JPH07238629A - Porous ceramic plate and manufacture thereof - Google Patents

Abstract

PURPOSE:To produce the design of various recessed and projected patterns without halting a baking furnace at the time of continuous baking by laminating a plurality of inorganic foaming granulated objects which differ in expansion ratio or melting temperature. CONSTITUTION:A plural kind of inorganic foaming granulated objects which differ in expansion ratio or melting temperature from each other are laminated in such a way that they provide adequate patterns and heated and baked for integration to manufacture a porous ceramic plate 1. A layered product consisting of a part 2a in which high foaming objects are baked and a part 2b in which low foaming objects are baked is obtained, and various recessed and projected patterns are produced on a surface by variously changing the way of lamination to increase value of product. Since a change of the recessed and projected patterns can be done at the stage of lamination of raw materials, continuous baking is possible without halting a baking furnace, and productivity and workability are improved.

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, it relates to a porous ceramic plate capable of exhibiting a wide variety of designs and a manufacturing method thereof.

[0002]

2. Description of the Related Art A porous ceramic plate is used as a building material because it is lightweight and has excellent fire resistance and heat insulating properties. This porous ceramic plate is provided with a concavo-convex pattern in order to improve the design of the surface. The concavo-convex pattern of the porous ceramic plate is obtained by uniformly laminating the inorganic expandable granules, heating and foaming the obtained laminated body in a firing furnace, and then forming a laminated body which is still in a softened state in the slow cooling process. It is pressed by an uneven roll to transfer the uneven shape to the surface of the laminate.

[0003]

By the way, in the above-mentioned porous ceramic plate, when it is desired to change the uneven pattern on the surface in accordance with demand, it is necessary to replace it with various roll shapes. However, there is a problem in that the firing furnace must be temporarily stopped during the roll replacement work, although continuous firing is desirable from the viewpoint of production and economy.

In view of the above circumstances, the present invention makes it possible to easily reveal a variety of designs of uneven patterns on the surface without stopping the firing furnace during continuous firing, which is a highly commercial porous ceramic. It is intended to provide a board and a manufacturing method thereof.

[0005]

The porous ceramic plate of the present invention comprises a laminate in which a plurality of inorganic expandable granules having different expansion ratios or melting temperatures are laminated so as to have an appropriate pattern. Is characterized by.

Further, in the method for producing a porous ceramic plate of the present invention, inorganic expandable granules having different expansion ratios or melting temperatures are laminated so as to have an appropriate pattern, and the obtained laminated body is heated and fired. It is characterized in that it is melted and integrated.

At least a surface decorative layer may be provided on the laminate.

[0008]

According to the porous ceramic plate and the method for producing the same of the present invention, the degree of foaming after firing is different due to the inorganic expandable granules having different expansion ratios or melting temperatures, and as a result, the surface is uneven. A ceramic plate can be obtained.

Further, at the stage of laminating the raw materials of the granulated product without stopping the firing furnace during continuous firing, it is possible to obtain a porous ceramic plate exhibiting a wide variety of concavo-convex patterns by changing the laminated state.

[0010]

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 partially cutaway perspective view showing one embodiment of the porous ceramic plate of the present invention, and FIG. 2 is a partially cutaway perspective view showing another embodiment of the porous ceramic plate of the present invention.

First, one embodiment of the present invention will be described.

As shown in FIG. 1, a porous ceramic plate 1
Is composed of a laminated body obtained by laminating inorganic expandable granules, and has a portion 2a where an inorganic expandable granule having a high expansion ratio (hereinafter referred to as a high foaming material) is fired and a foaming ratio thereof. Of the low-expanding inorganic expandable granules (hereinafter referred to as the low-foaming product).

Examples of the inorganic expandable granules include Al ₂ O ₃ − such as acid clay, shirasu, pearlite, firestone, and feldspar.
Using SiO ₂ minerals as the main raw material, a mixture of soda ash, sodium nitrate, glass powder, boric acid, borax and other fluxing agents, and dolomite, SiC, barium carbonate, potassium carbonate and other foaming agents. What was pulverized and granulated is used.

The expansion ratio can be freely changed by changing the melting point by adjusting the addition amount of the flux, adjusting the addition amount of the foaming agent, changing the type of the foaming agent, firing method, etc. Is.

The blended raw material is put in a pot mill together with a steam 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. The particle size of the granulated product is usually about 0.1 to 5 mm, and the particle size can be selected according to the type of the granulator.

The thickness of the laminate is not particularly limited in the present invention, but is usually about 3 to 35 mm, preferably about 10 mm.

In this embodiment, the high foamed material and the low foamed material are randomly distributed in the laminated body. for that reason,
The portion 2a containing a large amount of high foam constitutes a rising convex portion, and the portion 2b containing a large amount of low foam forms a concave portion with little rising. As a result, a porous ceramic plate 1 having an irregular surface pattern is obtained.

The concavo-convex pattern can be made various by changing the laminated state of the high-foamed material and the low-foamed material. For example, various patterns such as a striped pattern, a polka dot pattern, and a floral pattern can be obtained. You can

Next, another aspect of the present invention will be described.

