JP2016017022A - Clay molding fired/fumigated product and production method thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To develop and produce 'kyo-gawara(kyo tile)' provided with a variety of patterns excellent in designability and a production method capable of creating diversity of design and new possibilities of 'kyo-gawara'.SOLUTION: A production method of a clay molding fired/fumigated product comprises forming a silk screen plate including a region for an ink to pass through and a region for an ink not to pass through, based on a draft or a pattern, conducting silk screen printing by using the silk screen plate by means of an ink consisting of a clay water-dissolved on the surface of a clay molding formed by kneading and molding raw material clay and drying the resultant body and reducing the dried clay molding with strong reduction power in a step of firing and fumigating the clay molding under specified conditions so as to form carbon films different in texture and glossiness between a part applied with the ink on the surface of the clay molding and a part not applied with the ink.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a clay-molded and fired hatched product in which a pattern having an appearance and texture that has not been seen in the past is formed on the surface of an Ibushi tile-related product (for example, Ibushi tile, floor tile, wall tile, etc.) and a method for producing the same.

  Ibushi tile is a traditional roofing material that has been used for a long time on roofs of Japanese buildings, and has been widely used from ordinary private houses to important cultural properties. Such clay-molded and fired hatching products are now widely used not only as roofing materials but also as interiors and exteriors.

  The manufacturing process of Ibushi tile is roughly divided into three stages: clay kneading, molding, firing and hatching. First, add water to the raw clay, and then step firmly with your feet to make a mountain. The clay is put into a kneader and kneaded. After making the rough shape of the tile using the kneaded clay, it is molded using a specified mold, water is applied to the surface, the plate is boiled and then dried. After complete drying, firing is performed in a kiln. In the case of ordinary roof tiles, the manufacturing process is all of this, but in the case of smoked roof tiles, they are cooled to about 800-950 ° C. by natural cooling after firing and then hatched (or smoldered). In this process, hydrocarbon gas such as butane gas is supplied in a so-called strong reducing atmosphere in a state where the supply of oxygen is cut off, and the generated soot is deposited on the product surface.

  The main production areas for Ibushi tiles in Japan are Awaji Island and the Mikawa area of Aichi Prefecture, where most of the manufacturing process is automated. Ibushi tiles are also manufactured in other areas. Kyoto, where the townhouses and shrines and temples exist, was one of Japan's leading producers of Ibushi tiles. Traditionally manufactured roof tiles in Kyoto are called “Kyo roof tiles”. Among the Ibushi tiles, “Kyo tile”, which has both profoundness and elegance, has been regarded as a high-quality item from the old days in terms of quality, color, and gloss, and has spread widely from temples, shrines, sukiya to ordinary townhouses.

  One of the factors that make it a luxury product is the beauty of the surface due to “polishing” during the manufacturing process, which is synonymous with Kyoto tiles. After molding, after drying to a certain degree of hardness, place it on a dedicated stand, gently knead the surface with a gold spatula or trowel, and chamfering, smoothing small scratches and irregularities on the surface, The gloss of the product surface after completion increases, and the impression of the entire product becomes visible. The polishing process is a labor-intensive process that is manually performed by a manufacturing engineer because it is necessary to determine and work on the surface condition of each product.

  Here are some tips on how to polish your experience. Since polishing is the final stage of molding, the surface condition after polishing affects the beauty of the surface of the finished product. Even just touching the gold spatula on the surface will change the way light is reflected on the surface. When stroking the surface, instead of moving the spatula over a short distance, move it in the same direction as much as possible from the edge of the surface to be polished, or from an area that is not noticeable. Polish while maintaining the positional relationship that makes it as easy as possible, such as changing the angle of the product or changing the position of the worker.

  The former production of Kyoto tiles includes the Otsuchi area around Higashiyama where raw clay was mined and the Fukakusa area in Fushimi-ku, Kyoto. During the Meiji period, more than a dozen potteries were lined up. At present, few craftsmen inherit the traditional techniques of “Kyogawara”, and in fact, there are only two establishments in Kyoto that manufacture “Kyogawara”.

