JP2655977B2 - Foamed ceramic plate and manufacturing method thereof - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a foamed ceramic plate and a method for producing the same. More particularly, the present invention relates to a foamed ceramic plate capable of easily displaying various designs, and a method for producing the same.

[0002]

2. Description of the Related Art Conventionally, a large-sized inorganic and lightweight building material has been developed. As a method of making the surface of the material, foaming colored cosmetic raw materials, glazes and the like are granulated. The obtained granules are laminated on a base layer made of an inorganic foaming raw material, and are fired and integrated at the same time.

However, in such a method, only a granular multicolor design can be obtained, and a fine design such as a natural stone and a design other than a granular shape cannot be obtained. As described above, the surface design of the conventional large and lightweight ceramic plate is limited to a granular multicolor design, and there is a limit to the versatility as a building material.

SUMMARY OF THE INVENTION In view of the circumstances described above, an object of the present invention is to provide a foamed ceramic plate and a manufacturing method capable of easily solving a variety of designs by eliminating the limitations of designs which are disadvantages of the prior art. I do. That is, a glass plate is colored, printed, cut into an arbitrary shape, laminated on an inorganic foamed layer, and simultaneously baked and melted and integrated, or glass particles (such as rod-shaped ones). The present invention aims to provide a foamed ceramic plate having a variety of designs and a method of manufacturing the same by laminating colored glass particles on an inorganic foamed layer, and simultaneously firing and melting and integrating the same. And

[0005]

The foamed ceramic plate of the present invention is characterized in that a glass plate is welded to one or both sides of a base layer made of an inorganic foamed layer. Also,
The method for producing a foamed ceramic plate of the present invention is characterized in that a glass plate is laminated on one or both sides of a base layer made of an inorganic foaming raw material that is foamed by heating, and these are simultaneously fired and integrated.

[0006]

The foamed ceramic plate of the present invention is obtained by coating a glaze on one or both sides of a powdered or granulated inorganic foamed raw material layer, printing, or laminating a glass plate cut into an arbitrary shape. Alternatively, colored glass particles (including rod-shaped ones) or colored glass particles are laminated, and simultaneously fired to be melted and integrated.

[0007] Therefore, the glass plate or glass particles on one or both sides of the inorganic foaming raw material layer are also melted to form a skin layer. The glass plate or glass particles have good compatibility with the inorganic foaming raw material and form a skin layer having excellent design.

In order to further enhance the design, a transfer sheet containing a picture is pasted on a glass plate, printed directly on the glass plate, coated with a glaze, and a fluorescent material or a phosphorescent material which emits light by receiving ultraviolet rays is added. A glaze coated or the like is laminated on the above-mentioned inorganic foaming material layer, and simultaneously fired and melted and integrated to obtain a tasteful foamed ceramic plate with a very rich expression.

[0009] When a granular material (including a rod-like material) is colored, or when colored glass particles are laminated, simultaneously fired and melt-integrated, a foamed ceramic plate with a very rich expression is obtained.

[0010]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Inorganic foaming raw materials used in the present invention include:
A raw material that contains clay, glass powder, etc. as a main component, and, if necessary, a foaming temperature adjusting material such as soda ash and a foaming agent such as dolomite and silicon carbide. It is.

The inorganic foaming raw material may be in the form of powder or granulated material, but the granulated material is preferable in the case of a large-sized foamed plate because the effect of backfilling by crack foaming due to heat shrinkage is large.

The granulated product can be obtained by various granulation methods such as a roll granulation method, an extrusion granulation method, and a rotating disk granulation method. The size of the granulated material is not particularly limited in the present invention, but is preferably about 0.5 to 3 mm in diameter.

[0013] As raw materials for the decorative layer, 1121 lead-free transparent frit (Nippon Fellow Co., Ltd.), FA-803 zircon milk white frit (Nippon Fellow Co., Ltd.), glass powder and elutriation clay are mixed. Water is added to the pulverized powder, and the mixture is kneaded. The obtained kneaded product is extruded and granulated, and the resulting granulated product is put into a marmellaizer (manufactured by Fuji Powder Co., Ltd.) and centrifugally rotated to supply cosmetic powder. Cosmetic granules can be used. The raw material for the decorative layer is prepared by adding a pigment to the inorganic foaming raw material for coloring, or adjusting the melting state by slightly adjusting the blending for leveling of the surface,
The foaming amount may be adjusted to secure the surface hardness, but may be used as it is.

