JPH08208348A - Production of porous ceramic plate - Google Patents

Abstract

PURPOSE: To obtain a porous ceramic plate capable of enhancing the quality of a product as well as to allow a design to appear easily on a decorative surface by successively forming a decorative surface layer and a base layer made of expandable inorg. granules on a meshy body and melting the resultant laminated body by heating. CONSTITUTION: A decorative surface layer 1 and a base layer 2 made of expandable inorg. granules are successively formed on a meshy body B and the resultant laminated body is melted and integrated by heating to obtain the objective porous ceramic plate. A heat resistant meshy belt B surface-coated with a releasing agent 3 such as alumina and stretched in a firing furnace is preferably used as the meshy body. A glass sheet is also preferably used as the decorative surface layer. A meshy support 11 consisting of a latticed net body 11a and a supporting legs 11b which support the net body 11a is also preferably used as the meshy body.

Description

Detailed Description of the Invention

[0001]

FIELD OF THE INVENTION The present invention relates to a method for producing a porous ceramic plate. More specifically, the present invention relates to a method for producing a porous ceramic plate that can improve the surface design and make the product thickness uniform.

[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 insulation. This porous ceramic plate is subjected to surface decoration in order to improve the frost damage resistance and the surface design. As the surface makeup of such a porous ceramic plate, for example, as shown in FIG. 4, a glaze granule that is colored and mixed is laminated on a base layer 51 made of an expandable inorganic granule to form a surface makeup layer 52, The obtained laminated body is solution-integrated and integrated.

[0003]

However, in the porous ceramic plate having the above-mentioned structure, since the decorative surface is flat, there is a problem that the depth of the surface makeup cannot be obtained. In addition, the surface of the decorative layer 52 may be covered with a gas (a gas is contained in the interior and the surface is a thin film, so a surface defect such that the thin film is exposed when pressed with a nail) 53 occurs, or the decorative layer 52 and the base layer 51. There was a problem in that bubbles 54 frequently occurred at the interface of the. These have a high water content (8 to 15%) and a low moisture content (0 to 5) in the cosmetic particles.
%) Once transferred to the base particle side, it is caused by the transfer of the soluble fluxing agent and foaming agent components such as soda ash and sodium nitrate contained in the base particle into the boundary layer or into the cosmetic particles. ing. When the bubbles or bubbles are generated, there is a disadvantage that not only the appearance design is impaired as the product quality, but also the product thickness becomes uneven.

In view of the above circumstances, it is an object of the present invention to provide a method for producing a porous ceramic plate that can easily reveal a design on a decorative surface and improve the product quality.

[0005]

The method for producing a porous ceramic plate of the present invention comprises forming a surface decorative layer and a base layer made of an expandable inorganic granule on a mesh in order, and forming the obtained laminate. The feature is that it is heated to be melted and integrated.

It is preferable that the reticulate body is a heat-resistant mesh belt installed in a firing furnace having a surface coated with a release agent.

It is preferable that the surface decorative layer is made of a glass plate.

[0008] It is preferable that the mesh-like body comprises a lattice-like mesh body and supporting legs for supporting the mesh body.

[0009]

According to the manufacturing method of the present invention, the surface decorative layer is formed on the mesh body, for example, on the heat-resistant mesh belt coated with the release agent, and is heat-solubilized. Appeared as a design on the makeup surface of. When a mesh-like body is used and a mesh-like support is used, the gas that is likely to be generated in the decorative layer is crushed and is easily released to the outside, so that the designability can be improved.

[0010]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A method for manufacturing a porous ceramic plate according to the present invention will be described below with reference to the accompanying drawings.

FIG. 1 is a schematic explanatory view showing an embodiment of a method for producing a porous ceramic plate of the present invention, and FIG. 2 is a perspective view showing another example of a mesh body in the method of producing a porous ceramic plate of the present invention. 3 is an explanatory view showing an example of use of the mesh body in FIG.

