JP2001315110A - Method and apparatus for manufacturing tile - Google Patents

Abstract

PROBLEM TO BE SOLVED: To manufacture a tile which is decorated in an acute angle-like and distinct rift pattern. SOLUTION: Decorating powder raw materials 5 and 6 stored in a hopper 1 are allowed to flow out from a down side of the hopper. They are formed by pressurizing with two pieces of pressure rolls 7 and 8 arranged below the hopper 1. The sheet-like raw materials 15 are crushed by a crushing means 16 to make a flake-like small piece 15a. After scattering the small pieces 15a on a surface of main raw materials filled in a mold, they are formed by pressurizing to obtain a tile groundwork.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a method and an apparatus for manufacturing a tile.

[0002]

2. Description of the Related Art Conventionally, as a method of decorating a tile surface, a method of mixing a powder material for decoration with a main powder material of a tile and press-forming (first method), a method of decorating a main powder material, and the like. (2nd method), or a method in which glaze is applied to the surface of the formed base material in a fluttering manner. Third method) is known.

[0003]

In the first and second conventional methods, the pattern on the surface of the decorated tile is not blurred and does not have a sharp spot or stone pattern. In the glaze with the fluttering method as described in the above method, it is not possible to obtain an acute shape in the spot pattern.

Accordingly, an object of the present invention is to provide a method and an apparatus for manufacturing a tile having a decorative surface having a sharp acute-angle pattern such as a stone pattern.

[0005]

According to a first aspect of the present invention, a decorative powder material stored in a hopper is caused to flow out from below the hopper,
This was pressed into a sheet by two pressure rolls arranged at the lower part of the hopper, and the sheet-like raw material was crushed by crushing means into flake-like small pieces, and the small pieces were filled in a forming die. This is a method for producing a tile, characterized in that after being sprayed on the surface of a main raw material, these are pressure-formed to obtain a tile base.

According to a second aspect of the present invention, in the first aspect, the inside of the hopper is divided into two by providing a partition plate in the axial direction of the pressure roll, and the two divided tanks are provided. A different kind of powdered raw material for decoration is stored in the container, and the front and back of the sheet-like raw material to be pressed and formed by the two pressure rolls are formed of different kinds of raw material. This is a method for producing a tile in which the small pieces are mixed with each other, and the small pieces are dispersed on the surface of the main raw material.

According to a third aspect of the present invention, in the second aspect, a shield is provided partially in the axial direction of the pressure roll at an opening of one of the tanks of the divided hopper. A method of manufacturing a tile in which a striped pattern is formed on one surface of a sheet-shaped raw material that is pressure-formed by a pressure roll, using one of the decorative powder raw materials that has flowed out from the portion without the shielding material.

According to a fourth aspect of the present invention, there is provided a hopper for storing a decorative powder material, and the decorative powder material disposed below the hopper and flowing out of the hopper is formed into a sheet. Two pressure rolls to be pressure-formed, crushing means disposed below the pressure roll and crushing the sheet-like raw material pressed by the pressure rolls into flake-shaped small pieces, and the crushed A tile manufacturing apparatus comprising: a belt conveyor that conveys and scatters the flake-shaped small pieces to the surface of the main raw material in a molding die.

According to a fifth aspect of the present invention, there is provided a tile manufacturing apparatus according to the fourth aspect, wherein the inside of the hopper is divided into two by a partition plate arranged in the axial direction of the pressure roll.

According to a sixth aspect of the present invention, in the fifth aspect, the opening of one of the two tanks divided by the partition plate is partially shielded in the axial direction of the pressure roll. This is a tile manufacturing device.

A seventh aspect of the present invention is the tile manufacturing apparatus according to the fourth to sixth aspects, further comprising a gap adjusting means for adjusting a gap length between the two pressure rolls.

[0012]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described based on an embodiment shown in the drawings.

FIGS. 1 to 9 show a first embodiment.

