JP3048840B2 - Apparatus and method for producing porous ceramic plate - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an apparatus and a method for manufacturing a porous ceramic plate. More specifically, the present invention relates to an apparatus and a method for manufacturing a porous ceramic plate capable of increasing the thickness of a product without impairing the design.

[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 insulation. The size of such porous ceramic plates has also been diversified.
mm ^□ tile size products,
900mm × 1800mm or 900mm × 2400
A long ceramic plate such as mm is manufactured, and then cut into a predetermined size. FIG. 7 is a schematic perspective view of such a porous ceramic plate, which comprises a base layer 21 and a surface decorative layer 22.

[0003]

However, in the above-mentioned conventional method, the product has no flatness because the surface is flat, and on the other hand, the small edges (corners) of the surface decorative layer 22 are formed in order to obtain the thickness. When chamfering, there is a problem in that foam on the decorative surface can be seen in the chamfered portion, thereby reducing the product value.

In the cutting operation, since a long ceramic plate hardened by firing is cut, cracks are easily generated in the ceramic plate, and there is a problem that productivity is poor.

In view of the above circumstances, the present invention provides an apparatus and a method for manufacturing a porous ceramic plate which can increase the thickness of a product without impairing the design and improve productivity. The purpose is to:

[0006]

According to the present invention, there is provided an apparatus for producing a porous ceramic plate, comprising: (a) a firing furnace; (b) a carrier running inside and outside the firing furnace; An apparatus for manufacturing a porous ceramic plate comprising at least a base layer raw material supply device and a decorative layer raw material supply device disposed above a carrier body outside the furnace, wherein the firing furnace and the decorative layer raw material supply device are provided. In the meantime, a molding die for molding a laminated body laminated from each of the supply devices is provided.

Further, the method for producing a porous ceramic plate of the present invention comprises: (a) a laminating step of sequentially laminating at least a base layer raw material and a decorative layer raw material; and (b) transporting the obtained laminate to a firing furnace. And (c) a method for producing a porous ceramic plate comprising a sintering step in which the laminate is melted and integrated by the sintering furnace, wherein the molding is performed before the sintering step. It is characterized by having a process.

[0008] A recess surrounded by a circumferential groove is formed in the mold.

Further, it is preferable that a suction port is formed in the circumferential groove.

[0010]

According to the apparatus and method for manufacturing a porous ceramic plate of the present invention, a laminate comprising at least a base layer and a decorative surface layer is pressed by a molding die before firing. Then, a laminate having a predetermined shape is formed alone by the recess formed in the molding die. At the time of this molding, the extra raw material of the base layer and the raw material of the surface decorative layer that are pushed out around the recess are discharged to a peripheral groove surrounding the recess.

Next, when the single-molded laminate is heated and fired, the peripheral corners of the surface decorative layer are melted and wrap around the edge on the base layer. Therefore, after firing, the peripheral corners of the surface decorative layer become R-shaped, and a porous ceramic plate exhibiting a sense of thickness can be obtained.

The extra raw material discharged into the peripheral groove is sucked out through a suction port formed in the peripheral groove so as not to adversely affect the precision at the time of molding. The trouble of removing the body is lost.

[0013]

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of a porous ceramic plate manufacturing apparatus according to the present invention;

FIG. 1 is an explanatory view showing one embodiment of the apparatus for manufacturing a porous ceramic plate according to the present invention, and FIGS. 2 to 5 are explanatory views showing the operation of a molding die in FIG.

As shown in FIG. 1, in a manufacturing apparatus 1, a conveyor 2 formed of a mesh belt runs inside and outside a firing furnace 3. In addition, a supply device 4 such as a hopper and a supply device 5 are arranged above the transport body 2. A molding die 6 is provided between the supply device 5 and the firing furnace 3.

A base layer raw material 8 constituting the base layer 7 is supplied from the supply unit 4, and a decorative layer raw material 10 constituting the surface decorative layer 9 is sequentially supplied from the supply unit 5. Laminated.

In this embodiment, continuous lamination is performed. However, the present invention is not limited to this.
It can be an intermittent stack. However, since it is difficult to match the mold and the intermittent lamination at the same position, continuous lamination is preferred.

In the present invention, for example, glass powder may be laminated as an underlayer of the base layer, an intermediate layer between the base layer and the surface decorative layer, or an upper layer of the surface decorative layer.

As the base layer raw material 8, foamable inorganic granules or the like are used. The expandable inorganic granules are made of Al ₂ O such as acid clay, shirasu, perlite, anti-firestone and feldspar.
_The main raw material is a _3- SiO ₂ mineral, which contains soda ash,
It is made by powdering and granulating an auxiliary compound of a flux such as sodium nitrate, glass powder, boric acid and borax, and a foaming agent such as dolomite, SiC, barium carbonate and potassium carbonate. The types of raw materials and their mixing ratios are
What is necessary is just to select suitably according to a melting temperature etc., and it is not specifically limited in this invention.