As shown in FIG. 1, the porous ceramic plate comprises a surface decorative layer 1 and a base layer 2.

As the surface decorative layer 1, it is possible to use a mixture of colored glaze particles (decorative particles) which has been baked. 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 is not particularly limited in the present invention, but is usually about 3 to 7 mm,
It is preferably about 5 mm. The surface decorative layer 1 is not limited to a layer of glaze particles,
As shown in FIG. 3A, a glass plate 1a can also be used. In this case, a variety of designs can be made to appear by printing a pattern that does not disappear by heating on the surface where the design is made to appear. The thickness of the glass plate 1a is not particularly limited in the present invention either, but it is usually 0.
It is about 5 to 5.0 mm, preferably about 1 to 3 mm.

The base layer 2 is formed by firing an expandable inorganic granule. This expandable inorganic granule is 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, etc.
Granulate by granulating the raw material with auxiliary additives such as soda ash, sodium nitrate, glass powder, boric acid, borax, and other fluxing agents, dolomite, SiC, barium carbonate, potassium carbonate, and tri-talc talc. It is dried after being dried. The particle size of this granulated product is usually about 0.5 to 5 mm. For the types of raw materials and their mixing ratios, the expansion ratio,
It may be appropriately selected according to the melting temperature and the like, and is not particularly limited in the present invention. Also, the thickness of the base layer is not particularly limited in the present invention, but is usually about 3 to 35 mm, preferably about 7 to 3
It is 0 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.

The present invention is characterized in that the surface decorative layer and the base layer are sequentially formed on the mesh body, and the obtained laminated body is heated to be melted and integrated.

The reticulate body has a large number of openings, supports the surface decorative layer and the base layer, facilitates escape of gas generated during melting, and enables uniform baking by heating from below. At the same time, it plays the role of forming a design, and for example, a heat-resistant mesh belt B installed in a firing furnace A as shown in FIG. 1 can be used. On the surface of this heat-resistant mesh belt B, the release agent 3
Has been applied. In this case, the mold release agent 3 is alumina, silica, at least a base containing them as a main component, or a natural mineral having a melting point higher than that of the cosmetic compound. The mold release agent 3 may be applied by a method in which a powder in a dry state is attached to a mesh belt or in a sludge state, the powder is applied to the mesh belt and then dried. When the heat resistant mesh belt B is used as the mesh body,
Since the melting of the surface of the decorative particles of the surface decorative layer 1 that comes into contact with the release agent 3 applied on the heat-resistant mesh belt B is suppressed,
It is possible to obtain a design in a finished state (matte tone) in which a makeup grain boundary (a trace of grain boundaries of a makeup granule and a trace of unevenness of a release agent in contact with the granules) present on the makeup surface is present.

Further, the mesh body is not limited to the one using the heat-resistant mesh belt to which the release agent is applied, and as shown in FIG. 2, supports the mesh body 11a in the form of a lattice and the mesh body 11a. The mesh support 11 including the support legs 11b can be used. A wide variety of designs can be changed by changing the shape of the mesh 12 of the mesh body 11a. Further, when the glass plate 1a is used as the surface decorative layer, it is possible to make the depth of the joint portion of the uneven pattern on the decorative surface after firing uniform. The plate thickness of the glass plate 1a can be appropriately selected depending on the plate thickness of the fired product and the finished state of the surface (depth of uneven pattern, complexity of pattern, etc.). Further, by using the reticulated support 11, it is possible to prevent the bubbles and bubbles that are likely to be generated between the glass layer and the base layer 2 at the time of firing and to easily release the gas to the outside. Therefore, the design of the decorative surface is not impaired.

Next, the method for producing the porous ceramic plate of the present invention will be described based on examples, but the present invention is not limited to these examples.

