JP2683482B2 - Decorative tile manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing decorative tiles for exterior and interior purposes, in which a decorative pattern is formed on the surface without using a glaze.

[0002]

2. Description of the Related Art Conventionally, as a method of producing a non-glaze tile having a decorative pattern without using a glaze, a method of adding a pigment when the raw material is in a sludge state, a de-sinter powder or an Eirich powder in the raw material. There is known a method of mixing granules and the like.

However, all the tiles obtained by these manufacturing methods have a single pattern, and are decoratively scarcely changed.

On the other hand, for example, Japanese Patent Publication No. 20-2096
As described in Japanese Unexamined Patent Publication No. 2 (1999), the inside of a powder mass into which a material is charged is divided into a plurality of parts, and different colored powders are charged into these divided parts, whereby a plurality of colors are formed in a mold. A manufacturing method of filling powder is also adopted. By such a method, it is possible to relatively easily manufacture a tile having a colored pattern that is rich in two or more colors.

[0005]

However, since the distribution of different kinds of colored powders is limited by the mold sections, only a limited pattern can be obtained. For example, a complex camouflage pattern is formed. You cannot do it.

Further, when a plurality of colors are to be produced, the charging process of the coloring raw material in two or more steps is required, which causes serious problems in workability and productivity.

As described above, in the manufacturing method in which the tile product having the pattern exposed on the surface is obtained by the pressure press, the pattern of the pattern is easily restricted, which is an obstacle to the expansion of product specifications.

The problem to be solved in the present invention is to obtain various patterns by a single charging operation of raw materials and to improve productivity.

[0009]

SUMMARY OF THE INVENTION The present invention is a method of manufacturing a tile in which a raw material is placed in a lower die of a press for a tile and the raw material between the upper die and the lower die is press-formed. It has a plurality of ingredients inside and has an opening at the bottom.
Also, one unit with a slidable shutter at the lower end
The hopper of is moved back and forth along the lower mold,
The shutter controls the opening and closing of the opening at the bottom of the hopper.
Therefore, if the raw material in the hopper is uniformly filled in the mold,
In addition, the desired decoration is revealed .

Further, a plurality of coloring raw materials are stacked and stored, and the coloring raw materials are dropped from the charging passage, and
The lower mold may be charged by moving the charging path along the lower mold.

Further, the inside of the hopper may be provided independently for each of a plurality of coloring raw materials.

[0012]

The plurality of coloring raw materials are dropped from the charging passage, and the charging passage is moved along the lower mold, so that the lower mold is controlled by the number of colors, the amount and the order of the coloring raw materials charged into the lower mold. An arbitrary pattern is formed on.

By making the charging paths for a plurality of raw materials into the lower mold independent from each other, the distribution of the raw materials corresponding to the positions of the charging paths with respect to the lower mold is achieved. Then, by moving the charging path with respect to the lower mold and changing its position, a pattern made of a plurality of raw materials corresponding to the movement locus can be obtained. Therefore, it is possible to obtain a pattern of a molded product while simultaneously charging a plurality of raw materials into the lower mold.

[0014]

EXAMPLE FIG. 1 is a front view showing the outline of tile forming equipment for carrying out the manufacturing method of the present invention.

In the figure, the pressing device 1 is provided with a lower mold 1a and an upper mold 1b, and after filling the creation space on the lower mold 1a side with a material, the upper mold 1b is lowered to press down the tiles. Mold. A charging device 2 for conveying and charging the material to the lower mold 1a is provided on the side of the pressing device 1. The charging device 2 is provided with a hopper 3 for filling a material, a shutter 4 for opening and closing an opening at a lower end thereof, and a drive unit 5 for driving the hopper 3 and the shutter 4.

The hopper 3 has a vertical cross-sectional shape whose upper end and lower end are open and whose opening area is gradually narrowed toward the lower end side. In the illustrated example, a single partition plate 3a is provided in the moving direction of the hopper 3. The inside thereof is partitioned into a first chamber 3b and a second chamber 3c.

The shutter 4 slides on the lower end surface of the hopper 3 to open and close the discharge ports of the first and second chambers 3b and 3c.