Further, glazes and foaming glazes may be used as raw materials for the decorative layer.

As the glaze, those usually used for porcelain, tiles, enamels, etc. can be used as they are, but in the case of the present invention, in particular, at the foaming temperature of the inorganic foaming material or at a lower temperature. It is preferable to use one that softens and melts.

In addition to the glaze, an inorganic material such as volcanic rock or volcanic ash which melts at a temperature equal to or lower than the foaming temperature of the inorganic foaming raw material, or a material obtained by adding a pigment thereto, which has the same effect as the glaze, is used. In the present specification, “glazes” is a concept including all of these. For example, a material obtained by removing a foaming agent from the inorganic foaming material, a material obtained by adding a material for lowering the softening temperature such as sodium carbonate or borax, or a material obtained by adding a pigment thereto can be used.

Further, as the foamable glaze, those obtained by adding a foaming agent to the above glazes can be used.

The softening temperature of the glaze and the foaming glaze is particularly preferably equal to or lower than the foaming temperature of the inorganic foaming raw material (0 to 300 ° C. lower than the foaming temperature). The volume expansion coefficient is preferably substantially equal to or smaller than that of the inorganic foamed raw material.

As the glass plate, soda-lime glass, lead glass, aluminosilicate glass, borosilicate glass and the like can be used, but the softening point is relatively low, and soda-lime glass used in large quantities is optimal. It is.

As the glass particles, various colored glass (decorative glass, craft glass, colored plate glass, bottle glass, etc.), soda-lime glass particles, frit particles and the like can be used.

In the case of transparent glass, when it is plate-shaped,
It is preferable to coat or print a glaze on the front surface or the back surface because the design is excellent. It is preferable to use a glaze approximating the coefficient of thermal expansion of the glass plate, and the softening point may be appropriately set according to the configuration and purpose of the plate. For example, when coating the backside of a sheet of glass, if the softening point of the glaze is lower than that of the cosmetic raw material, the glaze will be blown into the raw material of the lower layer and the coloring will become rough, so the glaze of the lower layer (decorative layer, base layer) Those having a higher softening point are preferred. If the glass is to be impregnated with a glaze on the surface of the glass plate, a material having a lower softening point than that of the glass plate is preferable.

Further, in order to cope with the variety of designs, printed transfer paper may be pasted on a glass plate, printed directly on the glass plate, or coated with fluorescent glaze or printed. .

In the case of transparent glass particles, various designs can be obtained by coating the glass particles with a colored glaze or coating with a fluorescent glaze.

In the present specification, the term "grain" is a concept including various things such as circular or rod-shaped small pieces or fine pieces and crushed products obtained by simply crushing a glass plate, in addition to so-called granular materials.

The glass plate may be laminated on the entire surface or may be locally disposed. In addition, those cut into shapes corresponding to various designs, such as geometric shapes, animal and bird shapes, may be laminated. Similarly, glass particles may be sprayed over the entire surface or partially.

When a glass plate is further polished and used, a smooth and high-quality finish is obtained.

As a method of laminating the above-mentioned inorganic foaming raw materials, glazes, foam glazes, glass plates, etc., the layers may be laminated sequentially on a mesh belt, may be laminated in a mold, Others may be laminated on a press formed inorganic foaming raw material, these laminates are mesh belt,
A large-sized high-sensitivity ceramic plate can be obtained by being conveyed into a firing furnace by a roller or a cart and integrated by firing in the furnace.

When a roll is pressed in a firing furnace, a foamed ceramic plate having excellent smoothness can be obtained.

When a glass plate is directly laminated on an inorganic foaming raw material, the inorganic foaming layer protrudes around the glass plate to form a heat insulating layer for preventing cooling of the end of the glass. Less likely to occur.

Examples of the binder used for granulating the inorganic foaming raw materials, glazes, and foaming glazes from powder into granules include methylcellulose, molasses, water glass, and the like. Any of organic and inorganic substances can be used. There may be. However, when an organic substance affects foaming, it is preferable to use an inorganic binder such as water glass.