As shown in FIG. 2, the porous ceramic plate 1
1 is an inorganic expandable granule having a high melting temperature (hereinafter referred to as a high melt) unlike the porous ceramic plate 1 shown in FIG.
And an inorganic expandable granule having a low melting temperature (hereinafter referred to as a low melting material), which is a laminated body obtained by regularly laminating in a stripe shape. Therefore, by adjusting the firing time during heating and firing at a temperature below the melting temperature of the high melt or above the melting temperature, the line of the portion 12b where the low melt is fired rises and the high melt is fired. On the line of the formed portion 12a, there is little swelling and there is insufficient foaming, so that an uneven striped pattern can be provided on the surface.

The melting temperature can be easily changed, for example, by changing the addition amount of soda ash which is a flux.

It should be noted that the present invention is not limited to the above-mentioned laminated body, and a surface decorative layer, a glass layer or the like can be laminated thereon. As the surface decorative layer, colored glaze granules and the like can be used. The glaze granules are granulated by powdering a raw material in which glass powder, frit, or the like is used as a main raw material and an inorganic coloring pigment is mixed as a colorant. This particle size is usually 0.5-3.5 mm
It is a degree. The thickness of the surface decorative layer is usually 3 to 7
It is about mm.

Next, a method for producing the porous ceramic plate of the present invention will be described.

For the porous ceramic plate of the present invention, the raw materials prepared in advance as described above are supplied from a hopper or the like to form a predetermined laminated body, and the obtained laminated body is heated in a firing furnace. It can be obtained by firing and solution integration.

Hereinafter, the porous ceramic plate of the present invention will be described based on examples, but the present invention is not limited to such examples as a matter of course.

Example 1 Preparation of high foam raw material Otaniishi 64.5% (weight%, the same applies hereinafter), soda ash 18
%, Water glass powder 5%, Sanritsu Talc 12% and SiC
The mixed material composed of 0.5%, further added soda ash 1%, After that, the dry-milled during the 4 hours was placed in a pot mill together with the steel balls of the raw material 10 mm ^phi. The resulting powder was 325 mesh pass 96% or greater in size. This powder was granulated with a pan pelletizer while spraying a 15% molasses liquid to obtain a granulated product having a particle size of 1 to 4 mm.

Preparation of Low Foam Raw Material A mixture obtained by removing 1% of soda ash from the above high foam raw material was mixed and pulverized in the same manner as described above. The granulation procedure was also performed in the same manner.

Firing A laminate is made using the raw materials prepared as described above,
This was heat-fired and solution-integrated to obtain a porous ceramic plate.

As the firing furnace, a tunnel kiln having a total length of 39 m, on which a heat-resistant mesh belt was installed for transportation, was used.
Alumina was applied as a mold release material on a mesh belt having a width of 1 m, and the granules for base layer were uniformly laminated thereon to have a thickness of 10.5 mm. The obtained laminated body was conveyed to a preheated body, and then passed through a firing zone, a quenching zone, a slow cooling zone, and a cooling zone in that order, and unloaded from the furnace outlet.

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.

The obtained porous ceramic plate was visually observed to have an uneven pattern as shown in FIG. 1 on the laminate.

[0033]

As described above, according to the porous ceramic plate of the present invention and the method for manufacturing the same, the uneven pattern can be easily revealed. In addition, by changing the stacking method of the inorganic foamed granules having different expansion ratios or melting temperatures, it is possible to obtain a porous ceramic plate having a wide variety of uneven patterns, thus increasing the commercial value.

Further, since the uneven pattern can be changed at the stage of laminating the raw materials, the firing furnace is not stopped unlike the conventional case. Therefore, productivity and workability are improved.

[Brief description of drawings]

FIG. 1 is a partially cutaway perspective view showing an embodiment of a porous ceramic plate of the present invention.

FIG. 2 is a partially cutaway perspective view showing another embodiment of the porous ceramic plate of the present invention.

[Explanation of symbols]

 1, 11 Porous ceramic plate

Claims (8)

[Claims] 1. A porous ceramic plate having irregularities on its surface, comprising a laminated body in which a plurality of inorganic expandable granules having different expansion ratios are laminated so as to exhibit an appropriate pattern. 2. The porous ceramic plate according to claim 1, wherein at least a surface decorative layer is provided on the laminate. 3. A porous ceramic plate having irregularities on the surface, comprising a laminated body in which a plurality of inorganic expandable granules having different melting temperatures are laminated so as to have an appropriate pattern. 4. The porous ceramic plate according to claim 3, wherein at least a surface decorative layer is provided on the laminate. 5. A porous ceramic plate characterized in that inorganic expandable granules having different expansion ratios are laminated so as to have an appropriate pattern, and the obtained laminated body is heat-fired to be solution-integrated. Manufacturing method. 6. The method for producing a porous ceramic plate according to claim 5, wherein at least a surface decorative layer is provided on the laminate. 7. A porous ceramic plate, characterized in that inorganic expandable granules having different melting temperatures are laminated so as to have an appropriate pattern, and the obtained laminated body is heat-fired to be solution-integrated. Manufacturing method. 8. The method for producing a porous ceramic plate according to claim 7, wherein at least a surface decorative layer is provided on the laminate.