JPH07238634A - Porous ceramic board and manufacture thereof - Google Patents

Abstract

PURPOSE:To realize various novel hexagonal patterns with simple and easy execution of work by placing a fine particle layer being melted by heating on a base layer, and at the same time by integrally baking them. CONSTITUTION:A fine particle layer 13 being melted by heating is placed on a base layer 12 consisting of foaming inorganic granulated substances, and the obtained laminated body is baked and melted so as to be integrated for obtaining porous ceramic board 11. As a result, the fine particle layer 13 melts in the baking process and coagulates and swells in a scattered-spot shape, and a boundary between the region where the base layer 12 is dimly seen and the region where the base layer 12 is transparently seen is caused, and a hexagonal pattern B appears. Further, a surface decorative layer 14 consisting of color- mixed glaze grains or the like may be interposed on the fine particle layer 3 or between the base layer 12 and the fine particle layer 13.

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, the present invention relates to a porous ceramic plate capable of exhibiting various designs and a manufacturing method thereof.

[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 the design of the surface. As a surface makeup, a glaze granule that is colored and mixed is laminated on a base layer made of an expandable inorganic granule to form a surface makeup layer, and the obtained laminate is fired to be solution-integrated. There is.

[0003]

However, in the porous ceramic plate having the above-mentioned structure, the semi-glaze pattern on the decorative surface becomes a uniform uneven surface or a flat surface, and it tends to have a monotonous and planar expression, which is novel. There is a problem that it is not possible to obtain a perfect design.

In view of the above circumstances, it is an object of the present invention to provide a porous ceramic plate having a high commercial value, which can easily bring out a novel design, and a manufacturing method thereof.

[0005]

The porous ceramic plate of the present invention is characterized in that a powder layer which is melted by heating is provided on a base layer made of an expandable inorganic granule.

A surface decorative layer may be provided on the powder layer.

Further, it is preferable to provide a surface decorative layer between the base layer and the powder layer.

Further, in the method for producing a porous ceramic plate of the present invention, a powder layer which is melted by heating is provided on a base layer made of an expandable inorganic granule, and the obtained laminate is fired to be integrated by solubilization. The feature is to let.

A surface decorative layer is further provided on the powder layer,
The obtained laminate may be fired to be solution-integrated.

Further, it is preferable that a surface decorative layer is provided between the base layer and the powder layer, and the obtained laminate is fired to be solution-integrated.

[0011]

According to the porous ceramic plate of the present invention, the powder layer which is melted by heating is melted in the firing step and aggregated in a scattered manner. As a result, after firing, the melted powder layer aggregates on the surface of the base layer, and the area where the base layer appears to be blurred and the boundary where the melted powder layer remains and the base layer can be seen through Occurs, and a hexagonal pattern is formed.

Even when the surface decorative layer is provided on the powder layer, the granules constituting the surface decorative layer are aggregated together with the lower powder layer to form a hexagonal pattern.

[0013]

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 perspective view showing one embodiment of the porous ceramic plate of the present invention, and FIG. 2 is a 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, the porous ceramic plate 1
Is composed of a base layer 2 made of an expandable inorganic granule and a powder layer 3 provided on the base layer 2 and melted by heating.

The expandable inorganic granules are Al ₂ O ₃ —SiO ₂ such as acid clay, shirasu, pearlite, anti-fire stone, feldspar.
Based minerals as the main raw material, soda ash, sodium nitrate,
Fluxing agents such as glass powder, boric acid, borax, dolomite, Si
A mixture of C, barium carbonate, potassium carbonate, and other foaming agents, which are supplemented, is pulverized and granulated. 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.

The above-mentioned blended raw material is put into a pot mill together with a steam ball having a diameter of about 10 mm, and dry-ground for about several hours. The resulting powder is a 325 mesh pass
The size is about 96% or more, and the powder is granulated with a pan pelletizer while spraying a molasses aqueous solution or a CMC aqueous solution. The particle size of this granulated product is about 0.1 to 5 mm, and the appropriate particle size varies depending on the type of granulator.

The thickness of the base layer 1 is not particularly limited in the present invention, but is usually about 3 to 100 mm, and the thickness is appropriately set according to the application.

The powder of the powder layer 3 is the base layer 1
In addition to the raw material of the surface decorative layer 14, glass powder, a mixture of volcanic ash with a flux, and inorganic powder such as glaze powder are used. The particle size of the powder is such that a hexagonal pattern A as shown in FIG. 1 appears on the powder layer 3 depending on the particle size of the expandable inorganic granule and the firing conditions such as firing temperature and firing rate. For the sake of simplicity, it is usually 500 μm or less, and preferably the average particle size is about 100 μm or less. Similarly, the thickness of the powder is usually about 0.5 to 4 mm, and the thickness corresponding to the hexagonal pattern can be set.