The granulated material may or may not be dried after the granulation. However, in the case of a granulated material used for cosmetics, if the granules are coated with colored powder, the granules may be dried. It is preferable to use particles that do not dry because color unevenness occurs due to the falling off of the colored powder. The moisture content of the granulated material is preferably 5% or more,
Further, if the content is 10 to 25%, the color is stable without powder falling off.

Next, the method for producing the foamed ceramic plate of the present invention will be described in detail with reference to the drawings.

FIG. 1 is an explanatory sectional view of an apparatus for manufacturing a foamed ceramic plate according to the present invention.

In FIG. 1, A is a ceramic foam plate manufacturing apparatus. In this device A, a release agent 3 is applied to the surface of the conveyor by a release agent application device 2 when the conveyor 1 composed of a mesh belt runs. As the release agent 3, aluminum oxide powder, aluminum hydroxide powder, silica sand powder, calcium carbonate powder, clay powder and the like can be used.

Above the conveyor 1, an inorganic foam raw material hopper 4, a glaze or foam glaze raw material hopper 5,
A glass plate supply device 6 and a glass raw material hopper 7 are arranged.

From the hopper 4, powdered or granulated inorganic foam raw material 8, from the hopper 5, powdered or granulated glaze or foamable glaze raw material 9, and from the hopper 7, powdered or granulated Alternatively, the granulated or crushed glass 10 is sequentially dropped and supplied so as to be uniform with an appropriate thickness.

The glass plate 11 is placed on the glaze or foam glaze raw material 9. If necessary, the glazes or the foaming glaze raw material 9 may be deleted.

Further, a glass raw material 10, a glass plate 11, a glaze or foamable glaze raw material 9, and an inorganic foam raw material 8 may be laminated on the conveyor 1 in this order, and may be simultaneously fired to be melted and integrated.

It is also possible to produce a foamed ceramic plate having a glass grain 10 or a glass plate 11 laminated on both the upper and lower surfaces and having a decorative finish on both sides.

When laminating in a mold, a release paper 20 is placed on the mold 12 as shown in FIG.
1 and the inorganic foaming raw material 8 are sequentially laminated, fired simultaneously in a firing furnace, and melt-integrated to obtain a foamed ceramic plate. The lamination order of the glass plate 11 and the inorganic foaming raw material 8 may be completely reversed, or the glass plates 11 may be laminated on both sides of the inorganic foaming raw material 8. Further, a cosmetic granulation raw material may be provided between the glass plate 11 and the inorganic foam raw material 8 depending on the use.

The powdered inorganic foaming raw material 8 may be formed into a molded product by press molding, and the remaining raw materials may be laminated on the molded product, fired simultaneously, and melt-integrated.

The conveyer 1 on which the laminated bodies stacked as described above are sequentially passed through the pre-tropical zone 13, the sintering zone 14, the slow cooling zone 15 and the cooling zone 16 to obtain an integrated foamed ceramic by simultaneous sintering. be able to.

A roll 17 is provided in the vicinity of the exit of the sintering zone 14, and when the roll 17 presses the surface of the foamed ceramic plate, smoothness and a desired pattern are obtained, and the design is further improved.

Next, the foamed ceramic plate and the manufacturing method of the present invention will be described based on examples, but the present invention is not limited to the examples.

Example 1 Preparation of base material Raw material clay 61.6% (% by weight, hereinafter the same), Sanritsu clay 2
0.2%, powdered water glass (No. 3) 5.0%, soda ash 3.0%
The raw materials composed of 0.4% SiC and 0.4% SiC were placed in a 1-ton mill together with steel balls and mixed and pulverized for 12 hours. Powder
325 mesh was 96% through. The raw material powder was tumbled with a bread granulator while spraying Kelzan (trade name, fermented polysaccharide manufactured by Dainippon Pharmaceutical Co., Ltd.) as a binder,
A granulated product having a particle size of 1 to 3 mm was obtained using a sieve. This was dried with a rotary kiln so that the water content became 2% or less to obtain a base layer raw material.

