JP2004181754A - Method for producing ceramic product different in touch of both surfaces - Google Patents
Method for producing ceramic product different in touch of both surfaces Download PDFInfo
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- JP2004181754A JP2004181754A JP2002350914A JP2002350914A JP2004181754A JP 2004181754 A JP2004181754 A JP 2004181754A JP 2002350914 A JP2002350914 A JP 2002350914A JP 2002350914 A JP2002350914 A JP 2002350914A JP 2004181754 A JP2004181754 A JP 2004181754A
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Abstract
Description
【0001】
【発明の属する技術分野】
本発明は一般に、窯業製品の製造方法に関する。より詳細には、本発明は、両面の風合いが異なる窯業製品の製造方法に関する。なお、本発明における窯業製品には、レンガ、タイルの他、ブロック材、かわら材などが含まれる。また、語「風合い」は、色、粗度、手触り、風化度などを意味する。
【0002】
【従来の技術】
典型的な窯業製品であるレンガには、表面と裏面があり、表面を使用可能な面として製造するため、一般的には、裏面に一定の風合いを持たせるように製造することはない。また、タイルは、裏面が接着専用面として用いられるため、そもそも裏面に風合いを持たせるという発想がない。さらに、他の窯業製品も、裏面を使用できるようには製造されていない。
【0003】
【発明が解決しようとする課題】
本発明は、窯業製品に関するこのような現状に鑑みて、案出されたものであって、両面の風合いが異なる窯業製品を供給することによって、住宅購入者には施工直前まで外壁の変更が可能であり、住宅建築業者にとっては在庫管理が容易になる等の種々の利点を提供することを企図したものである。
【0004】
【課題を解決するための手段】
本発明者は、ワイヤで切断した原材料のピースを平積みから縦積みに積み替えて強制乾燥させると、乾燥による原材料の収縮によって、ピース間に好ましい隙間が発生し、この状態で原材料を焼成することによって、両面の風合いが異なる窯業製品を容易に製造することができることを見い出した。
【0005】
本願請求項1に記載の、原材料を成型する成型工程と、成型された原材料を乾燥させる自然乾燥工程及び強制乾燥工程と、乾燥した原材料を焼成する焼成工程とを含む、両面の風合いが異なる窯業製品の製造方法は、原材料を切断して複数のピースにし、乾燥工程における原材料の収縮によって、前記ピース間に隙間を発生させ、焼成することによって、ピースの両面に異なる風合いを生じさせることを特徴とするものである。
【0006】
本願請求項2に記載の、原材料を成型する成型工程と、成型された原材料を乾燥させる自然乾燥工程及び強制乾燥工程と、乾燥した原材料を焼成する焼成工程とを含む、両面の風合いが異なる窯業製品の製造方法は、前記成型工程において原材料を切断して複数のピースにする段階と、前記ピースを平積み状態で自然乾燥させる段階と、前記強制乾燥工程の前に前記ピースを平積み状態から縦積み状態に積み替える段階とを含むことを特徴とするものである。
【0007】
本願請求項3に記載の両面の風合いが異なる窯業製品の製造方法は、前記請求項2の製造方法において、前記強制乾燥工程が、温風乾燥させる前期強制乾燥工程と、乾燥炉内で乾燥させる後期強制乾燥工程とを含み、前記積み替える段階が、前期強制乾燥工程と後期乾燥工程との間に行われることを特徴とするものである。
【0008】
本願請求項4に記載の両面の風合いが異なる窯業製品の製造方法は、前記請求項2又は3の製造方法において、前記原材料の切断が成型機の出口に張られたワイヤによって行われることを特徴とするものである。
【0009】
【発明の実施の形態】
次に、レンガを例として、本発明の好ましい実施の形態に係る両面の風合いが異なるレンガの製造方法について詳細に説明する。図1は、本製造方法の工程を示したフロー図である。まず、成型機を用いてレンガの原材料(以下「レンガ原材料」という)を成型する。図2は、本製造方法の使用される成型機を概略的に示した図である。この成型機は、金属製の箱形の本体を備えている。本体の出口部分には、製造しようとするレンガの寸法・形状に従って、ワイヤ(例えば、ピアノ線)が水平方向に張られている。成型工程は、成型機の本体に原材料を入れ、図2の矢印で示されるように、ワイヤが張られている出口に向かって押し出すことによって行われる。原材料は、出口から押し出される際にワイヤによって(図示される例では4つのピースに)切断される。なお、図示されている成型機自体は、ワイヤが張られていることを除いて、公知の装置である。
【0010】
