JP2003020266A - Method for producing tile - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for producing a tile by which, in the production of a chamfered tile, the production time can be reduced, and as a result, the production cost can be reduced. SOLUTION: The cutting and chamfering of first green ware 5 are simultaneously performed by using a grinding wheel 20 for cutting.

Description

Detailed Description of the Invention

[0001]

TECHNICAL FIELD The present invention relates to a method for manufacturing tiles.

[Prior art]

[0002] A general method for manufacturing tiles is to form a tile-shaped raw material by molding a ceramic raw material, and calcinate the raw material as necessary to obtain a unglazed product. The raw material or the unglazed product is glazed. It is done and fired to obtain tiles.

When the tile thus obtained is used for a corner portion of a wall surface or a nosing of a stairway, it is preferable that the corner portion of the tile be chamfered. For this reason, conventionally, the corners of the tile after firing have been chamfered by grinding with a grinder or the like. At this time, when it is necessary to adjust the dimensions of the tile after firing, the tile is cut for the dimension adjustment, and then the chamfering is performed. Especially when manufacturing large tiles, the necessity is great.

[0004]

However, in the above-mentioned conventional manufacturing method, after cutting the tile after firing with a cutting member such as a diamond cutter, the corners are ground by using a grinding device such as a grinder. There has been a problem that the manufacturing time becomes long and eventually the manufacturing cost rises.

The present invention has been made in view of the above conventional circumstances, and when manufacturing a chamfered tile,
It is an object to be solved to provide a tile manufacturing method capable of shortening the manufacturing time and eventually realizing a reduction in manufacturing cost.

[0006]

Means for Solving the Problems A method for manufacturing a tile according to the present invention comprises a tile-shaped green body formed by molding a ceramic raw material, a tile-shaped unglazed product formed by calcining the raw material, or the green body or In a method of manufacturing a tile that handles a tile-shaped fired product obtained by firing the bisque-fired product, chamfering is performed simultaneously with the cutting of the green body, the bisque-fired product or the fired product.

According to the method for producing a tile of the present invention, the green substrate,
Since the chamfering is performed at the same time as cutting the unglazed product or the fired product, the manufacturing time of the chamfered tile can be shortened, and the manufacturing cost can be reduced.

In the method of manufacturing a tile according to the present invention, a green body, a unglazed product or a fired product can be adopted as a target to be chamfered simultaneously with cutting. Most preferably, the green body is cut and chamfered at the same time. This is because cutting and chamfering can be performed most easily with a green body.

That is, in the tile manufacturing method of the present invention, a molding step of molding a ceramic raw material to obtain a first green body,
In the case of adopting a tile manufacturing method having a cutting step of cutting the first green body to obtain a second green body and a baking step of baking the second green body to obtain a tile, the cutting step It is preferable to chamfer the second green body simultaneously with the cutting of the first green body. In this case, the time required for cutting and chamfering can be surely shortened, the consumption of the cutting member can be delayed, and the energy required for cutting and chamfering can be reduced. In addition, since the second green body does not have an extra portion removed after calcination or firing, no extra energy is used for calcination or firing.

Next, the case where the biscuit product is cut and chamfered at the same time is preferable. This is because the unglazed product can be cut and chamfered more easily than the baked product. Also in this case, the time required for cutting and chamfering can be shortened, the consumption of the cutting member can be delayed, and the energy required for cutting, chamfering, and firing can be reduced.

On the other hand, when chamfering a fired product at the same time as cutting, even if the fired product is deformed, the shape can be adjusted to a desired shape, and a tile with high dimensional accuracy can be obtained. You can

In the tile manufacturing method of the present invention, it is possible to perform cutting and chamfering with two cutting members, but it is desirable to perform cutting and chamfering with a single cutting member. In the latter case, since it is not necessary to separately prepare a member for cutting and a member for chamfering, it is not necessary to manage each member and it is possible to reduce the size of the cutting device including the cutting member. Therefore, space saving can be achieved.

