JPH0932149A - Soundproof board - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve soundproof performance and profitability, and to obtain sonorous appearance by sintering and unifying a base body layer and a surface layer on one surface of the base body layer consisting of material particles for a base body while the surface layer composed of material particles for a surface, in which amorphous stone particles are covered with a vitreous material, is made thinner than the base body layer. SOLUTION: The base section of a soundproof board is constituted of a base body layer 11, and sections, from which a surface section is removed, are formed. Particles, in which the surfaces of amorphous ceramic particles 13 having grain size of 0.15-0.18mm are covered with covering layers 14 such as a vitreous material, are used as material particles 21 for a base body configuring the base body layer 11. The surface section of the soundproof board is composed of a surface layer 12, and formed in a stratified shape thinner than the base body layer 11. Particles, in which the surfaces of unshaped stone particles 23 having grain size larger than the above- mentioned ceramic particles 13 are covered with covering layers 24 consisting of the vitreous material, are employed as material particles 22 for the surface of the surface layer 12, and the styles of the color and feeling of the soundproof board are improved. The above-mentioned base body layer 11 and the surface layer 12 are unified by sintering, thus manufacturing the porous tabular soundproof board.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a soundproof plate used for road shoulders, building halls and the like.

[0002]

2. Description of the Related Art Conventionally, a soundproof plate made of ceramic is often used for a soundproof wall installed on the side of a road. This ceramic soundproof plate has the advantages of excellent soundproofing performance (including sound absorbing performance; hereinafter used in the same meaning) and durability.

The ceramic soundproofing plate is prepared by, for example, mixing spherical porcelain particles (referred to as selben), which are specially fired and spherically granulated, with a glaze as a binder, and filling the mixture with a mold. Then, the surface is uniformly leveled, pressure molding is performed, and then drying and firing are performed.

[0004]

However, since the soundproof plate thus obtained is purposely fired as a soundproof plate and spherically granulated ceramic particles are used, it cannot be said to be economical in terms of cost. . Further, the soundproof plate has a monotonous appearance and has a strong artificial feel, and therefore, it may not be suitable for some places of use. In particular, in recent years,
Soundproofing is now required even in places where people gather, such as pools and entrance halls of hotels, etc. Moreover, in addition to a certain level of soundproofing, those places are also required to have a natural texture and high dignity. Because of the large number, it has been difficult for conventional soundproofing boards to meet those requirements.

On the other hand, when the material particles such as granite and marble are used for the selben, it is possible to obtain the above-mentioned soundproof plate with high appearance, but there is a problem that the manufacturing cost becomes high because these materials are extremely expensive. Have In order to suppress this cost, it may be considered to use the cerven as a mixture, but since the material particles such as granite have a relatively low melting point as compared with the cerven, the material particles are melted during firing and the In some cases, the gap is filled and the desired sound absorption performance is not exhibited.

The present invention has been proposed in view of the above problems, and an object thereof is to provide an economical soundproof plate which is excellent in soundproof performance, has a high surface quality, and is economical.

[0007]

That is, the soundproof plate of the present invention comprises a base layer composed of raw material particles for a base material, which is obtained by coating irregularly shaped ceramic particles having a particle size of 0.15 to 1.18 mm with a glass material. In, a surface layer made of surface material particles obtained by coating particles of irregularly shaped stone material having a particle size larger than the ceramic particles with a glassy material, is provided thinner than the base layer,
It is characterized by comprising a porous plate-like body in which the base layer and the surface layer are integrated by sintering.

The surface layer may be a mixed layer of the surface material particles and the substrate material particles.

[0009]

DETAILED DESCRIPTION OF THE INVENTION The present invention will be described in detail below with reference to the accompanying drawings. 1 is a perspective view showing an example of a soundproof plate of the present invention, FIG. 2 is a cross-sectional view thereof, and FIG. 3 is a view schematically showing a cross section of base material particles used in the soundproof plate of the present invention,
4 is a cross-sectional view schematically showing an example of the surface material particles, FIG. 5 is a stepwise view showing an example of manufacturing a soundproof plate, FIG. 6 is a cross-sectional view showing another example of the present invention, and FIG. FIG.

As shown in FIGS. 1 and 2, in the soundproof plate 10 of the present invention, a base layer 11 made of base material particles 21 and a surface layer 12 made of surface material particles 22 are sintered. It is composed of an integrated porous plate.

