MXPA01000163A - Method of manufacturing large-scale ceramics board - Google Patents

Abstract

A method of manufacturing large thin wall ceramics board includes pulverizing and uniformly mixing, in dry content conversion, plasticity clay in an amount of 30-40%by weight, wollastonite having an aspect ratio of more than 10 in an amount of 20-50%by weight, and feldspar and talc in an amount of 10 50%by weight to form a mixture. The mixture is added with a solution having a 16-21%weight of the weight of this mixture. The solution has 10%by weight of a paraffin emulsion. The clay-like composition is extruded with a vacuum kneading machine to form a cylindrical shape. The extruded clay-like composition is made into dough board compact of desired thickness after being partially cut parallel to the cylinder. The dough board compact is heated to approximately 80 degrees Celsius with far infrared radiation. The heated dough board is transported on a heat proof metal mesh belt having temperature of between 80 and 150 degrees Celsius, and then gradually heated and dried at 150 to 350 degrees Celsius to dehydrate the dough board. The dehydrated bough board is baked at 1000-1200 degrees Celsius in roller hearth kiln combustion heating device.

Description

METHOD TO MANUFACTURE A VERY MAGNITUDE CERAMIC TABLET CROSS REFERENCE WITH RELATED REQUESTS The present application claims the benefit of the right of priority of the Japanese application No. 605995 entitled METHOD FOR MANUFACTURING A CERAMIC TABLET OF GREAT MAGNITUDE, filed on March 10, 2000.

TECHNICAL FIELD OF THE INVENTION The present invention relates generally to a method of manufacturing a ceramic splint and more particularly to a method for improving the production efficiency when manufacturing large-scale ceramic tiles and improving the quality of the tiles.

BACKGROUND OF THE INVENTION A conventional method of producing tiles uses a small tile generally divided into approximately twenty pottery ceramic tiles and a plastic tile. The small tile forms a fragment of a thin tablet to be fixed on the wall. In Japan, this is usually called a pottery product. In this method, the raw material is molded into small rectangles of 10x10 cm or 5x15 cm, and then baked in the oven, for example, by the tunnel kiln. Another conventional method uses comparatively recent technology to use a large-scale ceramic tile, for example, covering an area of more than 1x1 m. In order to manufacture the large-scale ceramics, a wet method process and laminator manufacturing methods have been used. Other methods, for example, described in U.S. Patent No. 4,495,118, have the raw material particle in the line distribution in one direction to produce products of pronounced flexural strength. U.S. Patent No. 4,495,118 discloses a large-scale ceramic tablet of a thin board, the size of which is about 30 x 30 cm, with about 20 mm or less in thickness. The manufacturing method uses 15% moisture from the crushed natural clay, feldspar, and silica. The mixture is combined with the mixer (kneading mill) and aligned in one direction for distribution. As an extruder with a curved, rounded or spiral outlet leads to natural laminated clay, clay is formed to coat by partially cutting in a straight line in the direction of the shaft. Then, with a roller-type prepared forming machine, the thickness is leveled and when it is molded again, it becomes the splint for an internal sag that is suppressed. Then, it is cooked with the furnace of the laminator to obtain the product of the ceramic tablet of great magnitude. The described method, however, consumes a great deal of time and is expensive to build, producing non-economic results. In addition, the method described does not prevent hygroscopic moisture, such as rainwater aligned in the form of an arrow, which easily infiltrates the construction. Furthermore, although the extruder aligns the crystal grain in the natural clay in one direction, the selection of the raw material based on the shape of the crystal grain is insufficient, and the resistance to bending of the product achieved by this method is not yet enough. Therefore, because the size of 30x30 cm is considered as the average size for a large scale thin board and because the thickness is from 20 to 8 mm, it can be said that there is still a problem in the manufacturing method for the thin tablets of great magnitude that needs to be improved.

In addition, the prior art lamination rollers have edges at both ends that are open. When canvas-like clay is expanded in a longitudinal direction, irregularities in orientation and in density distribution occur because the edges are open at the ends. Therefore, it is also highly desirable to have a rolling roller that reduces the tendency to cause irregularities in the product.