The compounding raw material is put into a pot mill together with, for example, steel balls having a diameter of about 10 mm, and is dry-pulverized for about several hours. The obtained powder has a size of about 325 mesh pass 96% or more, and the powder is granulated by a pan pelletizer or the like while spraying an aqueous solution of molasses or an aqueous solution of CMC. The particle size of the granulated product is usually about 0.5 to 5 mm, preferably about 1.0 to 2.
5 mm.

The thickness of the base layer 7 is not particularly limited in the present invention, but is usually about 3 to 35 mm, and preferably about 10 mm.

As the material 10 for the decorative layer, glaze particles or the like mixed and colored can be used. The glaze particles are obtained by using a main material such as glass powder or frit and mixing the same with an inorganic coloring pigment as a colorant to form a powder and granulate. The particle size of the granulated product is usually 0.5 to
It is about 3.5 mm, preferably about 1 to 2.5 mm. Further, the thickness of the surface decorative layer 9 is usually 3 to
It is about 7 mm, preferably about 5 mm.

As shown in FIGS. 1 and 2, the molding die 6 is disposed above the laminated body S to be laminated as described above. The molding die 6 is formed with a substantially trapezoidal concavity 12 surrounded by four frame portions 11. Note that the number of recesses is not particularly limited in the present invention. A peripheral groove 13 is formed in the frame portion 11 so as to surround the recess 12.
A suction port 14 communicating with the outside from the outside 3 is formed. The cross-sectional shape of the frame 11 is substantially trapezoidal in order to make it easy to enter the raw material. The width of the peripheral groove 13 is not particularly limited in the present invention, but is usually 3 in consideration of the ease of discharging the raw material.
mm or more, preferably 5 to 30 mm.

By pressing the forming die 6 on the laminate S, a single laminate Sa having a shape close to the shape of the porous ceramic plate M as a finished product is formed.

The formed laminated body Sa is carried into the baking furnace 3 and passes through the pre-tropical zone, the baking zone, the slow cooling zone, and the cooling zone in order, and the base layer 7 and the surface decorative layer 9 are passed through the furnace outlet. Is carried out, and the porous ceramic plate M in which is integrated.

In the obtained porous ceramic plate M, the corners of the surface decorative layer 9 are melted and have an R shape.

As shown in FIG. 6, the porous ceramic plate may be partially cut at four ends. As a result, there is no cut portion of the decorative layer and it is covered with glaze, and only the base is cut, resulting in a beautiful finish.

Next, the operation of the molding die 6 will be described with reference to FIGS.

First, as shown in FIG.
Is driven so as to sequentially repeat descending a, forward b, ascending c, and retreat d. The device for driving is not particularly limited in the present invention,
A known drive device, for example, a motor drive device can be used.

The operation of the advance b is carried out by
Is controlled so as to be synchronized with the moving speed (for example, 25 cm / min).

As shown in FIGS. 2 and 3, the mold 6 is lowered a and pressed onto the laminate S. Thereby, the single laminated body Sa is formed into a predetermined shape in the recess 12. During molding, the base layer raw material 8 and the decorative layer raw material 10 extruded from the frame portion 11 are discharged into the circumferential groove 13.

As shown in FIG. 4, the excess raw material discharged into the circumferential groove 13 is sucked from the suction port 14 during the advance b, and is removed to the outside in the direction of the arrow in FIG. You. In addition, the device for suction is not particularly limited in the present invention, a known suction device,
For example, a dust collector can be used. Since the removed raw material can be reused by sorting, the yield of the material is not reduced.

When the molding is completed, the molding die 6 is raised c and retracted d as shown in FIG. Thereby, as shown in FIGS. 1 and 5, a plurality of single laminated bodies Sa having a shape similar to that of the porous ceramic plate M are obtained from the laminated body S.

Next, the method for producing the porous ceramic plate of the present invention will be described.

The porous ceramic plate of the present invention forms a continuous or intermittent laminate by supplying the raw material prepared in advance as described above from a hopper or the like. Thereafter, the laminate can be formed into a predetermined shape, and the obtained laminate can be heated and fired in a firing furnace to be melted and integrated.

Hereinafter, the method for producing the porous ceramic plate of the present invention will be described based on examples, but the present invention is not limited to these examples.

Example 1 Preparation of Raw Material for Base Layer 64.5% (weight%, hereinafter the same) of Otani stone, soda ash 18
%, Water glass powder 5%, Sanritsu talc 12% and SiC
The compounding material consisting of 0.5% was put into a pot mill together with a steel ball of 10 mm ^φ and was dry-pulverized for 4 hours. The resulting powder had a size of 325 mesh pass 96% or more. The powder was granulated with a pan pelletizer while spraying a 15% molasses solution to obtain a granulated product having a particle size of 1 to 4 mm. The obtained granules were dried to obtain a base layer material.