The hopper 3 and the shutter 4 are connected to the driving device 5a of the driving unit 5, respectively, and are movable independently of each other in the direction of the arrow in the drawing. The driving device 5a is controlled by the controller 5b, and the moving direction, moving speed, and timing are set using the operation panel 5c provided on the front surface.

The charging device 2 has the first and second chambers 3 with the lower end of the hopper 3 closed by the shutter 4 in the figure.
b and 3c are filled with the material, and the hopper 3 and the shutter 4 are
After being transported as a unit between the lower mold 1a and the upper mold 1b, the material is loaded into the lower mold 1a. At the time of this charging, for example, the hopper 3 is stopped and the shutter 4 is moved to the left at once, or the shutter 4 is simultaneously moved to the left while moving the hopper 3 to the left, and so on. The first and second
The charging pattern of the material in the chambers 3b and 3c to the lower mold 1a is variously changed. Of course, such operations of the hopper 3 and the shutter 4 are controlled by the controller 5b, and the operations are programmed in advance according to the pattern of the tile to be manufactured.

FIG. 2 is a perspective view showing an outline of the hopper 3 and the shutter 4. The first chamber 3b stores the raw material indicated by Δ, and the second chamber 3c stores the raw material indicated by x. These raw materials differ in color, particle size, etc., and tiles having various patterns can be formed by changing the distribution of these different raw materials when they are charged in the lower mold 1a.

FIG. 3 is a schematic diagram showing an example of distribution patterns of Δ and × raw materials.

FIG. 3A shows a pattern obtained by setting the hopper 3 right above the lower mold 1a and moving the shutter 4 to the left in FIG. In this case, the raw materials Δ and X corresponding to the size of the openings at the lower ends of the first and second chambers 3b and 3c are distributed separately in two regions.

Further, in FIG. 3B, the hopper 3 is attached to the lower mold 1
It is set right above a, the shutter 4 is moved to the left to make its stroke about half the length of the lower mold 1a, and the second chamber 3c is opened almost half. As a result, a distribution in which the Δ and X patterns are arranged from the right is obtained. Then, the shutter 4 is once closed, the hopper 3 is moved to the left, and the hopper 3 is positioned so as to correspond to the area where the raw material is not charged. After that, if the shutter 4 is moved so as to open about half of the second chamber 3c as in the previous case, the raw material patterns of Δ and × are obtained as in the right half pattern.

As described above, after forming various patterns in the lower mold 1a and pressing with the upper mold 1b, a tile product having a pattern according to the raw material pattern shown in FIG. 3 can be obtained. it can.

FIG. 4 is a schematic view showing an example in which a cutting plate 6 is provided on the bottom surface of the first chamber 3b of the hopper 3.

The cut-out plate 6 is incorporated in the lower end inside the first chamber 3b, and can be opened and closed by the shutter 4 as in the previous example. And the cutting plate 6
Shows that three slits 6a are opened as shown in (b) of the same figure, and the raw material of Δ is cut out from these slits 6a.

FIG. 5 shows Δ and × by the cutting plate 6.
It is a figure which shows the distribution pattern of the material of FIG. To obtain this pattern, the partition plate 3a of the hopper 3 may be set so as to be located at the right end of the lower mold 1a in FIG. 1, the shutter 4 may be opened, and the hopper 3 may be moved to the left.

FIG. 6 shows an example in which the plate 7 is arranged below the first chamber 3b of the hopper 3 in a direction orthogonal to the moving direction of the hopper 3.

The plate 7 is integrally mounted on the hopper 3 and can freely move in the direction of the arrow in the figure by an independent drive system. And the partition plate 3a of the hopper 3
Is set at the right end of the lower mold 1a, the shutter 4 is opened, and the plate 7 is moved while moving the hopper 3 to the left. By such an operation, as shown in FIG.
The raw material of Δ can be made to appear like a dough, and the raw material of Δ can be made to appear as a wavy pattern.

FIG. 8 shows the structure of the example of FIG. 6 provided with a sub-shutter for opening and closing the first chamber 3b.

