JP2774447B2 - Tile and its 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 ceramic tile, particularly an unglazed unglazed tile and a method for producing the same.

[0002]

2. Description of the Related Art In general, as a method for producing a ceramic tile, an extrusion method using an extruder is employed.

[0003] Among the clay tiles, unglazed clay tiles that are not glazed are, for example, silica stone,
A clay mixed with alumina, iron, feldspar or the like is used, and a clay for tile containing an appropriate amount of iron is used.

[0004] A general method of producing a tile is as follows. First, a clay containing an appropriate amount of iron is kneaded with a kneader as a raw material of the above-mentioned unglazed stoneware tile, and then a vacuum clay kneader and a kneader are used. It is formed into a tile cross-sectional shape as a tile body by a forming machine, and this is heated to a temperature higher than room temperature, for example, from 60 ° C. to 80 °.
C is dried with warm air for 2 to 3 days, finally sent to a firing furnace, and fired at 1100 ° C to 1250 ° C to finish the product.

[0005] The oxidation or reduction firing in the last firing step oxidizes the iron contained in the tile raw material and causes the surface to be variously shaded depending on the firing temperature such as reddish color or dark brown or the mixing ratio of iron. The result is the formation of an unglazed stoneware tile with a color.

It should be noted that, in the above-mentioned firing step, as described above, when each tile main body is fired, the surface of the tile is colored vividly because of the oxidation firing or the reduction firing. This is because the flame, i.e. the high temperature, directly touches the tile surface and is oxidized, so that there must be no obstruction between the tile bodies during firing, which blocks the surface of the tile bodies.

[0007] Further, the most important things in the above-mentioned tile manufacturing process are to reduce the manufacturing unit price by firing as efficiently as possible in the firing process, and to have a good yield as a product.

In the most recent prior art, the above-described firing step is performed as efficiently as possible. As shown in FIG. If the one formed in the tile cross-sectional shape is one unit, it is anastomosed integrally on the back side of each other, and a two-unit tile in a state where the through hole 21 and the cutout 22 are formed at the anastomosis boundary. The main body 23 is extruded and sent to the above-mentioned drying step in this state. Thereafter, the dried two-unit tile main bodies 23 are sequentially placed on a cart 24 for feeding into a firing furnace as shown in FIG. Are arranged in parallel to each other, and are further arranged directly in parallel in the same manner in a perpendicular state, and are arranged in parallel in such a manner.

After completion of the firing, as shown in FIG. 9, the two units of the tile body 23 are applied to the cuts 22 with an appropriate tool P such as a rag, so that the back surface of the tile unit 23 is applied. Tile T on which convex ridges 25 and concave ridges 26 alternately formed in the width direction on the side are formed
Is formed.

According to this manufacturing method, as shown in FIG. 8, two units of tile bodies 23 can be directly stacked vertically and horizontally in parallel on a trolley 24 and fired. Since there is no obstruction to the surface, there is no adverse effect on the color development of the surface.
Can be fired at once, so that taking only this firing step enables efficient firing, which contributes to a reduction in the manufacturing unit price in the firing step.

However, this conventional manufacturing method has a fatal disadvantage that the yield as a product is very poor. That is, as shown in FIG.
Is directly leaned in a multi-stage shape and fired, so that the product at the time of firing is bent or distorted as shown in FIG. Many occur. In order to avoid the occurrence of such curvature and distortion, it is necessary to increase the thickness of the tile main body 23, and there is a limit in reducing the thickness. Also, when the two-unit tile body 23 is cut from the cut 22 by the tool P after the firing is completed to finish the tile T,
As shown in FIG. 11, the uneven portion 27
In many cases, it cannot be used as a product, and the yield of finished products is low. Therefore, there is a disadvantage that the production unit price is not reduced.

It is to be noted that the above-mentioned vacuum kneading machine and forming machine are used to extrude or press the tile body of each unit formed into a tile cross-sectional shape as the tile body, and to bake it. However, in this case, since the tile body is thin, it cannot be leaned and fired, and as shown in FIG. Baking must be performed, and the amount to be fired at a time is limited, so that the firing efficiency is poor and the unit price is not reduced.

[0013]

As described above, in the conventional tile structure or the method of manufacturing the same, even if the firing efficiency of the firing step itself can be increased, the yield of the product finish is poor. Although no contribution could be made to the reduction, the present invention eliminates this drawback and improves the firing efficiency, and also improves the yield of the product finish, thereby contributing to the reduction of the product unit price. It is an object of the present invention to propose a tile that can be manufactured and a manufacturing method thereof.

[0014]

In order to solve the above-mentioned problems, in the invention according to claim 1, if the reference numerals shown in the embodiments are attached and shown, the surface side of the tile main body 1 is flat.
Is, on the back side of the tile body 1, the recess perpendicular with the convex portion 2 and the concave portion 3 became uneven alternately in the width direction is formed, in the longitudinal direction of the ridges 2 No. 4 employs a configuration of tiles formed innumerably at appropriate intervals in the longitudinal direction.