As a single cutting member, a disc-shaped main body having abrasive grains on at least the periphery thereof is provided concentrically on at least one end face side of the main body, and chamfers can be formed by having abrasive grains. It is possible to employ a grinding wheel for cutting which includes a boss portion having a chamfered surface. When adopting such a grinding wheel for cutting, the cutting wheel is rotated by a motor or the like around an axis parallel to the surface of the green body, the unglazed product or the baked product, and the relative position between the green body and the cutting wheel Grinding of the green body etc. is started by bringing the positions closer. When the grinding is further continued, the chamfer forming surface of the boss portion starts to come into contact with the surface of the green body or the like, and the chamfer is formed by grinding along the chamfer forming surface. In this way, cutting and chamfering of the green body and the like can be performed simultaneously with a single cutting member.

There are no particular restrictions on the type of abrasive grains used in this cutting wheel, but natural diamond, artificial diamond, carborundum, alumina, etc. of various grain sizes can be used as the abrasive grains. Further, the abrasive grains existing on the peripheral edge of the main body of the grinding wheel for grinding and the abrasive grains existing on the chamfer forming surface of the boss portion may be different in kind and particle size. In this case, the cut surface and the chamfered surface can have different finishes.

Further, in the tile manufacturing method of the present invention, it is possible to obtain the second green substrate having an arbitrary shape in the cutting step. In this case, since the second green body can be freely obtained from the single first green body, it is possible to manufacture various types of tiles without changing the molding process.

Further, in the tile manufacturing method of the present invention,
In the cutting step, a plurality of second green substrates can be obtained from one first green substrate. In this case, since a plurality of second green substrates can be obtained after one molding step, the cost required for molding can be reduced. Further, since a plurality of second green substrates are obtained from the homogeneous first green substrate, the physical properties such as the water content and the composition of each second green substrate can be made uniform,
The tile obtained by firing this second green body also has stable quality.

[0017]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments 1 and 2 embodying the present invention will be described below. It implemented as follows according to each process shown in FIG.

(Example 1) <Adjustment of tile raw material> First, the following mixing ratio (parts by mass)
Mixture 1 is prepared. Talc 50 Feldspar 25 Clay 12 Aggregate 10 Moisture 6

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

<Molding Step> Ceramic raw material 4 is filled in a press die of a large-sized press molding machine, and a plate-shaped first green substrate 5 having a thickness of 1300 mm × 1300 mm and a thickness of 25 mm is formed under a pressure of 3.19 × 10 ⁷ Pa. Get (step S3).

<Cutting and Chamfering Step> A grinding wheel 20 for cutting shown in FIGS. 2 and 3 is prepared. This grinding wheel 20 for cutting
Is composed of a disc-shaped main body 21 having a thickness of 2 mm and a boss portion 22.

As shown in FIGS. 2 and 3, the peripheral surface 23 of the main body 21 is formed in an arc shape which is continuous with both end surfaces and bulges radially outward. The boss portion 22 is provided concentrically on both end surface sides of the main body 21. In addition, in the central portion of the main body 21,
The shaft hole 26 is provided, and mounting holes 27 are provided at four positions around the shaft hole 26 so as to be concentric and symmetrical.

Further, as shown in FIG. 3, each outer peripheral surface of the boss portion 22 is continuous from the peripheral surface 23 side of the main body 21, and has a chamfer forming surface 22a formed by a curved surface which is concave radially inward with a curvature R. It is said that.

Abrasive grains 24 made of diamond of 100 mesh under are electrodeposited on the peripheral edge including the peripheral surface 23 of the main body 21 and the chamfer forming surface 22a of the boss portion 22, and a part of each abrasive grain 24 is a surface. Protruding from.

As shown in FIG. 4, the cutting wheel 20 for cutting is used.
And another cutting wheel 20 'for cutting provided on both sides of the cutting wheel 20 for cutting are fixed to the shaft connected to the rotating shaft of the motor at a constant interval. The cutting wheel 20 'for cutting does not have both boss portions 22 of the cutting wheel 20 for cutting.

