JPH03218934A - Ornamental vitreous foamed body - Google Patents

Abstract

PURPOSE:To improve the decorativeness and mechanical strength of the foamed body by integrally laminating a specified dense vitreous layer on a vitreous foamed layer. CONSTITUTION:A glass powder having <=150mum grain diameter and a foaming agent such as limestone and dolomite and the inorg. pigment, heat-resistant material and binder, as required, are mixed, and the mixture is granulated to obtain a vitreous foamed layer material. The formed layer material is then coated through an adhesive with the same glass material as before having 0.5-5mm grain diameter and a colored layer forming material in white, black or various colors having several to several ten mum grain diameter and the softening point below the foaming temp. of the foamed body and above the softening point of the foaming layer forming glass to obtain a dense glass layer material. The foamed layer material is then placed on a traveling lower belt to form a band, the vitreous material is placed thereon to form a laminated band, and the laminated band is clamped by the upper and lower belts to foam the foamed layer material and to fuse the vitreous material and then slowly cooled to form a dense vitreous layer 1 consisting of vitreous spotted matrixes 2, 2' and 2'' and the colored material coating layers 3, 3' and 3'' constituting the colored edge around the matrix on the glass foamed layer 4.

Description

[Detailed Description of the Invention] [Industrial Field of Application] The present invention is formed by laminating and integrating a dense vitreous layer and a vitreous cellular layer, and is suitable as a covering material for buildings, a material for furniture, etc.
This invention relates to a decorative glassy foam that is beautiful and has excellent mechanical strength.

[Prior art and its problems] The present applicant filed a patent application filed in 1986-215.
No. 199 discloses a vitreous foam material in which a see-through glass layer is laminated and integrated on a vitreous foam layer with a rippled upper surface to provide decorative properties and improve abrasion resistance, mechanical strength, etc. proposed.

Furthermore, in Japanese Patent Application No. 63488657, a dense vitreous layer is laminated and integrated on a vitreous foam layer having a rippled upper surface, and the dense vitreous layer is made of a transparent vitreous matrix and an inorganic colored net portion. We proposed a glassy polyfoam with more decorative properties and a three-dimensional mesh pattern that can be seen through.

However, if the softening point or melting point of the material forming the inorganic colored net portion of the dense glassy layer is too high, the net portion will not be sufficiently fused during molding, and cracks will propagate along the portion due to external impact, resulting in damage. It is easy to lead to On the other hand, if the softening point or melting point is too low, the formation of a dense vitreous layer will proceed before the foaming of the vitreous cellular layer during molding, and as a result, coarse bubbles and Cavities are likely to occur.

The present invention aims to eliminate such concerns and provide an improved decorative vitreous foam.

Another object of the present invention is to provide a stone-like decorative vitreous foam body in which the spots formed by the colored edges can be viewed three-dimensionally and exhibit a spotty pattern that is different from the net-like pattern.

Furthermore, in Japanese Patent Application Laid-Open No. 50-40614, fine glass powder is mixed with coarse glass for pattern formation. It has been disclosed that marble-like mottling is formed by firing, but the present invention does not involve simply forming surface mottling.
Different in effect.

[Means for solving problems]

The present invention provides a decorative vitreous foam body in which a dense vitreous layer is laminated and integrated on a vitreous foam layer, and the dense vitreous layer is composed of a transparent vitreous mottled matrix and a colored edge around it. The softening point or melting point of the edge forming material is set to be lower than the foaming temperature of the vitreous foam, but higher than the softening point of the glass forming the vitreous foam layer.

The present invention will be explained in detail below based on the accompanying drawings.

FIG. 1 is a partial side view of the decorative vitreous foam of the present invention.
1 is a glassy patchy matrix made from glass grains 2
, 2'', 2'' and a coloring material coating layer (hereinafter simply referred to as a colored layer) forming a colored edge around it 3 (for example, white), 3
This is a dense vitreous layer (hereinafter simply referred to as a dense layer) consisting of ゛ (for example, red) and 3'' (for example, black), and 4 is a vitreous cellular layer (hereinafter simply referred to as a cellular layer). The outer surface 5 of is polished to a mirror surface.

If the thickness of the colored layer is several hundred μm or more, a three-dimensional mottled decorative pattern in which the colored layer surrounds the glassy matrix 2, 2'', 2'' will be observed, and if the colored layer has a thickness of several tens of μm to 100 μm or more, a three-dimensional mottled decorative pattern will be observed.
If the thickness is as small as 1.0 m, it will be recognized as a three-dimensional network-like spread, and a ripple-like boundary line 6 between the foamed layer 4 and the foamed layer 4 will be observed.

