Chalkboard

Chalkboard: The Chalkboard is a Flat, Vertical writing surface on which anything can be inscribed by means of a Piece of Chalk. The device is generally used for Educational purposes, but it can also be found in the Workplace, the Home, and Restaurants. While Chalkboards can be Manufactured from a Variety of Materials, Porcelain Enamel is the most common Material used in today Chalkboard.

Reading Board: Eventually the Hornbook evolved into the Reading Board. This was a Strip of about 15 inches (38 cm) in Length, also Containing the Alphabet and other Learning Aids, that was Hung at the front of the late 18th Century Classroom. From the Reading Board came the Concept of one general Chalkboard for all students in the Classroom to both view and use.

Raw Materials: Most modern Chalkboards are made of Porcelain Enamel. In this Particular Manufacturing Process, a tough and durable material such as Steel is used as the base. There are Several Thicknesses of Steel used in the Manufacture of Chalkboards, but the most Common is 22 gauge. Another Crucial Element is Silica, a Crystalline Compound Derived from Quartz or Similar Minerals. Found in the Crust of the Earth, Silicon is a tough compound and is called Silica when Combined with Oxygen. Silica is found in most Rocks and is a Common Ingredient in many Glass and Ceramic Products. The Surface of a Chalkboard is usually a Blend of Inorganic Compounds such as a Powdered Glass Opacifier and Oxides, an Organic Element that Provides color to the Coating Material.

Design: Chalkboards can be Manufactured in a variety of Sizes, Styles, and Colors. The most common Hues are Green and Black, although Shades of Brown, Blue, and Gray are also available. They can be customized during the Manufacturing Process to include Special Graphic Elements. A music Department of a College or University, for Example, Chalkboard might request Classroom Chalkboards with Musical Staffs imprinted on the surface.

The Manufacturing Process:

Preparation of Steel: The Manufacture of Chalkboards begins when Large Sheets of Steel in Desired Sizes enter the Manufacturing Facility from an Outside Supplier. This Steel is Cold Rolled and Inspected for Irregularities upon Arrival. Next, the Large Sheets are sent into a Chemical Washer. This Chamber Washes, Rinses, and Dries the Steel. When this Step is completed, the Steel is again inspected for Flaws and Imperfections.

Applying slip: Next, a slip is applied to the Sheets of Steel. A slip is a mixture of Clay or another Organic Compound applied to a Surface During the Manufacture of Porcelain or other Ceramics. In this case, the slip is usually made from Silica, and applied to both sides of the Steel Sheet by Passing it through a Coating chamber. The Coating must be at least 0.0025 inches (.062 mm) thick. The Slip is set aside to Dry. The Sheets once again pass through an inspection Process before they are Transferred to the ground Coat Furnace area.

Firing: This ground Coat area of the Manufacturing Facility Typically houses a Large Furnace Chamber. The Sheets of Steel are fed into the Chamber and subjected to high Temperatures. This Softens the Steel and allows Fusion of the Slip with the Steel. This is a Crucial Step in all Porcelain Manufacturing and Fabrication of Industrial Ceramics.

Applying Surface Compounds: Once the newly Porcelained Material Leaves the Furnace, it is treated with a Surface Coating compound. Typically, this compound is Derived from Glass Opacifiers and imparts a Smoother Texture to the Board. Oxides for Color may also be added. Again, this Coating must be at least 0.0025 inches (.062 mm) thick. The boards are once again Sent to a Drying area. After they are Completely Cooled and Dried, they are once again inspected for Surface Blemishes and Uniformity of Color.

Fusing the Coats: Next, the Boards are Placed in a Cover Coat Furnace. The Purpose of this Heating Process is to Fuse the first ground Coat with the Surface Coat. A Temperature of at least 1200°F (649°C) is Needed to Successfully Complete this Process. Next, the Chalkboards are Passed through a Cooling Chamber, which gradually reduces the Temperature of the Steel so that the Flat Sheets do not Buckle or Weaken, which might occur if left to Cool by Themselves.

Final surface preparation: Next, the surface of the Chalkboard is laminated onto a fiberboard. This backing Material must be at least 0.44 (11 mm) inch Thick. A special Adhesive is used for this application. In the next few steps, the Finishing Touches are put on the board. A wood or Aluminum Trim is added to the Edges to make a Border, and Accessories such as Chalktrays, Map Rails and Hooks, and Flag Holders are attached.

Quality Control: The Manufacturing of Porcelain Enamel Chalkboards falls under the Category of industrial Ceramics, and Manufacturers of the product adhere to Standards set by the Porcelain Enamel Institute. One important Guideline of this Organization is its Gloss Standard. This is measured by a 45 degree Gloss Meter. According to the Specifications, the gloss of a Chalkboard cannot exceed three units as Measured by the Meter. This assures Uniformity of Writing Surface. Further Quality Specifications as to Durability are also Detailed in Porcelain Enamel Institute Guidelines.

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