JPH0477371A - Production of inorganic foamed board - Google Patents

Abstract

PURPOSE:To obtain a foamed board having original appearance and color tone of natural stone by constituting a surface decorative layer of a specified granular material in a method wherein the surface decorative layer is formed on a base layer made of the inorganic expandable granulated material to obtain a laminate and this laminate is heated, melted and integrated to obtain the foamed board. CONSTITUTION:The foamed board is obtained by forming a surface decorative layer on a base layer made of an inorganic expandable granulated material (e.g. the granulated material obtained by a mixture of acid clay, glass powder, soda ash, sodium nitrate, dolomite and zircon flower) and heating, melting and integrating the obtained laminate. In this method, the surface decorative layer is constituted of the granular material which is obtained by coating the surface of a core material (e.g. crushed defective porcelain) consisting of natural stone particle or sherd particle with glaze powder (e.g. the mixture of glass powder, R-2 frit, zirconite, elutriation clay, bentonite and coloring matter).

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Field of Application] The present invention relates to a method for manufacturing an inorganic foam board. More specifically, the present invention relates to a method for producing an inorganic foam board that has the natural color and texture of natural stone, and that can reliably prevent the surface from slipping when used as a flooring material.

[Prior Art and Problems to be Solved by the Invention] Inorganic foam boards are being used as building materials because they are lightweight and have excellent fire resistance and heat insulation properties. This inorganic foam board is surface decorated to improve its frost damage resistance and to improve its surface design. The surface decoration of conventional inorganic foam boards is achieved by laminating colored foam particles, glaze powder, or glass particles on a base layer made of inorganic foam granules to form a surface decoration layer, and then dissolving the resulting laminate. It was integrated. The surface cosmetic layer obtained in this way is a dense hard layer, and although the frost damage resistance mentioned above is improved and the design is improved to some extent, the appearance of the surface of the finished product is poor because the cosmetic powder is of the same quality. The problem was that it was stiff and lacking in style.

As a result of various studies to overcome the design defects of such inorganic foam boards, the present inventors coated the surface of natural stone grains or Cerben grains with glaze powder, and used the resulting granules to form a decorative surface layer. The present inventors have discovered that by forming a base layer and firing it together with the base layer, an inorganic foam board that expresses the original color tone and texture of natural stone can be obtained, and the present invention has been completed.

[Means for Solving the Problems] The method for manufacturing an inorganic foam board of the present invention involves forming a decorative surface layer on a base layer made of inorganic foamable granules, and heating the resulting laminate to melt and integrate it. The method for manufacturing an inorganic foam board is characterized in that the surface decorative layer is made of a granular material in which the surface of a core material made of natural stone grains or a core material made of Cervene grains is coated with glaze powder.

[Example] The inorganic foam board of the present invention is formed from a base layer made of an inorganic foamable granule and a surface decorative layer to be described later.

The inorganic foam granules constituting the base layer are AQ20s-5i0 such as acid clay, shirasu, perlite, anti-flintstone, and feldspar.
The main raw material is 2-series minerals, in addition to which fluxes such as soda ash, sodium nitrate, glass powder, boric acid, and borax, Flomite, and Sj
It is made by pulverizing and granulating C, barium carbonate, potassium carbonate, and other foaming agents.

The types of raw materials and their blending ratios may be appropriately selected depending on the expansion ratio, melting temperature, etc., and are not particularly limited in the present invention.

The blended raw materials are put into a pot mill together with steel balls having a diameter of about 10+nn, and dry-pulverized for about several hours. The powder you can get is 325 mesh passes and 96
It has a size of about 96 mm or more, and is granulated using a pan pelletizer or the like while spraying an aqueous molasses solution or an aqueous CMC solution onto this powder. The particle size is usually about 05 to 5 ++ ua.

The granules constituting the surface decorative layer are obtained by coating the surface of a core material made of natural stone grains or Cerben grains with glaze powder.

Natural stone grains are made by crushing natural stones such as andesite, rhyolite, granite, feldspar, pottery stone, rhostone, and mosilicate (weathered granite) into particles with a particle size of 1 to 6 mm using a crusher such as a hammer crusher. It is. Further, Cerben grains are obtained by pulverizing defective products such as so-called "cuts" and "cracks" that occur during bisque firing, compaction firing, final firing processes, etc. to a particle size of about 1 to 6II11.