The base layer 11 constitutes the base of the soundproof plate 10, and forms the part of the soundproof plate 10 excluding the surface part. The base material particles 21 forming the base layer 11 are
As shown in FIG. 3, the particle size is 0.15 mm to 1.18 m
The surface of the ceramic particles 13 having an irregular shape of m has a coating layer 14
It is covered with.

The ceramic particles 13 used for the base material particles 21 are not particularly limited, but if the discarded tiles, insulators, teacups or other crushed ceramic materials are used, the amount of waste can be reduced. Not only can the resources be reused, the raw material cost can be saved, and an inexpensive soundproof plate can be obtained.

Further, the ceramic particles 13 have a particle size of 0.1.
It is desirable to use an irregular shape of about 5 mm to 1.18 mm. As a result, the size of the gap formed in the soundproof plate 10 falls within a certain range, and the required soundproof performance is obtained. Moreover, since the shape of the voids varies, the range of frequencies absorbed by the voids is widened and high soundproofing performance is obtained. In addition, if the above-mentioned crushed material of discarded ceramic material is used, it is possible to obtain irregular-shaped particles having a desired particle diameter by a normal crushing operation without performing a special granulation process. Therefore, it is possible to easily reuse the waste that has been discarded in the past, and it is effective in terms of resource saving.

The particle size of the ceramic particles 13 is 0.15 mm.
If it is smaller than 1.0, the gap formed in the soundproof plate becomes too small and clogging is apt to occur.
If it is larger than 8 mm, the gap becomes too large and the soundproof performance is deteriorated. The ceramic particles can be easily and surely adjusted to a predetermined particle size by using a commercially available sieve having a determined mesh roughness.

A coating layer 14 for coating the ceramic particles 13
Is made of a glassy material, and is for bonding the ceramic particles 13 together when the soundproof plate, which is a porous plate-like body, is sintered and formed, and is composed of glass powder 15 and water glass 16.

As the glass powder 15, it is desirable to use a discarded glass plate, bottle or other crushed glass material. As a result, waste can be reused and raw material costs can be saved. The particle size of this glass powder 15 is
It is preferably about 0.044 mm to 0.25 mm. By adjusting the particle size of the glass powder 15 within the above range, it is possible to make the material particles for the substrate have an appropriate interval during firing, and to firmly bond the particles in the layer without density unevenness and to obtain sufficient strength. A soundproofing board having is obtained. Further, its soundproofing performance is also constant and good.

The particle size of the glass powder 15 is 0.044 m.
When it is less than m, the distance between the base material particles 21 in the layer becomes too small, so that it is difficult to obtain a predetermined soundproof performance, and the soundproof plate is apt to be clogged and washed with water. It is difficult to recover the desired soundproofing performance even after the treatment. On the other hand, when the particle size of the glass powder 15 is larger than 0.25 mm, the distance between the base material particles 21 of the soundproof plate becomes too large, and a predetermined soundproof performance cannot be obtained, which is unsatisfactory. .

On the other hand, the water glass 16 allows the particles to exhibit plasticity by the water added to the base material particles 21 during the production of the soundproofing plate, and can be easily molded into a desired shape in the subsequent molding step. It is for doing.

The surface of the ceramic particles 13 is coated with a vitreous material composed of the glass powder 15 and water glass 16 in advance to form a coating layer 14, and the ceramic particles 13 are dried to obtain the base material particles 21. .

The surface layer 12 constitutes the surface (design surface) of the soundproof plate 10, and the surface material particles 22 are
The base layer 11 is provided on one side of the base layer 11 so as to be thinner than the base layer 11. The thickness of the surface layer 12 is set appropriately, but an example of the thickness is about 3 to 8 mm. The surface material particles 22 determine the color and texture of the soundproof plate 10. As shown in FIG. 4, the surface of the stone particles 23 having a particle size larger than that of the ceramic particles 13 is used as the base material. The coating layer 24 is made of the same glassy material as the material particles 21. Reference numeral 25 is glass powder, and 26 is water glass.