In FIGS. 1 to 5, reference numeral 1 denotes a hopper for storing a powder material for decoration, and a belt in the tank is formed by a partition plate 2 arranged in the axial direction of pressure rollers 7 and 8 described later. It is divided into two parts in the moving direction of the conveyor 23.
Different powder materials for decoration 5 and 6 are stored in the divided one tank 3 and the other tank 4, respectively. Openings 3a and 4a at the lower ends of the two tanks 3 and 4 are described later. Pressure rolls 7, 8
It is elongated in the axial direction.

Below the openings 3a and 4a, a pair of pressure rolls 7 and 8 are arranged in parallel, and their opposing gaps are arranged at appropriate intervals, for example, at intervals of about 0.2 mm to 0.5 mm. Are located. The pressure rolls 7 and 8 are rotatably supported by the brackets 9 and 10 (the pressure roll 7 side can also move in the horizontal direction), and as shown in FIGS. These pressure gears are meshed with each other, and when one of the pressure rolls is rotated by a driving means 13 such as a motor, both pressure rolls 7 and 8 are moved in the direction of the arrow shown in FIGS. To rotate. Then, the two pressure rolls 7, 8
By rotating the hopper 1, as shown in FIG.
The two powder materials for decoration are formed by pressing with both pressure rolls 7 and 8 in a state where one of them is disposed on the front side and the other is disposed on the back side, and is supplied in the form of a sheet. . The decorative sheet material is denoted by reference numeral 15.

The one pressure roll 7 is provided with a gap adjusting means 14 for pressing the same against the other pressure roll 8 to generate the predetermined gap. The means 14 is provided on the shaft of the one pressure roller 7 and has a rotating pin 14a.
A lever 14b provided to be swingable to the other pressure roller 8 side with the center as a center, and a hydraulic cylinder 14d for pressing the lever 14b toward the other pressure roller 8 side with a projection 14c formed on the lever 14b. A stopper 14e is provided on the opposite side of the hydraulic cylinder 14d to be engaged with the projection 14c. Further, the stopper 14e is formed so as to be able to advance and retreat, and is formed by screwing an adjustment screw 14g into the fixed arm 14f in the example of the drawing. In this configuration, the stopper 14
3 can be adjusted in the left-right direction in FIG. 3 to adjust the gap between the two pressure rolls 7 and 8.
If an abnormal pressure occurs during this time, the rod 14h of the hydraulic cylinder 14d is pushed rightward in the drawing to absorb the abnormal pressure.

A crushing means 16 for crushing the supplied decorative sheet material 15 is provided below the pressure rolls 7 and 8. As shown in FIGS. 2 to 4, the crushing means 16 is disposed in parallel with the axial direction of the pressure rolls 7, 8, and has a pair of rotating shafts 17 rotatably provided on the brackets 9, 10. A large number of crushing rods 19 and 20 are radially protruded from 18. Furthermore,
The pair of rotating shafts 17 and 18 are connected to the shafts of the pressure rolls 7 and 8 by belts 21 and 22, and the two rotating shafts 17 and 18 are interlocked with the two pressure rollers 7 and 8 in FIG. It rotates in the direction of the arrow. In addition, both crushing rods 1
9 and 20 make the sheet material 15 for decoration into a predetermined size, for example, 5 mm to 20 mm by these rotations.
They are meshedly opposed to each other so as to be crushed into small flake-like pieces 15a having a size.

Below the crushing means 16, there is provided an upper belt conveyor 23 arranged to move in a direction perpendicular to the axial direction of the pressure rolls 7, 8 and the rotating shafts 17, 18. The upper belt conveyor 23 moves forward (in the direction of arrow A) and retreats (in the direction of arrow B) of the entire drive roll 24 and belt 25 by moving means (not shown).
The belt 25 is rotated by a driving roll 24 in the direction of arrow C.

