Loess plate with carbonized layer formed inside and manufacturing method thereof

Abstract

The present application relates to a manufacturing method of a loess plate with a carbonized layer built-in, and particularly relates to a loess plate and a manufacturing method thereof, which can keep the inherent functions of loess and charcoal such as antibacterial property, odor removal, moisture absorption and release, etc. in an excellent manner even if a coating film is formed on the surface of the loess plate, and the surface particles are not easy to fall off, and the surface of the loess plate will not be scratched and contaminated by sharp objects.

Description

Technical Field

[0001] This invention relates to a method for manufacturing a loess board with a built-in carbonized layer, and more particularly to a loess board and its manufacturing method that can excellently maintain the inherent functions of loess and charcoal, such as antibacterial, deodorizing, and moisture absorption and release properties, even when a coating is formed on the surface of the loess board, while the surface particles are not easily detached, and the surface of the loess board will not be scratched or contaminated even when a sharp object is used. Background Technology

[0002] In recent years, with the rise of well-being, there has been a trend to exclude synthetic resins such as plastics and widely use environmentally friendly materials such as charcoal and loess when choosing materials commonly used in daily life, such as tiles, pillows, mats, beds and cushions.

[0003] Due to the various beneficial effects of loess and charcoal mentioned above, the demand for loess and charcoal in building materials and daily necessities has been on a continuous upward trend in recent years.

[0004] As is well known, especially as an interior building material, loess slabs made from loess can emit a large amount of far-infrared rays to promote blood circulation, bringing very beneficial effects to the human body such as relieving stress and restoring chronic fatigue. They also have excellent air purification and deodorization functions, humidity regulation function, and can regulate indoor humidity. They also have detoxification and bactericidal effects, thus effectively killing indoor mites or bacteria. In addition, they also have the function of blocking electromagnetic waves.

[0005] As such, loess and charcoal are used as building materials and various household goods due to their various useful uses. Mixing loess and charcoal for use as building materials or household goods can be expected to produce the best overall effect.

[0006] However, using loess and charcoal as materials to manufacture building materials or household goods is very demanding. This is because when loess is shaped into building materials or household goods, it needs to undergo a high-temperature firing process. However, at this time, the physical properties of the charcoal change as it burns into ash, and all the useful functions of the charcoal are lost.

[0007] To address this issue, Korean Patent Office Registered Patent No. 10-0878834, "Method for Manufacturing Loess Board with Structure of Charcoal Embedded in Loess," discloses a method for manufacturing building materials by mixing loess and charcoal.

[0008] However, loess slabs manufactured in this way are weak and require a lot of manufacturing time, making mass production difficult.

[0009] In addition, the particles on the surface of loess slabs are easy to detach, which can stain clothes when they are scratched. Furthermore, due to the low surface hardness of loess slabs, they are easily scratched by sharp objects, and the surface of loess slabs is also prone to contamination.

[0010] In addition, loess boards manufactured using existing methods have issues with antibacterial properties, odor removal, and moisture absorption / release properties that are lower than expected. Summary of the Invention

[0011] The problem that the invention aims to solve

[0012] This invention was developed to solve the above-mentioned problems. Its purpose is to provide a loess board with a carbonized layer formed inside and a method for manufacturing the same. The particles on the surface of the loess board will not fall off, exhibiting excellent antibacterial, deodorizing, and moisture absorption / release properties. Furthermore, it can significantly reduce production time, enabling mass production.

[0013] Solution for solving the problem

[0014] To achieve the above objectives, the manufacturing method of the present invention includes:

[0015] The process includes: a ball milling step, in which loess, clay, and 8-20 parts by weight of wood flour (relative to 50-60 parts by weight of loess) are placed in a ball mill and stirred; a pressing and filtration step, in which the mixture from the ball milling step is pressed to remove moisture and form a filter cake; a primary drying step, in which the filter cake from the pressing and filtration step is dried and matured; a primary maturation step; a pulverizing step, in which the filter cake from the primary drying and maturation step is pulverized; a molding step, in which the powder pulverized in the pulverizing step is pressed into a plate shape; a secondary drying step, in which the molded object formed in the molding step is dried; a firing step, in which the molded object dried in the secondary drying step is heated in a chamber at a temperature of 760-860°C for 50-60 minutes; and a coating step, in which a coating liquid is applied to the surface of the loess plate from the firing step.