The stone particles 23 are not particularly limited, but since the stone particles 23 form the surface layer 12 constituting the surface of the soundproofing plate, a crushed product of architectural stone, such as granite or marble, which is excellent in decorativeness. Is preferred. that way,
The soundproofing board can give an elegant atmosphere as if it were made of granite or marble. In the present invention, a crushed granite product is used. Further, in particular, since the surface layer 12 is formed thinner than the base layer 11, even if an expensive material such as the granite is used, the manufacturing cost of the soundproof plate can be kept low. Moreover, the stone particles 2
Similar to the above-mentioned ceramic particles, if 3 is used as a crushed material such as discarded building stone material, resource saving and resource reuse can be further realized. The reason why the stone particles have an irregular shape is the same as in the case of the ceramic particles.

By the way, since most of the building stone materials such as the granite and the marble have a lower melting point than the above ceramics, when the plate-like body is sintered and molded, the ceramic particles 13
At the sintering temperature, the stone particles 23 may be melted and the gaps between the particles may be closed. Therefore, it is preferable that the particle size of the stone particles 23 is larger than that of the ceramic particles 13 so that a predetermined gap is maintained between the stone particles of the soundproof plate even by sintering. The particle size of the stone particles is preferably about 2.5 mm. Also,
When the particle size of the stone particles 23 is increased in this way, the particle interval (gap) of the surface layer 12 and the particle interval (gap) of the base layer 11 are different, but even in that case, the surface layer 12
Since the thickness of the base layer 11 is smaller than the thickness of the base layer 11 to reduce the ratio to the thickness of the soundproof plate, it is possible to reduce the influence of the change in the particle spacing between the base layer 11 and the surface layer 12 on the soundproofness of the soundproof plate.

As the glass material (glass powder 25 and water glass 26) forming the coating layer 24 of the stone particles 23, the same glass powder 15 and water glass 16 as the ceramic particles 13 are used. Then, the glass powder 25 and the water glass 26 are coated on the surface of the stone particles 23 in advance in the same manner as the base material particles to form the surface material particles 22, and the stone particles are used when the soundproof plate is sintered. 23 Join each other. In addition, this glass powder 25
The action of the water glass 26 is similar to that of the glass powder 15 and the water glass 16 which coat the ceramic particles 13.

Next, a production example of the soundproof plate of the present invention will be described. [Preparation of Material Particles for Substrate] First, the waste material of the tile was crushed, and irregular shaped ceramic particles having a particle size of 0.15 mm to 1.18 mm were selected by a sieve. Then, 7.07 kg of the selected ceramic particles were put in a container and kneaded with a pot mixer for 1 minute. Next, 1.5 g of glass powder having a particle size of 0.044 mm to 0.25 mm obtained by crushing the glass material such as discarded glass plates and bottles into the ceramic particles.
After adding 1 g and kneading with a pot mixer for 1 minute, 1.5 kg of water glass (JIS-3 standard product) was added and further kneading with a pot mixer for 2 minutes to obtain 10.08 kg of a mixture.

250 g of methanol was added to the obtained mixture, and the mixture was mixed again for 2 minutes with a pot mixer to partially remove the water content in the water glass and cure the mixture. In addition to methanol, ethanol or the like can be preferably used. In addition, the weight ratio of each component used is as follows:
8.5%, glass powder 14.5%, water glass 14.5
% And methanol 2.5%.

The cured mixture was transferred to a drying oven at 105 ° C.
It was dried with hot air for about 10 minutes. In this step, the water remaining in the water glass is heated and dried by the hot air to be removed. The heating temperature (temperature of the hot air) at that time varies depending on the heating time, but is usually about 80 ° C to 120 ° C. Further, the heating time is appropriately determined depending on the amount of raw material to be manufactured and the like. In this step, since the ceramic particles are further removed from the water glass in a state of being in contact with each other through the coating layer composed of glass powder and water glass covering the surface, the water glass is solidified. Innumerable lumps are formed. Then, the agglomerates are loosened into granules by a kneader or the like to obtain amorphous particles. Further, the particles are sieved to select the material particles for a substrate having a desired particle size. The particle size of the obtained base material particles was 1.7 mm or less.

[Preparation of Surface Material Particles] Granite waste was crushed, and irregular shaped stone particles having a particle size of about 2.5 mm were selected with a sieve. And the selected stone particles 7.0
7 kg was put in a container and kneaded with a pot mixer for 1 minute. Then, a particle size of 0.044 obtained by crushing the glass material such as discarded glass plates and bottles into the stone particles
After adding 1.5 kg of glass powder of mm-0.25 mm and kneading with a pot mixer for 1 minute, water glass (JIS-
No. 3 standard product) (1.5 kg) was added, and the mixture was kneaded with a pot mixer for additional 2 minutes to obtain 10.08 kg of a mixture.