Further, in the invention according to claim 2, the extruder 5 flattens the front side and alternately forms the concave and convex portions in the width direction of the rear side. Is extruded, and the extruded tile body 1 has a flat roll 6 on the front side and an uneven roll 7 on the back side.
And a plurality of concaves 4 perpendicular to the longitudinal direction are formed at appropriate intervals in the longitudinal direction on the ridges 2 of the tile main body 1 by the concave-convex rolls 7 on the back side during the passage. Is adopted.

According to the third aspect of the present invention, the extruder 5 flattens the front side and alternately forms the concavo-convex shape in the width direction on the back side. and one unit tile body 1 with, and adopts the configuration of the process according to claim 2, wherein the tiles the tile body 8 of the plurality of units is extruded in a state of continuous in the width direction.

[0017] In the invention according to claim 4, tile according to claim 3, wherein the plurality of units of tile body 8 that is extruded in a state of continuous in the width direction is adapted to directly fed to a drying step Is adopted.

Further, in the invention according to claim 5, the plurality of tile bodies 8 having undergone the drying step are divided into one-unit tile bodies 1 and the divided one-unit tile bodies 1 are separated.
5. The method according to claim 3 , wherein the slags are directly stacked in a plurality of stages and sent to the firing step.
The configuration of the method for manufacturing a tile described above is employed.

[0019]

In the invention according to claim 1, the tile body 1
On the back surface side, there are formed convex ridges 2 and concave ridges 3 alternately formed in the width direction, and concave portions 4 perpendicular to the longitudinal direction of the convex ridges 2 are provided at appropriate intervals in the longitudinal direction. Therefore, even if a large number of tile bodies 1 are stacked in a firing furnace such that the front and back sides thereof are in direct contact with each other, the flame or high temperature is stacked vertically in oxidation firing or reduction firing. The flames and high temperatures spread evenly over the entire area of the front and back surfaces by invading the front and back surfaces of the tile body 1 from the recessed ridges 3 between the tile bodies 1 and 1 and the countless recesses 4 orthogonal thereto.
It does not adversely affect the oxidative coloring of the surface by oxidative firing or reduction firing.

Accordingly, since a large number of tile bodies 1 can be fired at once in the firing step, the firing efficiency can be greatly increased.

Further, since a large number of tile bodies 1 are stacked and fired so that the front and back surfaces thereof are in direct contact with each other, even if the tile bodies 1 are curved or distorted in the drying step in the previous step, this is not affected. In the firing step, the tile body 1 is softened by the high-temperature firing, so that the tile body 1 is corrected to a flat shape by the softening, and when the firing is completed, it is possible to finish the tile in an orderly state without curving or distortion. Therefore, it is possible to reduce the wall thickness, and to produce a thin-walled tile,
Good production finish yield.

Further, in the invention according to claim 2, the extruder 5 extrudes the tile main body 1 having the ridges 2 and the ridges 3 alternately formed in the width direction on the back side. The formed and extruded tile main body 1 passes between the flat roll 6 on the front surface side and the uneven roll 7 on the back side, and the ridge portion of the tile main body 1 is passed by the uneven roll 7 on the back side during the passage. In FIG. 2, since a number of concave portions 4 perpendicular to the longitudinal direction are formed at an appropriate interval in the longitudinal direction, the production is easy, and the production time is the same as the conventional one. There is nothing to raise the unit production price.

According to the third aspect of the present invention, the tile body 1 having the convex ridges 2 and the concave ridges 3 alternately formed in the width direction on the back side is extruded by the extruder 5. Since a plurality of tile bodies 8 are extruded in a state of being connected in the width direction in a unit, a large number of tile bodies 1 can be formed at a time, so that the manufacturing unit price is naturally reduced. Will contribute.

According to the fourth aspect of the present invention, since a plurality of tile bodies 8 extruded in a state of being connected in the width direction are sent to the drying step as they are, the width of the tile bodies 8 in the drying step is reduced. The generation of curving or distortion in the direction is prevented by being restricted by the tile bodies 1 of each other, so that curving or distortion hardly occurs.

In the invention according to claim 5, the plurality of tile bodies 8 having undergone the drying step are divided into tile units 1 per unit, and the tile bodies 1 divided per unit are divided.
Are directly stacked in a plurality of stages as they are and sent to the firing step, so that the tile body 8 at the time of passing through the drying step is not yet cured,
The dividing operation is easy, and even if a slight unevenness occurs during the dividing, it can be easily repaired. Then, the divided tile main bodies 1 for each unit are directly stacked on each other as they are and sent to the firing step, so that the operation from the drying step to the firing step is easy.