Preparation of Raw Material for Decorative Layer A raw material composed of 62% glass powder, 25% frit, 5% elutriation viscosity and 8% zirconium silicate was mixed with a 10 mm ^φ
Was placed in a pot mill together with the steel balls of Example 1 and dry-ground for 5 hours. The resulting powder had a size of 325 mesh pass 96% or more. This powder was granulated with a pan pelletizer while spraying 10% molasses liquid, and the particle size was 1
Granules of ~ 2.5 mm were obtained. Next, a colored powder coating was applied around the obtained granules to obtain a raw material for a decorative layer.

Lamination and molding The raw materials prepared as described above were each supplied to the supply unit 4
And put in the feeder 5. Then, the base layer raw material is placed on the carrier 2 coated with alumina as a release material.
The material was uniformly charged so as to have a thickness of 0 mm, and the decorative layer material was further laminated thereon so as to have a thickness of 5 mm.

From the obtained laminate, a single laminate having a predetermined shape was formed by the molding die 6.

[0041] The Firing the shaped laminate is transported to a firing furnace 3, then preheating zone in order, firing zone, Johiyatai was passed through a cooling zone and out of the furnace outlet.

The firing temperature was 900 ° C. Further, the moving speed of the carrier was 25 cm / min, and the time required for putting in the firing furnace and exiting from the firing furnace was about 160 minutes.

When the obtained porous ceramic plate is visually observed, an R-shape is formed in the square portion of the surface decorative layer, so that a thick appearance can be obtained.

[0044]

As described above, in the apparatus and method for manufacturing a porous ceramic plate according to the present invention, a laminate is formed into a single laminate having a shape close to a finished porous ceramic plate by a molding die. After baking, the four-sided corners of the surface decorative layer wrap around the edge on the base layer due to melting, so that no bubbles are visible at the edge of the surface decorative layer. In addition, since the square portions of the surface decorative layer have an R shape, a porous ceramic plate having a thick appearance can be obtained.

Further, since it is not necessary to cut the long ceramic plate with a cutter or the like after firing, cracks do not occur and the productivity can be improved.

[Brief description of the drawings]

FIG. 1 is an embodiment of an apparatus for manufacturing a porous ceramic plate according to the present invention.

FIG. 2 is an explanatory view showing a lowering operation of a molding die in FIG. 1;

FIG. 3 is an explanatory view showing a molding operation of a molding die in FIG. 2;

FIG. 4 is an explanatory view showing a suction operation of a molding die in FIG. 3;

FIG. 5 is an explanatory view showing completion of molding of a molding die in FIG. 4;

FIG. 6 is a schematic perspective view of another example of a porous ceramic plate obtained by the manufacturing apparatus of the present invention.

FIG. 7 is a schematic perspective view of a conventional porous ceramic plate.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Manufacturing apparatus 2 Carrier 3 Firing furnace 4, 5 Feeder 6 Mold 8 Base layer raw material 10 Decorative layer raw material S Laminated body M Porous ceramic plate

──────────────────────────────────────────────────続 き Continued on the front page (58) Field surveyed (Int. Cl. ⁷ , DB name) C04B 35/00 C04B 35/622-35/636 B28B 3/00-5/12

Claims (6)

(57) [Claims] 1. A baking furnace, (b) a carrier running inside and outside the baking furnace, and (c) at least a base layer raw material disposed above the carrier outside the baking furnace. An apparatus for producing a porous ceramic plate, comprising: a supply device for supplying a decorative layer material; and a lamination body laminated from each of the supply devices, between the firing furnace and the supply device for the decorative layer material. An apparatus for manufacturing a porous ceramic plate, comprising: 2. The apparatus for manufacturing a porous ceramic plate according to claim 4, wherein a recess surrounded by a peripheral groove is formed in said molding die. 3. The apparatus for manufacturing a porous ceramic plate according to claim 2, wherein a suction port is formed in said peripheral groove. 4. A laminating step of sequentially laminating at least a base layer raw material and a decorative layer raw material; (b) a transporting step of transporting the obtained laminate to a firing furnace; A method for producing a porous ceramic plate, comprising a firing step of melting and integrating a laminate, comprising a forming step of forming the laminate with a mold before the firing step. Plate making method. 5. The method for producing a porous ceramic plate according to claim 4, wherein a recess surrounded by a peripheral groove is formed in said mold. 6. The method for producing a porous ceramic plate according to claim 5, wherein a suction port is formed in said peripheral groove.