Preparation of glass plate A glaze was applied to the surface of a 1 mm thick plate glass (manufactured by Nippon Sheet Glass Co., Ltd.) by spraying and dried to obtain a glass plate with a glaze. The glaze mix is based on a 100% lead-free transparent frit 3909 (Nippon Fellow Co., Ltd.), 20% water, 30% ethylene glycol and salmon pink pigment (Nissan Sangyo Co., Ltd.)
M-66) was mixed with a juicer for 25 minutes to obtain a slurry spray liquid. Drying was performed at 80 ° C. for 30 minutes using a warm air dryer.

The base material thus laminated and fired and granulated was placed in a hopper 4 shown in FIG. Further, a glass plate with a glaze was laminated on the base material (see 6 in FIG. 1).

The base material was uniformly supplied to the conveyor 1 by the hopper 4 so as to have a thickness of 15 mm, and a glass plate was laminated thereon.

This was transferred from pre-tropical zone 13 to firing zone 14 by conveyor 1
, And the glass plate and the base layer raw material were simultaneously fired and melt-foamed and integrated at the same time. Then slow cooling zone 15, cooling zone
It was further transported to 16 and a large, lightweight glass-plated ceramic plate was obtained.

The surface of the obtained foamed ceramic plate had a beautiful salmon pink glass-like finish, and had a very high surface hardness. The width of the ceramic plate was 900 mm and the length was 900 mm. The thickness is 15mm and the specific gravity is 0.9
And a beautiful ceramic foam plate having a glassy skin layer.

Example 2 Preparation of raw material for base layer A raw material composed of 63% of acid clay, 10% of soda ash, 4% of sodium nitrate, 10% of zircon flour, 3% of ZnO and 10% of powdered water glass was put into a 1-ton mill together with steel balls. The mixture was pulverized for 6 hours. Powder is 325 mesh pass 96%
It was all communication. 15% of water was added to this raw material powder, and kneaded with a kneader. The obtained kneaded material was granulated by an extrusion granulator having a large number of holes having a diameter of 1.5 mm, and then dried by a rotary kiln so that the water content was 2% or less, to obtain a base material.

Preparation of cosmetic layer raw material 1121 Lead-free transparent frit (manufactured by Nippon Fellow Co., Ltd.) 25%
FA-803 Zircon milk white frit (Nippon Fellow Co., Ltd.)
A compounding material consisting of 50%, glass powder 20% and elutriated clay 5% was put into a 1-ton mill together with alumina balls and mixed and pulverized for 12 hours. The powder was 325 mesh 96% through. 15% of water was added to this raw material powder, and kneaded with a kneader. The obtained kneaded material was extruded and granulated with a disc pelletizer (manufactured by Fuji Powder Co., Ltd.). Next, the granulated material obtained was put into a marmellaizer (manufactured by Fuji Powder Elder Co., Ltd.), and 20% of makeup powder was added while spinning centrifugally to obtain a cosmetic granulated product.

Preparation of Glass Plates Red, blue and yellow glass plates were cut into rods and stuck on a 0.06 mm thick transparent transfer sheet (manufactured by Yamamoto Silk Co., Ltd.) with scotch tape as shown in FIG. I attached.

Laminating and firing The raw material for the base layer, the raw material for the makeup, and the transfer sheet with a glass rod were charged in this order, fired simultaneously in the same manner as in Example 1, and integrated by melting.

A beautiful large ceramic plate having excellent surface hardness was obtained in which red, blue and yellow glass rods were randomly embedded in the glaze layer. The size was 900 mm x 1800 mm with a thickness of 15 mm.

Example 3 Preparation of base layer raw material Prepared in the same manner as in Example 2.

Preparation of Raw Material for Decorative Layer A raw material was prepared in the same manner as in Example 2.

Preparation of Colored Glass Particles To 100% of the compounding material for the decorative layer used in Example 2, 4.5% of M-3 dye (manufactured by Nissot Sangyo Co., Ltd.) and J-24 dye (Nissot) A mixture of 1.5% and 70% CMC solution (manufactured by Sangyo Co., Ltd.) was mixed with a pot mill for 60 minutes to obtain a slurry for glass particles.