The lower side of the upper belt conveyor 23 is shown in FIG.
The lower belt conveyor 26 is arranged as shown in FIG.
The lower belt conveyor 26 is also the upper belt conveyor 23.
Similarly, the entire drive roll 27 and belt 28 are moved forward (in the direction of arrow A) and retracted (in the direction of arrow B) by moving means (not shown).
The belt 28 is rotated by a drive roll 27 in the direction of arrow C.

As shown in FIG. 1, a molding die 29 is arranged on the lower belt conveyor 26 in the forward direction.

The molding die 29 comprises a mold frame 31 forming a molding chamber 30, a lower die 32, an upper die 33, and a charger 34 for charging a main raw material.

Next, a method of manufacturing a tile will be described with reference to FIG.

As shown in FIG. 6A, the two belt conveyors 23 and 26 are stopped at the origin position, and the flake-shaped small pieces 15a crushed in the previous process are placed on the belt 25 of the upper belt conveyor 23. First, FIG. 6
The belt 25 of the upper belt conveyor 23 as shown in FIG.
Is rotated in the direction of arrow C, and the entire upper belt conveyor 23 is retracted in the direction of arrow B. As a result, the flake-shaped small pieces 15a placed on the belt 25 of the upper belt conveyor 23 are removed from the belt 2 of the lower belt conveyor 26.
Secondary spraying on 8 is started. And FIG.
As shown in (c), when the secondary spraying of the small pieces 15a on the belt 25 of the upper belt conveyor 23 to the belt 28 of the lower belt conveyor 26 is completed, the upper belt conveyor 2
3 retreat is completed.

On the other hand, in the molding die 29, the charger 34 advances and the lower die 32 descends, so that the main raw material 35 of the tile is filled in the molding chamber 30.

Next, as shown in FIG. 7, the two pressure rolls 7, 8 rotate in the direction of the arrow, and the two tanks 3, 4 of the hopper 1 are rotated.
, For example, differently colored powdery raw materials 5, 6 of different colors are formed into a sheet by pressure. As shown in FIG. 5A, the sheet-shaped raw material 15 is formed into a sheet shape composed of different types of raw materials 5 and 6 under pressure, and is supplied downward.

When the sheet material 15 is supplied, the crushing rods 19 and 20 of the crushing means 16 rotate in the direction of the arrow, and the supplied sheet material 15 is flaked into small pieces 15.
Crush to a. The flake-shaped small pieces 15a are naturally formed of the decorative powder raw materials 5 and 6 having different front and back surfaces.

At the same time as the flakes 15a are crushed into pieces, the upper belt conveyor 23 moves forward in the direction of arrow A, and the crushed pieces 1
Primary spraying of 5a is performed.

Further, the lower belt conveyor 26 also advances primary in the direction of arrow A, and the charger 34 retreats to complete the filling of the main raw material 35.

Further, as shown in FIG. 8A, when the advance of the upper belt conveyor 23 is completed, the primary dispersion of the small pieces 15a on the belt 25 is completed, and the advance of the upper belt conveyor 23 is stopped. The crushing means 16 also stops. Further, the lower belt conveyor 26 starts the secondary advance, and its tip reaches the molding chamber 30 of the molding die 29, and the belt 28 rotates in the direction of the arrow to move the small pieces 15 a from the lower belt conveyor 26 into the molding chamber 30. To start spraying the small pieces 15 a on the upper surface of the main raw material 35.

Further, as shown in FIG. 8 (b), the lower belt conveyor 26 advances secondarily while rotating the belt 28, and scatters the small pieces 15a on the belt 28 over the entire surface of the main raw material 35. And complete the spraying.

Next, when the scattering of the small pieces 15a on the main raw material 35 is completed, as shown in FIG.
Retreats, and in the molding die 29, the upper die 33 descends to press the main raw material 35 in the molding chamber 30 and the decoration small pieces 15a scattered thereon, thereby pressing the tile base. Molding.