BRIEF DESCRIPTION OF THE INVENTION The present invention overcomes the shortcomings of the prior art and the difficulty associated with the manufacture of large-scale ceramic tiles used in the architectural material. The method of the present invention greatly improves the production efficiency and the flat grade during the manufacturing process. Ceramic tiles manufactured with the method of the present invention minimize the hygroscopic properties in that it improves the sanitary qualities of the tiles and reduces surface contamination. Ceramic tiles manufactured with the method of the present invention are made to be fireproof and are not subjected to deterioration of the sun's rays and harsh environmental conditions. The method of the present invention also improves the prior art manufacturing methods of large thin slab ceramic tiles by deeply reducing the tendency to crack easily than what is so often associated with thin slabs of large magnitude. The dried raw board containing the clay-like raw material, especially that of large area is likely to transmit cracking and transformation, and thus disrupts them, the prior art methods have used initial periods of dehydration. The initial periods of dehydration in the manufacturing method, however, lead to lower productivity. The method in the present invention of manufacturing thin, large ceramic slats is an efficient method that includes mass production achieved by process improvements in which the distribution organization of the natural mineral is uniformly aligned. The present invention also provides improvements to existing burners such as that described in U.S. Patent No. 4,495,118. In one aspect of the present invention, the plasticity clay in the dry content conversion of 30 to 40%, wollastonite with needle crystal aspect ratio greater than 10 in an amount of 20 to 50% by weight, feldspar and / or talcum what is 10 to 50% by weight are crushed and mixed uniformly. A solution in an amount of 16 to 21% of this mixture is added to the stir. The solution contains 10% paraffin emulsion solution. A composition of clay-like matter is extruded cylindrically with a vacuum kneader, which is then made into a compact pasty of tablet of desired thickness after being partially cut parallel in that cylinder. Then the paste is heated to 80 degrees Celsius with far infrared radiation. The paste is then placed on a heat resistant metal mesh band having a temperature of 80 to 150 degrees Celsius. The heat is suppressed, and the pasta is dried and dissected, then cooked at 1000-1200 degrees Celsius on a roll. In one aspect of the method of the present invention, the thin ceramic tablet of large magnitude is fired at the temperature of 1000-1200 degrees Celsius with the combustion heating device of the roller hearth furnace. Accordingly, the method includes spraying and uniformly mixing, in dry content conversion, the plasticity clay in an amount of 30 to 40% by weight, wollastonite having a phase ratio greater than 10 in an amount of 20 to 50% by weight, and feldspar and / or talc in an amount of 10 to 50% by weight to form a mixture; add to the mixture a solution in an amount of 16 to 21% by weight of this mixture, containing the solution 1 (3% by weight paraffin emulsion; extrude the clay-like composition to be cylindrically formed with a vacuum kneader; make the extruded composition in the form of clay in a compact pasty of tablet of desired thickness after being partially cut parallel to that cylinder, heat the compact pasty tablet to approximately 80 degrees Celsius with far infrared radiation, transport the tablet of heated paste over a heat-resistant metal mesh band that has a temperature between 150 and 350 degrees Celsius, heat and gradually dry the heated pasta board at 80 to 150 degrees Celsius to dehydrate the pasta board, and cook the dehydrated pasta board at 100-1200 degrees Celsius in a combustion heating ce of the roller hearth furnace Another aspect of the present invention Ion leaves space to the desired thickness of the pulp board up and down horizontally for the direction where the laminate of the pulp board progresses through the rolling roll and is composite. The range of the upper and lower roller is gradually reduced and at both ends the tightening tilt is installed, and the width size of the pulp board is prevented from expanding. Simultaneously, the hollow of the hemisphere of 0.2-0.3 mm is fixed in discontinuity on the surface of the roller. The manufacturing method of the large-scale thin ceramic tablet delaminates the roll and the dough board easily in the progress movement of the dough board. Yet another aspect of the present invention includes a method for heating the compact pasty tablet. The compact pasty tablet is heated in the heating zone having the remote infrared radiation body arranged alternately of wavelength of 15 micrometers or less and the infrared radiation body away from wavelength of 16 micrometers or greater. Additionally, the method for manufacturing the large-scale ceramic board of the present invention includes material used for the heat-resistant wire mesh band having a thermal capacity of approximately ten times the canvas board for each unit area compact of Contact. As described here above, the compact pasty of the board is transported by the heat resistant metal mesh band in the heating zone. Still further, one aspect of the present invention includes combustion heating of the roller hearth furnace to give a radiant heat heating effect. Radiant heat is achieved by radiation from the black body of the tube burner which in one embodiment comprises silicon carbide and silicon nitride qualities. Radiant heat is also obtained by remote infrared heat radiation. The tube burner has lengths that is 1.5 to 1.7 times the width of the material to be baked.

BRIEF DESCRIPTION OF THE DRAWINGS Figure 1 illustrates the front view of a rolling roller in the present invention; Figure 2 illustrates the front view of the radiant tube burner used in the present invention.

