JP2018140517A - Method for producing molding plate - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a production method where a molding plate provided with hollow holes is press-molded to form a step part, in which the amount of clay moving upon the press molding is suppressed to suppress the deformation of the step part from a shape following the mold of a press.SOLUTION: Provided is a method for producing a molding plate comprising: a first step where a planar molding plate 10 having a plurality of hollow holes 23 in parallel each other at the inside and made of clay is formed; and a second step where the edge parts of the molding plate 10 corresponding to the edge parts of the respective hollow holes 23 are partially crushed with a press to form a step part 16. Then, before the second step, a third step where the clay at the part corresponding to the step part 16 at the edge parts of the molding plate 10 is removed to form a tilted cut part 10K is formed is provided. In the third step, at the point of time before the third step, provided that the amount of the clay at the part corresponding to the step part 16 at the edge parts of the molding plate 10 is defined as A, the amount of the clay required for forming the step part 16 at the edge parts of the molding plate 10 is defined as B, and the amount of the clay required for clogging the edge parts of the respective hollow holes 23 is defined as C, the clay of the amount equivalent to A-(B+C) is removed.SELECTED DRAWING: Figure 3

Description

  The present invention relates to a method for producing a molded plate that can be fired and used as a roofing material, a wall material or the like.

  Patent Document 1 below discloses a molded plate formed by extrusion that can be used as a roofing material, a wall material, and the like. As shown in FIG. 24, the molded plate 1 has a plurality of hollow holes 4 along the extrusion direction of the viscous material extrusion. When the molded plate 1 is baked into a ceramic plate, and the ceramic plates are adjacent to each other in the extrusion direction and partially overlapped with each other, the height of the plate surface between adjacent ceramic plates is not stepped. Are formed with stepped portions 2 at the front and rear end portions in the extrusion direction. The step portion 2 is shaped to receive the porcelain plate on the lower surface side in the overlapping portion on the lower surface of the porcelain plate on the upper surface side in the overlapping portion, and the hollow hole 4 is closed in the step portion 2.

  The step portion 2 is formed by setting a molded plate 1 that has been extruded and cut to a predetermined size in a press machine (not shown), and crushing a portion corresponding to the step portion 2 with an upper and lower mold (not shown). Is formed.

Japanese Patent Laying-Open No. 2015-200122

  In many cases, the step portion 2 of the molded plate 1 thus press-formed does not have a beautiful shape following the upper and lower molds of the press machine. That is, as shown in FIGS. 24 and 25, the boundary wall surface 3 of the step portion 2 with the molded plate 1 main body is not a surface perpendicular to the upper surface of the step portion 2, but bulges toward the step portion 2 side. Not constant by. Therefore, when adjacent ones as porcelain plates are partially overlapped at the step portion 2, the step portions do not overlap as planned, and there is a problem that a gap is formed in the boundary wall surface 3 portion. Such a gap may cause rain leakage when the ceramic plate is used as a roofing material or an outer wall material. In order to avoid the problem, it becomes necessary to separately perform waterproofing treatment.

  In view of such a problem, an object of the present invention is to reduce the amount of viscous material that moves during press molding in a method for manufacturing a molded plate in which a molded plate having a hollow hole is press-molded to form a stepped portion. This is to suppress the deformation of the portion from the shape following the die of the press machine.

  The first invention includes a first step of forming a plate-shaped molded plate having a plurality of hollow holes parallel to each other and made of a viscous material, and an end of the molded plate corresponding to the end of each hollow hole. And a second step of forming a step portion by partially crushing the portion with a press. And before the said 2nd process, it has the 3rd process which removes the viscous body of the part corresponding to the above-mentioned step part in the end of the above-mentioned forming board, and in this 3rd process, the time before this 3rd process The amount of viscous material at the end of the molding plate corresponding to the step is A, the amount of viscous material required to form the step at the end of the molding plate is B, When the amount of viscous material necessary for closing the end of the hollow hole is C, an amount of viscous material corresponding to A− (B + C) is removed.

  In the first invention, various materials such as roof tile clay and porcelain clay can be used as the viscous material forming the molded plate. The stepped portion may be provided only on one end side of the end portion, or may be provided on both end sides. The step portion is formed as a ceramic plate by firing the molded plate, and achieves a function of absorbing the step so that no step is generated on the plate surface between the arranged ceramic plates when a plurality of ceramic plates are partially stacked and arranged. Can be. When the step portion is provided so as to fulfill the step absorption function and the step portion is provided only on one end side of the end portion, the step difference of the step portion is made equal to the plate thickness of the forming plate. Moreover, when providing a step part in the both ends side of an edge part, the level | step difference of a step part is made into half each plate | board thickness of a shaping | molding board at each edge part. Note that the stepped portion is not limited to a step for absorbing the step.

  According to the first aspect of the present invention, before the end of the molded plate is pressed to form the stepped portion, the viscous material corresponding to the stepped portion is removed. At this time, an extra amount of viscous material other than the total amount of viscous material B necessary to form the stepped portion and the viscous material amount C necessary to close the end of the hollow hole is previously removed. Is done. Therefore, when forming a step part in the edge part of a shaping | molding board, it is suppressed that an excess viscous body flows around a step part. As a result, it is possible to suppress the step portion from being deformed from the shape following the die of the press machine.

  A second invention includes the fourth step of sucking and transferring the molding plate by a negative pressure suction device after the second step in the first invention, wherein the negative pressure suction device is disposed on the stepped portion. A trimming member is provided at a corresponding part, and when the molding plate is transferred in the fourth step, the trimming member is fitted into the stepped portion, and an excess remaining on the boundary wall surface of the stepped portion with the molding plate main body. The viscous material is removed to smooth the boundary wall surface.