In this way, in the present invention, the facing portion exhibits a three-dimensional mottled shape or a three-dimensional mesh shape, and is highly aesthetically pleasing.

In the present invention, the raw material for the foam layer is glass powder with a particle size of 150 μm or less, preferably 70 μm or less, or a material powder that is easily vitrified by heating and softening, preferably soda lime, aluminosilicate lime, borosilicate soda glass, etc. It is prepared by mixing cullet powder and a foaming agent such as limestone, dolomite, or carbon, or by further appropriately mixing inorganic pigments, heat-resistant materials, etc., and granulating them using a binder if necessary.

The dense vitreous layer is made of a glass material similar to the above-mentioned foam layer with a particle size of 0.5 fi to 51 l, a particle size of several μm to several tens of μm, white, black, or various colors, and the foam molding temperature of the multifoam, e.g. The material for forming the colored layer has a softening point or melting point lower than about 800°C and higher than the softening point of the multi-cell layer forming glass, for example, 720°C or higher, and 5iv
About t% or less of the colored layer forming material is mixed with sodium silicate, polyvinyl acetate, etc. prepared by coating with other inorganic or organic adhesives.

Specifically, for example, glass particles coated with a coloring agent can be obtained by mixing glass particles and a colored layer-forming material that has been kneaded with an adhesive liquid in advance by a conventional means.

Alternatively, the glass particles may be immersed in a dispersion of the colored layer forming material and then taken out for coating.

In the preferred manufacturing method of the present invention, a pair of upper and lower endless heat-resistant belts are arranged and run. On the lower belt, the raw material for the foamed layer is continuously fed from Hosopar to form a band of the raw material for the foamed layer, and on top of that, the raw material for the dense layer, colored layer-forming material coated glass particles, is continuously fed from another hopper. A laminated band of the raw material for the foam layer and the raw material for the dense layer is formed, and the raw material for the foam layer is foamed while being compressed by upper and lower belts as it is led to a heating furnace, and the raw material for the dense layer is fused to each other, and the raw material for the dense layer is formed into a laminated band. and the foam layer are fused together, then introduced into an annealing furnace for slow cooling, and the top surface of the dense layer is polished to complete the process.

Of course, during the heat treatment, the foam layer raw material and the dense layer raw material may be sequentially stacked and filled in the heat-resistant frame and heated while being pressed with the upper lid.

When the colored layer-coated glass particles, which are the dense layer raw materials, are introduced onto the multi-foam layer raw materials, glass particles having a particle size in the range of 0.5 to 5 tsuru are used to preliminarily form an uneven interface that follows the particle size. be done. If the glass particle size is less than 0.51 m, it is difficult to form three-dimensional deep mottled or mesh shapes due to the colored edges, or even wavy patterns, and if it exceeds 5 fl, these patterns become rough and aesthetically undesirable. During firing, the colored layer-coated glass particles fuse on the surface, and the foam layer expands and infiltrates into the gaps between the colored layer-coated glass particles in the interface area, thereby creating an occlusal interface where further welding between the glass particles is prevented. In other words, ripples are formed. On the other hand, on the upper surface of the dense layer, the glass particles are welded and degassed together with the aid of the pressing action of the belt from above, forming a dense glass layer.

At the stage after firing and slow cooling, the surface of the dense layer is covered with a colored layer coated with glass particles, so it lacks transparency and it is difficult to recognize mottled or network patterns. However, by polishing the surface of the dense layer, a patchy or net-like area with colored edges arranged in the glass grain boundaries is exposed, and in the latter case, a ripple pattern is formed at the interface with the cellular layer through the glassy matrix. is seen through.

Note that if the material of the colored layer forming the colored edge in the dense glass layer has a softening point or melting point higher than the foam molding temperature of the glassy multifoam, the glass particles forming the dense layer may interact with each other during simultaneous integral molding. Furthermore, the adhesion with the foam layer is poor, and cracks are likely to occur along these interfaces due to external impact. On the other hand, if the softening point or melting point of the material of the colored layer is lower than the softening point of the glass forming the cellular layer, fusion and layer formation within the dense layer proceed before the cellular layer begins to soften and foam. During foaming in the multifoam layer, rough bubbles or cavities are likely to be formed between the foam layer and the dense layer.

