JP2713909B2 - Ceramic plate manufacturing equipment - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Application Field] The present invention forms a hollow continuous body by continuously extruding a raw material containing clay as a main component, and quickly and quickly dry the hollow continuous body. The present invention relates to an apparatus for continuously manufacturing hollow ceramic plates and the like by cutting into a baking furnace useful for baking a long body in a short time after cutting into a fixed length with a traveling cutter. [Conventional technology] For tiles and tiles, a continuous molded product sent from a molding machine is cut into short lengths, and further molded by pressing or the like, and then dried and fired, or a mold is filled with a material. It was manufactured by pressing, then drying and firing. It has also been known to use a microwave heater and a far-infrared heater to shorten the drying time. Moreover, temperature control was not easy for firing, and a tunnel dryer was used. [Problems to be Solved by the Invention] In this apparatus, since drying and baking steps require several days, productivity, cost, and drying in a continuous body in relation to location,
It could not be cut into a predetermined length and fired. Further, in the conventional apparatus, there is a disadvantage that the tile and the tile are twisted or cracked during drying and firing because the method of drying the uncured tile and the tile from the surface. Furthermore, in the conventional apparatus, the extruded body immediately after being extruded is soft, so it must be cut and dried to form a long body. Could only be produced. Further, in the conventional production method and apparatus, for example, since the extruded hollow molded body is dried by waste heat of a firing furnace, it is a method of drying from the surface of the extruded hollow molded body, so it takes several days to dry, and about 8 hours for firing. There was a drawback to spend. In addition, due to such a process requiring a long time, this type of conventional method cannot form a linear integrated line from extrusion to drying or firing furnace. That is, when this line is manufactured, there is a disadvantage that it requires enormous cost, vast land, and expensive energy cost. Also, if the hollow molded body is simply dried by microwaves or the like and the drying time is to be significantly reduced, an increase in the water vapor pressure and condensation in the hollow portion may occur in the hollow portion,
If the inner wall of the hollow portion and the outer surface are not properly dried due to misalignment between the inner wall and the outer surface, deformation such as explosion, generation of cracks, warpage, and twisting occurs. Moreover, in order to reduce the moisture content of the extruded product to 1% or less, it is necessary to raise the temperature of the microwave to 130 ° C. or higher. However, it takes considerable time and energy loss to raise the temperature to this temperature. In addition, there is a method of drying using far-infrared rays instead of microwaves, but raising the temperature of the extruded product to 130 ° C or more is much shorter than microwaves, but the weak point is that drying time is longer. there were. Further, in the tunnel dryer, since the dried bodies are stacked in multiple stages through the soot and baked, there are drawbacks that a lot of time is required for laminating the long body and a large number of sours are required for firing. Further, there is a disadvantage that such a long time is required when firing by baking step by step. [Means for Solving the Problems] The present invention has a core for forming a hollow hole in an extruded product, and air is supplied to the core from the outside in order to eliminate such disadvantages. An extruder for continuously extruding raw materials mainly composed of clay in a predetermined shape, and conveying the extruded product from the extruder to the next step. A transporter, at least a microwave heater and a far-infrared heater are arranged in series, and a dryer for rapidly drying the transported extruded body, and an extruded dry molded body delivered from the dryer are defined. Traveling cutter for cutting into length, take-out machine to be transported to the next process, 150 ~ 7
00 ° C preheating area, 800-1300 ° C firing area, 600-100 ° C
And a first cooling region for firing the dried body.