  According to the second aspect of the invention, when the forming plate having the step portion is sucked by the negative pressure suction device, the extra viscous material on the boundary wall surface of the step portion is removed by the trimming member. Therefore, it is possible to clean the boundary wall surface that cannot be formed beautifully only by forming the stepped portion by pressing.

  According to a third aspect of the present invention, in the first or second aspect of the invention, after the second step, a cutter is cut along a direction intersecting the hollow hole so as to cut a boundary wall surface between the stepped portion and the molded plate body. The extra viscous material remaining on the boundary wall surface is removed by sliding to smoothen the unevenness of the boundary wall surface.

  According to the third aspect of the invention, after the step is formed at the end of the molded plate, the excess viscous material on the boundary wall surface of the step is scraped off by the cutter. Therefore, it is possible to clean the boundary wall surface that cannot be formed beautifully only by forming the stepped portion by pressing.

  According to a fourth invention, in any one of the first to third inventions, in the second step, the deformation of the molding plate is suppressed in addition to the deformation so as to form the stepped portion at the end of the molding plate. In the second step, the plate surface is linearly pressed along the side end portion intersecting the end portion where the step portion of the molded plate is formed, in the second step, The viscous material at the side end is moved toward the opposing mold.

  When forming the molded plate, each surface is covered with a mold so that the molded plate is not deformed at a portion other than the step portion, but there is a slight gap between the mold and the molded plate. When the end of the molding plate is pressed to form the stepped portion, the viscous body moves around the stepped portion in the gap with the mold. Therefore, the deformation | transformation which the side edge part which cross | intersects with respect to the edge part in which the step part of a shaping | molding board is formed arises. According to the fourth invention, the plate surface of the molding plate is linearly pressed along the side end portion, and the viscous body on the plate surface side of the molding plate is moved toward the opposing mold surface. Thereby, the curvature of the side end face is corrected.

  5th invention is a ceramic board provided with the some hollow hole along the X direction which is one direction, Comprising: The several ceramic board adjoins to the said X direction, and the front-and-back end part which becomes the front and back of the said X direction In the state where the two are partially overlapped, the upper surface portion located on the upper surface side at the overlapping portion of the front and rear end portions is reduced in thickness by the amount of clay on the lower surface side to form a stepped portion. In addition, the lower surface portion located on the lower surface side in the overlapping portion of the front and rear end portions has a stepped portion with a reduced thickness due to a small amount of clay on the upper surface side, and the upper surface side portion. And both ends of the hollow hole are closed at each step portion of the lower surface side portion. In addition, in a state where a plurality of porcelain plates are adjacent to each other in the Y direction intersecting with the X direction, and the front and rear ends which are front and rear in the Y direction are partially overlapped, In order to prevent the ceramic plates adjacent to each other in the overlapping portion from being mechanically coupled to each other and to be separated in the Y direction along the plate surface, a convex portion is provided on the plate surface of the ceramic plate on the lower surface side in the overlapping portion. Moreover, the recessed part which fits into the said convex part is provided in the board surface of the ceramic board used as an upper surface side in an overlapping part, and a plate surface is recessed along the said X direction by the said edge part side of the said convex part. Grooves are formed.

  According to 5th invention, the groove | channel is formed in the edge part side of a convex part. Therefore, when a plurality of porcelain plates are arranged adjacent to each other in the Y direction and used as a roofing material or wall material, rainwater is generated on the end side of the convex portion of the ceramic plate that becomes the lower surface side at the overlapping portion. Even if it enters, the rainwater flows along the groove on the lower surface side portion of the ceramic plate and is suppressed from flowing into the gap between adjacent ceramic plates.

It is a flowchart which shows an example of the method of manufacturing a shaping | molding board and a ceramic board by this invention. It is a perspective view which shows an example of the extrusion molding process in the said manufacturing method, and a cutting process. It is a side view of the shaping | molding board explaining an example of the said cutting process. It is a side view of the shaping | molding board explaining the other example of the said cutting process. It is a front view which shows an example of the press machine of the press molding process in the said manufacturing method. It is a front view which shows the operation state of the said press. It is a side view of the lower mold | type in the said press. It is a top view of the lower mold | type in the said press. It is a side view of the upper mold | type in the said press. It is a bottom view of the upper mold | type in the said press. It is a block diagram of the control circuit part in the said press. It is a control flowchart of the control circuit in the said press. It is explanatory drawing explaining the deformation | transformation of the shaping | molding board in a press molding process. It is the XIV-XIV sectional view taken on the line of FIG. It is an expanded sectional view which shows the negative pressure suction apparatus of the carrying-out process in the said manufacturing method. It is an expanded sectional view which shows the cutter used at the carrying-out process in the said manufacturing method. It is a perspective view of the shaping | molding board extruded by the extrusion molding process in the said manufacturing method. It is sectional drawing which shows the extrusion shape of the shaping | molding board extruded by the said extrusion molding process. It is a surface side perspective view of an example of the shaping | molding board manufactured with the said manufacturing method. It is a back surface side perspective view of the shaping | molding board similar to FIG. FIG. 20 is a front view showing a state in which four molded plates similar to FIG. 19 are fired and arranged as ceramic plates on the vertical wall in the vertical and horizontal directions; It is a bottom view which shows the state which piled up the ceramic board similar to FIG. 21 up and down, right and left. FIG. 23 is a sectional view taken along line XXIII-XXIII in FIG. 22. It is a top view of the shaping | molding board explaining the prior art of this invention. It is a XXV-XXV line cross-sectional enlarged view of FIG.