Then, it is rotated about an axis parallel to the surface of the first green body 5 to bring the relative positions of the first green body 5 and the grinding wheel 20 for cutting close to each other. As a result, as shown in FIG.
The grinding of the first green body 5 is started by the peripheral surface 23 of the main body 21. At this time, since the peripheral surface 23 is formed in an arc shape that bulges radially outward, the first green body 5 is unlikely to be chipped.

When the grinding is further continued, as shown in FIG. 6, the chamfer forming surface 22a of the boss portion 22 starts to come into contact with the surface of the first green body 5, and the chamfering surface 22a is ground along the chamfer forming surface 22a. Is started.

When the grinding is further continued, as shown in FIG. 7, the cutting wheel 20 finishes cutting and chamfering the first green body 5 at the same time. A plurality of 250 mm × 250 mm tile-shaped second green substrates 6 each having a chamfer 6a formed on one corner of the upper surface thereof are cut out (step S4). It should be noted that the grinding wheels 20 and 20 ′ for cutting can be independently moved in the axial direction, and can be fixed at arbitrary positions. Therefore, the second raw green body 6 having an arbitrary shape can be obtained.

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

<Firing process> The second green substrate 6 that has been glazed
Is baked (step S6).

<Inspection Step> The obtained tile is inspected for color misregistration, shape, inclusion of foreign matter, etc. (step S7).

<Hole Machining Step> The tile after inspection is subjected to hole machining for mounting to obtain the tile 7 (step S8).

In the tile manufacturing method of Example 1 performed as described above, the cutting and chamfering of the first green substrate 5 can be performed at the same time, so that the manufacturing time of the chamfered tile 7 can be shortened. Therefore, the manufacturing cost can be reduced.

Further, in this manufacturing method, since the chamfer 6a is formed simultaneously with the cutting in the stage of the first green body 5, the cutting and the cutting are performed as compared with the case where those operations are performed after the calcination or the firing. The time required for chamfering can be surely shortened, the consumption of the grinding wheels 20, 20 'for cutting can be delayed, and the energy required for cutting, chamfering, and firing can be reduced.

Further, in this manufacturing method, since the cutting and the chamfering 6a are performed by the single grinding wheel 20 for cutting, the member for cutting and the member for chamfering are prepared separately. There is no need, and management of each member becomes unnecessary, and the cutting device can be downsized, and space can be saved.

Further, in this manufacturing method, the second raw green body 6 having an arbitrary shape can be obtained in the cutting and chamfering step S4 by adjusting the intervals between the respective grinding wheels 20 and 20 'for cutting shown in FIG. it can. Therefore, the second green body 6 can be freely obtained from the single first green body 5, and various types of tiles 7 can be manufactured without changing the molding step S3.

Further, in this manufacturing method, since it is possible to obtain a plurality of second green substrates 6 from one first green substrate 5, a plurality of second green substrates can be obtained after one molding step S3. 6
Thus, the cost required for molding can be reduced. Moreover, since a plurality of second green substrates 6 are obtained from the homogeneous first green substrate 5, the physical properties such as the water content and the composition of each second green substrate 6 can be made uniform, The tile 9 obtained by firing the base material 6 also has stable quality.

(Example 2) In the tile manufacturing method of Example 2, the cutting wheel 30 for cutting shown in FIG. 9 is used in the steps of cutting and chamfering the first green substrate 5. In this grinding wheel 30 for cutting, each outer peripheral surface of the boss portion 32 is
45 ° with respect to the plane 32a and a plane 32a that is continuous from the peripheral surface 33 side and is perpendicular to the first green body 5 when cut.
Is a chamfer forming surface 34 formed by a plane 32b that intersects with the plane 32b and a plane 32c that intersects the plane 32b at 45 ° and is a plane parallel to the first green body 5 when cut. Abrasive grains 35 are electrodeposited on the peripheral edge of the main body 31 including the peripheral surface 33 and the chamfer forming surface 34 of the boss portion 32, as in the grinding wheel 20 for cutting of the first embodiment. Other configurations are similar to those of the first embodiment.

