the ceramic material according to this embodiment, it is preferable that the color tone of the base material and the design material are different. As a result, a design with a natural texture is preferably formed by the design material exposed on the surface. The color tones of the base material, the design material, and the coloring material are different from each other. ＊ a ＊ b ＊ Chromaticity according to the color system (L ＊ , a ＊ , b ＊ ) can be expressed as chromaticity (L ＊ , a ＊ , b ＊The measurement of the color difference can be performed using a commercially available color difference meter. For example, a color difference meter CR-400 (manufactured by Konica Minolta, Inc.) can be used.

[0015] The color tone of the substrate is not particularly limited, but may be L ＊ may be 20 or more and 75 or less, 30 or more and 65 or less, or 38.7 or more and 55.7 or less. ＊ may be -5 or more and 5 or less, -3 or more and 3 or less, or 0.1 or more and 0.4 or less. ＊ may be -5 or more and 10 or less, -3 or more and 7 or less, or 2.1 or more and 4.0 or less. The color tone of the base material is the color tone of the base material that may contain a colorant.

[0016] The color tone of the decorative material is not particularly limited, but L ＊ may be 5 or more and 75 or less, and a ＊ may be greater than or equal to -5 and less than or equal to 15, ＊ may be greater than or equal to −5 and less than or equal to 40.

[0017] When the decorative material includes a first decorative material and a second decorative material, the color tone of the first decorative material is not particularly limited, but may be L ＊ may be 5 or more and 35 or less, 10 or more and 25 or less, or 13.6 or more and 18.6 or less. ＊ may be -5 or more and 5 or less, -3 or more and 3 or less, or 0.6 or more and 1.8 or less. ＊ may be -5 or more and 7 or less, or may be -2 or more and 4 or less, or may be 0.0 to 2.0. Such a first design material is, for example, smoked charcoal.

[0018] The color tone of the second decorative material is not particularly limited, but may be L ＊ may be 40 or more and 75 or less, 45 or more and 70 or less, or 51.7 or more and 62.1 or less. ＊ may be -5 or more and 15 or less, may be -2 or more and 12 or less, or may be 1.7 or more and 7.8 or less. ＊may be 0 or more and 40 or less, 10 or more and 30 or less, or 14.1 or more and 23.4 or less. Such a second decorative material is, for example, vermiculite.

[0019] The color tone of the colorant (color tone of the colorant alone) is not particularly limited, but may be L ＊ may be 0 or more and 30 or less, 1 or more and 20 or less, or 1.5 or more and 13.5 or less. ＊ may be -10 or more and 15 or less, may be -5 or more and 10 or less, or may be 0.4 or more and 1.9 or less. ＊ may be -10 or more and 15 or less, -5 or more and 10 or less, or 0.7 or more and 1.9 or less. An example of such a coloring material is bamboo charcoal.

[0020] (Color difference between the substrate and the decorative material) The color difference between the substrate and the decorative material is expressed as L ＊ Difference in value ΔL ＊ , a ＊ Difference in value Δa ＊ , and b ＊ Difference in value Δb ＊ , and ΔL ＊ , Δa ＊ , and Δb ＊ ΔE calculated from ＊ When expressed as ab, ΔL ＊ is preferably more than 0 and 70 or less, and Δa ＊ is preferably greater than 0 and equal to or less than 20, and Δb ＊ is preferably greater than 0 and equal to or less than 45, and ΔE ＊ ab is preferably greater than 0 and equal to or less than 73.8.

[0021] When the decorative material includes a first decorative material and a second decorative material, the color difference between the base material and the first decorative material is ΔL ＊ is preferably greater than 0 and equal to or less than 70, more preferably equal to or greater than 5 and equal to or less than 55, and even more preferably equal to or greater than 20.1 and equal to or less than 42.1. ＊ is preferably greater than 0 and equal to or less than 10, more preferably greater than 0 and equal to or less than 6, and even more preferably equal to or greater than 0.2 and equal to or less than 1.7.＊ is preferably greater than 0 and equal to or less than 15, more preferably greater than 0 and equal to or less than 9, and even more preferably equal to or greater than 0.1 and equal to or less than 4.0. ＊ ab is preferably greater than 0 and equal to or less than 72.3, more preferably equal to or greater than 5 and equal to or less than 56.1, and even more preferably equal to or greater than 20.1 and equal to or less than 42.4. Such a first design material is, for example, smoked charcoal.

