JPH07102739A - Porous ceramic plate and production thereof - Google Patents

Abstract

PURPOSE:To improve the appearance of a ceramic product and make stable the thickness of the product, by interposing s cutting-off layer composed of inorganic granules having an extremely low water content between a base layer and a superficial decorative layer. CONSTITUTION:A superficial decorative layer 3 is formed on a base layer 2 made of foamable inorganic granules through a cutting-off layer 4 composed of inorganic granules having an extremely low water content. The laminated material in the above way is heated to melt in as a unified body in order to obtain a porous ceramic plate 1. Accordingly, the transferrence of the component of the melting and foaming agent in the base granules to the decorative granules side is intercepted by the cutting-off layer 4. And blisters and bubbles conventionally caused by the transferrence are not brought about and the appearance of products is improved and the thickness thereof is made uniform.

Description

Detailed Description of the Invention

[0001]

FIELD OF THE INVENTION The present invention relates to a porous ceramic plate and a method for producing the same. More specifically, a porous ceramic capable of improving the appearance and making the thickness of the product uniform by preventing bubbles generated on the surface of the decorative layer and bubbles generated at the interface between the decorative layer and the base layer. A board and its manufacturing method.

[0002]

2. Description of the Related Art Porous ceramic plates are being used as building materials because they are lightweight and have excellent fire resistance and heat insulating properties. The porous ceramic plate is subjected to surface makeup in order to improve frost resistance and improve the design of the surface. As the surface makeup of such a porous ceramic plate, as shown in FIG. 2, the glaze particles which are colored and mixed are laminated on the base layer 11 made of the expandable inorganic granules to form the surface makeup layer 12, It has been practiced to melt and integrate the laminated body.

[0003]

However, in the porous ceramic plate having the above-described structure, the surface of the decorative layer 12 is covered (the inside contains gas and the surface is a thin film. (Surface defects such as peeling) 13
However, there is a problem in that bubbles are generated frequently at the interface between the decorative layer 12 and the base layer 11. They are,
Moisture in high-moisture content (8-15%) cosmetic particles once migrates to the low-moisture content (0-5%) base particle side, and soluble in soda ash, sodium nitrate, etc. contained in the base particles This is due to the fact that the components which are the fluxing agent and the foaming agent are transferred to the vicinity of the boundary layer or into the cosmetic particles. When the bubbles or bubbles are generated, not only is the quality of the product unfavorable in terms of appearance, but there is the inconvenience that the thickness of the product becomes uneven.

In this case, it is conceivable that the cosmetic particles having a high water content are dried to reduce the water content in advance, but if this is done, the cosmetic particles are pulverized, resulting in lack of color stability and charging. There is another problem that a defect occurs.

In view of the above circumstances, it is an object of the present invention to provide a porous ceramic plate and a method for producing the same, which prevents the migration of water from the cosmetic particles and prevents the formation of the swelling or foaming. And

[0006]

The porous ceramic plate of the present invention is a porous ceramic plate in which a base layer made of an expandable inorganic granule and a surface decorative layer are laminated, and It is characterized in that a barrier layer made of an inorganic granule is interposed between the surface decorative layer and the surface decorative layer.

In the method for producing a porous ceramic plate of the present invention, a surface decorative layer is formed on a base layer made of expandable inorganic granules through a barrier layer made of inorganic granules, and the obtained laminate is obtained. The feature is that the body is heated to be melted and integrated.

[0008]

In the present invention, a barrier layer of an inorganic granule having a low water content is interposed between the decorative layer and the base layer,
In the solution integration, the migration of water from the decorative layer to the base layer is prevented, so that the components that are flux and foaming agent in the base layer are prevented from dissolving in this water and migrating to the decorative layer side. To be done.

[0009]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The porous ceramic plate of the present invention and its manufacturing method will be described below with reference to the accompanying drawings.

FIG. 1 is a sectional explanatory view of an embodiment of the porous ceramic plate of the present invention.

The porous ceramic plate 1 has a base layer 2 and
It is composed of a surface decorative layer 3 and a blocking layer 4 interposed therebetween.