  FIG. 1 shows an example of a method for producing a molded plate according to the present invention. First, clay (corresponding to the viscous body in the present invention) is extrusion-molded in an extrusion-molding process to form an extrusion-molded board that is the basis of the molded board of the present invention. The extrusion molding step corresponds to the first step in the present invention. Extrusion-molded plates are cut into individual molded plates by cutting in the next cutting step. The cut molded plate is carried into a press machine in a carry-in process, and a step portion is formed in the press-molding process. The press molding step corresponds to the second step in the present invention. The finished molded plate after the press molding is unloaded from the press machine in the unloading process and baked in the baking process to form a ceramic plate.

  FIG. 17 shows an example of the extruded plate 10 formed by extrusion. FIG. 18 shows the cross-sectional shape. 17 and 18, each direction of the forming plate 10 is indicated by an arrow. The direction indicated by the front end and the rear end is the clay extrusion direction, and in the following description, this extrusion direction is referred to as the X direction, the left end perpendicular to the X direction, and the direction indicated by the right end is referred to as the Y direction. . Further, the direction orthogonal to the front and back surfaces of the molded plate 10 is referred to as the up-down direction. Descriptions about directions shall be based on these directions.

  A plurality of hollow holes 23 are formed in the molded plate 10 along the X direction. A convex portion 11 is formed on the left end of the molded plate 10 so as to protrude from the plate surface. A first groove 26 is formed on the plate surface on the part side. Further, at the right end portion of the molded plate 10, the back surface is scraped to form a recess 12, the right end of the recess 12 is a projecting piece portion 14, and the left end is an engaging portion 13. The projecting piece portion 14 is formed so as to project downward from the molding plate 10, and the engaging portion 13 is formed so as to project toward the projecting piece portion 14 in the recess 12.

  19 and 20 show an example of a molded plate (which becomes a ceramic plate after firing) 10 formed in the press molding process. 19 shows the front surface 10A side of the molding plate 10, and FIG. 20 shows the rear surface 10B side of the molding plate 10. In FIGS. 19 and 20, as in FIGS. 17 and 18, each direction of the molded plate 10 is indicated by an arrow, and a description regarding the direction is made based on these directions.

  The paper surface side of FIG. 19 is the front surface 10A of the ceramic plate 10, and the paper surface side of FIG. 20 is the back surface 10B of the ceramic plate 10. The end portions in the left-right direction toward the paper surface of FIG. 19 are front and rear end portions in the extrusion direction, and the left side is the rear end portion 10 </ b> C of the ceramic plate 10. Further, the right side of the paper surface of FIG. 19 is the front end portion 10D of the ceramic plate 10. The end portions in the vertical direction toward the paper surface of FIG. 19 are both end portions in the Y direction, and the upper side is the left end portion 10 </ b> E of the ceramic plate 10. Further, the lower side of the paper surface of FIG. The corner formed by the rear end portion 10C and the left end portion 10E is the first corner portion 10G, and the corner portion formed by the left end portion 10E and the front end portion 10D is the second corner portion 10H. A corner formed by the end 10C and the right end 10F is a third corner 10J.

  The left end portion 10E of the porcelain plate 10 is integrally provided with a convex portion 11 that protrudes toward the surface 10A and extends along the X direction, and a first groove parallel to the convex portion 11 is provided on the left end side of the convex portion 11. 26 and a second groove 27 are formed. The right end 10 </ b> F of the porcelain plate 10 includes a recess 12, a protruding piece 14, and an engaging portion 13 on the back surface 10 </ b> B side.

  As shown in FIG. 19, a through hole 22 is provided further on the end side than the convex portion 11 of the left end portion 10E. The through holes 22 are formed by a punching machine (not shown) after the molded plate 10 is baked to form the ceramic plate 10. Two through holes 22 are provided dispersed in the X direction. Screws (not shown) are inserted into the respective through holes 22, and the metal fittings 24 are respectively fixed on the left end portion 10 </ b> E of the ceramic plate 10 by these screws. Further, the screw penetrates the ceramic plate 10 through the through hole 22 and is screwed into a base material (not shown) such as a roof to fix the ceramic plate 10 to the base material. As shown in FIG. 23, each metal piece 24 has a J-shaped cross section, and is formed in the concave portion 12 of the right end portion 10F when a plurality of porcelain plates 10 are adjacent and partially overlapped in the Y direction. The metal fitting 24 engages with the engaged portion 13 formed. By this engagement, the porcelain plates 10 adjacent in the Y direction are prevented from increasing in the amount of overlap in the Y direction along the plate surface, and the porcelain plates 10 are prevented from being separated from each other in the vertical direction. Yes.

  The rear end portion 10C of the porcelain plate 10 is provided with a lower surface side portion 16 (corresponding to the step portion in the present invention) that is made by crushing clay from the surface 10A side, and the front end portion 10D of the porcelain plate 10 includes: An upper surface side portion 17 (corresponding to a step portion in the present invention) is formed by crushing clay from the back surface 10B side into a step portion. Accordingly, the lower surface side portion 16 and the upper surface side portion 17 are made thin by reducing the amount of clay in the vertical direction. Here, the upper surface side of the lower surface side portion 16 is integrally provided with a first protrusion 18 projecting toward the upper surface side and extending in the Y direction, and the lower surface side of the upper surface side portion 17 is directed toward the lower surface side. A second protrusion 19 that protrudes and extends in the Y direction is provided. In addition, the left end on the upper surface side of the lower surface side portion 16 includes a bank portion 15 that protrudes toward the upper surface side and extends in the X direction. The first protrusion 18 and the bank portion 15 are made to have the same protrusion width and height, and are joined at the ends. When the clay is crushed during the formation of the lower surface portion 16 and the upper surface portion 17, the clay extruded therefrom flows to the hollow hole 23 side formed along the X direction of the molding plate 10, Both ends of the hollow hole 23 are closed by clay.