  The Asada Tile Factory is an active pottery who manufactures Kyoto tiles. It is the only Kyogawara potter that conveys to the present age the skillful tile manufacturing technology that has disappeared nationwide due to the wave of mass production due to mechanization. So far, the tiles made by Asada Tile Factory have decorated the roofs of famous temples in Kyoto, including various temples throughout Nanzen-ji. The first generation, Tosaburo Asada, who returned from the Russo-Japanese War, began drug manufacturing and tile manufacturing in Kasoya-cho, Fushimi-ku in 1904. At the time of its founding, there was the Yamada family (Kaiyoshi Yaya) who has been producing tiles since the Dazai era. Tokusaburo said that he was able to work as a parent by learning the skills of craftsmen since he started making tiles. Tokusaburo was not always stable economically because his business was gradually increased. It finally became stable after there was a big typhoon and the tiles in stock were sold. The tiler and typhoon were closely related, and the tiler was pleased with the typhoon. I moved to the current Fushimi-ku stage town after the second generation, Reiji. Ryoji, who returned from Manchuria, began building tiles in full swing when he was 31 years old. Reiji, who is good at making eaves flat tiles using wooden shapes, has won the Minister of International Trade and Industry Award for traditional hanging tiles. Currently, Ryoji's eldest son, the third generation, Akihisa, has inherited the tradition of Kyo-gawara manufacturing, centered on Onikira. The current workshop is a modification of the miso storehouse, and it is even spectacular that various wooden patterns are lined up. With the decline of Kyoto tiles, the number of craftsmen that used to be 10 has decreased, and the early development of young people engaged in the manufacture of Kyoto tiles has become a recent issue related to the existence of Kyoto tiles.

  Asada's roof tile factory is conducting thorough temperature control in the firing process as a device for manufacturing long-lived roof tiles. The outline of firing and hatching conditions at the Asada tile factory is as follows: firing temperature 1100-1160 ° C, time to reach the firing temperature 30-40 hours, holding time of the firing temperature 2-3 hours, The temperature of the hatching process following the baking process is 830 to 850 ° C., and the time of the hatching process is 0.8 to 1.5 hours. The rate of temperature rise is changed according to the shape of the product to be fired and the wall thickness. Also, in order to prevent cracking and breakage of the product during firing, it must be pre-plated before the main firing, and a process of removing residual moisture in the product that could not be evaporated by drying is added. .

  In addition, we are also making efforts to develop a Kyoto tile with a beautiful surface. Currently, the Asada Tile Factory uses five types of clay blended in the Mikawa area as raw materials, but it contains a larger amount of sand than clay collected in Kyoto. For this reason, sand appears on the surface of the product after sintering, which is a factor that kills the beauty of polishing. Therefore, we are thinking of reproducing the old beautiful product by crushing the dried clay and removing the sand through the sieve, and scientifically analyze and examine the effects on the surface and structure. doing.

  In addition to producing the traditional technique “Kyo-gawara”, the Asada Tile Factory is actively developing tile materials in collaboration with the Iwata Laboratory of Kyoto Institute of Technology. In September 2011, the inventor Akihisa Asada obtained a PhD in research related to the polishing of Kyoto tiles, submitted a paper, and presented a conference. Specifically, as a result of preparing test pieces with different numbers of polishing steps and examining the surface properties, the surface roughness of the test pieces decreased as the polishing step increased, and the gloss and brightness increased. As for water resistance, the contact angle increased and the water absorption decreased. From the above, it was confirmed that the traditional technique “polishing” is an important process in terms of both aesthetics and function. Polishing, which is a characteristic of Kyoto tile, is done manually, so the skill level of the craftsmen who work is also important. We analyzed the movement of polishing with two craftsmen with different years of experience. As a result, the unskilled person moved only the hand, but the skilled person used not only the hand but the entire body to work, and the spatula was moved less frequently than the unskilled person, completing the polishing process in a shorter time Was. Presenting research results as described above at domestic and international conferences, spreading the scientific study of Kyoto roof tiles, a tradition of Kyoto, to the world.