DETAILED DESCRIPTION OF THE INVENTION The present invention is directed to a method of manufacturing large thin-walled ceramic clapboard. In one aspect, the method includes spraying and uniformly mixing, in the dry content conversion, the plasticity clay in an amount of 30 to 40% by weight with wollastonite having a phase ratio of more than 10 in an amount from 20 to 50% by weight, and feldspar and / or talc in an amount of 10 to 50% by weight to form a mixture. A solution in an amount of 16 to 21% by weight of this mixture is added to the hard mixture. The solution contains 10% by weight of a paraffin emulsion. The method also includes extruding the clay-like composition with a vacuum kneader to form a cylindrical shape. The clay-like extruded composition is formed in the compact pasty tablet of the desired thickness after being partially cut parallel to that cylinder. The method also includes heating the compact pasty tablet to approximately 80 degrees Celsius with distant infrared radiation. The heated pasta board is transported on a heat resistant metal mesh band having the temperature between 150 and 350 degrees Celsius. The method includes heating and gradually drying the heated pulp board at 80 to 150 degrees Celsius to dehydrate the pulp board to dry the pulp board. The dehydrated pasta tablet is baked at 1000-1200 degrees Celsius inside the combustion heating device of the roller hearth furnace. A novelty of the present invention lies in the selection of the raw material composition and also in the range of the mixing ratio chosen for the raw material. The wollastonite that forms the majority of the distribution orientation of the mineral crystal is preferably a needle-shaped mineral having ten or more phase relationships. For example, the elastic characteristic of the product may not be sufficiently demonstrated if the mixture includes less than 20% wollastonite by weight. On the other hand, if more than 50 weight percent of wollastonite is present in the mixture, the product may become unsuitable for the sintering condition. Talc is a lubricant material that distributes, smoothes and forms the probability of the orientation condition by extrusion. Talc also helps to decrease the flow resistance in the composition when the mixture is rolled and molded. The feldspar are raw materials of flow that act to decrease the water absorption of the product. The amount of feldspars used in the product can be adjusted according to the quality demanded in the product. The paraffin emulsion added with the water helps to improve the distribution characteristic and facilitates the delamination process when, for example, water repellent is used with the rolling roller. Another novelty of the present invention lies in the structure of the rolling roller. That is, the rolling roller of the present invention provides uniform orientation and distribution of the density in the product. The roller of the present invention includes hollow indentations on the surface of the roller such that when the raw material canvas and the roller surface are pressed to contact one another, the air is compressed and sealed within the gap. When the roller is released from the contact pressure, the air inside the hole prevents the raw material from adhering to the roller. In one embodiment, the hollow indentation or dent is formed as the hemisphere and disposed in discontinuity. Another novel aspect of the present invention is the system in which distant infrared radiation, for example, 10-103 micrometers, enters and heats the pulp board at a temperature higher than 80 degrees Celsius. A mesh band that has heat-resistant metal is placed horizontally and heated to approximately more than 80 degrees Celsius. The pulp board is transported to a hot air drying device where it is dried and dehydrated. Yet another novel aspect in the present invention includes a heating method used during the manufacturing process to reduce the tendency in ceramic tiles to crack easily, the quality often associated in this way with the large thin strips of the prior art. . To heat the pulp board or pulp board, the present invention uses distant infrared radiation, first using radiation having a long wavelength of 16 micrometers or greater and then using radiation having a wavelength of 15 micrometers or less. The powerful infrared radiation gives the heating effect in a short time. For example, it has been confirmed that a raw material tablet of 4 to 5 mm reaches 80 degrees Celsius every 5 to 10 minutes and that there was no transformation. On the other hand, the mesh band, which holds the pulp board, conducts heat from the part of the metallic wire which is in contact with the pulp board using a high thermal conductivity of the metal and discharges steam from the spaced part. The hot air containing moderate hygroscopic moisture inside the oven touches the surface layer and heats the total product ie the pulp board, uniformly. Another novel aspect of the present invention includes a combustion heating method of the roller hearth furnace. The present invention improves the gas burner of a conventional type of