[0016] At this point, the feature is that, in the above-mentioned ball milling step, 15 to 25 parts by weight of illite are further added to the ball mill relative to 50 to 60 parts by weight of loess.

[0017] Furthermore, the characteristic feature is that, in the above-mentioned pulverizing step, the mixture that was mixed and stirred in the ball milling step is pulverized to a particle size of 50 to 70 mesh.

[0018] Furthermore, the feature is that, in the above-mentioned secondary drying step, the molded article is dried to a moisture content of 7-12%.

[0019] Furthermore, the coating solution in the above-mentioned coating step is characterized by being composed of 0.1 to 0.5 parts by weight of glycerin mixed with 1 to 5 parts by weight of surfactant, and 20 to 30 parts by weight of the above-mentioned surfactant-glycerin mixture mixed with 100 parts by weight of water and diluted.

[0020] At this time, the above-mentioned coating solution can also be prepared by mixing 10 to 20 parts by weight of sodium silicate with 100 parts by weight of water to form a sodium silicate dilution, and then mixing 5 to 10 parts by weight of the above-mentioned sodium silicate dilution with 10 to 20 parts by weight of the above-mentioned surfactant-glycerol mixture.

[0021] Invention Effects

[0022] The present invention, as described above, mixes wood flour with loess and clay, and fires it at high temperature to form a carbonized layer (charcoal) inside and a loess ceramic layer on the outside, thereby producing a loess board that combines the useful functions of loess and charcoal.

[0023] In addition, it has the advantages that even if a coating is formed on the surface of the loess board, it can still maintain the inherent functions of loess and charcoal such as antibacterial, deodorizing, and moisture absorption / release properties, while the surface particles are not easy to fall off, and even if sharp objects are used, the surface of the loess board will not be scratched and is not easily contaminated. Attached Figure Description

[0024] Figure 1 This is a diagram showing a loess slab manufactured by the manufacturing method of the present invention.

[0025] Figure 2 This is a test report on the anti-mold properties of loess boards manufactured using the manufacturing method of this invention.

[0026] Figure 3 It is a test report that measures the far-infrared radiation emitted by loess slabs manufactured using the manufacturing method of this invention.

[0027] Figure 4 It is a test report that measures the negative ions emitted by loess boards manufactured using the manufacturing method of this invention.

[0028] Figures 5 to 7 This is a test report on the deodorization test conducted on loess boards manufactured using the manufacturing method of this invention, using formaldehyde and ammonia as the test subjects.

[0029] Figure 8 as well as Figure 9 This is a test report on the antibacterial properties of loess boards manufactured using the manufacturing method of this invention.

[0030] Figures 10 to 13It is a test report measuring the moisture absorption / release of loess boards manufactured by the manufacturing method of this invention. Detailed Implementation

[0031] The present invention will now be described in detail with reference to preferred embodiments and accompanying drawings, wherein the same reference numerals in the drawings denote the same components.

[0032] When a component is referred to as "comprising" another component in the detailed description of an invention or in the patent claims, it should not be construed as limited to consisting only of the aforementioned component, but rather as capable of further including other components, unless expressly stated to the contrary.

[0033] Terms such as “upper,” “lower,” “bottom,” “front,” “rear,” and “down” used in this specification are for ease of description only and refer to the orientation of the components shown in the figure.

[0034] The following will describe in detail the manufacturing method of the loess board with a carbonized layer formed inside according to the present invention.

[0035] The loess board manufacturing method of the present invention consists of the following steps: ball milling, pressure filtration, primary drying, primary curing, pulverizing, secondary curing, molding, secondary drying, firing, and coating.

[0036] The method for manufacturing the loess board of the present invention will be described in detail below, step by step.

[0037] Ball milling steps

[0038] The crushed loess and wood powder are put into a ball mill along with water and the ball milling process is carried out for 4 to 24 hours.

