JP2002370219A - Method for manufacturing ceramic industry product - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a ceramic industry product capable of manufacturing the product having excellent dimensional accuracy while realizing a low manufacturing cost. SOLUTION: The method for manufacturing the ceramic industry product comprises (a molding step S3) of obtaining a first green body 5 by a dry press molding process, (a cutting step S4) of obtaining a second green body 6 by cutting the first green body 5, and (a baking step S6) of obtaining a tile 7 by baking the second green body 6.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

[0001] The present invention relates to a method for producing a ceramic product. This manufacturing method is particularly suitable for use in manufacturing large tiles.

[0002]

2. Description of the Related Art A general method for manufacturing ceramic products such as tiles includes a forming process of forming ceramic raw materials to obtain a green body of a predetermined shape, and a firing process of firing the green body to obtain a ceramic product. Have. Then, in order to make the final product a desired size, a cutting step of cutting the ceramic product after the firing step may be also employed.

For example, large tiles used for building walls and floors are required to have high dimensional accuracy, so that a cutting step may be performed on the tiles after the firing step for dimensional adjustment. In addition, such a large-sized tile is not only constructed as one complete building material board, but may be cut and constructed according to a construction site, and therefore, a cutting step may be performed for this purpose. . In this cutting step, a cutting means such as a diamond cutter is used. Then, the large tile after cutting is shipped as a final product.

[0004]

However, when cutting a ceramic product obtained by firing a green body as described above, the cutting means is liable to wear, and the cutting process requires a long time and a large amount of energy is required. Becomes Further, in this case, a part of the fired ceramic product is removed by cutting, so that a part of the energy required for firing is wasted. This has led to an increase in manufacturing costs.

[0005] In this regard, it is considered that the above problem can be solved by cutting at the stage of green substrate. As such an example, it is known that a cutting process is performed on a first green body extruded by a vacuum extruder or the like, and a second green body after the cutting is fired to obtain a ceramic product as a final product. (JP-A-8-72036). In this case, since the cutting step is performed at the stage of the first green body where cutting is easy, the cutting means is less likely to be worn, and the cutting step can be completed in a short time to reduce the energy required for cutting. Further, in this case, since the fired ceramic product can be used as the final product as it is, part of the energy required for firing is not wasted. Therefore, the manufacturing cost can be reduced.

However, in this production method, since the extrusion molding method is employed, it is necessary to increase the water content of the ceramic raw material to impart plasticity. For this reason, when the second green body is fired, the shrinkage becomes large, and it is difficult to obtain a ceramic product having excellent dimensional accuracy.

SUMMARY OF THE INVENTION The present invention has been made in view of the above-mentioned conventional circumstances, and has an object to provide a manufacturing method capable of manufacturing ceramic products having excellent dimensional accuracy while realizing a low manufacturing cost. Tasks to be done.

[0008]

Means for Solving the Problems The inventors of the present invention have made intensive studies to solve the above problems, obtained a first green body using a dry press molding method, and cut the first green body. Thus, the inventors have found that the above-mentioned problems can be solved, and have completed the present invention.

That is, the method for producing a ceramic product of the present invention comprises a forming step of forming a ceramic raw material to obtain a green body, and a firing step of firing the green body to obtain a ceramic product. At

In the forming step, a first green body is obtained by a dry press forming method, and after the forming step, a cutting step of obtaining a second green body by cutting the first green body by a cutting means is performed. In the step, the second green body is fired to obtain the ceramic product.

In the method for manufacturing a ceramic product of the present invention, a cutting step is performed on the first green body obtained by the dry press molding method. Therefore, as compared with the case where cutting is performed after firing, the cutting means is less likely to be worn, and the cutting step can be completed in a short time to reduce the energy required for cutting.
And in this manufacturing method, the second green body after the cutting step can be fired to obtain a ceramic product. For this reason, since the fired ceramic product can be used as the final product as it is, part of the energy required for firing is not wasted. For this reason, in this manufacturing method, it is possible to reduce the manufacturing cost.

Further, in this manufacturing method, since the dry press molding method is employed, the first green body having a low moisture content can be molded. For this reason, the moisture content of the second green body is low, and the shrinkage ratio when firing the second green body is small, so that the ceramic product can maintain high dimensional accuracy. In addition,
When the first green body is removed from the press mold, even if the first green body expands (so-called demold expansion), it is possible to correct the expansion by cutting the first green body. The dimensional accuracy of ceramic products does not deteriorate.

Therefore, according to this manufacturing method, a ceramic product having excellent dimensional accuracy can be manufactured while reducing the manufacturing cost.

The method for producing a ceramic product of the present invention can be performed with or without glazing on the first green body in the cutting step, but it is preferable that the glazing is not performed. In this case, the glaze is not mixed into the soil and the cutting powder because the glaze is generated in the cutting process, so that the use efficiency of the glaze is increased.