  When crushing the clay to form the lower surface portion 16, a notch is formed in the third corner portion 10 </ b> J that is a corner portion on the right end 10 </ b> F side of the lower surface portion 16, and the notch portion 21 is provided. .

  FIG. 21 shows a state in which a plurality of ceramic plates 10 are laid on a roof, a wall, or the like. Here, four ceramic plates 10 are combined in both the X and Y directions and partially overlapped with each other, but the same thing is repeated for a combination of four or more ceramic plates 10. Become.

  In a portion where a plurality of ceramic plates 10 are adjacent in the X direction, the upper surface side portion 17 and the lower surface side portion 16 of the front and rear end portions in the X direction are overlapped. A passage 25 communicating in the Y direction is formed between the lower surface side of the upper surface side portion 17 and the upper surface side of the lower surface side portion 16 (see FIG. 22). This passage 25 fulfills the function of a water channel through which rainwater that adheres to the surface 10A of the ceramic plate 10 and falls on the upper surface of the lower surface portion 16 is passed. Here, the protrusions 18 and 19 on the upper surface side of the lower surface side portion 16 and the lower surface side of the upper surface side portion 17 are arranged so that rainwater flowing through the passage 25 does not leak into the gap between the ceramic plates 10 adjacent in the X direction. Plays a function.

  Further, in the portion where the plurality of ceramic plates 10 are adjacent in the Y direction, the end portion of the right end portion 10F is a cover portion 10a, the end portion of the left end portion 10E is a covered portion 10b, and the cover portion 10a is covered. It is superimposed on the upper side of the cover part 10b. At this time, the convex portion 11 of the left end portion 10E is fitted into the concave portion 12 of the right end portion 10F, and the adjacent ceramic plates 10 are mechanically coupled to each other at the overlapping portion, and the Y direction along the plate surface. It is designed to prevent them from being pulled apart. Further, a cutout portion 21 is provided in the third corner portion 10J of the ceramic plate 10. Therefore, when the lower left ceramic plate 10 and the lower right ceramic plate 10 are overlapped with each other in the X direction in FIG. 21, when the upper right ceramic plate 10 is overlapped in the Y direction, the convex portion 11 of the lower left ceramic plate 10 is Thus, the cutout portion 21 of the upper right ceramic plate 10 is a corresponding position. Thereby, it is avoided that the lower surface side part 16 of the upper right ceramic board 10 interferes with the convex part 11 of the lower left ceramic board 10. The size of the notch in the notch 21 in the X direction is substantially the same as the size of the lower surface side portion 16 in the X direction on the lower surface of the lower surface side portion 16. Further, the size of the notch in the notch portion 21 in the Y direction is such that the lower surface side portion 16 does not interfere with the convex portion 11 and can be overlapped with the upper surface of the upper surface side portion 17 of the covered portion 10b. ing.

  FIG. 23 shows a state in which the two ceramic plates 10 are overlaid in the X direction as described above, and further the ceramic plate 10 is overlaid on the upper side in the Y direction. At this time, since the notch 21 is provided in the third corner portion 10J of the ceramic plate 10 forming the cover portion 10a, the convex portion 11 of the ceramic plate 10 forming the covered portion 10b is the concave portion of the ceramic plate 10 forming the cover portion 10a. 12 can be fitted. Further, the metal fitting 24 fixed to the covered portion 10b of the ceramic plate 10 constituting the covered portion 10b engages with the engaging portion 13 of the ceramic plate 10 constituting the cover portion 10a. As is apparent from FIG. 23, the right end portion 10F side of the lower surface side portion 16 of the porcelain plate 10 constituting the cover portion 10a is located above the upper surface side portion 17 of the porcelain plate 10 constituting the covered portion 10b. The rainwater flowing on the side portion 16 flows from the lower surface side portion 16 of the ceramic plate 10 forming the cover portion 10a to the upper surface side portion 17 of the ceramic plate 10 forming the covered portion 10b. Therefore, it is avoided that rainwater flowing on the lower surface portion 16 enters the gap between the ceramic plates 10 arranged in the Y direction. Since the convex portion 11 is not provided on the surface side of the upper surface side portion 17, rainwater that has flowed to the upper surface side portion 17 is not obstructed by the convex portion 11.

  According to the ceramic plate 10 described above, when a plurality of ceramic plates 10 are arranged in the X direction of the ceramic plate 10 and they are partially overlapped, the upper surface side portion 17 and the lower surface side portion 16 of the overlapping portion have a plate thickness. Between them, a passage 25 communicating in the Y direction is formed between them. Therefore, when the ceramic board 10 is used as a roofing material or an outer wall material, when rainwater flows into the passage 25 from the surface 10A side of the ceramic board 10, it is drained through the passage 25. At that time, since the first protrusion 18 is provided on the lower surface portion 16 and the second protrusion 19 is provided on the upper surface portion 17, the rainwater flowing into the passage 25 is adjacent to the adjacent ceramic plate 10. Soaking into the gap is suppressed. Further, the first corner 10G, which is the end of the lower surface portion 16, is provided with a bank 15, and the ceramic plate 10 is installed so that the side on which the bank 15 is provided is located above the horizontal plane. The rainwater flowing into the passage 25 can be suppressed from flowing to the left end portion 10E side of the ceramic plate 10. When there is no bank 15, rainwater that has flowed into the passage 25 may flow to the left end 10 </ b> E side of the ceramic plate 10 due to wind pressure, but this flow can be stopped by the bank 15. Accordingly, it is possible to eliminate or simplify the need for providing a waterproof treatment separately.