図3(a)は、成型工程によって得られたレンガ原材料を平積みにした状態を示した図である。成型工程に引き続き、1次乾燥工程を実施する。1次乾燥工程では、レンガ原材料を図3(a)に示されるようにラックに平積みにした状態で自然乾燥させる。1次乾燥工程に要する時間は、夏期で3週間程度、冬期で4週間程度である。1次乾燥工程は、レンガに亀裂が発生することを避けるために行われる。成型後の水分含有率が約16重量%〜約18重量%であるレンガ原材料は、1次乾燥によって、水分含有率が約12重量%となる。ここで、水分含有率とは、レンガ原材料の(湿潤重量−乾燥重量)/(湿潤重量)によって定義される値である。
【0011】
次いで、2次乾燥工程を実施する。2次乾燥工程では、レンガ原材料をラックに平積みにした状態で温風乾燥させる。2次乾燥に要する時間は、3日間程度であり、約25°Cから開始して約40°Cまで温風の温度を上昇させる。2次乾燥によって、水分含有率が約6重量%となる。
【0012】
次いで、積替え工程を実施する。積替え工程では、レンガ原材料を、図3(b)に示されるように、焼成用台車上に縦積みにする。なお、図3(b)に示される例では、レンガ原材料が2段に縦積みにされているが、縦積みの段数を1段にしてもよく、適当な保持手段があれば、3段以上にしてもよい。積替え工程の時点では、隣接するレンガ原材料の間には隙間がなく、密接している。
【0013】
次いで、3次乾燥工程を実施する。3次乾燥工程では、縦積みにされたレンガ原材料を乾燥炉内で乾燥させる。3次乾燥に要する時間は、2日間程度であり、約40°Cから開始して約160°Cまで温風の温度を上昇させる。3次乾燥工程が終了した時点で、乾燥による原材料の収縮のため、隣接するレンガ原材料の間に隙間W(約2mm〜約3mm)が発生する。3次乾燥によって、水分含有率が約1重量%となる。なお、積替え工程において、レンガ原材料を縦積みにした理由は、レンガ原材料を平積みにしたままでは、レンガ原材料の自重のため、収縮による隙間が発生しないからである。
【0014】
次いで、焼成工程を実施する。焼成工程では、レンガ原材料をキルン内で所定時間(通常は、60時間程度)、所定温度で(通常は、焼成開始後約30時間経過時に最高温度約1170°Cまで上昇させ、その後、時間をかけて約60°Cまで温度をゆっくり下降させる)焼成する。レンガ原材料の間に隙間Wが設けられているので、焼成されたレンガは、両面の風合いが異なる。
【0015】
このようにして得られたレンガをパッキングして、出荷に備える。
【0016】
本発明は、以上の発明の実施の形態に限定されることなく、特許請求の範囲に記載された発明の範囲内で、種々の変更が可能であり、それらも本発明の範囲内に包含されるものであることはいうまでもない。
【0017】
たとえば、前記実施の形態では、乾燥工程が1次から3次までの3工程に分かれているが、乾燥工程を自然乾燥工程と強制乾燥工程の2工程に分けた場合にも、本製造方法を適用することができる。その際には、自然乾燥工程と強制乾燥工程との間に、積替え工程を実施する。
【0018】
また、前記実施の形態では、成型工程でレンガ原材料を4つのピースに切断しているが、4つ以外の任意の数のピースに切断してもよい。また、成型機のワイヤが水平方向に張られているが、ワイヤを垂直方向に張ってもよい。
【0019】
さらに、前記実施の形態では、レンガを例として説明されているが、レンガ以外の他の窯業製品、例えば、タイル、ブロック材、かわら材などにも、本製造方法を適用することができる。
【0020】
【発明の効果】
本発明により、両面の風合いが異なる窯業製品を容易に提供することができる。両面の風合いが異なる窯業製品は、1種類の製品でA面、B面、AB混合面の3パターンの風合いを表現することが可能であり、これにより、住宅建築業者にとっては、在庫管理が容易になる他、顧客へのアピール度を増すことができ、また、住宅購入者にとっては施工直前まで外壁の変更が可能である等の効果が得られる。
【図面の簡単な説明】
【図1】本発明の好ましい実施の形態に係る製造方法の工程を示したフロー図である。
【図2】本発明の製造方法に用いられる成型機の一例を概略的に示した図である。
【図3】各工程におけるレンガ原材料の積み方を示した図であって、(a)は、2次乾燥工程までの状態を示した図、(b)は、積替え工程における積替えの状態を示した図、(c)は、3次乾燥工程終了時点における状態を示した図である。[0001]
BACKGROUND OF THE INVENTION
The present invention generally relates to a method for manufacturing ceramic products. More specifically, the present invention relates to a method for manufacturing ceramic products having different textures on both sides. The ceramic products in the present invention include bricks, tiles, block materials, straw materials, and the like. The term “texture” means color, roughness, texture, weathering degree, and the like.