In the method for producing a ceramic product of the present invention, it is preferable that a plurality of second green bodies are obtained from one first green body in the cutting step. In this case, since a plurality of second green bodies are obtained after one molding step, the cost of the molding step can be reduced. Further, in order to obtain a plurality of second green bodies from the homogeneous first green ground, physical properties such as water content and composition of each second green body can be made uniform, and the second green ground is fired. The resulting ceramic products also have stable quality.

Further, the method for producing a ceramic product of the present invention comprises:
As the cutting means, a plurality of cutting blades can be employed. If this is the case, a plurality of second
It is possible to obtain a green body at the same time, and it is possible to reduce the cost required for the cutting step. Also, in this case,
The first green body is cut while being fixed between the cutting blades. For this reason, it is not necessary to provide a fixing means for fixing the first green body, and it is possible to reduce the manufacturing cost by simplifying the equipment, and to stably finish the cutting process to obtain a high quality second metal.
It is possible to obtain raw materials and, consequently, high quality ceramic products.

In this case, it is preferable that the distance between the cutting blades can be adjusted. In this case, a second green body having an arbitrary shape can be obtained, and a ceramic product having an arbitrary shape can be obtained.

[0018]

Embodiments of the present invention will be described below. According to each process shown in FIG. 1, it implemented as follows.

<Adjustment of Tile Raw Material> First, a mixture 1 having the following mixing ratio (parts by mass) is prepared. Talc: 50 Feldspar: 25 Clay: 12 Aggregate: 10 Moisture: 6

The mixture 1 is pulverized by a wet mill (step S1), and the obtained slurry 2 is spray-dried and granulated by a spray drier (step S2). Thus, a clay 3 having a water content of 4 to 8% by mass and a secondary average particle size of 500 μm is obtained. The kneaded clay 3 is used as a ceramic raw material 4 for tiles.

<Molding Step> The ceramic raw material 4 is filled into a press die of a large press molding machine, and a plate-shaped first green body 5 having a thickness of 1300 mm × 1300 mm and a thickness of 25 mm is formed under a pressure of 3.2 × 10 ⁷ Pa. Obtain (step S3).

<Cutting Step> The first green body 5 is cut by the following method (step S4). A cutting wheel 20 for cutting as a cutting blade shown in FIGS. 2 and 3 is prepared. The cutting wheel 20 is composed of a disk-shaped main body 21 having a thickness of 2 mm and a boss 2.
And 2.

As shown in FIGS. 2 and 3, the peripheral surface 23 of the main body 21 is formed in an arc shape that is continuous with both end surfaces and expands radially outward. The boss portions 22 are provided concentrically on both end surfaces of the main body 21.

As shown in FIG. 3, each of the outer peripheral surfaces of the boss portion 22 is continuous with the peripheral surface 23 of the main body 21 and is a chamfered surface 22a formed by a concave surface having a curvature R inward in a radially inward direction. It has been.

Abrasive grains 24 of 100 mesh under diamond are electrodeposited on the periphery including the peripheral surface 23 of the main body 21 and the chamfered surface 22a of the boss portion 22.

As shown in FIG. 4, a cutting wheel having no chamfered surface can be used for each outer peripheral surface of the boss portion 22 '.

As shown in FIG. 5, the cutting wheel 20
And another cutting wheel 20 ′ provided on both sides of the cutting wheel 20 are fixed at fixed intervals to a shaft connected to the rotating shaft of the motor. The cutting wheel 20 'has no boss portions 22 of the cutting wheel 20. The cutting wheel 20 and the cutting wheel 20 'can be independently moved in the axial direction, and can be fixed at any position.

Then, by rotating around the axis parallel to the surface of the first green body 5 to bring the relative position between the first green body 5 and the grinding wheel 20 close, as shown in FIGS. The cutting and chamfering of the first green body 5 are performed simultaneously. Thus, a 300 mm × 300 in which the chamfer 6 a is formed at one corner of the upper surface as shown in FIG.
A plurality of mm-shaped tile-shaped second green bodies 6 are cut out (step S4). At this time, since the peripheral surface 23 is formed in an arc shape bulging in a radially outward direction, the first green body 5 is not easily chipped.

When the grinding wheel 20 'having no chamfered surface shown in FIG. 4 is employed, a second green body having no chamfer is obtained.

<Glazing Step> The second green body 6 is glazed (step S5).

<Baking process> Glazed second green body 6
Is fired (step S6).

<Inspection Step> The obtained tiles are inspected for color misregistration, shape, contamination, etc. (step S7).

<Drilling Step> The tile after inspection is drilled for mounting to obtain a tile 7 (step S8).