[0026]

FIG. 1 shows a tile according to an embodiment of the present invention. A strip-plate-shaped tile body 1 has a flat surface as shown at a and four rounded edges. In the longitudinal direction on the back side, convex and concave portions 2 and 3 are formed alternately in the width direction as shown by b and c. 2, a number of concave portions 4 which are perpendicular to the longitudinal direction and are slightly shallower than the depth of the concave ridge portions 3 are formed at an appropriate interval in the longitudinal direction.

FIG. 2 shows the shape of the tile main body 1 in the course of manufacturing. More specifically, FIG.
Using clay mixed with iron, feldspar and the like, first kneading with a kneading machine, then forming into a tile cross-sectional shape as a tile main body with a vacuum clay kneading machine and a shaping machine, and then forming a tile having a temperature higher than room temperature, for example, 60 It shows the shape until drying with warm air at 2 ° C to 80 ° C over 2 to 3 days.

That is, the extruder (vacuum kneader) 5 shown in FIG. 4 combines the tile main body 1 having the ridges 2 and the ridges 3 alternately formed in the width direction on the back side. This shows a state in which a plurality of units of the tile main body 8 are extruded in a state of being connected in the width direction, and a cut 9 is made in a boundary portion of each tile main body 1 as shown in FIG. It is. By forming a plurality of tile main bodies 1 at a time in a row in the width direction at a time in this manner, it is possible to naturally increase the production efficiency and to prevent the occurrence of curvature and distortion in the next drying step as much as possible. be able to.

The most important part of the present invention is that an uneven portion 7a is formed in the circumferential direction as shown in FIG.
As shown in FIG. 4, as shown in FIG. 4, a convex-concave shape formed by using an uneven roll 7 formed so as to extend over the entire area in the axial direction and having an irregular shape alternately formed in the width direction on the rear surface side by an extruder (vacuum kneader) 5. Article 2
Body 1 extruded to have a ridge 3
The tile body 1 passes between the flat roll 6 on the front side and the uneven roll 7 on the back side, and the tile main body 1 is moved by the uneven roll 7 on the back side during the passage.
As shown in FIG. 2A, a number of recesses 4 perpendicular to the longitudinal direction are formed on the convex ridges 2 at an appropriate interval in the longitudinal direction with a depth slightly smaller than the concave ridges 3. Has become.

As described above, after a plurality of units of the tile main body 8 are extruded in a state of being connected in the width direction, this is solidified to some extent by passing through a drying process. The worker is divided into the tile main bodies 1 by the manual operation or the mechanical operation along the cuts 9 described above. If there are slight irregularities at the time of division, repair with a knife or the like. Even if a slight curvature or distortion is generated in the tile main body 1 through the drying step, the tile body 1 is sent to the next firing step without being discarded.

FIG. 5 shows a stacked state of the tile main body 1 on a carriage 10 fed into a firing furnace, and shows a three-dimensional shelf 11 formed of fire bricks or the like framed in a multi-stage form.
A large number of tile bodies 1 are stacked in a plurality of stages, for example, four stages, with the front and back surfaces directly contacting each of the shelves 11a.
It is fired at 1250 ° C. for one day and one night, and then naturally cooled one day later and taken out of the firing furnace.

During firing, on the back side of the tile main body 1, ridges 2 having irregularities alternately formed in the width direction thereof are provided.
And the concave ridges 3 are formed, and the concave ridges 4 orthogonal to the longitudinal direction are formed in the convex ridges 2 innumerably at appropriate intervals in the longitudinal direction. Even if the stacking is performed so that the front and back sides are in contact with each other, the flame or high temperature in the oxidation firing or the reduction firing causes the indented portions 3 between the tile bodies 1, 1 stacked vertically and the innumerable rectangular portions 3 orthogonal thereto. The flame and the high temperature enter the front and back surfaces of the tile main body 1 from the concave portion 4 and spread evenly over the entire front and back surfaces, and do not adversely affect the oxidative coloring of the surface by oxidative firing or reduction firing.

Accordingly, since a large number of tile bodies 1 can be fired at once in the firing step, the firing efficiency can be greatly increased.

Further, since a large number of tile bodies 1 are stacked and fired so that their front and back surfaces are in direct contact with each other, even if the tile bodies 1 are curved or distorted in the drying step in the previous step, they are shown in FIG. Even if the tiles are stacked in this manner, in this firing step, the tile main body 1 is softened by high-temperature firing, so that the tile main body 1 or the shelf 11a can move along the flat surface of the lower tile main body 1 or each shelf 11a by the softening and the own weight of the tile main body 1 itself. When the firing is completed, the tiles can be finished in a regular state without curving or distortion.
Therefore, it is possible to reduce the thickness of the tile, to produce a tile having a small thickness, and to obtain a good yield in the production finish.

