JPH0610441A - Porous ceramic panel - Google Patents

Abstract

PURPOSE:To increase flexural strength by forming a surface decorative layer on a base layer made from inorganic foaming granulated material, and providing an unfoaming reinforcing layer on the opposite surface of the surface layer. CONSTITUTION:An AI2O3-SiO2 mineral such as acid clay, loam, pearlite, pumice and feldspar is used as a main constituent and a flux such as soda ash, sodium nitrate or glass powder and a foaming agent such as dolomite, SiC or pottasium carbohydrate are supplementarily admixed therein and the mixture is pulverized and then granulated to form a base layer 1. A surface decorative layer 2 made from glaze powder, glass powder or frit, etc., is formed on the base layer 1. A reinforcing layer 3 made from inorganic crushed powders or the like is provided on the opposite surface of the surface decorative layer 2. The unfoaming reinforcing layer 3 increases flexural strength and the porous ceramics panel can be used as a double-side panel such as a partition panel.

Description

Detailed Description of the Invention

[0001]

FIELD OF THE INVENTION This invention relates to porous ceramic plates. More specifically, it relates to a porous ceramic plate having improved bending strength.

[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 frost resistance and improve the design of the surface. As the surface makeup of such a porous ceramic plate, a glaze powder or glass particles colored and blended on a base layer made of an inorganic expandable granule is laminated to form a surface makeup layer,
The obtained laminated body is solution-integrated and integrated.

A general cross-sectional structure of such a porous ceramic plate is shown in FIG. The base layer 11 shown in FIG.
Is a foam layer, and the surface decorative layer 12 is a non-foam layer.

[0004]

By the way, when a load is applied to the ceramic plate of the structure shown in FIG. 2 from above (in FIG. 2), the foam layer having a low strength receives a tensile force, so that the foam layer is relatively weak. There has been a problem that the ceramic plate is cracked or broken with a small load. Further, since the decorative layer is provided only on one side, it cannot be used as a member such as a partition panel which is visible to both sides.

In view of the above circumstances, it is an object of the present invention to provide a porous ceramic plate having improved bending strength.

[0006]

The porous ceramic plate of the present invention comprises a base layer made of an inorganic expandable granule and a surface decorative layer formed on the base layer. It is characterized in that a non-foamed reinforcing layer is provided on the surface opposite to the surface decorative layer.

[0007]

DESCRIPTION OF THE PREFERRED EMBODIMENTS FIG. 1 is a sectional explanatory view of an embodiment of the porous ceramic plate of the present invention.

In the present invention, the inorganic expandable granules constituting the base layer 1 are mainly composed of Al ₂ O ₃ —SiO ₂ type minerals such as acid clay, shirasu, pearlite, anti-fire stone, feldspar. Soda ash, sodium nitrate, glass powder, boric acid,
Fluxing agent such as borax, dolomite, SiC, barium carbonate,
It is obtained by pulverizing and granulating a mixture of a foaming agent such as potassium carbonate and the like, which is auxiliary. 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 compounded raw material is put into a pot mill together with a steel ball having a diameter of about 10 mm, and dry-ground for about several hours. Obtained powder is 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 is usually 0.5 to 5 mm.

The thickness of the base layer 1 is not particularly limited in the present invention, but is usually about 3 to 35 mm, preferably about 10 mm.

As the surface decorative layer 2, colored glaze particles, glass particles, frit and the like can be used. The thickness of the surface decorative layer 2 is not particularly limited in the present invention, but is usually about 3 to 10 mm, preferably about 7 mm.

The particle diameters of the base layer 1 and the surface decorative layer 2 are
Although not particularly limited, each is usually 1 to 2.5 mm.

The present invention is characterized in that a reinforcing layer made of pulverized inorganic particles is provided on the surface of the base layer 1 opposite to the surface decorative layer 2. The pulverized inorganic particles are pulverized inorganic materials that have been once fired and dried, and examples of such inorganic materials include waste materials of porous ceramic plates, waste glass, frits, natural glassy raw materials, and the like.
Of these, it is preferable to use waste materials from the viewpoint of cost reduction as well as resource recycling.