[0022] Similarly, the color difference between the base material and the second design material is ΔL ＊ is preferably greater than 0 and equal to or less than 55, more preferably equal to or greater than 0 and equal to or less than 40, and even more preferably greater than 0 and equal to or less than 23.4. ＊ is preferably greater than 0 and equal to or less than 20, more preferably greater than 0 and equal to or less than 15, and even more preferably equal to or greater than 1.3 and equal to or less than 7.7. ＊ is preferably greater than 0 and equal to or less than 45, more preferably equal to or greater than 3 and equal to or less than 33, and even more preferably equal to or greater than 10.1 and equal to or less than 21.3. ＊ ab is preferably greater than 0 and equal to or less than 73.8, more preferably equal to or greater than 3 and equal to or less than 54, and even more preferably equal to or greater than 10.2 and equal to or less than 32.6. An example of such a second decorative material is vermiculite.

[0023] <Particle size of each component in the ceramic material> In the ceramic material according to this embodiment, it is preferable that the particle size of the base material and the design material be different. This allows the design material exposed on the surface to preferably create a natural-looking design. The particle size is, for example, a particle size distribution, and may be an average particle size: median diameter (D50) or a mode diameter. The average particle size can be determined from a particle size distribution obtained by a laser diffraction / scattering method. The particle size of each component in the ceramic material can be determined by measuring the particle size of the base material and the design material exposed on the surface of the ceramic material. Commercially available devices can be used to measure particle size. For example, a particle size distribution meter (Partica LA-960V2, manufactured by Horiba, Ltd.) can be used to measure the particle size distribution of raw materials, and a microscope (digital microscope VHX-6000, manufactured by Keyence) can be used to measure the particle size exposed on the substrate surface. When measuring the particle size using a microscope, for example, three or more particles can be arbitrarily selected and the particle size can be calculated as the average value.

[0024] Unless otherwise specified, the particle sizes below refer to the median (D50) of the particle size distribution determined by a laser diffraction / scattering method. The particle size of the base material raw material is preferably 1 to 700 μm, more preferably 2 to 400 μm, and even more preferably 2.3 to 262.4 μm. The particle size of the cement used as the base material may be 2.3 to 29.9 μm. The particle size of the silica sand used as the base material may be 1.32 to 26.1 μm. The particle size of the mica used as the base material may be 5.12 to 262.4 μm.

[0025] The particle size of the design material is preferably 500 to 10,000 μm, more preferably 500 to 7,000 μm, and even more preferably 600 to 5,000 μm. The particle size of the smoked charcoal used as the design material may be 500 to 4,500 μm. The particle size of the vermiculite used as the design material may be 600 to 4,537.4 μm. The particle size of the coloring material is preferably 1 to 1,500 μm, and more preferably 1 to 1,000 μm. The particle size of the bamboo charcoal used as the coloring material may be 10 to 200 μm.

[0026] The particle size (μm) of the decorative material exposed on the substrate surface can be determined using a microscope as described above, and is preferably 500 to 10,000 μm, more preferably 500 to 7,000 μm, and even more preferably 600 to 5,000 μm.

[0027] The particle size difference (particle size of decorative material - particle size of substrate) (μm) between the decorative material and the substrate is preferably greater than 0 μm and not greater than 10,000 μm. The particle size difference is more preferably greater than 0 μm and not greater than 7,000 μm, and even more preferably greater than 0 μm and not greater than 4,537 μm.

[0028] The particle size difference (μm) between the design material and the colorant, i.e., the particle size difference between the design material and the colorant (particle size of the colorant - particle size of the design material), is preferably greater than 0 μm and not greater than 10,000 μm. The particle size difference is more preferably greater than 0 μm and not greater than 7,000 μm, and even more preferably greater than 0 μm and not greater than 4,537 μm.

[0029] The ceramic material according to this embodiment preferably contains a design material having an average particle size (D50) of 50 μm or more and a coloring material having an average particle size (D50) of 1 to 200 μm.

[0030] The standard deviation of the particle size of the decorative material is preferably 3 μm or more. The standard deviation of the particle size of the smoked charcoal used as the decorative material may be 1600 μm or less, 800 μm or less, or 370.0 to 728.9 μm. The standard deviation of the particle size of the vermiculite used as the decorative material may be 40 μm or less, 20 μm or less, or 3.7 to 124.9 μm. The standard deviation of the particle size of the bamboo charcoal used as the coloring material may be 1600 μm or less, 800 μm or less, or 364.8 to 894.7 μm.