flame jet in which the temperatures fluctuate in the direction of the width of a particularly wide product. The fluctuation is mainly due to direct contact with the thrown flames circulating inside the oven. In this method, thermal transmission greater than 5 to 10 degrees Celsius per one meter was detected. The method of the present invention, in one aspect, achieves thermal transmission using radiant heat and radiant heat radiations in a line. The present invention includes a novel radiant tube burner having a black body comprising silicon carbide or silicon nitride which are powerful infrared radiation bodies. An example of the manufacturing method of the large-scale ceramic splint will now be described in more detail below. In a dry content conversion (calculated as the dry weight), the clay of usual plasticity (40% by weight), the wollastonite (45% by weight) containing needle crystal of phase ratio of 10 to 15, talc ( 15% by weight) are ground and mixed to form a mixture. A solution including 10% by weight paraffin emulsion is added in an amount of 17% by weight relative to the mixture such that the total moisture content is about 15%. Then, the mixture is mixed uniformly so that the composition of plasticity raw material is prepared. The composition is extruded with the vacuum kneader in a cylindrical manner, divided in the direction of the axis, and then forming the thick tablet of pulp, passed through a roller. Figure 1 is a figure illustrating the front view of a roller 1. The interval between the upper roller 2 and the lower roller 3 can be adjusted to a desired thickness of the pulp board 4. Furthermore, the gap 5 of a Hemisphere type is formed irregularly or randomly on the surface of the upper and lower rollers. The width of the pulp board is limited precisely and uniformly because both ends of the rolling roll 1 include tightening tilt 6 to prevent the pulp board from extending laterally. The roller 1 illustrated in Figure 1 produces, for example, 4 millimeters ("mm") in thickness and 50 tablets of pasta of one meter by 1 meter in size ("m"). As described hereinbefore, the pulp board does not adhere to the roller and delaminates or completely disengages the roller 1. The pulp board is then transported into a device for cooking by far-infrared radiation, in which the application of short-range powerful infrared radiation, for example, 10 micrometers, and long-range long-range infrared radiation, for example, 20 micrometers are repeated alternately ten times every 25 seconds causing the temperature to reach 80 degrees Celsius for approximately eight minutes in total. Eight minutes is a shortened duration (1/2 or 1/3) that the methods of the prior art have previously achieved. In this way, a thin splint of large magnitude is formed and then baked at 1150 degrees Celsius in a roll hearth furnace. Figure 2 illustrates the front view of the radiant tube burner 7 of the present invention, used inside the roller hearth furnace. The radiant tube burner 7 has the flame coming out of the gas burner 8 and is expelled horizontally from the flame hole 10 through the tube 9 in such a way that the flame does not come into direct contact with the thing that is going to cook, that is, the thin tablet. The finished product produced from the use of the method of the present invention effectively reduces the defect rate identified in the products of the prior art. As seen from the foregoing, the novel aspects of the present invention include technical and structural conditions of rolling molding, drying and the firing process. The mixing ratio also provides an important novel feature in the present invention and may vary according to the quality demanded in the finished product. The method of the present invention provides the following improvements in the finished product as well as in the manufacturing process. 1) 1.6 times greater productivity of the product with a defect rate reduced by approximately 50% to demonstrate the huge reduction in costs that is shown. 2) As a special effect on the natural compound, the improvement of the crystal mineral in the form of a needle against the distribution organization rate of the wollastonite also improves the fragility that has been a disadvantage of the ceramic products. That is, using the method of the present invention, the remarkable effect of the improvement with respect to the modulus of elasticity was confirmed. The modulus of elasticity of the ceramics produced using the method of the present invention is 3.5-3.7x10"5pgf / cm2 as compared to the method of the prior art which produces elasticity of 10x10" 5pgf / cm2 3) The use of the Far infrared radiation greatly shortens the amount of time required for the drying process and at the same time improves the production efficiency of the cooking process. Although the invention has been particularly shown and described with respect to a preferred embodiment thereof, it will be understood by those skilled in the art that the above and other changes in form and detail may be made therein without departing from the spirit and scope of the invention. the invention.