As described above, in the method for manufacturing the tile of this embodiment, the first green body 5 obtained by the dry press molding method is used.
Is subjected to a cutting step S4. Therefore, as compared with the case of cutting after firing, the cutting wheel 20 and the cutting wheel 20 'are less likely to be worn, and the energy required for cutting can be reduced by completing the cutting step S4 in a short time. . In this manufacturing method, the second green body 6 after the cutting step S4 is fired to
Can be obtained. Therefore, since the fired tile 7 can be used as a final product as it is, part of the energy required for firing is not wasted. For this reason,
According to this manufacturing method, it is possible to reduce the manufacturing cost.

In this manufacturing method, since the dry press molding method is employed, the first green body 5 having a low moisture content can be molded. For this reason, the moisture content of the second green body 6 is reduced, and the shrinkage ratio when the second green body 6 is fired is also reduced, so that the tiles 7 can maintain high dimensional accuracy.
When the first green body 5 is removed from the press mold, even if the first green body 5 is released from the mold, the expansion can be corrected by cutting the first green body 5. Therefore, the dimensional accuracy of the tile 7 does not deteriorate.

Therefore, according to the manufacturing method of this embodiment, it is possible to manufacture a ceramic product having excellent dimensional accuracy while realizing a low manufacturing cost.

Further, in this manufacturing method, since the first green body 5 is not glazed, it is apt to be generated in the cutting step S4, so that the glaze is not mixed into the soil and the cutting powder, and the utilization efficiency of the glaze is reduced. Is high.

Further, in this manufacturing method, since a plurality of second green bodies 6 are obtained from one first green body 5 in the cutting step S4, a plurality of second green bodies 6 are obtained after one molding step S3. As a result, the cost of the molding step S3 can be reduced. Further, since a plurality of second green bodies 6 are obtained from the first green body 5, the physical properties such as the water content and the composition of each second green body 6 can be made uniform. Tiles 7 obtained by firing the substrate 6
Will also have stable quality.

Further, in this manufacturing method, a plurality of cutting wheel 20 and cutting wheel 20 'are used as cutting blades.
Is employed, a plurality of second green bodies 6 can be obtained simultaneously by the respective grinding wheels 20, 20 ', and the cost required for the cutting step S4 can be reduced. In this case, the first green body 5 is cut while being fixed between the cutting wheel 20 and the grinding wheel 20 '.
It is not necessary to provide a fixing means for fixing the material, the production cost can be reduced by simplification of the equipment, and the cutting process S4 is stably completed, so that the second raw material 6 of high quality, and thus high quality Can be obtained.

In this manufacturing method, the grinding wheel 2 for cutting is used.
Since the distance between the cutting wheel 0 and the cutting wheel 20 'can be adjusted, the second green body 6 having an arbitrary shape can be obtained, and the tile 7 having an arbitrary shape can be obtained.

[Brief description of the drawings]

FIG. 1 is a work process diagram of an embodiment.

FIG. 2 is a cross-sectional view of the grinding wheel of the embodiment.

FIG. 3 is a sectional view of a main part of a grinding wheel for cutting according to the embodiment.

FIG. 4 is a cross-sectional view of a main part of the cutting wheel of the embodiment.

FIG. 5 is a schematic view of a cutting step.

FIG. 6 is a sectional view of a cut portion at the start of cutting the first green body.

FIG. 7 is a cross-sectional view of a cut portion during chamfering of the first green body.

FIG. 8 is a cross-sectional view of a cut portion at the end of cutting and chamfering the first green body.

FIG. 9 is a perspective view of a second green body.

[Explanation of symbols]

 4: Raw material for ceramic industry 5: Green body (first green body) 6: Green body (second green body) S3: Forming process S6: Firing process 7: Ceramic product (tile) S4: Cutting process 20, 20 ': Cutting means , Cutting blade (grinding wheel for cutting)

Continued on the front page (72) Inventor Daiki Fujikawa 5-1-1 Koiehonmachi, Tokoname-shi, Aichi F-term in Inax Co., Ltd. 4G055 AA07 AB01 AC03 BB05 BB12

Claims (5)

[Claims] 1. A method for manufacturing a ceramic product, comprising: a forming step of forming a ceramic raw material to obtain a green body; and a firing step of firing the green body to obtain a ceramic product. After the forming step, a cutting step is performed to obtain a second green body by cutting the first green body by a cutting means. In the firing step, the second green body is fired. A method for producing a ceramic product, comprising obtaining the ceramic product. 2. The method according to claim 1, wherein the first green body in the cutting step is not glazed. 3. The method according to claim 1, wherein in the cutting step, a plurality of second green bodies are obtained from one first green body. 4. The method for producing a ceramic product according to claim 1, wherein the cutting means is a plurality of cutting blades. 5. The method for manufacturing a ceramic product according to claim 4, wherein the distance between the cutting blades is adjustable.