[0031] <Content of each component in ceramic material> The content of the design material is preferably 1 to 50 mass% and the content of the coloring material is preferably 0 to 25 mass% based on the total solid weight of the ceramic material. When the design material includes a first design material and a second design material, the content of the first design material is preferably 1 to 25 mass%, more preferably 5 to 15 mass%, and even more preferably 7.5 to 12.7 mass%. Such a first design material is, for example, smoked charcoal. The content of the second design material is preferably 1 to 15 mass%, more preferably 2 to 9 mass%, and even more preferably 2.76 to 4.80 mass%. The content of bamboo charcoal as a coloring material is preferably 5 to 25 mass%, and more preferably 11.0 to 14.0 mass%.

[0032] The content ratio (mass ratio) of the coloring material to the design material is preferably 0 to 25. The content ratio of the bamboo charcoal as the coloring material to the smoked charcoal as the design material is preferably 0.04 to 25, more preferably 0.2 to 3.0, and even more preferably 0.87 to 1.86. The content ratio of the bamboo charcoal as the coloring material to the vermiculite as the design material is preferably 0.04 to 15, more preferably 1.0 to 10, and even more preferably 2.30 to 5.08.

[0033] The total content of the design material and coloring material is preferably 10% by mass or more. This allows the ceramic material to have a desirable design. From the viewpoint of maintaining the strength of the ceramic material, the total content of the design material and coloring material is preferably 50% by mass or less, more preferably 44% by mass or less, and even more preferably 32% by mass or less. From the viewpoint of achieving both design and strength, the total content of the design material and coloring material is preferably 10 to 40% by mass, more preferably 10 to 27% by mass, and even more preferably 10 to 17.5% by mass.

[0034] <Bulk specific gravity of each component in the ceramic material> The bulk specific gravity of the design material is preferably 0.02 to 0.4, and the bulk specific gravity of the coloring material is preferably 0.3 to 0.8. This allows the specific gravity and porosity of the ceramic material to be adjusted within suitable ranges. The bulk specific gravity of smoked charcoal as a design material is preferably 0.05 to 0.25, and more preferably 0.08 to 0.13. The bulk specific gravity of vermiculite as a design material is preferably 0.05 to 0.25, and more preferably 0.08 to 0.15. The bulk specific gravity of bamboo charcoal as a coloring material is preferably 0.35 to 0.7, and more preferably 0.4 to 0.6.

[0035] <Strength of Ceramic Material> The ceramic material according to this embodiment preferably has a bending strength of 4 MPa or more, more preferably 5 MPa or more. The bending strength can be measured by a method in accordance with JIS A 5422 and JIS A 1408.

[0036] <Porosity of ceramic material> The ceramic material according to this embodiment preferably has a porosity of 40 to 65%. The porosity can be calculated by dividing the pore volume of the ceramic material by the bulk volume of the ceramic material. The pore volume can be measured using a commercially available device, such as a pore distribution measuring device (Pore Master 60-GT (manufactured by Anton Paar)). The porosity is more preferably 45 to 60%, and even more preferably 50 to 60%. By having the porosity in the above range, the specific gravity of the ceramic material can be adjusted to a suitable range and frost damage can be suppressed.

[0037] <Specific Gravity of Ceramic Material> The specific gravity of the ceramic material is preferably 0.80 to 1.10, more preferably 0.85 to 1.05, and even more preferably 0.90 to 1.00. The ceramic material according to this embodiment can have a lower specific gravity than conventional ceramic materials. This reduces transportation costs and improves workability.

[0038] The ceramic material according to the above embodiment defines its design through the color and shape of the decorative material itself. Therefore, a natural-looking design can be realized. Furthermore, because the decorative material is distributed almost uniformly within the ceramic material, cutting allows the design on the cut surface to be similar to the design on the other surfaces, making it easy to adjust to any shape. Furthermore, because carbonized materials are used as the decorative material, the ceramic material is not only cost-effective and environmentally friendly, but also easily cut and processed. Processing similar to that of wood can be performed, including riveting, mortising, tenoning, drilling, nailing, and screwing. Therefore, for example, shapes that were impossible with conventional ceramic materials can be realized, and shaping can be performed on-site. Furthermore, the maintenance described below can be easily performed at low cost. Furthermore, because the ceramic material according to this embodiment has a natural-looking design on its surface, dirt is less noticeable, reducing the frequency of maintenance.

