KR970001035B1 - Light weight ceramic panel and manufacturing method thereof - Google Patents

Abstract

A mixture of calcium carbonate 0.5-0.7wt.%, glass enamel-alkaline silicate 2wt.% and bauxite-wollastonite 1.5-6wt.% is mixed with glass powder for forming a lightweight layer which is made of heat-foamy inorganic materials. The free pellets comprising pigment is less than 1.5wt.% and zirconium, alumina or their mixture is less than 2.0wt.% are coated more than 1 time with a mixture containing is less than 1.5wt.% pigment for forming a glassy patterned layer, which is formed on the lightweight layer and heat treated to obtain a built-in type lightweight ceramic panel.

Description

Lightweight ceramic panel and manufacturing method

1 is a cross-sectional view of the lightweight ceramic panel of the present invention.

2 is an electron micrograph of the fracture surface of the lightweight layer of the lightweight ceramic panel of the present invention.

(a) Electron micrographs of 100 times the pore structure of fracture surface.

(b) 500 times electron micrograph with fracture surface pore structure and needle structure.

* Explanation of symbols for main parts of the drawings

1: vitreous pattern layer consisting of multicolored pellets 2: light weight layer

The present invention relates to a lightweight ceramic panel and a method of manufacturing the same, and more particularly, to a lightweight ceramic panel, which is an interior and exterior finishing material for building having excellent light weight, large size, and decorative stain resistance by using soda-petrified glass in glass industry wastes. It relates to a manufacturing method.

Conventionally, many methods of manufacturing panels using inorganic materials such as tiles have been used, but high energy is required due to high temperature heat treatment and high temperature molding at 1100 ° C. or more, and a lot of investment costs are required.

On the other hand, a method of manufacturing a panel using glass has been proposed in Japanese Patent Application Laid-Open No. 59-111948 and Japanese Patent Application Laid-open No. Hei 2-28342, but this also has a high energy consumption, a beautiful pattern or a three-dimensional pattern. Has the disadvantage of being difficult.

In addition, as a method of manufacturing a foamed glass (USP 2215223, USP 2233608, USP 237706, USP 2544954, Japanese Patent Laid-Open No. 58-60634, Japanese Patent Laid-Open No. 59-169943, and Japanese Patent Laid-Open No. 61-2618). As reported in the report, Maori is manufactured by adding a foaming agent such as calcium carbonate or carbon to heat treatment at around 850 ° C., followed by slow cooling, and is suitable for use as lightweight aggregates, heat insulating materials, and cold insulating materials. It is not suitable to be used as a product, and there is a weakness that the productivity is low due to low thermal shock due to not only using a mold but also a low thermal shock.

Accordingly, the present invention solves the problems of the various panels, such as providing a lightweight ceramic panel having a lower layer made of heat-expandable inorganic material and a beautiful glass upper layer made of multicolored pellets, while at the same time decorating, surface smoothness, surface strength The purpose of the present invention is to provide a method of integrating the lower layer and the upper glass layer at the same time to improve them.

Hereinafter, the present invention will be described in more detail.

The present invention consists of a light-weight layer made of a heat-foamed inorganic raw material and a glass-patterned layer made of multicolored pellets on the light-weight layer, and a glass-patterned layer made of a heat-expandable inorganic raw material layer and multicolored pellets is heat-treated at the same time for fusion and solidification. The present invention relates to a lightweight ceramic panel and a method of manufacturing the same.

Hereinafter, the present invention will be described in more detail.

The present invention can produce a lightweight ceramic panel in the following procedure.

First, a lower layer consisting of a heat-foamable inorganic raw material made of a pulverized product of clear plate glass, pattern glass, color glass, reflective glass, tempered glass, and bottle glass, which are soda-lime glass as the main raw materials, and an upper pattern layer made of multicolored pellets thereon. Are stacked.

In the present invention, the heat-expandable inorganic raw material is a known method, and in the present invention, glass enamel and alkali silicate are added to a glass powder of 400 µm or less as a blowing agent and calcium carbonate as a blowing agent.

In particular, in the present invention, 1.5 to 6% by weight of bauxite, which is a raw material of alumina (AlO ₃ ), and wollastonite having a needle structure were added to increase thermal shock and mechanical strength. If less than 1.5% by weight has a small impact on the annealing and slow cooling time reduction, when added in excess of 6% by weight has a disadvantage that the manufacturing cost increases.

In the ceramic industry, it is well known that alumina improves thermal shock resistance, and in the present invention, since alumina is expensive, a low-order baokisite calcined at 950 to 1000 ° C. is used, and wollastonite is substituted for asbestos. It is known to play a role of reinforcing fiber of widely used in the plastic industry as a reinforcing fiber and filler (filler), the wollastonite used in the present invention is produced in Korea and distributed in Danyang and Yeongdeok area can be easily used at low prices There is an advantage.

Thus, 0.5 to 0.7% by weight of the blowing agent, 1.5 to 2.0% by weight of the flux, and 1.5 to 6% by weight of the bokisite and wollastonite as reinforcing agents are sufficiently mixed with the organic powder and remixed using an organic binder to pelletize M / C) pellets of 0.5 to 5 mm were made.