The glaze powder coated on the core material may include pulverized glazes used for ceramics, roof tiles, roof tiles, etc., as well as volcanic rock, volcanic ash, etc. that melt at a temperature below the foaming temperature of inorganic foaming granules. It includes anything that acts in the same way as a so-called normal glaze, such as inorganic materials or materials with pigments added to them. Specifically, glass powder, R
-2 Frit, zirconite, bentonite, and other blended raw materials may be ground together with steel balls in a pot mill, and a pigment may be added and mixed.

The surface decorative layer may be formed from one type of granular material, or it may be formed from a mixture of two or more types of granular material coated with glaze powder of different pigments.

The inorganic foam board is manufactured by firing and integrating a laminate consisting of the base layer and the surface decorative layer in a firing furnace such as a tunnel kiln.

When the inorganic foam board obtained by the manufacturing method of the present invention is used as a flooring material, the surface will be prevented from slipping.

In other words, conventional inorganic foam boards have a smooth glassy surface, which poses a risk of slipping, but in the inorganic foam board of the present invention, glaze powder is coated on polygonally crushed natural stone grains or Cervene grains. It is heated and melted. As a result, the glaze powder melts and fills the grain boundaries, and the natural stone grains and Cervene grains are welded and integrated, resulting in a decorative structure where the heads of the natural stone grains and Cervene grains are covered with a thin glaze layer and protrude from the smooth glaze surface. The layers can be changed. On such a glazed surface, the protruding angles of the crushed grains prevent slipping, and the natural stone grains and Cervene grains have greater abrasion resistance than the glassy decorative layer. Stone pieces are scattered throughout, creating a chic floor surface. In this way, an inorganic foam board with a strong, clean, and elegant decorative layer can be obtained.

Next, the present invention will be described in detail based on Examples, but the present invention is not limited to these Examples.

Example 1 Preparation of base layer raw materials Acidic clay 52% (wt%, same hereinafter), glass powder 20%
, 10% soda ash, 4% sodium nitrate, 7% dolomite and 7% zircon flour.
The mixture was placed in a pot mill with steel balls and dry ground for 6 hours.

The obtained powder had a 325 mesh pass of 96% or more. This powder was sprayed with a binder (15% molasses solution) and then granulated using a pan-type granulator to obtain granules with a particle size of 1 to 2.5 mm. This granulated material was dried in a vipul lift transfer hot air dryer so that the granulated moisture content was 2% or less.

Preparation of raw materials for decorative layer Glass powder (manufactured by Union Glass) 62%, I? -2 Mixed raw materials consisting of 2596 Fritz (manufactured by Kasai Glaze ■), 8% zirconite (manufactured by Nisto Sangyo ■), 3% Kibushi clay (manufactured by Okumura Ceram ■), and 2% bentonite (manufactured by Sanritsu Mining Co., Ltd.) were mixed into 10 mm' The mixture was placed in a bot mill together with still balls and dry ground for 3 hours. The obtained powder is 44μ
It was 96% below, and this powder was used as the basic raw material.

Using an Eirich mixer, 100 parts by weight of the obtained basic raw material and 05 parts by weight of Z-205 (pigment manufactured by Nisto Sangyo ■) were mixed into 3 parts by weight.
After mixing for 0 seconds, glaze powder A (eye poly color) was obtained.

In addition, 100 parts by weight of the basic raw material, 3 (Nichito Sangyo ■
Glaze powder B (orange color) was obtained by mixing 4.5 parts by weight of J-24 (pigment manufactured by Nisto Sangyo Co., Ltd.) for 30 seconds using an Eirich mixer.

Furthermore, 100 parts by weight of the basic raw material and 3.0 parts by weight of J-24 (pigment manufactured by Nisto Sangyo ■) were mixed for 30 seconds using an Eirich mixer to obtain glaze powder C (black color).

On the other hand, porcelain tableware (defective products) was coarsely crushed in a show crusher, and then finely crushed in a hammer mill to obtain a particle size of 3.
It was sieved to a range of 0 to 6.0+n++ and used as a core material.

Mix 1.7 g of this core material and 400 cc of CMCl0% solution well to wet the entire surface of the core material, and add the glaze powder A into the mixture.
200 g was added, and the surface of the core material was coated with glaze powder A (coloring raw material A) while rolling in a pan-type granulator.

In the same manner, 1711 core materials each coated with glaze powder B (coloring raw material B) and core materials coated with glaze powder C (coloring raw material C) were prepared.

Coating coloring raw material A-C prepared as above
into a container with a hole diameter of 2.0 mm on the bottom and a thickness of 10 mm.
It was placed in a drying oven and dried to a moisture content of 2.0% or less.