Asada's roof tile factory inherits the traditional manufacturing method of Kyoto roof tiles as described above. In addition, we have conducted original research and research on polishing, which is a characteristic of Kyoto tiles, and the inventor has obtained a PhD in their research content and is theoretically independent of experience. It is possible to explain Kyoto tiles. The inventor has eagerly worked on the development of effective surface treatment techniques other than polishing and the invention of applicable expression techniques. If there is a novel and effective surface treatment method or expression technique that can be applied to Kyo roof tiles, the range of designs that can be expressed will be widened, and it will be possible to develop and manufacture Kyo roof tiles with excellent design characteristics. This will lead to the creation of new possibilities for sexuality and Kyoto tiles.
The important thing is that the new technique does not completely erase the beauty of the surface obtained by polishing. In addition to the beauty of polishing of Kyoto tile, it is a different surface from polishing. It needs to be a processing method or technique that produces the texture of the material.

JP-A-5-138629

  By the way, the surface of ceramic building materials, such as roof tiles, is smoothed without “polishing” to save labor in the manufacturing process. As those that can be used for wall tiles and the like, those described in the above-mentioned patent documents are known.

  However, the material described in this patent document uses the material of the lower layer part press-formed into two layers as a base material raw material for powder material used for glaze tiles, tiles, etc., and the material of the upper layer part, A material suitable for smoldering tiles is used as an auxiliary material in powder form, and the two-layered body is dried, fired, and hatched to provide ceramic building materials that exhibit silvery luster. However, the surface has excellent design and there is no pattern with different gloss.

  It is an object of the present invention to provide a clay-molded and fired hatched product having various patterns excellent in design properties and to provide a production method thereof to enable development and production of a new Kyoto tile.

  The clay-molded fired hatching product of the present invention is a clay-molded fired hatched product formed with patterns with different gloss on the surface. First, based on the design and pattern, the area where ink passes and the area where ink does not pass Make a silkscreen version. Next, raw clay is kneaded and molded to produce a clay molded product. The surface of the clay molded product that has undergone the production process is silk screen printed using the screen plate and dried using water-soluble clay as an ink. Let Subsequently, the clay molded product that has undergone this printing / drying step is fired and hatched under predetermined conditions. In the firing / incubating step, the clay molded product is reduced by strong reducing power and applied to the surface of the clay molded product. A carbon film having a different texture and gloss is formed between the applied part and the non-applied part.

  The water-soluble clay used as the ink is obtained by, for example, dissolving clay powder pulverized into a powder having a particle size of 0.15 mm or less or a particle size of 0.18 mm or less in a large amount of water. It is possible to change the texture of the product surface after the baking and hatching process by changing the viscosity of the ink.

  Examples of the material of the screen in the above process include a cloth of synthetic fiber such as polyester and nylon. The photosensitive agent used to make the area where ink passes and the area where ink does not pass on the screen uses minolite which is a water-resistant photosensitive emulsion. Alternatively, other water-resistant photosensitive emulsions can be used. In the silk screen printing / drying process, an appropriate amount of ink material is placed on the screen, squeezed firmly onto the screen, and moved in a fixed direction across the entire surface of the screen, allowing the ink to perforate the screen. It is also possible to use a method of extruding to a clay molding or a method of obtaining a similar effect.

  The predetermined conditions of the above steps are conditions for firing and hatching the smoldering tile, for example, the firing temperature is 1100 to 1160 ° C., the arrival time to the firing temperature is 30 to 40 hours, and the firing temperature The holding time is 2 to 3 hours, the temperature of the hatching treatment following the baking treatment is 830 to 850 ° C., and the incubation time is 0.8 to 1.5 hours. According to the above configuration, in the hatching process, it is reduced by strong reducing force, and the silk screen printing / drying process is performed and the areas where the ink coating is not performed, that is, where the ink is applied and where the ink is not applied. By forming carbon films with different luster and gloss, it is possible to manufacture Kyoto tile-related products by forming various textures and patterns with different luster on the surface while retaining the beauty of the surface by polishing the roof tile. It becomes.

  According to the clay-molded and fired hatched product using the silk screen printing process of the present invention and the method for producing the same, the carbon having different texture and gloss is different between the portion where the ink is applied and the portion where the ink is not applied in the strongly reducing atmosphere in the smoldering process. Since a coating can be formed, it is possible to manufacture a Kyoto tile-related product with a delicate pattern on the surface while retaining the beauty of the surface by polishing the Kyoto tile.