If it is out of the above range, the optimum filling degree for the lamination work cannot be obtained, and there is a problem in the storage and storage relationship.

Multicolored pellets to be laminated on a lightweight layer made of a flexible foamed inorganic raw material, which is a pellet of 0.5 to 5 mm, were prepared as follows.

Zircon (ZrSiO ₄ ) and alumina 0.5-2% by weight and inorganic pigment 1.5% by weight or less are added to the glass powder of 200 μm or less, and the mixture is sufficiently mixed with an organic binder, followed by extrusion pelletizer. Pre-pellets of 3-8 mm were made.

Since these pre-pellets are mono-color, it is difficult to obtain various patterns. Therefore, in order to obtain multicolored pellets, 0.1 to 1.5% by weight of the same or different pigments used in the pre-pellets, and 0 to 2% by weight of ZrSiO ₄ and alumina are added to the glass powder of 200 µm or less in weight ratio. After sufficient mixing, the mixture was dried on a frit-pellet of 3 to 8 mm while being coated with an organic binder using a powder sprayer.

In order to obtain a variety of colorful patterns, the number of coatings on the 3-8 mm pre-pellets described above and the types of coating materials are different, and the size of the multicolored glass pellets used in the present invention is 3-12 mm. Range.

The raw materials prepared as described above are sent to a continuous feeder and laminated in the order of the heat-expandable inorganic light weight layer and the multicolored glass pattern layer. In this stacking, the continuous feeding device installed on the upper part of the mesh belt in a continuous continuous furnace using a heat-resistant mesh belt provides a volume of 0.5 to 5 mm light layer and 3 to 12 mm multicolored glassy pellets sequentially. After being charged and laminated, they enter the heat treatment furnace. The thickness of the vitreous pattern layer made of multicolored pellets after heat treatment is 1.6 to 6.5 mm.

In particular, this continuous volume feeding method does not require a mold, and it is possible to continuously manufacture a lightweight ceramic panel like a manufacturing method of a ceiling sound absorbing plate of inorganic fiber. By using SAW), there is an advantage that it can be enlarged according to the demand of the consumer by lateral cutting, and there is a great advantage that the cutting loss can be reduced.

As described above, the light-weight layer made of a heat-expandable inorganic raw material and the glass-patterned upper layer made of multicolored pellets are sequentially laminated to a constant thickness through a volume supply method by each continuous supply device, followed by a heat treatment furnace. Is transferred to.

In the firing process of the heat treatment furnace, the temperature is increased by 15 ° C. per minute up to 750 ° C., slightly higher than the swallowing point temperature of the soda-lime glass, and the temperature is increased by 5 ° C. per minute until the thermal decomposition of calcium carbonate is completely completed. When the pyrolysis of calcium carbonate is completely finished, the lower layer and the upper layer are integrated with each other by heat fusion.

However, in order to complete the foaming and obtain a dense structure between the light weight layer and the upper pattern layer, it must be reheated after pressurizing with a pressure roller in a section between 850 and 900 ° C.

In this case, the surface of the lightweight ceramic panel is pressed by at least one pressurizer, and the number of pressers depends on the final thickness to be obtained, the smoothness of the surface of the lightweight ceramic panel, the type of raw materials used, and the like. It is not limited.

The finished lightweight ceramic panel is subjected to slow cooling according to the slow cooling method of glass products. In the slow cooling process, cooling is performed at 5 to 7 ° C. per minute in the viscoelastic region and at 8 to 12 ° C. per minute in the elastic region. In the entire heat treatment process, it is possible to speed up the cooling process by adding 1.5 to 6 wt% of bauxite and wollastonite which are excellent in mechanical strength and thermal shock in the light-weight layer made of heat-expandable inorganic raw material, Because the connection between the light weight layer and the upper glass pattern layer is more densely formed, the long-term slow cooling process is unnecessary, and thus, a lightweight ceramic panel with high productivity can be manufactured.

Hereinafter, the present invention will be described in more detail with reference to Examples, but the present invention is not limited to Examples.

Example 1

According to the composition of Table -1, the glass powder source was made using clear plate glass, patterned glass, colored glass, reflecting glass, tempered glass and bottle glass, which are soda-lime glass, pulverizing the glass crushed material, and then calcium carbonate as foaming agent. 0.5% by weight, 2.0% by weight of glass enamel and alkali silicate as flux and 1.5% by weight of bokisite as reinforcement were mixed well, and after mixing was completed, water-soluble binder was added and remixed to make pellets of 3mm and dried. After the heat-expandable inorganic lightweight layer of raw material.

Multicolored pellets are mixed well by adding 0.5% by weight of alumina to obtain the desired color in the above glass powder, and after mixing, it is mixed again by adding a water-soluble organic binder and then extruded into a pelletizer. Make a 6-mm pre-pellet.

0.2% by weight of an inorganic pigment is added to the glass powder in order to obtain a desired color in order to make a monochromatic pre-pellet colored. The mixture is mixed well, and after the mixing is completed, the mixture is sprayed simultaneously with an organic binder using a powder sprayer. While drying the pre-pellets while corning, to produce a multi-colored pellet as a raw material of the upper pattern layer.