  On the other hand, when a plurality of ceramic plates 10 are arranged in the Y direction of the ceramic plate 10 and are partially overlapped, the convex portion 11 of the covered portion 10b in the overlapping portion is fitted into the concave portion 12 of the cover portion 10a. The arranged ceramic plates 10 can be combined with each other. Therefore, the arranged ceramic plates 10 can be prevented from separating in the Y direction. In addition, at this time, since the cutout portion 21 is provided in the third corner portion 10J, it is possible to prevent the convex portion 11 of the covered portion 10b from interfering with the lower surface side portion 16 of the cover portion 10a.

  Rain water flowing on the lower surface portion 16 may flow to the convex portion 11 side of the ceramic plate 10 located at the lower right in FIG. However, the rainwater is guided by the first groove 26 onto the lower surface side portion 16 of the ceramic plate 10 that forms the covered portion 10b. Therefore, it is avoided that rainwater flowing on the lower surface portion 16 enters the gap between the ceramic plates 10 arranged in the Y direction. The first groove 26 corresponds to the groove in the present invention.

  FIG. 2 shows a specific example of the extrusion process. 17 and 18 is formed by being extruded from a die 51 of an extrusion molding apparatus (not shown). The molded plate 10 that is pushed out and fed on the roller train 61 is cut to a predetermined length. Therefore, a slider 62 having a cutter 65 is disposed so as to cross the molding plate 10 on the roller row 61. The slider 62 is guided by guide bars 63, 64 disposed on both sides of the roller row 61 and moves together with the molding plate 10, and the cutter 65 is moved along the slider 62 during the movement to form the slider 62. The plate 10 is cut.

  The cutter 65 is a plate-like blade whose front end is bent at an obtuse angle, and the molded plate 10 is cut by the cutter 65 as shown in FIG. The cutting shape of the cut molded plate 10 is such that the front end portion (corresponding to the rear end portion 10C in the molded plate 10 formed as shown in FIGS. 19 and 20) is cut perpendicularly to the bottom surface, and the top surface on the front end side is inclined. It cut | disconnects so that it may become a surface, and comprises the inclination cut part 10K. As described above, the step of cutting the end portion of the molded plate 10 with the cutter 65 corresponds to the third step in the present invention. The cut molding plate 10 is carried into a press machine for press molding.

  5-12 shows the specific example of a press molding process. In each drawing, each direction is indicated by an arrow corresponding to the direction of the forming plate 10 in FIGS. 19 and 20 correspond to each direction: X1 = rear end, X2 = front end, Y1 = left end, Y2 = right end, Z1 = upper, Z2 = lower.

  The basic structure of the press machine 100 is conventionally known, and the upper mold 120 can be moved up and down with respect to the lower mold 110 on the base F. In this case, an electric motor and a hydraulic actuator are used as a drive source for driving each operation unit of the press machine 100. Of course, the drive source is not limited to these.

  The lower mold 110 and the upper mold 120 include surfaces that are in contact with the front surface 10A and the back surface 10B of the molding plate 10. An upper mold motor 120A and a slide 120B are provided on the upper side of the upper mold 120 in the press machine 100 as upper mold moving means. In the upper mold moving means, the upper mold 120 is moved relative to the lower mold 110 by moving the slide 120B in the vertical direction by the upper mold motor 120A. The molding plate 10 is placed on the lower mold 110 with its back surface 10B facing down, and the upper mold moving means is configured to hold the upper mold 120 in contact with the surface 10A of the molding plate 10. Has been. 6 illustrates the position of the upper mold 120 when the upper mold 120 is held in contact with the surface 10A of the molded board 10, although the molded board 10 is not illustrated. The method of placing the molding plate 10 on the lower mold 110 may be a method of placing the surface 10A of the molding plate 10 downward. In addition, when it is desired to decorate both the front surface 10A and the back surface 10B of the molding plate 10 or a pattern or the like, the decoration is applied to both the upper surface of the lower mold 110 and the lower surface of the upper mold 120, or one of them. Can be attached.

  A first pressing die 130 is fixed to the end portion of the upper die 120 on the X1 side so as to be movable up and down (Z1-Z2 direction). The first pressing die 130 presses the rear end portion 10 </ b> C in the X direction (X1-X2 direction) of the forming plate 10 sandwiched between the upper die 120 and the lower die 110 from the surface 10 </ b> A side of the forming plate 10. On the lower surface of the first pressing die 130, a groove 130a for forming the first protrusion 18 of the lower surface side portion 16 of the forming plate 10 and a groove 130b for forming the bank portion 15 are formed. The first pressing die 130 is pressed by first pressing means 150 configured to include a hydraulic actuator. The first pressing means 150 is fixed to the upper mold 120. With the upper mold 120 in contact with the surface 10 </ b> A of the molding plate 10, a part of the hollow hole 23 of the molding plate 10 is placed on the first pressing mold 130. It is pressed and stopped until it is crushed and the one end side of the hollow hole 23 is closed.

  In addition, the second pressing die 140 is fixed to the X2 side end of the lower die 110 so as to be movable up and down (Z1-Z2 direction). The second pressing die 140 presses the front end portion 10D in the X direction (X1-X2 direction) of the forming plate 10 sandwiched between the upper die 120 and the lower die 110 from the back surface 10B side of the forming plate 10. On the upper surface of the second pressing die 140, a groove for forming the second protrusion 19 of the upper surface side portion 17 of the forming plate 10 is formed. The second pressing die 140 is pressed by a second pressing means 160 that includes a hydraulic actuator. The second pressing means 160 is fixed to the lower mold 110. With the upper mold 120 in contact with the surface 10A of the molding plate 10, the second pressing mold 140 is part of the hollow hole 23 of the molding plate 10. It is pressed and stopped until it is crushed and the other end side of the hollow hole 23 is closed.