[0002]
[Prior art]
Brick, which is a typical ceramic product, has a front surface and a back surface, and the surface is manufactured as a usable surface. Therefore, it is generally not manufactured so that the back surface has a certain texture. In addition, since the back surface of the tile is used as an adhesive-dedicated surface, there is no idea that the back surface has a texture in the first place. In addition, other ceramic products are not manufactured so that the back side can be used.
[0003]
[Problems to be solved by the invention]
The present invention has been devised in view of the current situation regarding ceramic products, and by supplying ceramic products with different textures on both sides, the home buyer can change the outer wall until immediately before construction. It is intended to provide various advantages such as easy inventory management for the homebuilder.
[0004]
[Means for Solving the Problems]
When the present inventor transfers a piece of raw material cut with a wire from flat stack to vertical stack and forcibly drys, a preferable gap is generated between the pieces due to shrinkage of the raw material due to drying, and the raw material is fired in this state. It was found that ceramic products with different textures on both sides can be easily manufactured.
[0005]
The ceramic industry having different textures on both sides, comprising a molding step for molding a raw material according to claim 1, a natural drying step and a forced drying step for drying the molded raw material, and a firing step for firing the dried raw material. The manufacturing method of the product is characterized in that the raw material is cut into a plurality of pieces, and a gap between the pieces is generated by shrinkage of the raw material in the drying process, and firing is performed to produce different textures on both sides of the piece. It is what.
[0006]
A ceramic industry having different textures on both sides, comprising a molding step for molding a raw material, a natural drying step and a forced drying step for drying the molded raw material, and a firing step for firing the dried raw material according to claim 2 The method of manufacturing a product includes a step of cutting raw materials into a plurality of pieces in the molding step, a step of naturally drying the pieces in a flat state, and a step of putting the pieces in a flat state before the forced drying step. And a step of transshipment to a vertically stacked state.
[0007]
The method for manufacturing ceramic products having different textures on both sides according to claim 3 of the present invention is the manufacturing method according to claim 2, wherein the forced drying step is performed in a forced drying step in which warm air is dried, and drying is performed in a drying furnace. Including the latter-stage forced drying step, and the transshipment step is performed between the first-stage forced drying step and the latter-stage drying step.
[0008]
The method for manufacturing ceramic products having different textures on both sides according to claim 4 of the present invention is characterized in that, in the manufacturing method of claim 2 or 3, the cutting of the raw material is performed by a wire stretched at the outlet of the molding machine. It is what.
[0009]
DETAILED DESCRIPTION OF THE INVENTION
Next, a brick manufacturing method according to a preferred embodiment of the present invention with different textures on both sides will be described in detail using a brick as an example. FIG. 1 is a flowchart showing the steps of the manufacturing method. First, a brick raw material (hereinafter referred to as “brick raw material”) is molded using a molding machine. FIG. 2 is a diagram schematically showing a molding machine used in the manufacturing method. This molding machine includes a metal box-shaped main body. A wire (for example, a piano wire) is stretched in the horizontal direction at the exit portion of the main body according to the size and shape of the brick to be manufactured. The molding process is performed by putting the raw material into the main body of the molding machine and pushing it toward the outlet where the wire is stretched, as shown by the arrows in FIG. The raw material is cut (by four pieces in the example shown) by the wire as it is extruded from the outlet. The illustrated molding machine itself is a known apparatus except that a wire is stretched.
[0010]
Fig.3 (a) is the figure which showed the state which piled up the brick raw material obtained by the formation process. Subsequent to the molding process, a primary drying process is performed. In the primary drying step, the brick raw material is naturally dried in a state of being stacked on a rack as shown in FIG. The time required for the primary drying process is about 3 weeks in summer and about 4 weeks in winter. A primary drying process is performed in order to avoid that a crack generate | occur | produces in a brick. A brick raw material having a moisture content after molding of about 16 wt% to about 18 wt% has a moisture content of about 12 wt% by primary drying. Here, the moisture content is a value defined by (wet weight-dry weight) / (wet weight) of the brick raw material.
[0011]
Next, a secondary drying step is performed. In the secondary drying step, the brick raw material is dried in warm air in a state of being stacked on a rack. The time required for the secondary drying is about 3 days, and the temperature of the warm air is increased from about 25 ° C to about 40 ° C. Secondary drying results in a moisture content of about 6% by weight.