Glass particles having a particle diameter of 1 to 3 mm were placed in a circular rotary granulator, and the glass particles were colored while spraying a slurry.

The raw material for the base layer was uniformly charged so as to have a lamination and firing thickness of 11 mm, and then the raw material for the decorative layer was charged so as to have a thickness of 5 mm. Glass particles were sprinkled randomly on this with a glass particle sprinkling device, co-fired in the same manner as in Example 1, and melted and integrated.

A large ceramic plate having a high surface hardness and excellent abrasion property was obtained in which red, green, yellow and other colored glass grains were embedded and scattered in the glaze layer. The size was 900 mm x 1800 mm with a thickness of 15 mm.

Example 4 The base material used in Example 2 was uniformly charged on the glass plate used in Example 1 so as to have a thickness of 10 mm, and a more beautiful flower pattern was printed thereon. A glass plate to which the transfer paper was attached (the glass plate was the same as in Example 1) was laminated.

The obtained laminate having a three-layer structure was simultaneously fired in the same manner as in Example 1, and was melted and integrated to obtain a foamed ceramic plate.

A beautiful ceramic plate with a high surface hardness was obtained, having a beautiful glass layer on the front side with a floral pattern printed on glaze and a matte glass layer on the back side with a granite style.
The size was 900 mm x 900 mm with a thickness of 15 mm.

Example 5 Preparation of base layer raw material Prepared in the same manner as in Example 2.

Preparation of Raw Material for Decorative Layer A raw material was prepared in the same manner as in Example 2.

The raw material for the base layer was uniformly charged to a thickness of 7 mm on the laminating and firing conveyor, and the raw material for the decorative layer was uniformly charged thereon to a thickness of 5 mm. Next, a glass mold (5 cm square) with a black transfer sheet attached was partially placed on the raw material for the decorative layer as shown in FIG.

The obtained laminate was co-fired in the same manner as in Example 1, and was melted and integrated to obtain a foamed ceramic plate.

A beautiful large ceramic plate having a high surface hardness was obtained in which small pieces of black glass were embedded in the glaze layer. The size was 10 mm thick and 900 mm x 900 mm.

Example 6 Preparation of base layer raw material A base layer raw material was prepared in the same manner as in Example 2.

Preparation of Glass Plate A nylon net having a pore size of 0.1 mm was attached to an aluminum frame, and the net was coated with a photosensitive emulsion Azofix No. 1 (Kurita Chemical Laboratory Co., Ltd.). Next, a negative pattern paper is created by decomposing the printed pattern by color, and the negative pattern paper is layered on a nylon mesh coated with a photosensitive emulsion, light-sensitive cured by lightning, and then washed with water to wash the uncured emulsion. The net was opened.

Next, a screen was set on the glass plate used in Example 1. Ink is cerazole on top paint (melting at 800-900 ℃) with luminescent glaze of any color
210 (squeegee oil manufactured by Nagoya Yuka Co., Ltd.) was added and kneaded to form a cream. When this creamy pigment is placed on a screen and pulled with a squeegee, the pigment is transferred to the glass plate through the screen.

A color pattern, which reminded of a bird by being overpainted for each color, was transferred to a glass plate. After drying, 104 Ceracoat (Covercoat, manufactured by Nagoya Yuka Co., Ltd.) was printed on the entire surface so that the pigment did not peel off from the glass plate, thereby completing the printing of the glass plate.

The raw material for the base layer was uniformly charged to a thickness of 15 mm on a lamination and firing conveyor, and a printed glass plate was placed thereon.

The obtained laminate was co-fired in the same manner as in Example 1, and was melted and integrated to obtain a foamed ceramic plate.

The obtained foamed ceramic plate was a beautiful large and lightweight ceramic plate with a bird pattern.

Example 7 The raw material for the base layer used in Example 1 was tile-shaped (300 m
m square), and a glass plate (a glass plate used in Example 1) on which a floral pattern was printed was laminated thereon.
Simultaneous firing was performed in the same manner as described above, and the resultant was integrated by melting to obtain a foamed ceramic plate.

A beautiful lightweight tile with a floral pattern on the glass finish was obtained.