  A cutter 122 is provided at a corner of the upper mold 120 that is the X1 side end and the Y2 side end. The cutter 122 is a rear end portion 10C of the forming plate 10 and cuts off the third corner portion 10J of the forming plate 10 which is the right end portion 10F in the Y direction (Y1-Y2 direction). The end of the cutter 122 in the X2 direction coincides with the end of the first pressing die 130 in the X2 direction. As a result, the size of the third corner 10J of the molded plate 10 in the X direction (X1-X2 direction) is the X direction (X1-X2) of the lower surface side portion 16 formed by being crushed by the first pressing die 130. Direction) dimension.

  The plate | board body which comprises the sucks 171 and 172 is being fixed to the side wall of the Y1 side end and Y2 side end of the lower mold | type 110. FIG. The sacks 171 and 172 function as a guide for positioning when the molding plate 10 is placed on the lower mold 110, and the pressing plate 10 is pressed when the molding plate 10 is pressed by the first pressing mold 130 and the second pressing mold 140. The molding plate 10 is supported so as not to be deformed or distorted by being sandwiched from the Y1 and Y2 directions. Further, plate bodies constituting the sacks 173 and 174 are fixed to the side walls of the upper mold 120 on the X1 side end and the X2 side end. The sack 173 is positioned on the X1 side of the first pressing mold 130, and the sack 174 is positioned on the X2 side of the second pressing mold 140 when the upper mold 120 approaches the lower mold 110 as shown in FIG. The sacks 173 and 174 are crushed by the first pressing die 130 and the second pressing die 140 while the forming plate 10 is sandwiched from the X1 and X2 directions when the molding plate 10 is pressed by the first pressing die 130 and the second pressing die 140. The clay is prevented from being extruded in the X1 direction and the X2 direction. Note that the sacs 171 to 174 may be fixed to the lower mold 110 and the upper mold 120 in combinations other than those described above. 5 and 6, the illustrations of the sacks 171 and 172 are omitted in order to make the lower mold 110 and the upper mold 120 easy to see.

  On the upper surface of the lower mold 110, as shown in FIG. 8, a convex portion 124 is provided integrally along the X1-X2 direction near the Y2 side end. When the molding plate 10 is placed on the upper surface of the lower mold 110, the convex portion 124 is fitted into the concave portion 12 of the molding plate 10 so that the concave portion 12 is not crushed during molding of the molding plate 10. Further, as shown in FIG. 10, a concave portion 123 is provided integrally on the lower surface of the upper mold 120 along the X1-X2 direction near the Y1 side end. When the molding plate 10 is sandwiched between the lower mold 110 and the upper mold 120, the concave portion 123 receives the convex portion 11 of the molding plate 10 so that the convex portion 11 is not crushed during molding of the molding plate 10. I have to.

  On the lower surface of the upper mold 120, a first convex portion 120 a and a second convex portion 120 b are provided in parallel to the concave portion 123 on the Y 1 side of the concave portion 123. FIG. 14 shows a state when the forming plate 10 is formed by the upper mold 120. As described above, the concave portion 123 receives the convex portion 11, and the first convex portion 120 a is fitted into the first groove 26 so that the first groove 26 is not deformed during molding of the molded plate 10. Further, the second protrusion 120 b forms the second groove 27. By forming the second groove 27 at the Y1 side end of the molding plate 10, the clay on the plate surface side of the molding plate 10 is moved to the Y1 side during the molding of the molding plate 10. In FIG. 14, the Y1 side end of the forming plate 10 is moved from the position indicated by the phantom line to the position indicated by the solid line. Movement at this time is regulated by the sack 171. In this way, the plate surface side of the molded plate 10 is linearly pressed to be deformed to the Y1 side, thereby deforming the molded plate 10 during the molding of the molded plate 10 as shown by a virtual line in FIG. Suppressed.

  Specifically, the clay around the lower surface portion 16 and the upper surface portion 17 is formed when the lower surface portion 16 and the upper surface portion 17 are formed by sandwiching the molding plate 10 between the lower mold 110 and the upper mold 120. Is pushed so that the periphery of the lower surface side portion 16 and the upper surface side portion 17 of the molding plate 10 is expanded to the Y1 side. When molding the lower surface side portion 16 and the upper surface side portion 17 so that such deformation does not occur, the four sides of the molding plate 10 are surrounded by the sacks 171 to 174, but there are slight gaps. As described above, the above-described deformation occurs in the molded plate 10. On the other hand, by forming the second groove 27 by the second convex portion 120b on the plate surface side of the molding plate 10 during the molding of the molding plate 10, the Y1 side of the molding plate 10 as shown by the phantom line in FIG. The deformation on the plate surface side of the forming plate 10 is suppressed by moving the clay on the plate surface side of the forming plate 10 to the Y1 side with respect to the deformation in which the end surface is recessed at the center in the X direction.

  FIG. 11 shows a control system of the press machine 100. A signal from the start switch 190 is input to the control circuit 180, and the control circuit 180 outputs an operation signal to the upper mold motor 120A, the first pressing actuator 150A, and the second pressing actuator 160A. . Although the detailed configuration is omitted, the control circuit 180 is configured by a sequence circuit. However, a control function similar to that of the sequence circuit may be realized by a microcomputer.