The sub-shutter 8 is connected to the drive unit 5 so that it can operate independently of the shutter 4, the hopper 3 is set on the lower mold 1a, the shutter 4 is opened, and the plate 7 is opened as in the previous example. At the same time, the sub-shutter 8 is operated to intermittently close the first chamber 3b. By combining the movements of the plate 7 and the sub-shutter 8 as described above, it is possible to obtain a pattern in which the X raw material is used as the cloth and the Δ raw material is expressed as stripes as shown in FIG.

Further, FIG. 10 is a schematic view showing another example of the hopper, (a) of which is a perspective view thereof and (b) of which is a plan view thereof.

The hopper 9 comprises a large main chamber 9a for accommodating the material of x and two sub-chambers 9 for accommodating the material of Δ.
b. The sub chambers 9b are arranged in two rows at the right end of the main chamber 9a. The hopper 9 is also connected to the drive unit similarly to the example shown in FIG. 1, and the shutter 10 is attached as shown in FIG.

When the right end of the hopper 9 is set so as to coincide with the right end of the lower mold 1a and the shutter 10 is opened, x and Δ materials are charged from the main chamber 9a and the sub chamber 9b, respectively. As shown, the X and Δ raw materials can be made to appear as a striped pattern.

FIG. 13 is a schematic view of an example in which different raw materials are charged by two hoppers, (a) of the figure is a front view, and (b) of the figure is a plan view.

In the figure, the second hopper 12 is connected to the front surface of the first hopper 11 for accommodating the X raw material in the direction in which the first hopper 11 is moving toward the pressing device 1. These hoppers 11 and 12 have shutters 11a and 12 which can be independently opened and closed.
a. Then, the second hopper 12 is the first hopper 1
It is made possible to move in the direction of the arrow in the drawing by a driving device (not shown) in a direction orthogonal to the traveling direction with respect to 1.

When the two hoppers 11 and 12 are provided, the first hopper 11 is set right above the lower mold 1a, the shutter 11a is opened, and the X material is first charged into the lower mold 1a. . Next, when retracting the first and second hoppers 11 and 12, the shutter 12a of the second hopper 12 is opened, and the second hopper 12 is moved left and right as shown in FIG. As a result, a pattern is obtained in which the raw material of Δ is dispersed in a spotted manner on the surface of the raw material of x.

As described above, one hopper is divided into two parts so that different raw materials can be cut out independently, or various operations can be carried out from the two hoppers to give various patterns to the lower mold 1a. Can be made. Therefore, by making the colors of the raw materials different, for example, a camouflage pattern which is intricately intertwined can be obtained, and since the pattern is formed by the movement of the hopper, it is not necessary to charge the raw material lower mold 1a many times.

Further, FIG. 14 shows an example in which the hopper 13 is filled with three kinds of raw materials in layers and then charged into the lower mold 1a.

In this example, since three different kinds of raw materials are stored in the hopper 13, when the hopper 13 moves in the direction of the arrow in the figure with respect to the lower mold 1a, the lower raw materials are sequentially fed out. . Therefore, it is possible to form a tile in which three kinds of raw materials are arranged in a striped pattern as shown in FIG.

Further, FIG. 15 shows that two kinds of raw materials are used in the hopper 13.
This is an example of forming a tile having a striped pattern of these raw materials as in the case of FIG.

Even in this case, a striped tile can be obtained by moving the hopper 13 with respect to the lower mold 1a.
By making the moving speed of 3 slow and fast or changing the layer thickness, it is possible to form a pattern in which the thickness of the stripe is variously changed.

Similar to FIGS. 14 and 15, FIGS. 16 and 17 show two kinds of raw materials stored in the hopper 13.
The striped pattern has variations depending on the shape of the discharge port of the hopper 13.

In the case of FIG. 16, as shown in (a) of the same figure, the discharge port of the hopper 13 is inclined with respect to the moving direction, so that as shown in (b) of the same figure. Diagonal stripes can appear on a square tile.

In the example of FIG. 17, the discharge port of the hopper 13 has a gentle wave shape as shown in FIG. 17A, and the tiles obtained by this have two types as shown in FIG. It is possible to give a wave pattern by the raw material of.

[0046]

According to the present invention, a plurality of coloring materials are charged into the lower mold by dropping them from the charging path and moving the charging path along the lower mold. , A pattern made of multiple coloring materials is formed in the lower mold,
By pressing this, a pattern composed of a plurality of colors can be easily formed on the tile surface by a single operation.