A long firing molded body comprising a second firing furnace and a second firing furnace for setting the temperature at 700 to 1300 ° C. and performing glaze firing, main firing, painting, and inglazing on the fired molded body. It is intended to provide an apparatus for manufacturing a hollow ceramic plate which can be produced in large quantities in a short time, at a low cost, without cracks, twists, warpages or bendings. [Embodiment] Hereinafter, an embodiment of a porcelain plate manufacturing apparatus according to the present invention will be described in detail with reference to the drawings. FIG. 1 is an explanatory view showing a typical example of the above apparatus. In the drawing, reference numeral 1 denotes an extruder for extruding a raw material mainly composed of clay into, for example, a shape as shown in FIG. 2, and the extrusion speed varies depending on the shape, width and thickness of the extruded hollow molded body A. Is about 200
~ 2000 mm / min. In the case of extruding the extruded hollow molded article A as shown in FIG. 2, for example, an extruded hollow molded article having a hollow portion through a base 2 and a core 3 as shown in FIGS. The molded body A is continuously extruded. More specifically, the core 3 supplies air to the plurality of outlets 4 and the common part 5 from outside, or air from inside,
The outlet 4 is formed in a hollow body having the same cross-section as the cross-sectional shape of the hollow part a of the extruded hollow molded body A. It is formed integrally with the common part 5 so as to correspond to the arrangement of the hollow parts a of A. Moreover, the core 3 is an extruder
The clay extruded from the extruding port 1 ′ is formed, for example, in a streamlined shape from the tip 3 a to the non-end 3 b so that the clay 2 can be extruded from the die 2 with a continuous body having a hollow part a of a predetermined shape without any trouble. It is. A required amount of one or more of air, dry air, wet air, hot air, etc. is supplied to the hollow portion 3c of the core 3 from a pump 7 installed outside via a hose 8, or the water vapor in the hollow portion a is discharged. In addition to promoting the drying of the hardly-dried hollow portion a of the extruded hollow molded body A, it functions to eliminate adverse effects such as deformation at that time. The above-mentioned clay is a natural product and has different components depending on the place of production. These advantages and disadvantages are mutually offset to obtain a predetermined mixed clay. As a specific example, pottery stone, feldspar, kaolinite, halloysite, metahalloysite, Kibushi clay, Frogme clay, Shigaraki clay, chamotte, and the like are crushed and kneaded with water. The clay may be iron-removed by a magnet if necessary. Reference numeral 9 denotes a conveying device which conveys the soft extruded hollow molded body A extruded from the extruder 1 to the next step without deforming and in synchronism with or almost in synchronism with the extrusion speed. Examples of the configuration include those shown in FIGS. 4 (a) to 4 (e).
(A) is a transporter 9 composed of only a free roller 10, (b)
The figure shows a conveyor 9 in which a backup roller 12 having a free roller structure is provided on a drive belt 11, (c), (d) shows (a),
Conveyor 9 which combined the (b), in (e) drawing (a) view and a conveyor 9 which either one of the driving rollers Furirora 10. Reference numeral 13 denotes a dryer which dries the moisture of the extruded hollow molded article A containing about 22 to 15% of water to about 8 to 1% without change in shape in about 5 to 30 minutes,
This is one of the main reasons for producing a dried plate A obtained by firing a soft extruded hollow molded body A (hereinafter, referred to as an extruded molded body). 5 (a) to 5 (d) show specific examples thereof. FIG. 5 (a) shows a dryer 13 in which a microwave heater 14 and a far infrared heater device 15 are arranged in series, and FIG. a) A dryer 13 that supplies hot air from the hot air zone 16 to the atmosphere shown in the figure.
(C) shows a dryer 13 in which hot air zones 16 are arranged in series in FIG. The microwave heater 14 has a continuous oven structure, and mainly converts the microwave into heat energy without penetrating the inside of the extruded product A and conducting heat for a few seconds to several seconds. It has the ability to generate heat in minutes and evaporate 5 to 10% of the water in the clay. The volume of the extruded product A shrinks until the water content becomes about 5 to 8%. However, when the water content is less than 5%, the volume does not shrink. Is a free roller,
Alternatively, it is composed of a combination of a free roller and a drive belt (including a net belt) having a speed corresponding to the contraction of the extruded product A. The far-infrared heater 15 is used to reduce the water content of the extruded product A to about 1 to 0%.
The temperature is raised to 130 ° C. or higher, and the transport means includes one or more of a free roller, a drive roller, and a drive belt.
Further, the hot air zone 16 blows hot air at a temperature of about 60 to 150 ° C. depending on the purpose. 17 is a traveling cutter,
The dried extruded product A is cut into a predetermined length. Reference numeral 18 denotes a take-out mechanism for feeding the dried plate A, which has been dried and cut to a predetermined length, to the next step, and can convey it at a speed higher than the extrusion speed. Reference numeral 19 denotes a primary baking furnace made of a roller hearth kiln, which bake the drying plate A continuously at a temperature of 700 to 1300 ° C. in a short period of time. It is much more compact than that. That is, the primary firing furnace 19 is as shown in FIG.