  FIG. 12 shows the control content realized by the control circuit 180. When activation is instructed by the activation switch 190, it is determined in step S1 whether or not the molding plate 10 has been transferred onto the lower mold 110. Before the transfer is completed, a negative determination is made in step S1 and the processing shown in FIG. 12 ends. However, when the transfer is completed and an affirmative determination is made in step S1, in step S2, the upper mold motor 120A is operated. The upper mold 120 is lowered toward the lower mold 110. At this time, the upper mold 120 is stopped at a position where it abuts on the molding plate 10 placed on the lower mold 110, and the position is held.

  In the next step S3, operation signals are output to the first pressing actuator 150A and the second pressing actuator 160A, and the first pressing mold 130 and the second pressing mold 140 are moved. As a result, the rear end portion 10C and the front end portion 10D of the molded plate 10 are press-molded. At this time, it is preferable that the movement of the first pressing die 130 and the second pressing die 140 has a slight time difference. Thus, even if there is air that is pushed into the hollow hole by the side that is first press-molded among the rear end portion 10C and the front end portion 10D of the molded plate 10, the air is discharged from the side that is later press-molded. Can do. The configuration for providing the time difference may be electrically performed by the control circuit 180, or may be mechanically performed by the first pressing actuator 150A or the second pressing actuator 160A.

  In the next step S4, a signal for returning the upper mold motor 120A, the first mold actuator 150A, and the second mold actuator 160A to the initial positions is output. As a result, the upper mold 120, the first pressing mold 130, and the second pressing mold 140 are returned to the initial positions to prepare for the next molding plate 10.

  According to the press machine 100 described above, when the lower surface side portion 16 and the upper surface side portion 17 are formed on the extruded molded plate 10, the molded plate 10 is formed at the rear end portion 10C and the front end portion 10D. 10 is pressed by the first pressing mold 130 and the second pressing mold 140 from the front surface 10A side and the back surface 10B side, respectively. At that time, the end of the hollow hole 23 of the molding plate 10 is closed by the pressing of the first pressing mold 130 and the second pressing mold 140. Therefore, it is not necessary to separately provide a step of closing the end of the hollow hole 23, and productivity can be improved. Further, when the molding plate 10 is pressed by the first pressing mold 130 and the second pressing mold 140, the front surface 10 </ b> A and the back surface 10 </ b> B of the molding plate 10 are in contact with the upper mold 120 and the lower mold 110. Therefore, when the lower surface side portion 16 and the upper surface side portion 17 are formed by the first pressing die 130 and the second pressing die 140, it is possible to suppress deformation and distortion of the molding plate 10. In addition, after the front surface 10A and the back surface 10B of the molding plate 10 are brought into contact with the upper die 120 and the lower die 110, the first pressing die 130 and the second die 140 are pressed by the first pressing die 130 and the second pressing die 140. When the molding plate 10 is pressed by the two-push mold 140, excess air enters the hollow hole 23, and air exceeding the original volume enters the hollow hole 23, so that the volume of the hollow hole 23 expands after molding. Is suppressed. Therefore, it is possible to suppress the deformation and distortion of the hollow hole 23 portion of the molded plate 10.

  The forming plate 10 formed by the press machine 100 has a shape that forms an inclined cut portion 10K as shown in FIG. The inclined cut portion 10K corresponds to a portion where the lower surface side portion 16 forming the step portion is formed. Therefore, when the part is pressed by the first pressing mold 130 and the lower surface part 16 is formed, the clay moves so as to close the hollow hole 23, but this clay is less because the part is cut. 24 and 25, it is possible to suppress the formation of bulges due to the movement of clay on the boundary wall surface 20. That is, when the clay is not cut, the amount of clay pressed by the first pressing mold 130 is A as shown in FIG. 3, and the amount of clay necessary for forming the lower surface side portion 16 forming the step portion is B. The amount of A-B clay moves so as to fill the hollow hole 23. Although the amount of clay required to fill the hollow hole 23 is C, the amount of clay of AB is larger than C, and therefore, the strain that the boundary wall surface 20 swells toward the lower surface portion 16 side occurs.

  On the other hand, when the inclined cut portion 10K is formed on the molded plate 10, the amount of clay pressed by the first pressing die 130 is less than A, so the amount of clay that moves to fill the hollow hole 23 is small. Thus, the distortion that the boundary wall surface 20 swells toward the lower surface portion 16 side is suppressed. Therefore, the amount of clay cut by forming the inclined cut portion 10K on the molded plate 10 is desirably A− (B + C).

  In FIG. 3, the portion where the lower surface side portion 16 is formed has been described. However, regarding the portion where the upper surface side portion 17 is formed, the idea is completely different only in the arrangement of the lower surface side portion 16 and the upper surface side portion 17. It is the same. Therefore, also for the portion where the upper surface side portion 17 is formed, by forming the inclined cut portion 10K at the front end portion of the molding plate 10, the distortion of the boundary wall surface of the upper surface side portion 17 bulging toward the upper surface side portion 17 is suppressed. .

  FIG. 4 shows an example in which the amount of clay at the end of the molded plate 10 is cut by the groove cut portion 10L. In this example, only the cut shape is different from that in the example of FIG. 3, and the same effect as the example described in FIG. 3 can be achieved by making the cut amount of clay the same.