The raw material prepared as described above is sent to the continuous feeder installed on the upper part of the continuous heat-resistant mesh belt, and the light-weight layer of heat-expandable inorganic material and the multi-colored pellets are sequentially laminated to a certain thickness by volumetric feeding method and then transferred to the heat treatment furnace (爐). do.

In the heat treatment furnace, the temperature of the firing process is increased by 15 ° C. per minute up to 750 ° C., and the temperature is increased by 5 ° C. per minute up to 850 ° C. at the point where the thermal decomposition of calcium carbonate is completed. After recalculation, the firing process was carried out so that the lower layer and the upper vitreous pattern layer could be integrated and densified, and then transferred to a slow cooling process, and 5 to 7 ° C. per minute in the viscoelastic region and 8 to 12 ° C. per minute in the elastic region.

Examples 2-7

A light weight ceramic panel was manufactured by the same process and heat treatment conditions as Example 1 except for changing the composition as shown in Table 1.

Comparative Examples 1 to 4

A light weight ceramic panel was manufactured by the same process and various conditions as in Example 1 except that the composition was changed as shown in Table 2.

The lightweight ceramic panel made of the composition of Table 1 and Table 2 measured the bending strength, specific gravity, surface absorption rate, and the thickness distribution of the glass pattern layer on the upper and lower cooling wave according to the items in Table 3, and to determine the cooling rate 400mm × 300mm After checking the specific gravity and the glass thickness distribution of the upper pattern layer, put it in a slow cooling furnace and raise it by 5 ℃ per minute to 650 ℃, and keep it for 10 minutes to keep the temperature of the whole specimen constant and then The cooling rate was 5-7 ° C. per minute, and the elastic section was cooled at 8-12 ° C. to confirm the presence of a cooling wave.

As shown in Table 3, the lightweight ceramic panel prepared with the composition of Table 1 was found to be a lightweight ceramic panel having excellent mechanical strength as well as no breakage in the cooling rate.

In addition, in the case of Comparative Examples 1 to 4 as a result of Table 3, the mechanical strength is not less than about 10% compared to the difference in specific gravity, and in particular, Comparative Examples 1 to 3 have a problem in that the cooling rate cannot be increased. City productivity was considered to be vulnerable.

In addition, as a result of visually examining the pattern of the glass pattern as the upper layer, when the composition ratio of the pre-panel and the coating mixture is the same as in Examples 2, 5 and Comparative Example 2, the preparation of the interface between the pellets was not clearly revealed. Preferred glass-patterned patterns cannot be obtained, so there is no flatness, and in Examples 1, 3, 4, 5, 7, and Comparative Examples 1, 3, and 4, the presence of the interface between pellets is clearly revealed, which is beautiful due to the marble effect. The colored glass pattern layer was obtained and was excellent in microcrystallization.

The visual inspection results are shown in Table 4.

Claims (6)

A light layer made of a heat-foaming inorganic raw material containing 0.5-0.7% by weight of calcium carbonate, 2% by weight of glass enamel and alkali silicate, 1.5-% of bauxite and wollastonite as a blowing agent in the glass powder; On the light-weight layer, the pre-pellet containing 1.5 wt% or less of the pigment to the glass powder, 2.0 wt% or less of zircon, alumina or a mixture thereof is coated in one or more times with a mixture of at least 1.5 wt% of the pigment to the glass powder. Lightweight ceramic panel, characterized in that the glass-like patterned layer is heat-treated at the same time, fused and consolidated. The light weight ceramic panel according to claim 1, wherein the light weight layer made of the heat-foaming inorganic raw material is made of 0.5-5 mm pellets. The lightweight ceramic panel according to claim 1, wherein the multi-color pellets have a size of 3-12 mm. A light layer made of a heat-foaming inorganic raw material containing 0.5-0.7% by weight of calcium carbonate as a blowing agent, 2% by weight of alkali enamel of glass enamel, and 1.5-6% of bauxite and wollastonite in the glass powder; On the light-weight layer, the pre-pellet containing 1.5 wt% or less of the pigment to the glass powder, 2.0 wt% or less of zircon, alumina or a mixture thereof is coated in one or more times with a mixture of at least 1.5 wt% of the pigment to the glass powder. The laminated glass pattern layers were sequentially laminated on the heat-resistant belt by a continuous volume supply device, and then they were simultaneously melted by predetermined heat treatment, and the surface layer of the panel was pressurized by a press and then reheated to fully integrate and slow cooled. Method for producing a lightweight ceramic panel, characterized in that. The method of claim 4, wherein the thickness of the glass pattern layer made of the multi-colored pellets after heat treatment is 1.5-6.5 mm. The method of claim 4, wherein the calcining and heat treatment step is to increase the temperature by 15 ℃ per minute to 750 ℃, 5 ℃ per minute to 850 ℃, pressurized and reheated at 850-900 ℃, the slow cooling process per minute in viscoelastic section Method for producing a lightweight ceramic panel, characterized in that the cooling by 5-7 ℃ and 8-12 ℃ per minute in the elastic section.