[0039] At this point, it is preferable to add 8 to 20 parts by weight of wood flour to the ball mill relative to 50 to 60 parts by weight of loess.

[0040] If the wood flour is mixed in less than 8 parts by weight, the carbonized layer cannot be formed properly inside after firing. If the wood flour is mixed in more than 20 parts by weight, not only will the pressing and molding not be able to proceed properly, but the strength of the loess board will also be reduced, and it will be prone to cracking or breakage. Therefore, it is preferable to add 8 to 20 parts by weight of wood flour to the ball mill, relative to 50 to 60 parts by weight of loess.

[0041] Loess emits far-infrared rays, which promote blood circulation in the body, and has excellent air purification and deodorization functions, as well as humidity regulation.

[0042] In addition, wood flour refers to wood in powder form. Wood flour from oak, pine, bamboo, willow, etc. can be used, as well as wood chips produced as a by-product of wood processing plants or furniture factories. However, oak wood flour is preferred because it exhibits the best charcoal effect after carbonization.

[0043] After subsequent firing steps, the wood powder forms a carbonized layer inside the loess board.

[0044] In addition to loess, it is preferable to mix clay and sandy soil and add them to the ball mill.

[0045] Clay increases the cohesive force of the mixture, thereby increasing the strength and durability of the produced loess boards, while sand can prevent the loess boards from cracking.

[0046] Instead of 50-60 parts by weight of loess, it is preferable to add 15-20 parts by weight of clay and 5-15 parts by weight of sand into the ball mill.

[0047] If the clay is mixed in less than 15 parts by weight, the mixture will have weak adhesive force, making it impossible to achieve proper pressing and molding. If the clay is mixed in more than 20 parts by weight, the content of loess and carbonized layer (charcoal) will be reduced, making it difficult to obtain the inherent functions of loess and charcoal. Therefore, it is preferable to mix 15 to 20 parts by weight of clay compared to 50 to 60 parts by weight of loess.

[0048] In addition, relative to 50 to 60 parts by weight of loess, it is preferable to also contain 15 to 25 parts by weight of crushed illite.

[0049] Illite is a mica group mineral belonging to the monoclinic crystal system. When mixed into slab-shaped products, it can adsorb formaldehyde, ammonia, and radon from the air.

[0050] The mixture fed into the ball mill is crushed and agitated as the ball mill operates.

[0051] Filtration step

[0052] The mixture produced by the ball milling step described above is fed into a filter press and pressed under high pressure to remove moisture from the mixture and form a filter cake.

[0053] One drying step

[0054] The filter cake produced by the above-described pressure filtration step is dried in a dryer or naturally dried to achieve a moisture content of 15% to 19%. This is to maintain a certain moisture content in the filter cake so that the moisture content can be made uniform during the subsequent ripening step.

[0055] One-step maturation

[0056] This is a step of maturing the filter cake that has been dried in the above-mentioned drying process for 48 hours. The maturation process ensures that the moisture in the filter cake is evenly distributed.

[0057] By allowing the filter cake to mature and become evenly moist, its formability can be improved, resulting in high-quality loess slabs.

[0058] Grinding step

[0059] The block filter cake, which has achieved uniform internal moisture distribution through the above-mentioned one-time maturation step, is crushed into a size of 50-70 mesh, preferably 60 mesh.

[0060] When the particle size of the mixture of soil and wood powder is 60 mesh, it is organically combined with the moisture content of the slab material fed into the firing machine and the firing temperature conditions, while preventing the loess slab from cracking or developing cracks during the firing process, thereby producing a high-strength loess slab.

[0061] Secondary ripening step

[0062] The filter cake powder, which has been pulverized into powder through the above-mentioned pulverization steps, is aged for 12 to 45 hours to ensure that the moisture in the filter cake powder is evenly distributed.

[0063] The secondary curing process ensures that the moisture content inside the filter cake powder is evenly distributed, which improves its formability and produces high-quality ceramic molded products. It also prevents the loess slabs from breaking during the firing process.

[0064] Molding steps

[0065] The powder formed by crushing the filter cake through the above crushing steps is placed into a pressing and molding machine and formed into a plate shape.