The base layer 2 is obtained by firing an expandable inorganic granule. The expandable inorganic granules are mainly made of Al ₂ O ₃ —SiO ₂ type minerals such as acid clay, shirasu, pearlite, anti-firestone, feldspar, Otani stone, horse head clay and soda ash, sodium nitrate. , Powdered glass, boric acid, borax, and other fluxing agents, and dolomite, SiC, barium carbonate, potassium carbonate, tritium talc, and other foaming agents, which have been auxiliary compounded, and then granulated and dried. is there. The particle size of this granulated product is usually about 0.5 to 5 mm. The type of raw material and the mixing ratio thereof may be appropriately selected according to the expansion ratio, the melting temperature, etc., and are not particularly limited in the present invention. Also, the thickness of the base layer 1 is not particularly limited in the present invention, but is usually about 3 to 35 mm, preferably about 10 mm.

The blended raw material is put in a pot mill together with a steel ball having a diameter of about 10 mm and dry-ground for about several hours. The obtained powder has a size of about 325 mesh pass and 96% or more, and is granulated by a pan pelletizer while spraying a molasses aqueous solution or a CMC aqueous solution on the powder.

As the surface decorative layer 3, it is possible to use a product obtained by firing glaze particles mixed and colored. The glaze granules are obtained by pulverizing and granulating a raw material in which glass powder, frit, zirconium silicate, and elutriated clay are used as main raw materials, and an inorganic coloring pigment is mixed as a colorant. This particle size is usually about 0.5 to 3.5 mm. The type of raw material and the mixing ratio thereof may be appropriately selected and are not particularly limited in the present invention. Also, the thickness of the surface decorative layer 2 is not particularly limited in the present invention, but is usually about 3 to 7 mm, preferably about 5 mm.
mm.

The present invention is characterized in that a blocking layer 4 made of an inorganic granule is interposed between the base layer 2 and the surface decorative layer 3. This inorganic granule is made of glass powder, obsidian, anti-fire stone, pearlite and other inorganic materials as the main raw material, and after elutriated clay, dolomite, bentonant, etc. are auxiliary compounded into the raw material, this is What was dried after granulating is used. In this case, in order to reliably block the migration of water, the average particle diameter of the blended raw material powder is about 5 to 40 μm, preferably 10 to 30 μm.
m. The particle size of the granulated product is 0.2 to 2.5 mm
The range is about 0.25 to 0.6 mm. For drying, a rotary external heating type drying furnace (rotary dryer) is used, and the surface temperature of the object to be dried is 100%.
Approximately 5 to 30 minutes until the temperature reaches to 200 ° C.

The thickness of the barrier layer 4, which is related to the particle size of the granulated product, is usually in the range of 1.0 to 6.0 mm, preferably about 1.0 to 4.0 mm.

Since the inorganic granules have a very low water content of 0 to 2%, it is possible to reliably prevent the water from the grains constituting the decorative layer from migrating to the base layer.

Next, the porous ceramic plate of the present invention is shown in Table 1.
However, the present invention is not limited to this.

Example 1 Preparation of Raw Material for Base Layer The raw materials for compounding shown in Table 1 were put in a pot mill together with steel balls having a diameter of 10 mm and dry-ground for 4 hours.
The resulting powder was 325 mesh pass 96% or greater in size. A granulated product was obtained with a pan pelletizer while spraying a 15% molasses liquid on this powder.

Preparation of Surface Decorative Layer Raw Material The mixed raw materials shown in Table 1 were put into the pot mill and dry-ground for 5 hours. The resulting powder was 325 mesh pass 96% or greater in size. A granulated product was obtained with a pan pelletizer while spraying 10% molasses liquid on this powder.

Preparation of Blocking Layer Raw Material The blended raw material shown in Table 1 was put into the pot mill and dry-ground for 3 hours. The resulting powder was 325 mesh pass 96% or greater in size. A granulated product was obtained with a pan pelletizer while spraying 5% molasses liquid on this powder.

[0022]

[Table 1]

Firing A laminated body was made using the granulated material prepared as described above, and this was fired to be melted and integrated to obtain a porous ceramic plate.