Claims (24)

1. A method for manufacturing the large thin-walled ceramic board, comprising: mixing, in dry content conversion, plasticity clay in an amount of 30 to 40% by weight, wollastonite having a phase ratio of not less than 10 in an amount of 20 to 50% by weight, and at least one of feldspar and talc in an amount of 10 to 50% by weight to form a mixture; adding to the mixture a solution in an amount of 16 to 21% by weight of the mixture, the solution including 10% by weight of a paraffin emulsion; extruding the clay-like composition to form a predetermined figure; making the clay-like extruded composition in a compact pasty of tablet of desired thickness; heating the pasty tablet compact to a predetermined heating temperature; drying the compact pasty of heated tablet at a predetermined drying temperature to dehydrate the compact pasty tablet; and cooking the compact paste of dehydrated tablet at a predetermined cooking temperature.

The method for manufacturing the large thin-walled ceramic splint according to claim 1, wherein the step of extruding includes extruding the clay-like composition to form a cylindrical shape.

The method for manufacturing the large thin-walled ceramic splint according to claim 2, wherein the step of extruding includes extruding the clay-like composition to form a cylindrical shape with the vacuum kneader.

The method for manufacturing the large thin-walled ceramic splint according to claim 2, wherein the method further includes cutting the extruded clay-like composition in a direction parallel to the axis of the cylindrical clay-like composition.

The method for manufacturing the large thin-walled ceramic splint according to claim 4, wherein the step of forming the extruded clay-like composition includes pressing the clay-like composition cut into a plurality of stages each of the which includes pressing the cut clay-like composition with a roller device having upper and lower rollers, in which the respective roller devices are aligned in line.

6. The method for manufacturing the large thin-walled ceramic splint according to claim 1, wherein the step of heating further includes heating the compact pasty tablet with far infrared radiation.

The method for manufacturing the large thin-walled ceramic splint according to claim 1, wherein the step of heating includes heating the compact pasty tablet to 80 degrees Celsius with the far-infrared radiation.

8. The method for manufacturing the large thin-walled ceramic splint according to claim 1, the method further comprising transporting the compact pasty of hot splint onto a heat-resistant metal mesh strip before the drying step.

9. The method for manufacturing the large thin-walled ceramic splint according to claim 1, wherein the step of drying further includes gradually heating to dry the compact pasty of heated splint. The method for manufacturing the large thin-walled ceramic splint according to claim 1, wherein the drying step includes drying the pasty compact of the heated board at a temperature between 150 and 350 degrees Celsius. The method for manufacturing the large thin-walled ceramic splint according to claim 1, wherein the cooking step includes firing the compact pasty dehydrated splint at a temperature of between 1000-1200 degrees Celsius. 12. The method for manufacturing the large thin-walled ceramic splint in accordance with claim 1, wherein the cooking step further includes cooking within a combustion heating device of the roller hearth furnace. The method for manufacturing the large thin-walled ceramic splint according to claim 1, wherein the method further includes spraying the mixture before the extrusion step. 14. A roller to make large thin-walled ceramic slats, the roller comprising: an upper roller having slanted edges at the opposite ends of the upper roller; a lower roller having inclined edges at the opposite ends of the lower roller; and the upper roller and the lower roller are arranged to form a space between the upper roller and the lower roller to receive the dough board, the space made to be adjusted according to the desired thickness of the dough board, and the narrowing space at the inclination edges of the upper roller and the lower roller, wherein the inclination edges of the upper roller and the lower roller prevent the dough board from laterally extending when the dough board is rolled between the upper roller and the lower roller. 15. The roller for manufacturing the large thin-walled ceramic tablet according to claim 14, the upper roller and the lower roller also including cylindrical surfaces, the cylindrical surfaces having a plurality of indentations, wherein the air is compressed and sealed inside the indentations to prevent the paste board from adhering to the surfaces when the paste board is laminated between the surfaces. 16. The roller according to claim 15, wherein the plurality of indentations are hemispherical dents of 0.2 to 0.3 millimeters. 17. The roller according to claim 15, wherein the plurality of indentations are distributed discontinuously on the surfaces of the upper roller and the lower roller. The method for manufacturing the large thin-walled ceramic tablet according to claim 1, wherein the step of heating the compact pasty tablet includes heating the compact pasty tablet within a heating zone in which the radiation Powerful infrared with wavelength no less than 16 micrometers and powerful infrared radiation with wavelength no greater than 15 micrometers are made alternately. The method for manufacturing the large thin-walled ceramic splint according to claim 18, wherein the step of heating the compact pasty tablet further includes placing the compact pasty tablet over a metal mesh band under test. heat that has a thermal capacity of ten times the compact pasty tablet per unit area in which the compact pasty tablet and the mesh band are in contact. The method for manufacturing the large thin-walled ceramic splint according to claim 1, wherein the step of heating the compact pasty splint includes heating with black body radiation. The method for manufacturing the large thin-walled ceramic splint according to claim 20, wherein the black body includes one of silicon carbide and silicon nitride. The method for manufacturing the large thin-walled ceramic splint according to claim 5, wherein the plurality of stages are from 3 to 5. 23. The method for manufacturing the large thin-walled ceramic splint in accordance with Claim 5, wherein the plurality of stages are 4. The method for manufacturing the large thin-walled ceramic splint according to claim 20, wherein the heating with the black body thermal radiation is done using a burner. of tube which is arranged extending perpendicular to a direction where the compact pasty tablet is transferred, the tube burner having a length of 1.5 to 1.7 times the width of the compact pasty tablet.