[0012]
Next, a transshipment process is performed. In the transshipment process, the brick raw material is vertically stacked on a baking cart as shown in FIG. In the example shown in FIG. 3 (b), the brick raw materials are vertically stacked in two stages, but the number of vertically stacked stages may be one, and if there is an appropriate holding means, three or more stages. It may be. At the time of the transshipment process, there is no gap between the adjacent brick raw materials, and they are in close contact.
[0013]
Next, a tertiary drying step is performed. In the tertiary drying process, the brick raw materials stacked vertically are dried in a drying furnace. The time required for the tertiary drying is about 2 days, and the temperature of the warm air is increased from about 40 ° C to about 160 ° C. When the tertiary drying process is completed, a gap W (about 2 mm to about 3 mm) is generated between adjacent brick raw materials due to shrinkage of the raw materials due to drying. The moisture content becomes about 1% by weight by tertiary drying. In the transshipment process, the reason why the brick raw materials are stacked vertically is that when the brick raw materials are left flat, gaps due to shrinkage do not occur due to the weight of the brick raw materials.
[0014]
Next, a firing step is performed. In the firing step, the brick raw material is raised in a kiln for a predetermined time (usually about 60 hours) and at a predetermined temperature (usually, about 30 hours after the start of firing, to a maximum temperature of about 1170 ° C, and then the time is increased. And slowly lower the temperature to about 60 ° C.). Since the gap W is provided between the brick raw materials, the fired bricks have different textures on both sides.
[0015]
The bricks thus obtained are packed to prepare for shipment.
[0016]
The present invention is not limited to the above-described embodiments, and various modifications can be made within the scope of the invention described in the claims, and these are also included in the scope of the present invention. Needless to say, it is something.
[0017]
For example, in the above-described embodiment, the drying process is divided into three steps from the primary to the tertiary. Can be applied. At that time, a transshipment process is performed between the natural drying process and the forced drying process.
[0018]
Moreover, in the said embodiment, although the brick raw material is cut | disconnected in four pieces at the formation process, you may cut | disconnect in arbitrary numbers other than four pieces. Further, although the wire of the molding machine is stretched in the horizontal direction, the wire may be stretched in the vertical direction.
[0019]
Furthermore, in the said embodiment, although the brick was demonstrated as an example, this manufacturing method is applicable also to ceramic products other than a brick, for example, a tile, a block material, a straw material, etc.
[0020]
【The invention's effect】
According to the present invention, ceramic products having different textures on both sides can be easily provided. Ceramic products with different textures on both sides can express the texture of A pattern, A surface, B surface, and AB mixed surface with one kind of product, which makes it easy for homebuilders to manage inventory. In addition, the degree of appeal to the customer can be increased, and for the home buyer, effects such as the ability to change the outer wall until immediately before construction can be obtained.
[Brief description of the drawings]
FIG. 1 is a flowchart showing the steps of a manufacturing method according to a preferred embodiment of the present invention.
FIG. 2 is a diagram schematically showing an example of a molding machine used in the production method of the present invention.
FIGS. 3A and 3B are diagrams illustrating how brick raw materials are stacked in each process, where FIG. 3A illustrates a state up to a secondary drying process, and FIG. (C) is the figure which showed the state in the end of a tertiary drying process.
Claims (4)
原材料を切断して複数のピースにし、乾燥工程における原材料の収縮によって、前記ピース間に隙間を発生させ、焼成することによって、ピースの両面に異なる風合いを生じさせることを特徴とする方法。A method for manufacturing ceramic products having different textures on both sides, including a molding process for molding raw materials, a natural drying process and forced drying process for drying the molded raw materials, and a firing process for firing the dried raw materials In the method
A method of cutting a raw material into a plurality of pieces, generating a gap between the pieces by shrinkage of the raw material in a drying step, and firing, thereby producing different textures on both sides of the piece.
前記成型工程において原材料を切断して複数のピースにする段階と、
前記ピースを平積み状態で自然乾燥させる段階と、
前記強制乾燥工程の前に前記ピースを平積み状態から縦積み状態に積み替える段階と、
を含むことを特徴とする方法。A method for manufacturing ceramic products having different textures on both sides, including a molding process for molding raw materials, a natural drying process and forced drying process for drying the molded raw materials, and a firing process for firing the dried raw materials In the method
Cutting the raw material into a plurality of pieces in the molding step;
Naturally drying the pieces in a stacked state;
Re-loading the pieces from a flat stack to a vertical stack prior to the forced drying step;
A method comprising:
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