For the firing, a roller hearth kiln firing furnace having a total length of 39 m, in which a heat-resistant mesh belt was installed for transportation, was used. Alumina is applied as a release material on a mesh belt with a width of 1 m, and granules for the base layer are applied on it for 18 m.
evenly charged to a thickness of m, and the granules for the blocking layer are evenly laminated thereon to a thickness of 4 mm,
Further, a granulated product for a decorative layer was laminated thereon so as to have a thickness of 5 mm. The obtained laminated body was conveyed to the pre-tropical zone, and was then passed through the firing zone, the quench zone, the slow cooling zone, and the cooling zone in that order to complete the firing.

The firing temperature was 900 ° C. The moving speed of the mesh belt was 25 cm / min, and the time required to put in and out of the furnace was about 160 minutes.

Example 2 Preparation of raw materials for the base layer, surface decorative layer and barrier layer is shown in Table 1.
The same procedure as in Example 1 was performed except that the compounded raw material was used.

Next, a laminated body was prepared by using the prepared granulated material, and this was fired and solution-integrated to obtain a porous ceramic plate.

The firing was carried out in the same furnace as in Example 1 and under the same conditions.

However, the thickness of the granules for the base layer, the granules for the barrier layer and the granules for the decorative layer are 20 mm, respectively.
It was set to 3 mm and 6 mm.

Comparative Example 1 and Comparative Example 2 Porous ceramic plates were manufactured by the same method as in Examples 1 and 2 except that no barrier layer was interposed.

When the appearance of the porous ceramic plate obtained above was visually observed, Examples 1 and 2 were obtained.
Was not observed at all on the surface of the decorative layer or bubbles at the interface between the decorative layer and the base layer, but in Comparative Example 1 and Comparative Example 2 which are conventional products, a large number of bubbles or bubbles were observed respectively. It is understood that the quality of the porous ceramic plate of the present invention is excellent.

Then, a test piece of a porous ceramic plate (having a size of 100 mm length × 100 m width) was prepared by the same manufacturing method as described above.
m) was prepared and a surface water permeation rate test based on JIS A 5403 (6.5) was conducted. From this result, as shown in Table 1, it is recognized that the surface water permeation amount of Example 1 and Example 2 is smaller than that of Comparative Example 1 and Comparative Example 2. Therefore, since the porous ceramic plate of the present invention is less likely to allow water to permeate from the surface, it can be suitably used as a wall material or an outer wall material in the vicinity of a bathroom or kitchen where water is used.

It has been confirmed that the porous ceramic plate of the present invention has no problem in performance such as strength.

[0034]

As described above, in the porous ceramic plate of the present invention, since the barrier layer made of the inorganic granule having a very low water content is provided between the base layer and the surface decorative layer, the solubilization is performed. When integrated, it is possible to reliably prevent the migration of water from the cosmetic particles to the base particles. For this reason,
The migration of the component that is a fluxing agent and a foaming agent in the base particles to the cosmetic particles side is prevented, and the swelling and foaming caused by this migration does not occur and the appearance as the quality of the product is improved. At the same time, a porous ceramic plate having a stable product thickness can be obtained. Further, since the surface water permeability is small, it can be suitably used as a wall material or an outer wall material in a place where water is used such as a washroom or a kitchen.

[Brief description of drawings]

FIG. 1 is a cross-sectional explanatory view of an embodiment of a porous ceramic plate of the present invention.

FIG. 2 is a cross-sectional explanatory view of a conventional porous ceramic plate.

[Explanation of symbols]

 1 Porous Ceramic Plate 2 Base Layer 3 Surface Decorative Layer 4 Blocking Layer

Claims (2)

[Claims] 1. A porous ceramic plate in which a base layer made of an expandable inorganic granule and a surface decorative layer are laminated, and the porous ceramic plate is made of an inorganic granule between the base layer and the surface decorative layer. A porous ceramic plate having a blocking layer interposed. 2. A surface decorative layer is formed on a base layer made of an expandable inorganic granule through a barrier layer made of an inorganic granule, and the obtained laminated body is heated to be melted and integrated. Characteristic porous ceramic plate manufacturing method.