  FIG. 15 shows an example of the unloading process after the press molding process. Here, the molded plate 10 is carried out by the negative pressure suction device 70. The negative pressure suction device 70 has a large number of negative pressure passages 73 formed in a main body 71 formed with an area corresponding to the surface 10 </ b> A of the molding plate 10, and supplies negative pressure to the negative pressure passages 73. In addition, a negative pressure chamber 72 is formed on the upper surface of the main body 71. A sponge 74 is attached to a portion of the lower surface of the main body 71 facing the surface 10A of the molding plate 10. When negative pressure is supplied to the negative pressure chamber 72, the sponge 74 becomes negative pressure between the lower surface of the main body 71 and the surface 10A of the molding plate 10, and the molding plate 10 is pressed by lifting the main body 71 in this state. It can be lifted from the machine 100 and carried out. Thus, the process of lifting the molded plate 10 from the press 100 by the negative pressure suction device 70 and carrying it out corresponds to the fourth process in the present invention.

  A trimming member 75 having a size corresponding to the upper surface of the lower surface portion 16 is fixed to a portion of the lower surface of the main body 71 facing the lower surface portion 16 of the molding plate. The trimming member 75 is brought into contact with the upper surface of the lower surface portion 16 when the negative pressure suction device 70 sucks and lifts the molding plate 10. At that time, the end portion of the trimming member 75 is in sliding contact with the boundary wall surface 20 of the molding plate 10. Therefore, even if the bulge remains on the boundary wall surface 20 as indicated by 20a, the bulge is removed by the sliding contact of the end of the trimming member 75.

  FIG. 16 shows an example in which a trimming process is performed on the molded plate 10 after it is unloaded from the press molding process. Here, the trimming process is performed by applying the blade of the cutter 80 to the boundary wall surface 20 of the molding plate 10. Therefore, the cutter 80 is supported by the cutter support 83 and is slidable by the slider 82 with respect to the support plate 81. That is, the support wall 81 is placed on the molding plate 10 so that the blade of the cutter 80 contacts the boundary wall surface 20 of the molding plate 10, and the cutter 80 is slid along the slider 82, thereby indicating 20 a on the boundary wall surface 20. The remaining bulge is removed.

  As described above, the boundary wall surface 20 can be cleaned by removing the swelling of the boundary wall surface 20 by the trimming member 75 and the cutter 80. As a result, when the ceramic plates 10 are arranged side by side and used as a roofing material or a wall material, the overlapping portions of the ceramic plates 10 can be continued without gaps, and measures against rain leakage can be made unnecessary.

  As mentioned above, although specific embodiment was described, this invention is not limited to those external appearances and structures, A various change, addition, and deletion are possible in the range which does not change the summary of this invention. For example, the ceramic board 10 can also be used as an inner wall material of a building or the like in addition to a roof material and an outer wall material.

10 Molded plate (extrusion molded plate, ceramic plate)
10A Front surface 10B Back surface 10C Rear end portion 10D Front end portion 10E Left end portion 10F Right end portion 10G First corner portion 10H Second corner portion 10J Third corner portion 10K Inclined cut portion 10L Groove cut portion 10a Cover portion 10b Covered portion 11 Convex part 12 Concave part 13 Engaging part 14 Protruding piece part 15 Bank part 16 Lower surface side part (step part)
17 Upper surface side part (step)
18 1st protrusion 19 2nd protrusion 20, 20a Boundary wall surface 21 Notch 22 Through hole 23 Hollow hole 24 Metal fitting 25 Passage 26 First groove 27 Second groove 51 Base 61 Roller row 62 Slider 63, 64 Guide bar 65 Cutter 70 Negative pressure suction device 71 Main body 72 Negative pressure chamber 73 Negative pressure passage 74 Sponge 75 Trimming member 80 Cutter 81 Support plate 82 Slider 83 Cutter support 100 Press machine 110 Lower mold 120 Upper mold 120A Upper mold motor 120B Slide 120a First convex part 120b Second convex part 122 Cutter 123 Concave part 124 Convex part 130 First pressing mold 130a, 130b Groove 140 Second pressing mold 150 First pressing means 150A First pressing actuator 160 Second pressing means 160A Second pressing actuator 171, 172, 173, 174 Sack 180 Control circuit 19 Start switch

Claims (4)

A first step of forming a plate-like molded plate having a plurality of hollow holes parallel to each other and made of a viscous material;
A second step of forming a step by partially crushing the end of the molding plate corresponding to the end of each hollow hole with a press,
Before the second step, comprising a third step of removing the viscous material at the portion corresponding to the stepped portion at the end of the molded plate,
In the third step,
At the time before the third step, the amount of the viscous body at the end of the molded plate corresponding to the stepped portion is A,
The amount of viscous material required to form the stepped portion at the end of the molded plate is B,
When the amount of viscous material necessary to close the end of each hollow hole is C,
A method for producing a molded plate, wherein an amount of viscous material corresponding to A- (B + C) is removed. In claim 1,
After the second step, comprising a fourth step of sucking and transferring the molding plate with a negative pressure suction device,
The negative pressure suction device includes a trimming member at a portion corresponding to the step portion, and when the molding plate is transferred in the fourth step, the trimming member is fitted into the step portion to A method for producing a molded plate, wherein an excess viscous material remaining on a boundary wall surface with the molded plate body is removed to make the boundary wall surface uneven. In claim 1 or 2,
After the second step, an excess viscous body remaining on the boundary wall surface by sliding the cutter along the direction intersecting the hollow hole so as to cut the boundary wall surface of the stepped portion with the molded plate body. A method for producing a molded plate, which removes the unevenness of the boundary wall surface. In any one of Claims 1-3,
In the second step, each direction is covered with a mold so as to suppress deformation of the molded plate other than deforming so as to form the stepped portion at the end of the molded plate,
In the second step, a die that presses the plate surface linearly along a side end portion that intersects an end portion of the molded plate where the stepped portion is formed, and opposes the viscous material at the side end portion. Method for manufacturing a molded plate that moves toward the surface.

Images