[0039] <Ceramic material maintenance method> The ceramic material maintenance method according to this embodiment includes at least a polishing step of polishing the surface of the deteriorated ceramic material. The polishing step removes the deteriorated portion of the surface, revealing a new surface. The polishing method used in the polishing step is not particularly limited, and any known method can be used. Because the ceramic material according to this embodiment has decorative material uniformly distributed inside, the design of the new surface is substantially indistinguishable from the design of the ceramic material before deterioration. Therefore, according to the ceramic material maintenance method according to this embodiment, ceramic material can be maintained easily and at low cost.

[0040] The ceramic material according to this embodiment preferably does not have a coating film formed from a paint composition or other articles such as a sheet attached to the surface disposed on its surface. The absence of a coating film or the like on the surface of the ceramic material can improve the maintainability of the ceramic material. Conventional ceramic materials with a coating film or the like disposed on the surface required work such as repainting or replacement when stains, scratches, deterioration, etc. occurred on the surface. In contrast, the ceramic material according to this embodiment does not have a coating film or the like on its surface, and therefore can be easily maintained.

[0041] <Method for manufacturing ceramic material> The method for manufacturing the ceramic material according to this embodiment is not particularly limited, but may include, for example, a preparation step, a slurry production step, a molding step, and a curing step for curing the molded raw material slurry.

[0042] (Preparation step) The preparation step is a step of preparing a composition containing each component constituting the base material and the design material. The components contained in the composition are the same as those exemplified in the description of the ceramic material, and may also contain components other than those mentioned above.

[0043] (Slurry Production Step) The slurry production step is a step of adding water to the composition prepared in the preparation step and kneading to produce a raw material slurry. The slurry production step is not particularly limited, and a known method using a mixer or the like can be applied. In the slurry production step, the design material and coloring material are dispersed approximately uniformly in the slurry.

[0044] (Forming step) The forming step is a step of forming the raw material slurry obtained in the slurry production step. The forming step is not particularly limited, and known methods such as extrusion molding, cast molding, paper molding, and press molding can be applied.

[0045] (Curing step) The curing step is a step of curing and hardening the raw material slurry formed in the forming step to obtain a hardened body (ceramic building material). The curing conditions (temperature, relative humidity, time, pressure, etc.) can be set arbitrarily depending on the properties of the slurry.

[0046] The above is an example of a method for manufacturing a ceramic material according to this embodiment, and other steps known as methods for manufacturing a ceramic material may be included as long as they do not impair the effects of the present disclosure.

[0047] The ceramic material according to the embodiment of the present disclosure has been described above. However, the present disclosure is not limited to the above embodiment and can be modified as appropriate.

[0048] The present disclosure will be described in more detail below based on examples, but the present disclosure is not limited to the following examples.

[0049] [Preparation of Composition and Raw Material Slurry] The compositions according to each Example were prepared in the amounts shown in the following tables. Unless otherwise specified in the tables, the compositions were prepared with 15% solids mass ratio of smoked charcoal as a design material, 5% solids mass ratio of vermiculite as a design material, and 15% solids mass ratio of bamboo charcoal as a colorant. Other components constituting the base material included ordinary Portland cement, silica sand, mica, pulp, and a water repellent. Water was then added and kneaded to obtain the raw material slurry according to each Example. Note that the percentage of addition in the following tables refers to the solids mass ratio (%) of the ceramic material, unless otherwise specified.

[0050] [Curing] The raw material slurry prepared above was poured into a mold to form it, and if necessary, steam curing or high-temperature, high-pressure curing was carried out to obtain a hardened body according to each example.

[0051] [Color Tone of Design Material and Colorant] As shown in Tables 1 to 6 below, the color tone of the design material and colorant in the ceramic material according to each example, the color tone difference between the design material and the base material, the color tone difference between the design material and the colorant, and the color tone difference between the first design material and the second design material were measured, and the design of the ceramic material was evaluated. The color tone was measured using a color difference meter CR-400 (manufactured by Konica Minolta, Inc., attachment diameter 10 mm, mode: L ＊ a ＊ b ＊ ) and measurements were carried out with N=3.

[0052]

[0053]

[0054] In Tables 1 and 2, the color tone (L ＊ ) were used.

[0055]

[0056]

[0057]

[0058] [Particle size of design material and colorant] As shown in Tables 6 to 8 below, the maximum particle size of the design material and colorant in each example of the ceramic material was measured, and the ceramic material's design was evaluated. A particle size distribution analyzer (Partica LA-960V2, manufactured by Horiba, Ltd.) was used for the measurements. The real term for vermiculite was 1.62, and the imaginary term was 0; the real term for charcoal was 1.92, and the imaginary term was 0.522; and the real term for bamboo charcoal was 1.92, and the imaginary term was 0.522. The transmittance was 70 to 90%. The maximum particle size difference between the design material and the colorant was also changed as shown in Tables 9 and 10 below, and the ceramic material's design was evaluated in the same manner. The results are shown in Tables 6 to 10.