  The water-soluble clay used as the ink is obtained by, for example, dissolving clay powder pulverized into a powder having a particle size of 0.15 mm or less or a particle size of 0.18 mm or less in a large amount of water. By changing the viscosity of the ink, it is possible to variously change the texture and gloss of the product surface after the baking and hatching process.

The flowchart which shows the manufacturing process of the clay shaping | molding baking hatching using a silk screen technique. The photograph which shows an example of the clay shaping | molding baking hatching manufactured by this invention.

  Hereinafter, embodiments for carrying out the present invention will be specifically described with reference to examples. The scope of the technical idea of the present invention is not limited to the specific shapes and numerical values of these examples.

  FIG. 1 is a flowchart showing a manufacturing process of a clay-molded fired hatching product using silk screen technology. The clay-molded and fired hatched product of the present invention is a clay-molded and fired hatched product obtained by kneading, molding and calcining raw material clay. As shown in FIG. It consists of three processes: a printing / drying process and a baking / incubation process, and a screen plate-making process is added to it.

  The clay molding process is a process also found in the conventional Kyoto tile manufacturing process. Add an appropriate amount of water to the raw clay and knead the raw clay to make the moisture distribution uniform. Using the kneaded clay, it is molded into a required shape.

  “Polishing” is performed after the molding step is completed. After being dried to a certain degree of hardness, it is placed on a dedicated stand, carefully rubbed with a gold spatula or trowel, and chamfered to smooth out small scratches and irregularities on the surface. The product surface becomes beautiful and the overall impression of the product becomes tight. “Polishing” is performed by an engineer ascertaining the surface condition of each product. Even just touching the gold spatula on the surface will change the way light is reflected on the surface. When stroking the surface, the spatula is not moved many times over a short distance, but it is long from the edge of the surface to be polished or a conspicuous part, and if it is moved in the same direction as much as possible, the surface structure tends to be uniform. Polish while maintaining the positional relationship that makes it as easy as possible, such as changing the angle of the product and changing the position of the worker.

  The screen plate-making process is a process for producing a silk screen plate by creating a region through which ink passes and a region through which ink does not pass using a photosensitive emulsion based on a predesigned design or pattern. Prepare a wooden frame that is about 10cm larger on each side than the prepared design, and fix the screen to the wooden frame with resin while pulling. Thereafter, the screen is degreased so that the light-sensitive emulsion is successfully applied. Apply a light-sensitive emulsion on a degreased screen with a wooden frame using a brush and dry it in a dark room. After that, the tracing paper onto which the design has been transferred in advance is covered with a dried framed screen and exposed to light. After exposure for an appropriate time, the unexposed emulsion is washed with water using a sponge or the like and dried. It is important to proceed quickly after applying the photosensitive emulsion on the screen until exposure. After drying, masking the wooden frame with a waterproof tape such as gummed tape will complete the screen.

The next step is a silk screen printing / drying step in which the screen plate produced in the screen plate making step is placed on the surface of the clay molding, and silk screen printing and drying are performed using water-soluble clay as an ink. The raw clay is dried and finely crushed with a pestle and mortar.
Pass through a sieve with 80mesh or 100mesh mesh, and adjust the particle size to 0.15mm or less and 0.18mm or less to make it easy to pass through the screen plate. The clay powder having the same particle diameter is dissolved in water and used as ink. Depending on the weight ratio of the clay powder and water, that is, the difference in the viscosity of the ink, it is possible to make a difference in the way the image printed on the surface of the clay molding is projected. If the ink is dark, it will be strong, and if it is thin, it will be light.

Place the screen plate on the clay molding and fix it firmly so that it does not move during the printing process. Next, put ink on the top of the screen plate and slowly squeeze it down. Keep the squeegee angle at about 45 degrees. Furthermore, it is necessary to make sure that the ink does not run out while moving the squeegee. Although depending on the design to be printed, if the printing range is wide, a larger amount of ink is required than expected, so it is preferable to test print on paper or the like. It is preferable to print as much as possible once, but if it can be printed at most twice, it will be beautiful. After the squeegee has been moved, the screen plate is lifted vertically from the surface of the clay molding and separated from the clay molding to dry the clay molding.
Drying is performed in the shade at first, and when the edges of the clay molding have become white, they are exposed to direct sunlight in the sun and dried until they are completely white. After use, the screen plate is washed with water to remove the ink clogged in the screen holes and dried.