Example 1 Preparation of Surface Decorative Layer Raw Material A compounded raw material consisting of 62% of glass powder, 25% of frit, 5% of elutrix viscosity and 8% of zirconium silicate was prepared as 10 mmφ.
Was placed in a pot mill together with the steel balls of Example 1 and dry-ground for 5 hours. The resulting powder had a size of 325 mesh pass 96% or more. This powder is granulated with a pan pelletizer while spraying a 10% molasses solution,
A 2.5 mm granulated product was obtained.

Preparation of base layer raw material Otaniishi 64.5% (weight%, the same applies hereinafter), soda ash 18
%, Water glass powder 5%, Sanritsu talc 12% and SiC
The compounded raw material consisting of 0.5% was put into a pot mill together with a steel ball of 10 mmφ and dry-ground for 4 hours. The resulting powder was 325 mesh 96% or more in size. The powder was granulated with a pan pelletizer while spraying a 15% molasses solution to obtain a granulated product having a particle size of 1 to 4 mm.

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, as shown in FIG. 1, a firing furnace of a tunnel kiln having a total length of 39 m in which a heat-resistant mesh belt B was installed for transportation was used. Mesh belt B with a width of 1 m
Alumina was applied as a release agent 3 on top, and the granules for the decorative layer were uniformly charged to have a thickness of 5 mm, and the granules for the base layer had a thickness of 18 mm. Laminated. 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.

Visual observation of the thus obtained porous ceramic plate revealed that Example 1 was a finished porous ceramic plate in which particles were left on the decorative surface.

Example 2 As the surface decorative layer, a glass plate having a plate thickness of 3 mm was used. The raw material for the base layer was prepared in the same manner as in Example 1.

Next, as shown in FIG. 3 (a), the granules of the glass plate 1a and the base layer 2 are successively laminated on the reticulated support 11 and baked to be melted and integrated to form a porous material. A ceramic plate was obtained (see FIG. 3 (b)). The laminated thickness of the granulated product for base layer was set to 20 mm. In addition, the firing, using an electric furnace, the temperature is raised to 900 ℃ in 1 hour,
After the firing was completed, in order to avoid distortion caused by rapid cooling, the mixture was allowed to cool to room temperature in the furnace.

When the appearance of the porous ceramic plate obtained above was visually observed, it was found in Example 2 that the surface of the decorative layer of glass was completely covered with bubbles and bubbles were not observed at the interface between the decorative layer and the base layer. However, it was found that the uneven ceramic joint was a uniform porous ceramic plate.

[0029]

As described above, a surface decorative layer is formed on a reticulated body such as a heat-resistant mesh belt or a reticulated support to which a releasant is applied, and the solution is heated and solubilized so that the releasant is applied to the decorative surface. It is possible to easily bring out the design by the shape such as. Further, by using a reticulated support as the reticulated body, it is possible to prevent swelling or foaming. As a result, it is possible to obtain a high quality porous ceramic plate that is excellent in design.

[Brief description of drawings]

FIG. 1 is a schematic explanatory view showing one embodiment of a method for producing a porous ceramic plate of the present invention.

FIG. 2 is a perspective view showing another example of a mesh body in the method for producing a porous ceramic plate of the present invention.

FIG. 3 is an explanatory diagram showing a usage example of the mesh body in FIG.

FIG. 4 is a cross-sectional explanatory view of a conventional porous ceramic plate.

[Explanation of symbols]

 3 Release agent 11 Reticulated support B Heat-resistant mesh belt

Claims (4)

[Claims] 1. A porous ceramic characterized in that a surface decorative layer and a base layer made of an expandable inorganic granule are sequentially formed on a reticulated body, and the obtained laminated body is heated to be solution-integrated. How to make a board. 2. The method according to claim 1, wherein the reticulated body is a heat-resistant mesh belt installed in a firing furnace on the surface of which a release agent is applied. 3. The method according to claim 1, wherein the surface decorative layer is a glass plate. 4. The method according to claim 3, wherein the mesh-like body is composed of a lattice-like mesh body and supporting legs that support the mesh body.