[0059]

[0060]

[0061]

[0062]

[0063]

[0064] [Contents of design material and coloring material] The contents of the design material and coloring material were changed as shown in Tables 11 to 13 below, and the design of the ceramic materials was evaluated. In addition, the content ratio of coloring agent to design material was changed as shown in Tables 14 to 15 below, and the design of the ceramic materials was evaluated in the same manner. The results are shown in Tables 11 to 15.

[0065]

[0066]

[0067]

[0068]

[0069]

[0070] [Bulk specific gravity of design materials and coloring materials] The bulk specific gravity of the design materials and coloring materials was changed as shown in Tables 16 to 18 below, and the design of the ceramic materials was evaluated. In addition, the difference in bulk specific gravity between the design material and coloring material, and the difference in bulk specific gravity between two types of design materials were changed as shown in Tables 19 to 21 below, and the design of the ceramic materials was evaluated in the same manner. The results are shown in Tables 16 to 21.

[0071]

[0072]

[0073]

[0074]

[0075]

[0076]

[0077] [Standard deviation of particle size of design materials and coloring materials] The standard deviation of particle size of the design materials and coloring materials was changed as shown in Tables 22 to 24 below, and the ceramic materials were evaluated for design. The particle size was measured in the same manner as in Tables 6 to 10. The results are shown in Tables 22 to 24.

[0078]

[0079]

[0080]

[0081] [Porosity of ceramic material] The porosity of the ceramic material was changed as shown in Table 25 below, and bending stress (MPa) was measured and design evaluation was performed. The porosity was calculated by dividing the pore volume by the bulk volume of the ceramic material, and the pore volume was measured using a pore distribution measuring device (Pore Master 60-GT (manufactured by Anton Paar)). The bending stress (MPa) was measured using a Technograph TG-10kN (manufactured by MinebeaMitsumi). The results are shown in Table 25.

[0082]

[0083] [Water repellent content] The content of the silane-based water repellent used as the water repellent was changed as shown in Table 26. The frost expansion coefficient was measured and the design was evaluated after the frost damage test. The frost expansion coefficient was measured by carrying out a freeze-thaw cycle test in accordance with ASTM C666-A.

[0084]

[0085] [Relationship between the content of colorant and decorative material and the bulk density, bending stress, and design evaluation of ceramic materials] The content of colorant and decorative material was changed as shown in Table 27 below, and the bulk density and bending stress of the ceramic materials were measured, and design evaluation was performed. The Archimedes method was used to measure the bulk density of the ceramic materials. The bending stress was measured using the same method as in Table 25. The results are shown in Table 27.

[0086]

[0087] Preferred aspects of the present disclosure are described below.

[0088] [1] A ceramic material comprising a substrate and a decorative material, wherein at least a portion of the decorative material is exposed on the surface and has a particle size and / or a color tone different from that of the substrate.

[0089] [2] The ceramic material according to [1], wherein the decorative materials include a first decorative material and a second decorative material, and further include a coloring material, wherein the difference between the bulk specific gravity of the first decorative material and the bulk specific gravity of the coloring material is 0.35 to 0.54, the difference between the bulk specific gravity of the second decorative material and the bulk specific gravity of the coloring material is 0.33 to 0.54, and the difference between the bulk specific gravity of the second decorative material and the bulk specific gravity of the first decorative material is 0 to 0.2.

[0090] [3] The ceramic material according to [1] or [2], further comprising a coloring material, and comprising three or more kinds of the design material and the coloring material.

[0091] [4] The ceramic material described in any of [1] to [3], wherein the decorative materials include a first decorative material and a second decorative material, and further include a coloring material, wherein the difference between the average particle diameter (D50) of the first decorative material and the average particle diameter (D50) of the coloring material is 10,000 μm or less, and the difference between the average particle diameter (D50) of the second decorative material and the average particle diameter (D50) of the coloring material is 10,000 μm or less.

Claims

1. A ceramic material comprising a base material and a decorative material, at least a part of the decorative material being exposed on the surface, the base material and the decorative material differing in particle size and / or color tone.