Three types of dried coloring raw materials A-C were mixed into 60% by volume of coloring raw material A, 20% by volume of coloring raw material B, and 20% by volume of coloring raw material C.
The mixture was placed in a rocking mixer at a mixing ratio of 1, and mixed for 2 minutes. Each color was mixed uniformly, and the surface skin of each colored grain was slightly peeled off and transferred to the surface of different colored grains.

Firing An inorganic foam board was fired using the granules or granules prepared as described above.

The firing furnace has a total length of 3 with a heat-resistant mesh held installed for transportation.
A 9rn tunnel kiln was used. Alumina was applied as a mold release material onto a 111 m mesh belt, and inorganic foam granules were uniformly charged to a thickness of 15+nm, and the three types of mixed colored granules were added to a thickness of 6 nm. They were stacked so that the distance was .0. The resulting laminate is transported to a preheating zone, and then sequentially transferred to a firing zone, rapid cooling zone, gradual cooling zone, and
It passed through a cooling zone and was carried out from the furnace outlet.

The firing conditions were as follows: preheating zone: 350-650" C1 firing zone: 700-870°C; rapid cooling zone: 700-710°C; slow cooling zone: 620-480°C; cooling zone: 450-60°C. The moving speed was 25 cm/min, and the time required to enter the furnace and exit the furnace was approximately 160 minutes.The resulting inorganic foam board was cut into pieces of 1190 cm and 100 mm long, but the foaming of the base layer The pores were fine and the pores were aligned in a foamed state.The cross section of the surface decorative layer showed that the coated glaze raw material had melted and filled the gaps between the Cerben grains, becoming one and fused to the foam layer. Cervene grains covered with a thin glaze layer were protruding here and there.The surface color is ivory yellow as a whole, but there are ocher, black, silver, and maroon square grains dotted around it, giving it an elegant appearance. It had a nice color tone.

When the degree of abrasion of the glaze layer and the Selven grains was measured in accordance with JISA5209, the abrasion loss of the glaze layer was 0.04 g, and that of the Selven grains was 0.01 g.

Example 2 Preparation of base layer raw materials Acidic clay 52% (wt%, same hereinafter), glass powder 20%
, 10% soda ash, 4% sodium nitrate, 7% dolomite and 7% zircon flour.
Put it in a pot mill with IIlβ steel ball 6
Dry milled for a while.

The powder obtained had a 325 mesh bath of 96% or more. This powder was sprayed with a binder (molasses 15% solution) and then granulated using a pan-type granulator to obtain granules with a particle size of 1 to 2.5 mm. This granulated material was dried in a vipul lift transfer hot air dryer so that the granulated moisture content was 2% or less.

Preparation of raw material for decorative layer Algae strain (weathered granite) was coarsely crushed using a hammer crusher and adjusted to a particle size of 1 to 3 ++ue to obtain a natural stone core material.

30% glass powder and R-2 frit (manufactured by Kasai Glaze)
A glaze layer was obtained by mixing and pulverizing 70% of the mixture in a pot mill with a porcelain hole of 10 to 15 m+*' for 5 hours.

2500 g of the glaze layer was coated on 1.711 algae powder adjusted to a particle size of 1 to 3 using a pan-type granulator while spraying a 1.0% CMC solution onto the core material to prepare decorative granules.

The obtained cosmetic granules were dried using an externally heated rotary kiln to prepare a raw material for the cosmetic layer.

An inorganic foam board was fired in the same manner as in Example 1 using the fired granules or granules.

The glaze raw material coated on the algae strain melted and embraced the algae strain powder, forming a glass layer. Although the surface is rough with convexities due to the algae powder, it is smooth overall, and although there is devitrification in some places, the biotite, silica, and feldspar grains of the algae grains can be seen through the glass layer. I was able to fully express the taste of granite.

[Effects of the Invention] As explained above, according to the manufacturing method of the present invention, an inorganic foam board having the color tone and texture inherent to natural stone can be obtained. Furthermore, when the inorganic foam board obtained by the manufacturing method of the present invention is used as a flooring material, it has the effect of reliably preventing slippage due to the protrusion of natural stone grains or Cerben grains in the surface decorative layer.

Claims (1)

[Claims] 1. A method for producing an inorganic foam board, in which a decorative surface layer is formed on a base layer made of an inorganic foamable granule, and the resulting laminate is heated to melt and integrate, the surface decorative layer being made of natural stone grains. A method for manufacturing an inorganic foam board, characterized in that it is made of a core material made of or a granular material whose surface is coated with glaze powder.