Therefore, the material for the colored layer must have a softening point or melting point below the foam molding temperature of the vitreous multifoam, but above the softening point of the glass forming the multifoam layer.

The bulk specific gravity of the foam layer is preferably in the range of 0.2 to 1.0. If it is less than 0.2, it will be too fragile to be used as internal, exterior, or exterior wall materials for buildings, and if it exceeds 1.0, it will impair heat insulation, reduce light weight, and be inferior in handling and construction.

On the other hand, the specific gravity of the compact layer is around 2.5 as mentioned above,
There is a significant difference in physical properties, especially a difference in thermal properties, between the two layers, which tends to cause distortion, but in order to prevent this, an intermediate foam layer may be provided.

The intermediate foam layer preferably has a bulk specific gravity of about 1.0 to 1.8, and a thickness of 0.5 days or more.

It should be noted that, based on the present invention, applications such as having a structure with only a dense layer and an intermediate porous layer and omitting the porous layer can be made as appropriate.

〔Example〕 Specific examples are shown below.

Add 0.3wt of commercially available calcium carbonate fine powder to soda-lime glass powder with a particle size of 270 mesh or less and a softening point of 720℃.
%, lwt% of pyrofluorite fine powder as a heat-resistant material
The mixture was added and mixed, compressed into agglomerates, and crushed to a diameter of about 1 tsile, which was prepared as a raw material for a multi-foam layer.

In addition, as a dense layer raw material, the particle size is 10 to 16 mesochets (diameter 1 to
1. Soda-lime-based glass particles similar to those described above and colored glass powders having a particle size of 10 μm or less and exhibiting red, white, and black tones at a softening point of 730° C. were prepared.

First, soda lime glass particles were immersed in a polyvinyl acetal solution as an adhesive and taken out to obtain glass particles coated with an adhesive. The glass particles were divided into three parts, each of which was placed in a dish-shaped container containing glass powder of each color, and the containers were shaken to obtain colored glass powder-coated glass particles.

The glass particles were air-dried and then mixed together to form a dense layer raw material. Note that the layer thickness of the colored glass powder was approximately 600 μm.

The foam layer raw material and the dense layer raw material are stacked in this order into a steel frame, and then a steel drop lid is placed on top and heated in a heating furnace.
The sample was heat-treated at 00°C for 30 minutes, slowly cooled, and then the sample was taken out and the surface of the dense layer was polished.

The obtained sample has a foam layer with a bulk specific gravity of 0.7 and a thickness of 30 m, and a dense layer with a bulk specific gravity of 2.5 and a thickness of 3 m, which are fused and integrated.
The dense layer has a matrix made of colorless transparent glass with colored edges of red, white, and black, and a three-dimensional mottled pattern is observed.
It was extremely beautiful.

As shown in the partial side cross-sectional view of Fig. 2, when a chisel is applied to point A and a hammer is used to strike it, the fractured surface will appear at the interface between the glass particles 2, 2 and the foam layer 4, as shown by the broken line It is clear that it does not necessarily follow the interface.

On the other hand, for comparison, in the case where a vitreous foam was produced in the same manner as in the example except that colored glass powder was used as the material for forming the colored layer and a valve pattern with a melting point of 1500°C or higher was used, the partial side cross-sectional view of FIG. As shown, when a similar impact is applied at point B, the fracture surface is often along the interface between the glass particles 2, 2 or the interface with the foam layer 4, as indicated by broken lines Y, Y", Y". This clearly shows that the bonding force at these interfaces is weak and therefore the mechanical strength is inferior to that of the example.

〔Effect of the invention〕

The present invention has an extremely decorative appearance by forming a three-dimensional mottled or mesh pattern with colored edges on the dense layer, and also has excellent bonding between glass grains in the dense layer and between the dense layer and the porous layer. It is strong and has excellent mechanical strength, making it suitable for building materials, furniture materials, etc.

[Brief explanation of drawings]

FIG. 1 is an enlarged partial side sectional view of the present invention, and FIGS. 2 and 3 are side sectional views of an example and a comparative example, respectively, showing the state of breakage due to external impact.

Claims (1)

[Claims] (1) A decorative vitreous foam body in which a dense vitreous layer is laminated and integrated on a vitreous foam layer, and the dense vitreous layer is composed of a transparent vitreous mottled matrix and a colored edge around it; 1. A decorative vitreous foam, characterized in that the softening point or melting point of the edge forming material is below the foaming temperature of the vitreous foam, but above the softening point of the glass forming the vitreous foam layer.