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

As shown in FIG. 2, the porous ceramic plate 11
Unlike the porous ceramic plate 1 shown in FIG. 1, a surface decorative layer 14 is further provided on the powder layer 13 on the base layer 12.

As the surface decorative layer 14, colored glaze granules or 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 about 0.5 to 3.5 mm, and the particle size is set according to the design. The thickness of the surface decorative layer is not particularly limited in the present invention, but is usually 3 to 7
It is about mm, preferably about 5 mm.

The particle size of the powder of the powder layer 13 in the present embodiment is such that the surface decorative layer 14 has a hexagonal shape as shown in FIG. In order to facilitate the appearance of the pattern B, it is usually 0.25 mm or less, preferably the average particle size is about 0.2 mm or less. Also,
Similarly, the thickness of the powder is usually about 0.5 to 5 mm, and the thickness may be set according to the hexagonal pattern.

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

Unlike the porous ceramic plate 1 shown in FIG. 1, the porous ceramic plate of this embodiment is provided with a surface decorative layer between the base layer and the powder layer.

The particle size of the powder in the powder layer in this embodiment is
In order to facilitate the appearance of a hexagonal pattern on the powder layer due to the particle size of the granulation of the surface decorative layer and the firing conditions, it is usually 0.
It is 25 mm or less, and preferably the average particle size is about 0.2 mm or less. Similarly, the powder thickness is usually 0.5 to 5 mm,
The thickness can be set according to the turtle shell pattern.

Further, in this embodiment, since the powder layer acts as a barrier layer, it is possible to effectively prevent the moisture from entering from the surface.

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

In 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 laminate, and the obtained laminate 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.

[0032] Example 1 base layer prepared Oya 64.5% of raw material (% by weight, hereinafter the same), soda ash 18% water glass powder 5%, the blended raw material comprising a three elevational talc 12% and ^SiC0.5% 10mm φ It was put in a pot mill together with the steel ball of No. 3 and dry-ground for 4 hours. The resulting powder was 325 mesh pass 96% or more 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.

The surface decorative layer prepared glass powder 62% of the raw material, the frit 25%, was dry-pulverized during the 5 hours were placed in a pot mill together with steel balls of 10mm a mixed material consisting of elutriation viscosity 5% and 8% zirconium silicate ^φ . The resulting powder was 325 mesh pass 96% or more in size. This powder was granulated with a pan pelletizer while spraying a 10% molasses liquid to obtain a granulated product having a particle size of 1 to 2.5 mm.

Preparation of Powder Layer Raw Material As a powder, a finely crushed waste material of a porous ceramic plate was used. The average particle size of the powder at this time is about 45μ
It was m.

Baking A laminated body was made using the granules and the like prepared as described above, and this was fired and solution-integrated to obtain a porous ceramic plate.

For the firing, a tunnel kiln having a total length of 39 m, on which a heat-resistant mesh belt was installed for transportation, was used. Width 1
Alumina is applied as a mold release material on the m mesh belt, and the granules for the base layer are uniformly charged to have a thickness of 10.5 mm, and the powder has a thickness of about 3 mm. The granules for a decorative layer were further laminated thereon so as to have a thickness of 4 mm. The obtained laminated body was conveyed to the pre-tropical zone, and then passed through the firing zone, the quenching zone, the slow cooling zone, and the cooling zone in that order, and then discharged 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 enter and exit the furnace was about 160 minutes.

When the obtained porous ceramic plate was visually observed, it had a turtle shell-like pattern having a novel design as shown in FIG. 2 on the surface decorative layer.

[0039]

As described above, according to the porous ceramic plate of the present invention, a novel hexagonal design can be easily appeared, and the particle diameter and thickness of the powder can be variously changed. Therefore, various turtle shell designs can be obtained, and the commercial value can be increased.

[Brief description of drawings]

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

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

[Explanation of symbols]

 1, 11 Porous ceramic plate 2, 12 Base layer 3, 13 Powder layer 14 Surface decorative layer A, B Turtle pattern

Claims (6)

[Claims] 1. A porous ceramic plate comprising a base layer made of an expandable inorganic granule and a powder layer which is melted by heating. 2. The porous ceramic plate according to claim 1, wherein a surface decorative layer is provided on the powder layer. 3. The porous ceramic plate according to claim 1, wherein a surface decorative layer is provided between the base layer and the powder layer. 4. A porous ceramic plate characterized in that a powder layer which is melted by heating is provided on a base layer made of an expandable inorganic granule, and the obtained laminated body is fired to be melted and integrated. Manufacturing method. 5. The method for producing a porous ceramic plate according to claim 4, wherein a surface decorative layer is further provided on the powder layer. 6. The method for producing a porous ceramic plate according to claim 4, wherein a surface decorative layer is provided between the base layer and the powder layer.