METHOD TO MANUFACTURE FOAM-CERAMIC PRODUCTS WITH FACING LAYER Russian patent published in 2014 - IPC C04B38/02 B32B18/00 

FIELD: construction.

SUBSTANCE: in this method to manufacture foam-ceramic products with a facing layer, including preparation of slurry and foam, their mixing to produce a foam-ceramic mass, moulding of products, drying and baking, from the slurry they additionally produce a press powder by dehydration of the slurry in a tower spray dryer to moisture of 4-9 wt % with subsequent delay for averaging by moisture for 46-48 hours, and products are manufactured as multi-layer, containing external layers: facing one and substrate one, with an aerated ceramic layer placed between them; besides, external layers are made from press powder by means of sheets moulding from it with thickness from 0.5 to 5 mm at specific pressing pressure within 300-500 kg/cm², and the internal aerated layer is made from foam-ceramic mass mineralised with previously ground press powder to produce a plastic foam mass with moisture of 16-23 vol % and subsequent moulding of plates from it with thickness from 10 to 50 mm; then moulded external and internal layers are exposed to drying to zero moisture, and at the outlet from the dryers - laying onto each other to create a multi-layer structure, besides, between the upper and lower external layers they place from 2 to 10 plates of the aerated layer, afterwards all layers laid into a stack are exposed to baking until they are sintered with each other at temperature of 1200-1250°C for 50-100 min, at the same time prior to baking the upper face layer is decorated by ceramic dyes or glazes by the method of digital printing.

EFFECT: manufacturing of foam-ceramic products with a facing layer and improved heat-protective properties due to manufacturing of an aerated layer of any required thickness inside external finishing layers.

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