By cutting the first green substrate 5 by using the grinding wheel 30 for cutting, the second green substrate having a chamfer formed at a plane angle of 45 ° with respect to the upper surface of the first green substrate 5 is cut. The base 6 is obtained. Other functions and effects are similar to those of the first embodiment.

[Brief description of drawings]

FIG. 1 is a work process diagram of Examples 1 and 2.

FIG. 2 is a cross-sectional view of a grinding wheel for cutting according to a first embodiment.

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

FIG. 4 is a schematic diagram of a cutting and chamfering process.

FIG. 5 is a cross-sectional view of the cut portion at the start of cutting the first green body of the first embodiment.

FIG. 6 is a cross-sectional view of a cut portion during chamfering of the first green body of Example 1.

FIG. 7 is a cross-sectional view of the cut portion at the end of cutting and chamfering the first green body according to the first embodiment.

FIG. 8 is a perspective view of a second green body of the first embodiment.

FIG. 9 is a sectional view of a main part of a grinding wheel for cutting according to a second embodiment.

[Explanation of symbols]

4 ... Ceramic raw materials 5, 6 ... Green substrate (5 ... 1st green substrate, 6 ... 2nd green substrate) 6a ... Chamfer 20, 30 ... Cutting member (grinding wheel for cutting) 23, 33 ... Circumferential surface 24, 35 ... Abrasive grains 21, 31 ... Main body 22, 32 ... Boss part 22a, 34 ... Chamfer forming surface 7 ... tiles S3 ... Molding process S4 ... Cutting process (cutting and chamfering process) S6 ... Firing process

Continuation of front page (51) Int.Cl. ⁷ Identification code FI theme code (reference) // B24B 27/06 B24B 27/06 J (72) Inventor Daiki Fujikawa 5-chome, Koiemotocho, Tokoname City, Aichi Prefecture Stock In-company F-term (reference) 3C049 AA02 AA09 CA01 CA04 CB03 CB05 3C058 AA02 AA09 AA18 CA01 CA05 CB05 3C069 AA01 BA04 BB01 BB02 BB04 BC02 CA12 EA01 4G055 AA07 AB01 AC03 BA66 BB12

Claims (6)

[Claims] 1. A tile-shaped green body formed by molding a ceramic raw material, a tile-shaped unglazed product obtained by calcining the raw material, or a tile-shaped baked product obtained by firing the raw material or the ware-baked product. In the method for producing a tile, the method for producing a tile is characterized in that the raw green body, the unglazed product, or the fired product is cut and chamfered at the same time. 2. The method for producing a tile according to claim 1, wherein cutting and chamfering are performed by a single cutting member. 3. A chamfer having a disc-shaped main body, which is concentric with at least one end face side of the main body, and has a disc-like shape, and has chamfers capable of forming chamfers. A grinding wheel for cutting comprising a boss portion having a forming surface, which is carried out while rotating the grinding wheel for grinding around an axis parallel to the surface of the green body, the unglazed product or the fired product. 2. The method for producing a tile according to 2. 4. A molding step of molding a ceramic raw material to obtain a first green body, a cutting step of cutting the first green body to obtain a second green body, and a step of firing the second green body. A method of manufacturing a tile, comprising: a firing step of obtaining a tile; and the second step simultaneously with the cutting of the first green body in the cutting step.
The method for manufacturing a tile according to claim 1, wherein the green substrate is chamfered. 5. The method for manufacturing a tile according to claim 4, wherein a second green body having an arbitrary shape is obtained in the cutting step. 6. The method for manufacturing a tile according to claim 4, wherein a plurality of second green substrates are obtained from one first green substrate in the cutting step.