After the pressure molding, the upper mold 33 and the lower mold 32 are lifted and demolded, and the molded tile base is taken out.

As described above, the state returns to the state shown in FIG. 6A, and thereafter, the above steps are repeated.

As described above, the flake-like small pieces 15a sprayed on the main raw material 35 are obtained by crushing the sheet-like raw material 15 by the crushing means 16 as described above. As shown in (b), the small pieces 15a have a sharp pattern and the boundary with the main material 35 is clear. For this reason, the surface of the main raw material 35 is decorated with a small sharp spot pattern and a sharp pattern, and becomes a stone pattern.

Further, as described above, the flake-shaped small piece 1
5a from the upper belt conveyor 23 to the lower belt conveyor 26
To the upper belt conveyor 23
A part of the large number of small pieces 15a is turned over and transferred onto the lower belt conveyor 26. In addition, when it is sprayed onto the main raw material 35 from the lower belt conveyor 26, the same is reversed. Therefore, as shown in FIG. 5 (b), the surface made of one of the decorating powdery raw materials 5 has an upward facing small piece 15a.
And the small piece 15a whose surface made of the other powder material 6 for decoration is upward is mixed and scattered on the main material 35.

FIGS. 10 to 13 show a second embodiment.

In this embodiment, one of the tanks 3 and 4 in the hopper 1, for example, the opening 4 a of the tank 4 is
The shielding material 40 is partially provided in the longitudinal direction, and the decorative powder material 6
And as shown in FIGS. 11 and 12 (a),
A striped (streaked) pattern composed of the decorative powder material 6 is formed on one surface of the sheet material 15.

Other structures and manufacturing methods are the same as those in the first embodiment.

In the second embodiment, the sheet material 15 formed as shown in FIG.
As shown in FIG. 12 (b), the flakes 15a having a stripe (streak) pattern
Is formed. FIG. 13 shows a tile base formed by spraying such small pieces 15a on the main raw material 35 and pressing.

In both of the above embodiments, two kinds of decorative powder raw materials 5 and 6 are used.
One kind of decorating powder material is stored in the hopper 1 without providing the partition plate 2 in the sheet material, and as shown in FIG. May be formed and crushed as described above, and as shown in FIG. 14 (b), the surface of the main raw material may be decorated with flake-shaped small pieces 15a made of one type of raw material.

[0041]

As described above, according to the first aspect of the present invention, the powder material for decoration is formed into a sheet by pressure, and this is crushed into flake-like small pieces to form a flake on the main material. The surface of the main raw material is decorated in a stone pattern with sharp, small and sharp small pieces, so that a tile having an unconventional decorative surface can be manufactured.

According to the second aspect of the invention, the flake-shaped small pieces are made of decorative powder raw materials having different front and back surfaces, and these are dispersed on the main raw material with their front and back surfaces intermingled. As a result, the tile surface can be made into various decorative surfaces.

According to the third aspect of the present invention, on one surface of the flake-shaped small piece, stripes (streaks) of one of the powdery materials for decoration are provided.
Since the shape of the tile is formed, the tile surface can be made into a more various decorative surface.

According to the fourth aspect of the invention, it is possible to provide a tile manufacturing apparatus applicable to the manufacturing method of the first aspect.

According to the fifth aspect of the invention, it is possible to provide a tile manufacturing apparatus applicable to the manufacturing method of the second aspect.

According to the invention described in claim 6, it is possible to provide a tile manufacturing apparatus applicable to the manufacturing method described in claim 3.

According to the seventh aspect of the present invention, the thickness of the decorative sheet material can be further adjusted.

[Brief description of the drawings]

FIG. 1 is a schematic side sectional view showing a first embodiment of the present invention.

FIG. 2 is a schematic side sectional view showing a hopper section, a pressure roller section, crushing means, and an upper belt conveyor section in FIG.