It becomes a mountain-like temperature distribution from the inlet 19a to the outlet 19b, and is divided into the preheating region 20, the firing region 21, and the cooling region 22 in this order.The temperature of the preheating region 20 is 150 to 700 ° C, and the firing region 21 is
800 to 1300 ° C., and the cooling area 22 is set to about 600 to 100 ° C. Of course, depending on the type and composition of the clay, the temperature setting between the respective regions is different, and the temperature between the respective regions is not a clear division but a tentative division in continuous firing. Further, the first firing furnace 19 will be described. The first firing furnace 19 burns a combustible gas, for example, an LPG gas, to fire the drying plate A, and the arrangement of burners (not shown) for that purpose is as follows. It is provided corresponding to each of the regions. Further, as a conveying means of the drying plate A in the firing furnace 19 , a mesh belt, a metal roller, a ceramic roller,
An alumina roller or the like is used. In particular, since the temperature in the range of the sintering region 21 rises to about 1300 ° C., for example, as shown in FIG. 7, an alumina roller 25 is placed between the metal spindles 23 and 24 to conduct heat conduction. The sheet is conveyed without being transmitted to the drive source. The sintering region 21 of the first sintering furnace 19 is made of a furnace made of refractory bricks and the like, and is made to pass straight through the furnace. An exhaust damper (not shown) is provided between each device and region. ) Is provided. Numeral 26 is for firing the fired body A, which has been primarily fired in the secondary firing furnace, directly or after cooling to room temperature, and then firing at 700 to 1300 ° C.
It is the same as the next firing furnace 19, and performs glaze baking, main baking, painting, ingress and the like. Next, the operation will be described. First, a clay consisting of Shigaraki clay, chamotte, water reducing agent and water is prepared as a raw material. The weight percentage is, for example, 61.5% of Shigaraki clay, 18% of chamotte, 0.5% of water reducing agent (trade name: Cellflow, manufactured by Daiichi Kogyo Seiyaku Co., Ltd.), and 20% of water by a dough kneader (MP-100 type manufactured by Miyazaki Tekko Co. ). Further, as the extruder 1 , a model name MV-FM-A-1 (manufactured by Miyazaki Iron Works) having an extrusion capacity of 100 to 150 l / hr was used. The pump 7 connects the dry air heated by compression at the time of blowing to 20 to 50 ° C. with a ring blower to the connection pipe 6 exposed to the outside of the base 2 through the hose 8, and connects another hose (not shown) to the micro tube. The wave heater 14 was connected to the air inlet / outlet. The far-infrared heater device 15 is a far-infrared heater.
Ten pieces are arranged in 10 meters, and the moisture inside the extruded product A is diffused to the surface to speed up the dehydration, and the moisture can be reduced to 1% or less. Further, the extrusion speed of the extruder 1 is
Extruded at the cross section shown in Fig. 2 at 200mm / min, the extruded body A is cut to a length of 900mm and 3030mm, and the straight line distance from the base 2 to the traveling cutter 17 is 15m.
And Of course, the length of this line is set in accordance with the shape, size, and thickness of the extruded product A. The maximum temperatures of the first sintering furnace 19 and the second sintering furnace 26 are set to 1200 ° C. and 1000 ° C. with temperature curves matching the compositions. The pass line of the extruded body A was set at the same height, and the moving speed of the conveyor 9 was set to be a little higher than the extruding speed. This is to prevent the extruded body A from being deformed by being pressed even though it is soft. Then, the raw material mainly composed of clay is continuously extruded from the extruder 1 onto the conveyor 9 in a cross section shown in FIG. The extruded product A extruded is fed to the microwave heater 14 at the above-mentioned speed, and while passing through the space to be heated of the microwave heater 14, the extruded product A and the hollow part a of the extruded product A are A large amount of water vapor generated by microwave heating by air or the like fed to the surface is blown off simultaneously inside and outside the hollow portion a to make the environment easy to evaporate, thereby eliminating the occurrence of dew condensation and making the soft extruded body A soft. In a short time, increase the rigidity to an average, avoid cracking, warping, explosion due to overheating, and evaporate 1/3 of the moisture content of the extruded body A in about 5 to 10 minutes, and from the outlet The extruded product A was fed to the far-infrared heater device 15, dried to a moisture content of 1% or less, fed to the traveling cutter 17, and the dried continuous strip-shaped extruded product A was cut into a predetermined length. The extruded body A was dried in a short time of about 15 to 30 minutes from extrusion to cutting and as a continuous body. In addition, when the extruded product A was simply heated using microwaves, the extruded product A was rapidly heated from the inside in a short period of time, so that the explosion and dew condensation had a serious adverse effect, making it impractical. Next, a predetermined length, for example, 606 to 7272 mm