2. The design material has a different color tone from the base material at least, and the color tone difference between the base material and the design material is L ＊ a ＊ b ＊ the chromaticity (L ＊ , a ＊ , b ＊ ) of the base material and the design material according to the L ＊ value difference ΔL ＊ , a ＊ value difference Δa ＊ , and b ＊ value difference Δb ＊ , and when represented by ΔE ＊ ab calculated from ΔL ＊ , Δa ＊ , and Δb ＊ , ΔL ＊ is greater than 0 and less than or equal to 70, Δa ＊ is greater than 0 and less than or equal to 20, Δb ＊ is greater than 0 and less than or equal to 45, and ΔE ＊ ab is greater than 0 and less than or equal to 73.

8. The ceramic material according to claim 1.

3. The decorative material differs from the base material in at least particle size, and the particle size difference (average particle size of the decorative material (D50) - average particle size of the base material (D50)) (μm), which is the difference in the average particle size (D50) between the decorative material and the base material, is more than 0 μm and 10,000 μm or less. The ceramic material according to claim 1 or 2.

4. The decorative material differs from the base material in at least particle size, and the standard deviation of the particle size of the decorative material is 3 μm or more. The ceramic material according to any one of claims 1 to 3.

5. The ceramic material according to any one of claims 1 to 4, comprising a decorative material having an average particle size (D50) of 50 μm or more and a coloring material having an average particle size (D50) of 1 to 200 μm.

6. The particle size of the decorative material exposed on the surface of the base material is 500 to 10,000 μm. The ceramic material according to any one of claims 1 to 4.

7. The content ratio (mass ratio) of the coloring material to the decorative material is 0.025 to 25. The ceramic material according to claim 5.

8. Further comprising a water repellent, and the ratio of the water repellent in the ceramic material is 0.01 to 5% by mass in terms of solid content mass ratio. The ceramic material according to any one of claims 1 to 7.

9. The decorative material includes a carbonized material obtained by carbonizing waste materials or biomass materials. The ceramic material according to any one of claims 1 to 8.

10. The porosity is 40 to 65%. The ceramic material according to any one of claims 1 to 9.

11. The ceramic material according to any one of claims 1 to 10, having no coating film on the surface.

12. The specific gravity of the ceramic material is 0.80 to 1.

10. The ceramic material according to any one of claims 1 to 11.

13. The particle size difference (average particle size of the decorative material (D50) - average particle size of the coloring material (D50)) (μm), which is the difference in the average particle size (D50) between the decorative material and the coloring material, is more than 0 μm and 10,000 μm or less. The ceramic material according to claim 5.

14. The bulk specific gravity of the decorative material is 0.02 to 0.4, and the bulk specific gravity of the coloring material is 0.3 to 0.

8. The ceramic material according to claim 5.

15. The content of the decorative material in the ceramic material is 1 to 40% by mass, and the content of the coloring material in the ceramic material is 1 to 25% by mass. The ceramic material according to claim 5.

16. The said decorative material includes a first decorative material and a second decorative material, the content of the first decorative material in the said ceramic material is 1 to 25% by mass, and the content of the second decorative material in the said ceramic material is 1 to 15% by mass. The ceramic material according to claim 15.

17. When the color tones of the design material and the coloring material are represented by chromaticity (L ＊ a ＊ b ＊ ) in the L ＊ , a ＊ , b ＊ ) color system, L of the design material ＊ is 5 or more and 75 or less, a of the design material ＊ is -5 or more and 15 or less, b of the design material ＊ is -5 or more and 40 or less, L of the coloring material ＊ is 0 or more and 30 or less, a of the coloring material ＊ is -10 or more and 15 or less, b of the coloring material ＊ is -10 or more and 15 or less. The ceramic material according to claim 5 18. The design material includes a first design material and a second design material, and when their color tones are represented by chromaticity (L ＊ a ＊ b ＊ ) according to the L ＊ , a ＊ , b ＊ ) color system, the L ＊ of the first design material is 5 or more and 35 or less, the a ＊ of the first design material is -5 or more and 5 or less, the b ＊ of the first design material is -5 or more and 7 or less, the L ＊ of the second design material is 40 or more and 75 or less, the a ＊ of the second design material is -5 or more and 15 or less, and the b ＊ of the second design material is 0 or more and 40 or less. The ceramic material according to claim 17.

19. The total content of the said coloring material and the said decorative material in the said ceramic material is 10% by mass or more. The ceramic material according to claim 5.

20. The total content of the said coloring material and the said decorative material is 10% by mass or more and 40% by mass or less, and the flexural stress of the said ceramic material is 5 MPa or more. The ceramic material according to claim 19.

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