250 g of methanol was added to the obtained mixture, and the mixture was mixed again for 2 minutes with a pot mixer to partially remove the water content in the water glass and cure the mixture. In addition to methanol, ethanol or the like can be preferably used. The weight ratio of each component used is 68.5% for stone particles and 1 for glass powder, as in the case of the material particles for a substrate.
It is 4.5%, water glass 14.5%, and methanol 2.5%.

The cured mixture was transferred to a drying oven, dried in the same manner as in the case of the base material particles, and the obtained lumps were loosened into particles with a kneader or the like.

[Manufacture of Plate-Like Body] A plate-like body is molded from the base material particles and the surface material particles obtained as described above. First, as shown in FIG. 5A, 1800 g of the base material particles 21 are weighed. Then, as shown in (B), 54 g of water is added to the base material particles 21 to impart plasticity to prepare a base forming raw material. The amount of water added is preferably 3 to 5% with respect to the amount of raw material particles. The surface material particles 22 are also 900 g in the same manner.
Weigh and add 27 g of water to give plasticity to prepare a surface forming material.

Then, as shown in (C), the base forming material 21a is put into a mold of a desired size for about the eighth minute to form the base layer 11. Subsequently, as shown in (D), the surface forming raw material 22a is put on the upper surface of the base layer 11 to stack the surface layer 12 thinner than the base layer 11. The base forming material 21a and the surface forming material 22
The order of adding a may be reversed.

Each molding raw material in the mold is pressed,
Mold into the shape of a mold as shown in (E). Pressing pressure at that time is about 8~13kg / cm ^2, in this example a 10 kg / cm ^2. After molding, the molded product is released from the mold as shown in (F) and sintered in a furnace as shown in (G) to integrate the base layer 11 and the surface layer 12 into a porous plate-shaped body. And The firing conditions at that time are about 1000 ° C to 1100.
5 to 15 minutes at ° C. In this example, firing was performed at 1050 ° C. for 10 minutes.

A plate-like body having a thickness of 30 cm square and 2 cm was obtained by the above procedure. This plate-shaped body, as can be seen from FIG.
Base material particles 21 and surface material particles 22 in each layer
Are bonded together through the coating layers 14 and 24, and a large number of voids are formed inside and outside the plate-like body to form a porous structure. After demolding,
The surface of the plate-shaped body is polished as desired to form a soundproof plate. In particular, since granite is used for the surface material particles 22 in this embodiment, the surface is glossy by polishing, and the entire soundproofing plate has a dignified and high-class appearance as if it was formed by granite. Becomes

In the soundproof plate thus formed, the surface layer 12 is provided on one surface of the base layer 11 made of the base material particles 21 so as to be thinner than the base layer 11. Even if an expensive material such as granite is used as the stone particles of the working material particles 22, the manufacturing cost of the soundproofing plate can be kept low. Since the stone particles of the surface material particles 22 have a larger particle size than the ceramic particles of the base material particles 21, the stone particles are made of granite or marble having a lower melting point than the ceramic particles forming the base material particles. Even when configured, the stone particles in the surface layer are not melted at the temperature at which the plate-like body is sintered and the gap is not crushed, and the deterioration of the soundproofing performance can be prevented. Therefore, it can be suitably used in a place where not only the soundproof effect but also excellent designability is required, such as a floor or a wall surface of a hall or entrance of various buildings.

FIGS. 6 and 7 show another example of the soundproof plate of the present invention. Reference numeral 30 is a soundproof plate, 31 is a base layer, 32 is a surface layer, 33 is a base material particle, 34 is a surface material particle, 35 is a ceramic particle, 36 is a stone particle, 3
Reference numerals 7 and 38 are coating layers made of a glassy material. In the soundproof plate 30 shown here, the surface layer 32 has the surface material particles 34.
And a base material particle 33.

According to the soundproof plate 30, the surface becomes more attractive due to the mixture of stone particles and ceramic particles. In addition, by appropriately changing the mixing ratio of the base material particles 33 and the surface material particles 34 of the surface layer 32, or preparing the material particles in which the types of stone particles and ceramics particles are changed in advance, and appropriately adjusting them. Surface layer 32 in combination
The appearance of the soundproofing plate can be freely determined by mixing and using it.