The dried plate A 'cut into a predetermined position is fed to the primary furnace 19 through the take-out mechanism 18, preheated, fired, cooled, and sent out as a fired body A "from the outlet. The product is cooled, painted, glazed, and sent to the second firing furnace 26, where it is fired at 100 ° C. to obtain a product.The firing time is the thickness, size, and length of the dried plate A ′. It depends on the feeding, temperature control, etc., but it takes about 30 minutes to 3 hours, and the porcelain plate produced by this device has no crack, warp, twist, explosion and has a predetermined length. Is merely an embodiment of the apparatus according to the present invention, and a glaze machine, a painting machine, and a printing machine can be provided at the positions indicated by dashed lines in Fig. 1. Further, extruded products A and B 8 (a) to 8 (m), 9 (a),
(B), it can also be formed as shown in FIGS. 10 (a) and (b). 10 (a) and 10 (b) show an extruded product A in which an air vent hole and a slit are formed on the back surface. [Effects of the Invention] As described above, according to the apparatus for manufacturing a porcelain plate according to the present invention, extrusion of clay, reduction of moisture, drying, firing, cooling,
There is a great feature that firing can be performed in a straight line, within a short time, and at a high speed as a long body. In the present invention, in the case of a hollow extruded molded product containing about 22 to 15% (by weight) of water, two-stage heating and blowing of air or the like to the hollow portion, the exposed surface, and the heated space of the extruded hollow molded product are performed. This eliminates steam, dew condensation, etc., which are generated in large quantities during heating, from the inside and outside of the extruded hollow molded body, from the atmosphere, and creates an environment that is easier to dry, so there is no crack, warpage, torsion, explosion during drying and continuous It has the characteristic that it can be dried quickly by the body.
Productivity was 10% faster than the speed required in the past few days.
It is characterized in that it can be dried in about 60 minutes, then cut into a predetermined length, and fired twice in about 60 minutes to 6 hours. Furthermore, although the volume of the extruded hollow molded article shrinks by 10% or more during drying compared to the volume at the time of extrusion, there is an advantage that the adverse effect on the extruded hollow molded article can be absorbed by a free roller and a drive belt or the like to produce the extruded hollow molded article. Further, in the present invention, since the steps from extrusion to drying are arranged in series, there is a feature that a long body and a continuous body can be dried quickly. Furthermore, since the glaze can be formed thinly and accurately on the fired extruded product, an expensive glaze can be reduced and used.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic structural view showing an embodiment of a porcelain plate manufacturing apparatus according to the present invention, and FIGS. 2 (a) to 8 (n) and 9 (a).
To (c), FIGS. 10 (a) and (b) are explanatory diagrams showing an example of an extruded product, and FIG. 3 (a) is an explanatory diagram showing an outlet of an extruder for extruding an extruded hollow molded product. (B) is an explanatory diagram showing the extracted core, FIGS. 4 (a) to (e) are explanatory diagrams showing an example of the transporter, and FIGS. 5 (a) to (d) are examples of the dryer. FIG. 6 is an explanatory view showing a configuration example of a primary and secondary firing furnace, and FIG. 7 is an explanatory view showing an example of a firing area. 1 ... Extrusion molding machine, 3 ... Core, 7 ... Pump, 9 ...
Conveyor, 14: microwave heater, 15: far-infrared heater, 17: traveling cutter, 19 , 26 : primary and secondary firing furnaces.

Claims (1)

(57) [Claims] Having a core for forming a hollow hole in the extruded body,
The core has a function of supplying air from the outside and sending air into the molded body, and an extruder for continuously extruding a raw material mainly composed of clay in a predetermined shape, and an extruder for extruding from the extruder. A transporter for transporting the formed product to the next step, a dryer configured to arrange at least a microwave heater and a far-infrared heater in series, and a dryer for rapidly drying the transported extruded product; A traveling cutter that cuts the extruded and dried molded product sent out from the machine to a fixed size, a take-out machine that conveys to the next process, a preheating region of 150 to 700 ° C, a firing region of 800 to 1300 ° C, 6
A first baking furnace for baking the dried body, and a baking formed body with a temperature set at 700 to 1300 ° C. An apparatus for manufacturing a porcelain plate, comprising a secondary firing furnace for attaching and inlaying.