[0079]

As described above, the foamed ceramic plate of the present invention is obtained by laminating a decorative layer as required on a base layer made of an inorganic foamed raw material, and further firing glass particles or a glass plate at the same time. ing. Since foaming, fusion of particles or powder, melting of glazes, fusion of glass plates or glass particles, and fusion are performed in one step in a heating process, the process is simplified and the ceramic foam plate is economically manufactured. You can get.

The foamed ceramic plate of the present invention can be suitably used as an outer wall material, a floor material, a roof material or a heat insulating material of a house.

[Brief description of the drawings]

FIG. 1 is an explanatory sectional view of an apparatus for manufacturing a foamed ceramic plate of the present invention.

FIG. 2 is an explanatory view when a raw material is stacked in a mold.

FIG. 3 is an explanatory diagram when a glass plate is laminated in Example 2.

FIG. 4 is an explanatory diagram when a glass plate is laminated in Example 5.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Mesh belt 4 Inorganic foam raw material hopper 5 Glaze or foam glaze hopper 6 Glass plate feeder 7 Glass raw material hopper 13 Pretropical zone 14 Firing zone 15 Slow cooling zone 16 Cooling zone

Continued on the front page (72) Inventor Daishi Horie 1-1-12 Shinsenri-Nishimachi, Toyonaka-shi, Osaka National Housing Industry Co., Ltd. (72) Inventor Shigeru Matsuoka 1-1-1-1 Shinsenri-Nishimachi, Toyonaka-shi, Osaka No. Within National Housing Industry Co., Ltd. (72) Inventor Ryo Nagai 228 Kawai, Izumicho, Toki City, Gifu Prefecture (72) Yoshio Nagaji 702-1, Hida, Hidacho, Toki City, Gifu Prefecture 1 (72) Inventor Kazuo Imabashi Chofu, Tokyo 4-23 Tsutsujigaoka-shi, Jindaidanchi 27-402

Claims (14)

(57) [Claims] 1. A foamed ceramic plate characterized in that a glass plate is welded to one or both sides of a base layer made of an inorganic foamed layer. 2. A foam ceramic plate, wherein a decorative layer is formed on one or both sides of a base layer comprising an inorganic foam layer, and a glass plate is welded to the entire surface or a part of the surface of the decorative layer. 3. The foam ceramic plate according to claim 2, wherein said glass plate is printed. 4. The foam ceramic plate according to claim 2, wherein said glass plate is coated with a luminescent glaze. 5. A foam ceramic plate characterized in that transparent or colored glass particles are entirely or partially welded to one or both surfaces of a base layer comprising an inorganic foam layer. 6. A foaming method wherein a decorative layer is formed on one surface or the entire surface of a base layer made of an inorganic foamed layer, and transparent or colored glass particles are welded to the entire surface or a part of the surface of the decorative layer. Ceramic plate. 7. The foamed ceramic plate according to claim 6, wherein said glass particles are coated with a luminescent glaze. 8. A method for producing a foamed ceramic plate, comprising: laminating a glass plate on one or both sides of a base layer made of an inorganic foaming raw material which is foamed by heating, and simultaneously firing and integrating them. 9. A decorative layer raw material is laminated on one or both sides of a base layer made of an inorganic foaming raw material which is foamed by heating, and a glass plate is placed on the whole or a part of the decorative layer raw material, and these are simultaneously fired. A method for producing a foamed ceramic plate characterized by being integrated. 10. The method for producing a foamed ceramic plate according to claim 9, wherein the glass plate is printed in advance. 11. The method for producing a foamed ceramic plate according to claim 9, wherein the glass plate is coated with a luminescent glaze in advance. 12. A foamed ceramic characterized in that transparent or colored glass particles are scattered on one or both sides of a base layer made of an inorganic foaming raw material which is foamed by heating, and which are baked simultaneously and integrated. Plate making method. 13. A decorative layer raw material is laminated on one or both sides of a base layer made of an inorganic foaming raw material which is foamed by heating, and transparent or colored glass particles are sprayed on the whole or part of the decorative layer raw material, and these are simultaneously fired. A method for producing a foamed ceramic plate characterized by being integrated. 14. The method for producing a foamed ceramic plate according to claim 13, wherein said glass particles are previously coated with a luminescent glaze.