[0037]

As shown and described above, according to the soundproof plate of the present invention, the thin surface layer made of the surface material particles and the base layer made of the base material particles are integrally sintered. Therefore, the soundproof plate gives an impression as if it were formed of the stone particles, and a high-quality atmosphere is obtained. Furthermore, if the stone particles are highly decorative, such as granite, and a high-grade architectural stone is used, the soundproofing plate has an extremely dignified atmosphere as if it was formed of a high-grade stone material such as granite. Like Moreover, since the surface layer is thinner than the base layer, the amount of stone particles used for the surface layer may be small, and even if expensive stone particles are used, the soundproof plate should be extremely economical. You can

Further, since the stone particles have a larger particle size than the ceramic particles of the base material particles, even if a material having a low melting point is used for the stone particles, the stone particles are melted during sintering. As a result, the required soundproof performance can be obtained without closing the gap in the plate body. Therefore, it can be suitably used in a place where not only the soundproof effect but also excellent designability is required, such as a floor or a wall surface of a hall or entrance of various buildings.

[Brief description of drawings]

FIG. 1 is a perspective view showing an example of a soundproof plate of the present invention.

FIG. 2 is a sectional view thereof.

FIG. 3 is a diagram schematically showing a cross section of base material particles used in the soundproofing plate of the present invention.

FIG. 4 is a cross-sectional view schematically showing an example of surface material particles.

FIG. 5 is a diagram showing, step by step, an example of manufacturing a soundproof plate.

FIG. 6 is a sectional view showing another example of the present invention.

FIG. 7 is a sectional view of the same.

[Explanation of symbols]

 10 Soundproof Plate 11 Base Layer 12 Surface Layer 13 Ceramic Particle 14 Coating Layer 15 Glass Powder 16 Water Glass 21 Base Material Particle 22 Surface Material Particle 23 Stone Particle 24 Coating Layer 25 Glass Powder 26 Water Glass

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[Procedure amendment]

[Submission date] August 24, 1995

[Procedure amendment 1]

[Document name to be amended] Statement

[Correction target item name] 0038

[Correction method] Change

[Correction contents]

Further, since the stone particles have a larger particle size than the ceramic particles of the base material particles, even if a material having a low melting point is used for the stone particles, the stone particles are melted during sintering. As a result, the required soundproof performance can be obtained without closing the gap in the plate body. Therefore, it can be suitably used in a place where not only the soundproof effect but also excellent design is required, such as a hall of various buildings or a wall surface of an entrance . ─────────────────────────────────────────────────── ───

[Procedure amendment]

[Submission date] August 29, 1995

[Procedure amendment 1]

[Document name to be amended] Statement

[Correction target item name] 0034

[Correction method] Change

[Correction contents]

In the soundproof plate thus formed, the surface layer 12 is provided on one surface of the base layer 11 made of the base material particles 21 so as to be thinner than the base layer 11. Even if an expensive material such as granite is used as the stone particles of the working material particles 22, the manufacturing cost of the soundproofing plate can be kept low. Since the stone particles of the surface material particles 22 have a larger particle size than the ceramic particles of the base material particles 21, the stone particles are made of granite or marble having a lower melting point than the ceramic particles forming the base material particles. Even when configured, the stone particles in the surface layer are not melted at the temperature at which the plate-like body is sintered and the gap is not crushed, and the deterioration of the soundproofing performance can be prevented. Therefore, the halls and entrances of various buildings
It can be suitably used in a place where not only a soundproof effect but also excellent designability is required, such as a wall surface of a cloth.

Claims (2)

[Claims] 1. An amorphous material having a particle size larger than said ceramic particles on one side of a substrate layer made of material particles for a substrate obtained by coating amorphous ceramic particles having a particle size of 0.15 to 1.18 mm with a glassy material. From a porous plate-like body in which a surface layer made of surface material particles obtained by coating the above-mentioned stone particles with a glassy material is provided thinner than the base layer, and the base layer and the surface layer are integrated by sintering. Soundproofing board. 2. The soundproofing plate according to claim 1, wherein the surface layer comprises a mixed layer of surface material particles and substrate material particles.