  And in a baking and hatching process, baking and hatching of the clay molding after the said silk screen printing and drying process are performed on predetermined conditions. The predetermined condition may be a condition for firing and hatching the smoldering tile. The present invention performs the firing and hatching process under the conventional firing and hatching conditions, creates a strongly reduced state in the hatching process, and has different textures and glosses in the areas where the ink is applied and where it is not applied. A film is formed. The firing treatment temperature is 1100 to 1160 ° C., the time to reach the firing treatment temperature is 30 to 40 hours, the firing treatment temperature holding time is 2 to 3 hours, and the temperature of the hatching treatment following the firing treatment is 830 to 850 C., and the hatching time is 0.8 to 1.5 hours. However, it is necessary to change the temperature increase rate depending on the shape and thickness of the product to be fired. The Asada Tile Factory uses butane gas as fuel and soot for firing.

  Before starting the firing process, open the kiln door a little and fire it for about 4 hours with extremely weak heating power, raise the temperature inside the kiln to around 100 ° C, stop the fire, and from 8 It is desirable to remove the moisture remaining in the product by leaving it for 10 hours. As a method of increasing the temperature during firing, specifically, 300 ° C for 10 hours, 700 ° C for 20 hours, 1000 ° C for 30 hours, and so on, cracks due to extreme temperature rise Serves to prevent outbreaks. When the temperature exceeds 1000 ° C, pay attention to the adjustment of the thermal power and adjust the temperature inside the kiln to 1100-1160 ° C. When the temperature reaches 1100 to 1160 ° C., the heating power is adjusted so that the temperature is maintained for 2 to 3 hours. After that, the fire is completely stopped and cooled naturally to a temperature of 830-850 ° C. suitable for hatching. At that time, care should be taken so that the outside air does not flow into the kiln and the temperature drops rapidly.

  As a hatching agent used for hatching, a flammable material such as a solid fuel such as pinewood or coal, a liquid fuel such as heavy oil or light oil, or a hydrocarbon gas such as butane gas is used. In the case of this example, when hatching is performed, butane gas is directly supplied to the inside of the kiln when the temperature inside the kiln becomes 830 to 850 ° C. with the oxygen supply turned off after the combustion treatment, and the generated soot The method of vapor-depositing on the product surface is taken. The time spent in the hatching process is 50 to 60 minutes as a guideline. Instead of supplying a large amount of butane gas suddenly, increase the supply amount slowly.

  Sudden temperature changes may cause cracks in the product, so even after the completion of the smoldering process, care was taken to prevent outside air from flowing into the kiln, and the temperature was slowly lowered to near room temperature. After confirming that, open the door little by little.

  A clay molded and fired hatching product of an Ibuki tile-related product having an appearance and a texture, which has not been conventionally used using a silk screen technology, and a manufacturing method thereof are widely applied to an Ibuki tile-related product.

Claims (2)

  Based on the designs and patterns, a silk screen plate with areas through which ink passes and areas through which ink does not pass is manufactured. On the other hand, clay is kneaded and molded to produce a clay molding, and the clay that has undergone the manufacturing process In the step of firing and hatching the clay molded product that has been printed and dried on the surface of the molded product using water-clay clay as an ink, performing silk-screen printing using the silk-screen plate, and drying. A clay-molded and fired hatched product obtained by forming a carbon film having a different texture and gloss at a portion where the ink is applied and a portion where the ink is not applied on the surface of the clay-molded product, which is reduced by strong reducing power.   A screen plate making process for producing a silk screen plate with areas through which ink passes and areas through which ink does not pass based on designs and patterns, a process for kneading and forming raw clay to form a clay molded product, and molding A silk screen printing / drying step of performing silk screen printing on the surface of the clay molding using a silk screen plate prepared in the screen plate making process using water-soluble clay as an ink, and then drying the silk screen printing; and the silk screen printing In the firing / incubation step in which the clay molded product that has undergone the drying process is fired / incubated under predetermined conditions, and in the firing / incubation step, the clay molded product is reduced by a strong reducing force, and the clay molded product is And a step of generating a carbon film having different textures and glossiness between the area where the ink is applied and the area where the ink is not applied. Clay molded baked smoked product manufacturing method according to.