[0066] Secondary drying step

[0067] The plate-shaped material formed through the above molding steps is dried to achieve a moisture content of 7-12%.

[0068] The secondary drying step is a step before the firing step. In the secondary drying step, the slab is dried to a moisture content of 7-12% to prevent the loess slab from cracking, breaking, or deforming during the firing process.

[0069] Firing steps

[0070] The plate-shaped material dried through the above-mentioned secondary drying steps is placed in a chamber and heated at 760~860°C for 50~60 minutes to form a ceramic-shaped material.

[0071] The slab is made of a mixture of loess, clay, sand, illite and wood flour with a particle size of 50 to 70 mesh. Through the above firing steps, while the slab is being heated, the wood flour on the surface of the slab is completely burned, leaving only loess, clay, sand and illite on the surface of the slab to form the outer layer.

[0072] In addition, during the firing process, the wood flour inside the slab is carbonized, forming a carbonized layer.

[0073] That is, the cross-section of the sheet metal formed after the above firing steps is as follows: Figure 1 As shown, the wood powder on the surface is completely burned, forming an outer layer with a thickness of 1 to 3 mm. Inside, a black carbonized layer is formed, consisting of charcoal, loess, clay, sand, and illite.

[0074] When the wood powder is completely burned, pores are formed on the outer layer of the board, and the functionality of the loess board is manifested through these pores.

[0075] In this invention, the plate-shaped material is heated at a temperature of 760~860°C in the firing step, the matured filter cake (a mixture of loess, clay, sand, illite and wood flour) is crushed to a size of 50~70 mesh in the crushing step, and the plate-shaped material is dried to a moisture content of 7~12% in the drying step before firing. In the firing step, it is fired at a temperature of 760~860°C. Thus, while having excellent strength, the plate-shaped material will not crack, deform or break during the firing process.

[0076] If the firing temperature is below 760℃, the hardness and strength of the formed loess slab will decrease. If the firing temperature exceeds 860℃, the loess slab will be vitrified and its pores will be blocked, thus losing its various functions such as moisture absorption / release and deodorization. Therefore, the firing process should be carried out at a temperature of 760~860℃.

[0077] Application steps

[0078] The coating step involves spraying a coating liquid onto the surface of the loess slab manufactured through the above-mentioned firing step.

[0079] For loess slabs that have completed the firing process, when clothes brush against them, loess particles will stick to the clothes, or the surface is easily scratched and contaminated during daily life. To prevent this, a coating liquid is sprayed onto the surface of the loess slabs manufactured through the above firing process to form a coating film.

[0080] Regarding the application solution, 0.1 to 0.5 parts by weight of glycerin are mixed with 1 to 5 parts by weight of surfactant, and 20 to 30 parts by weight of the above surfactant-glycerin mixture are mixed with 100 parts by weight of water, and then diluted to prepare a surfactant-glycerin diluted mixture.

[0081] By mixing surfactants, the mixture is stabilized (emulsion stability), and glycerol (C3H8O3) imparts viscosity to the mixture, which stabilizes the coating film formed on the surface of the loess slab after application and imparts lubricity to the coating film, thus preventing foreign matter from adhering to the surface and causing contamination.

[0082] Surfactants can be any known type of surfactant.

[0083] Compared to 1 to 5 parts by weight of the above surfactant, 0.1 to 0.5 parts by weight of glycerin are mixed. If less than 0.1 parts by weight of glycerin is mixed, the viscosity of the coating solution will decrease, causing the coating solution to run down after the coating operation, which will reduce the quality of the coating film and prevent the anti-fouling function from working properly.

[0084] Furthermore, if more than 0.1 to 0.5 parts by weight of glycerol are mixed with 1 to 5 parts by weight of surfactant, the viscosity will be too high, resulting in reduced operability. Therefore, it is preferable to mix 0.1 to 0.5 parts by weight of glycerol with 1 to 5 parts by weight of surfactant.

[0085] In addition, a sodium silicate dilution solution is prepared by diluting 10 to 20 parts by weight of sodium silicate relative to 100 parts by weight of water.

[0086] The addition of sodium silicate imparts a certain level of water resistance to the coating and helps it adhere firmly to the surface of the loess slab.