FIG. 3 is a side view of FIG. 2;

FIG. 4 is a view as seen from the left side in FIG. 3;

5 (a) shows a cross section of a sheet-like raw material formed by pressure using a pressure roll in the embodiment of FIG. 1, and FIG. 5 (b) shows a flake-crushed small piece.

6 (a) to 6 (c) are views showing a state in which the upper belt conveyor is retracted and small pieces are transferred to the lower belt conveyor in the manufacturing process of the tile in the embodiment shown in FIG.

FIG. 7 is a view showing a step of crushing a sheet-like raw material into flakes in the same tile manufacturing process.

8 (a) and 8 (b) are views showing a process of dispersing flake-like small pieces on a main material by a lower belt conveyor in the same manufacturing process.

FIG. 9 is a diagram showing a state in which the lower belt conveyor is retracted and the main raw material and the small pieces are pressed by a molding die in the same tile manufacturing process.

FIG. 10 is a side sectional view of a main part showing a second embodiment of the present invention.

FIG. 11 is a perspective view showing a state in which a striped sheet-like raw material is pressure-formed according to the embodiment of FIG. 10;

12A is a view showing a sheet-like raw material in a cross section taken along line XX in FIG. 11, and FIG. 12B is a view showing a flake-like small piece obtained by crushing the sheet-like raw material.

FIG. 13 is a perspective view showing a tile base obtained by spraying the small pieces of FIG. 12 (b) on a main material.

14A is a view showing a sheet-like raw material formed in a third embodiment of the present invention, and FIG. 14B is a view showing flake-like small pieces obtained by crushing the raw material.

[Explanation of symbols]

 Reference Signs List 1 hopper 2 partition plate 3, 4 tank 5, 6 decorative powder material 7, 8 pressure roll 14 gap adjusting means 15 sheet material 15 a flake-shaped small piece 16 crushing means 23, 26 belt conveyor 29 molding die 35 main material

Claims (7)

[Claims] 1. A decoration powder material stored in a hopper is discharged from below the hopper, and is formed into a sheet by two pressure rolls disposed at a lower portion of the hopper.
The sheet-shaped raw material was crushed by crushing means to form flake-like small pieces, and the small pieces were sprayed on the surface of the main raw material filled in the mold, and then these were pressure-formed to obtain a tile base. A method for producing a tile, comprising: 2. The interior of the hopper is divided into two parts by providing a partition plate in the axial direction of the pressure roll, and different decoration powder materials are stored in the two divided tanks. The front and back of a sheet-shaped raw material formed by pressing with a pressure roll are formed of different kinds of raw materials, and the sheet-shaped raw material is crushed into flake-shaped small pieces. The tile manufacturing method according to claim 1, wherein the tile is scattered on the surface of the tile. 3. A shielding material is partially provided in the opening of one of the tanks of the divided hopper in the axial direction of the pressure roll, and is provided on one surface of a sheet-like raw material formed by pressure with the pressure roll. 3. The method for manufacturing a tile according to claim 2, wherein a striped pattern is formed by one of the decorative powder materials flowing out of the portion without the shielding material. 4. A hopper for storing a powder material for decoration,
Two pressure rolls disposed at a lower portion of the hopper to press-form the decorative powder material flowing out of the hopper into a sheet shape; and a pressure roll disposed at a lower portion of the pressure roll. Crushing means for crushing the sheet-like raw material pressed in the above into flake-like small pieces, and a belt conveyor for conveying and scattering the crushed flake-like small pieces to the surface of the main raw material in the molding die. Characteristic tile manufacturing equipment. 5. The tile manufacturing apparatus according to claim 4, wherein the inside of the hopper is divided into two by a partition plate arranged in an axial direction of the pressure roll. 6. The tile manufacturing apparatus according to claim 5, wherein an opening of one of the tanks divided by the partition plate is partially shielded in the axial direction of the pressure roll. 7. The tile manufacturing apparatus according to claim 4, further comprising a gap adjusting means for adjusting a gap length between the two pressure rolls.