By stacking a plurality of coloring raw materials and storing them, the coloring raw materials are dropped from the charging passage, and the charging passage is moved along the lower mold so that the coloring raw materials are charged into the lower mold. It is possible to easily form an arbitrary pattern composed of a plurality of colors.

Further, by making the charging passages independent for each of a plurality of coloring raw materials, different coloring raw materials can be formed in an arbitrary distribution ratio in the lower mold in correspondence with the movement trajectory of the charging passages. It is possible to efficiently produce an arbitrary pattern tile having a variety of colors.

[Brief description of the drawings]

FIG. 1 is a schematic diagram of a tile forming facility for carrying out the method of the present invention.

FIG. 2 is a perspective view of a hopper in FIG.

FIG. 3 is a diagram showing an example of forming a pattern of a raw material by the hopper of FIG.

FIG. 4 is an example in which a cutout plate is provided at a lower portion of a hopper, in which FIG. 4A is a perspective view thereof and FIG. 4B is a perspective view of the cutout plate.

5 is a diagram showing an example of forming a pattern of a raw material obtained by the hopper of FIG.

FIG. 6 is a schematic view showing an example in which a blind plate is provided at the bottom of a hopper.

7 is a diagram showing an example of forming a pattern of a raw material obtained by the hopper of FIG.

FIG. 8 is a schematic view showing an example in which a sub-shutter is further added to the example of FIG.

9 is a diagram showing an example of forming a pattern of a raw material obtained by the hopper of FIG.

FIG. 10 is another example of the hopper, in which FIG. 10A is a perspective view thereof and FIG. 10B is a plan view thereof.

11 is a diagram showing a situation in which the hopper of FIG. 10 is provided with a shutter.

12 is a diagram showing an example of forming a pattern of a raw material obtained by the hopper of FIG.

FIG. 13 is an example including two hoppers, (a) of which is a front view thereof and (b) of which is a plan view.

FIG. 14 is an example of accommodating three types of raw materials in layers in a hopper and exposing a striped pattern of these raw materials on a tile. FIG. 14A shows the storage of raw materials in a hopper. Schematic diagram, (b) of the figure is a diagram showing the obtained tile.

FIG. 15 is an example in which two kinds of raw materials are stored in layers in a hopper, wherein (a) of the figure is a schematic diagram thereof, and (b) of the same figure is a moving speed of the hopper, a thickness of a raw material layer, etc. It is a figure which shows the tile which has a striped pattern which changes variously with.

FIG. 16 is an example in which the discharge port of the hopper is inclined with respect to the moving direction thereof, (a) of the figure is a schematic diagram thereof, and (b) of the figure shows the obtained tile.

FIG. 17 is an example in which the discharge port of the hopper has a wavy shape,
(A) of the figure is a schematic diagram thereof, and (b) of the figure shows the obtained tiles.

[Explanation of symbols]

1 Press Device 4 Shutter 1a Lower Die 5 Drive Unit 1b Upper Die 6 Cutting Plate 2 Charging Device 7 Plate 3 Hopper 8 Sub Shutter 3a Partition Plate 9 Hopper 3b First Chamber 9a Main Chamber 3c Second Chamber 9b Sub Chamber 10 Shutter

Claims (3)

(57) [Claims] 1. A method for manufacturing a tile, comprising charging a raw material into a lower mold of a pressing device for a tile and press-molding the raw material between an upper mold and a lower mold, wherein a plurality of tiles are provided inside. Raw material
It can be stored and has an opening at the bottom and can slide freely at the lower end
A hopper with a simple shutter is placed along the lower mold.
And reciprocate, and the shutter causes
Adjust the opening at the bottom of the hopper to adjust the opening
A method for producing a decorative tile, which comprises uniformly filling a mold and allowing a desired decoration to appear . 2. A plurality of coloring raw materials are stacked and stored, the coloring raw materials are dropped from the charging passage, and the charging passage is moved along the lower mold to thereby move to the lower mold. The method of manufacturing a decorative tile according to claim 1, wherein the decorative tile is loaded. 3. The method of manufacturing a decorative tile according to claim 1, wherein the inside of the hopper is made independent for each of a plurality of coloring raw materials.