[0087] The above-mentioned sodium silicate is diluted with 10 to 20 parts by weight relative to 100 parts by weight of water. If the amount of sodium silicate is less than 10 parts by weight, the adhesion of the coating film to the surface of the loess board will be reduced. If the amount of sodium silicate is more than 20 parts by weight, the pores on the surface of the loess board will be blocked by the coating liquid, which may reduce or lose the inherent moisture absorption / release and deodorization functions of the loess board. Therefore, it is preferable to dilute with 10 to 20 parts by weight of sodium silicate relative to 100 parts by weight of water.

[0088] Furthermore, the application solution is composed of 5 to 10 parts by weight of sodium silicate dilution mixed with 10 to 20 parts by weight of the above-mentioned surfactant-glycerin dilution mixture.

[0089] If less than 5 parts by weight of sodium silicate diluent are mixed relative to 10-20 parts by weight of surfactant-glycerol diluent, the adhesion and waterproofing of the coating film will decrease. If more than 10 parts by weight of sodium silicate diluent are mixed, the pores of the loess board will be blocked, or the moisture absorption / release function will decrease rapidly. Therefore, it is preferable to mix 5-10 parts by weight of sodium silicate diluent relative to 100 parts by weight of surfactant-glycerol diluent.

[0090] When the above-mentioned coating liquid is applied to the loess board to form a coating film, the hardness of the loess board surface increases due to the coating film. Even when scratched with a sharp object, it is not easy to produce scratches. The strength is increased, surface pollution is significantly reduced, and it exhibits a certain level of waterproofing ability.

[0091] At the same time, the pores on the surface of the loess are preserved, allowing its functions such as moisture absorption / release, deodorization, sterilization, far-infrared radiation, and negative ion radiation to continue to function.

[0092] As in the above embodiments, the coating solution can be formed by mixing the surfactant-glycerol dilution mixture with the sodium silicate dilution solution, but the surfactant-glycerol dilution mixture can also be used alone as the coating solution. In this case, although the waterproofness of the formed coating film and its adhesion to the loess board surface are reduced, its function as a coating film can be fully utilized.

[0093] Figure 2 This is a test report on the antifungal properties of loess boards manufactured using the manufacturing method of the present invention. The absence of mycelial growth in the inoculated portion of the test piece confirms that the loess boards of the present invention have excellent antifungal properties.

[0094] Figure 3 This is a test report measuring the far-infrared radiation emitted by loess slabs manufactured using the manufacturing method of this invention. Figure 4 This is a test report measuring the negative ions emitted by the loess board manufactured by the manufacturing method of the present invention. It can confirm that the loess board of the present invention radiates high levels of far-infrared rays and releases a large number of negative ions.

[0095] Figures 5 to 7 This is a test report on the deodorization test conducted on loess boards manufactured using the manufacturing method of this invention, using formaldehyde and ammonia as the test subjects.

[0096] In a similar prior art, namely Korean Patent Office Registered Patent No. 10-1552458, entitled "Ceramic Molded Articles of Various Colors with an Internal Carbonized Layer and an External Embossed Pattern, and a Method for Manufacturing the Same," the formaldehyde removal rate is shown to be 28.6% after 30 minutes, 38.8% after 60 minutes, 46.9% after 90 minutes, and 50.0% after 120 minutes. However, as... Figure 7As shown, the present invention exhibits odor removal rates of 97.4% after 30 minutes, 97.2% after 60 minutes, 97.2% after 90 minutes, and 97.1% after 120 minutes, thus confirming a higher level of formaldehyde removal effect than existing technologies.

[0097] Furthermore, Korean Patent Office Registered Patent No. 10-1552458 shows ammonia deodorization rate of 69.4% after 30 minutes, 75.5% after 60 minutes, 75.5% after 90 minutes, and 77.1% after 120 minutes. Figure 6 As shown, the present invention demonstrates a deodorization rate of 99.5% after 30 minutes, 99.5% after 60 minutes, 99.5% after 90 minutes, and 99.5% after 120 minutes, thus confirming a higher level of ammonia deodorization effect than the prior art.