Since the reinforcing layer 3 is a non-foamed layer, it has a large strength against a tensile force and therefore contributes to an increase in the bending strength of the panel. Further, if a non-foamed decorative layer is adopted as the reinforcing layer 3, it can be used as a double-sided type panel such as a partition panel because it has not only the reinforcing effect but also surface makeup. In this case, when manufacturing a panel by stacking the raw materials on a mesh belt and baking, lay a ceramic sheet, alumina sheet, etc. in advance on the belt to prevent the pattern of the mesh belt from being transferred to the product. Is preferred.

The thickness of the reinforcing layer 3 is usually in the range of 2 to 6 mm, preferably about 4 mm, when it is intended only to reinforce using a waste material and the like, and as a decorative layer. When used, it is usually in the range of 3-10 mm,
Of these, about 7 mm is preferable.

When inorganic crushed particles are used, the particle size can be appropriately selected within the range of usually 0.5 to 1.5 mm.

Next, the porous ceramic plate of the present invention will be explained based on examples, but the present invention is not limited to such examples as a matter of course.

[0018] Preparation Oya 64.5% in Example 1 base layer material (% by weight, hereinafter the same), 18% soda ash, water glass powder 5%, the three-elevational talc 12% and a mixed material consisting of 0.5% SiC of 10 mm ^phi It was put in a pot mill together with steel balls 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 milled between elutriation clay 5% and 5 hours was placed in a pot mill to mixed material consisting of 8% of zirconium silicate with steel balls of 10 mm ^phi . 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 Reinforcing Layer The above-mentioned base layer raw material and decorative layer raw material were laminated and fired to pulverize the waste material of the porous ceramic plate to obtain inorganic pulverized particles having a particle diameter of 0.5 to 1.5 mm.

Firing A porous ceramic plate was fired using the granulated product prepared as described above.

As the firing furnace, a tunnel kiln having a total length of 39 m, in which a heat-resistant mesh belt was installed for transportation, was used. Alumina was applied as a mold release material on a mesh belt with a width of 1 m, and inorganic crushed particles for reinforcing layer were uniformly charged to have a thickness of 4 mm, and granules for base layer with a thickness of 10 mm were applied on it. Then, the granules for a decorative layer were laminated thereon to a thickness of 7 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.

The bending strength (according to JIS A1408) of the obtained porous ceramic plate was measured to be 78 kg / cm.
^{Was 2} .

Example 2 Example 1 was repeated except that granules for a surface decorative layer were used (charge thickness: 7 mm) in place of the inorganic pulverized particles as the raw material for the reinforcing layer.
A porous ceramic plate was manufactured in the same manner as in. Instead of applying alumina, an alumina sheet was laid on the mesh belt.

The porous ceramic plate thus obtained had a beautiful appearance by being coated on both sides, and the bending strength was measured in the same manner as in Example 1 and found to be 81 kg / cm ² .

Comparative Example 1 A porous ceramic plate was manufactured in the same manner as in Example 1 except that the thickness of the base layer was increased by that amount instead of providing the reinforcing layer. The bending strength of the obtained porous ceramic plate was measured in the same manner as in Example 1 and was 62 kg / cm.
^{Was 2} .

[0028]

As described above, in the porous ceramic plate of the present invention, since the non-foamed reinforcing layer is provided on the surface of the base layer opposite to the surface decorative layer, the bending strength can be increased. it can. Further, when a non-foamed decorative layer is adopted as the reinforcing layer, a decorative effect is obtained in addition to the reinforcing effect, and it can be used as a double-sided type panel such as a partition panel.

[Brief description of drawings]

FIG. 1 is a cross-sectional explanatory view of an embodiment of a porous ceramic plate of the present invention.

FIG. 2 is a cross-sectional explanatory view of a conventional porous ceramic plate.

[Explanation of symbols]

 1 Base layer 2 Surface decorative layer 3 Reinforcing layer

Claims (2)

[Claims] 1. A base layer made of an inorganic expandable granule,
A porous ceramic plate comprising a surface decorative layer formed on the base layer, and a non-foaming reinforcing layer provided on the surface of the base layer opposite to the surface decorative layer. 2. The porous ceramic plate according to claim 1, wherein the reinforcing layer is made of crushed inorganic particles obtained by crushing a porous ceramic plate.