[0098] Figure 8 as well as Figure 9 This is a test report on the antibacterial properties of loess boards manufactured using the manufacturing method of this invention, confirming that they possess excellent antibacterial properties.

[0099] Figures 10 to 13 It is a test report measuring the moisture absorption / release of loess boards manufactured by the manufacturing method of the present invention.

[0100] like Figure 10 As shown, the present invention exhibits 55.20 g / m³. 2 The moisture absorption capacity is 42.56 g / m³. 2 Based on the moisture release capacity, it can be seen that when this invention is used as an interior decoration material, it has an excellent effect on regulating indoor humidity.

[0101] The present invention, as described above, mixes wood flour with loess and clay, and fires it at high temperature to form a carbonized layer (charcoal) inside and a loess ceramic layer on the outside, thereby producing a loess board that combines the useful functions of loess and charcoal.

[0102] In addition, it has the advantages that even if a coating is formed on the surface of the loess board, it can still maintain the inherent functions of loess and charcoal such as antibacterial properties, deodorizing properties, and moisture absorption / release properties. At the same time, the surface particles are not easy to fall off, and even if sharp objects are used, the surface of the loess board will not be scratched and is not easily contaminated.

[0103] The technical concept of the present invention has been observed through the above embodiments.

[0104] Obviously, those skilled in the art can make various modifications or changes to the embodiments described above based on the present invention.

[0105] Furthermore, even if not explicitly shown or explained, it is obvious to those skilled in the art that various modifications, including the technical concept of the invention, can be made based on the description of the invention, and these modifications still fall within the scope of the invention.

[0106] The embodiments described above with reference to the accompanying drawings are for the purpose of explaining the present invention, and the scope of the present invention is not limited to these embodiments.

Claims

1. A method for manufacturing a loess slab with an internal carbonized layer, characterized in that, include: In the ball milling step, loess, clay, and 8 to 20 parts by weight of wood powder relative to 50 to 60 parts by weight of loess are put into a ball mill along with water for ball milling and stirring. The pressure filtration step involves pressing the mixture that has undergone the ball milling step to remove moisture and form a filter cake. A primary drying step, which dries and matures the filter cake that has undergone the pressure filtration step; and a primary maturation step; The pulverizing step involves pulverizing the filter cake that has undergone the first drying and first ripening steps. The forming step involves pressing the powder pulverized in the crushing step into a plate shape. A secondary drying step is performed to dry the molded article formed through the molding step. In the firing step, the molded article dried in the second drying step is heated in a chamber at a temperature of 760°C to 860°C for 50 to 60 minutes. as well as The coating step involves applying a coating liquid to the surface of the loess slab that has undergone the firing step. The coating solution in the coating step is... To a ratio of 1 to 5 parts by weight of surfactant, mix 0.1 to 0.5 parts by weight of glycerol. It is composed of 20-30 parts by weight of the surfactant-glycerol mixture mixed with 100 parts by weight of water and diluted.

2. The method for manufacturing loess slabs with an internally formed carbonized layer as described in claim 1, characterized in that, In the ball milling step, 15 to 25 parts by weight of illite are further added to the ball mill relative to 50 to 60 parts by weight of loess.

3. The method for manufacturing loess slabs with an internally formed carbonized layer as described in claim 1, characterized in that, In the pulverizing step, the filter cake that has undergone the first maturation is pulverized to a particle size of 50 to 70 mesh.

4. The method for manufacturing loess slabs with an internally formed carbonized layer as described in claim 1, characterized in that, In the secondary drying step, the molded article is dried to a moisture content of 7% to 12%.

5. The method for manufacturing loess slabs with an internally formed carbonized layer as described in claim 1, characterized in that, The coating solution is, A sodium silicate dilution is prepared by mixing 10-20 parts by weight of sodium silicate with 100 parts by weight of water. It is prepared by mixing 5 to 10 parts by weight of the sodium silicate dilution with 10 to 20 parts by weight of the surfactant-glycerol mixture.

6. A loess slab with an internal carbonized layer, characterized in that, Manufactured by the manufacturing method according to any one of claims 1 to 5.

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