[0035]

According to the first aspect of the present invention, even when a large number of tile bodies are directly stacked in a firing furnace so that the front and back surfaces thereof are in contact with each other, the flame or high temperature is not increased in the oxidation firing or the reduction firing. The flames and high temperatures are uniformly distributed over the entire area of the front and back surfaces by invading the front and back surfaces of the tile body from the concave ridges between the vertically stacked tile bodies and countless recesses orthogonal to the ridges, and oxidative firing or reduction firing. Does not adversely affect the oxidative coloring of the surface due to the above, and therefore, a large number of tile bodies can be fired at once in the firing step, so that firing efficiency can be greatly increased.

Further, since a large number of tile bodies are stacked and fired so that the front and back surfaces thereof are in direct contact with each other, even if the tile body is curved or distorted in the previous drying step, this firing step is performed. Since the tile body is softened by high-temperature firing, the tile body is corrected to a flat shape by the softening, and when the firing is completed, it is possible to finish the tile in a regular state without curving or distortion. Therefore, it is possible to reduce the thickness of the tile, to produce a tile having a small thickness, and to obtain a good yield in the production finish.

According to the second aspect of the present invention, since the production is easy and the production time is the same as the conventional one, there is no increase in the production unit price in this molding step. After all, according to this manufacturing method, it is possible to significantly reduce the unit manufacturing cost of the tile.

According to the third aspect of the present invention, since a large number of tile bodies can be formed at one time, it naturally contributes to a reduction in the manufacturing cost.

According to the fourth aspect of the present invention, since a plurality of tile bodies extruded in a state of being connected in the width direction are sent to the drying step as they are, the width direction of the tile body during the drying step is reduced. The generation of curvature and distortion is restricted by the tile bodies and is prevented from occurring. Curvature and distortion are less likely to occur, and from this aspect, it is possible to contribute to a reduction in the manufacturing cost.

In the invention according to claim 5, since the tile body at the time of passing through the drying step is not yet cured, the dividing operation is easy, and a slight unevenness is generated at the time of the dividing. Can also be easily repaired. And
Since the divided tile units are stacked directly on each other and sent to the baking process, the work from the drying process to the baking process is easy, and this aspect also greatly contributes to a reduction in the manufacturing unit price. be able to.

[Brief description of the drawings]

FIG. 1 shows an embodiment of the present invention, in which a is a perspective view seen from the front side, b is a perspective view seen from the back side,
c is a side view.

FIG. 2 shows a tile main body in a manufacturing process according to an embodiment of the present invention, wherein a is a perspective view seen from the front side, and b is a perspective view seen from the back side.

FIG. 3 is a perspective view of a concavo-convex roll used in a manufacturing process of one embodiment of the present invention.

FIG. 4 is a perspective view showing a manufacturing process of one embodiment of the present invention.

FIG. 5 is a front view showing a main part of the manufacturing process.

FIG. 6 is a front view showing a conventional manufacturing process.

FIG. 7 is a perspective view showing a state in which a tile body of the related art is being manufactured.

FIG. 8 is a perspective view showing a firing state in a firing step of the tile main body of FIG. 7;

FIG. 9 is a perspective view showing a state of the product of FIG. 7;

FIG. 10 is a perspective view showing the state of the product of FIG. 7;

FIG. 11 is a perspective view showing the state of the product of FIG. 7;

[Explanation of symbols]

 REFERENCE SIGNS LIST 1 tile main body 2 convex ridge 3 concave ridge 4 concave 5 extruder 7 uneven roll 8 tile main body with tile main body 1 connected

Claims (5)

(57) [Claims] 1. A tile body having a flat front surface side, and a convex ridge portion and a concave ridge portion alternately formed in the width direction are formed on the rear surface side of the tile main body. A tile in which innumerable concave portions perpendicular to the longitudinal direction are formed in the convex ridge portion at an appropriate interval in the longitudinal direction. 2. The surface side is made flat by an extruder.
Then, a tile body having convex and concave ridges alternately formed in an irregular shape in the back side width direction is extruded, and the extruded tile body is a flat roll on the front side and an uneven roll on the back side. And a plurality of concave portions perpendicular to the longitudinal direction are formed at appropriate intervals in the longitudinal direction on the ridges of the tile main body by the concave and convex rolls on the back side while passing through. 3. The surface side is made flat by an extruder.
And, as a one unit tile body having its convex portion on the back side width direction becomes alternately uneven and concave portions, it is extruded in a state in which the tile body of a plurality units are continuous in the width direction A method for manufacturing a tile according to claim 2 . 4. The method of manufacturing a tile according to claim 3, wherein a plurality of units of the tile main body are directly sent to a drying step. 5. The tile body of a plurality of units having undergone the drying step is divided into tile bodies of each unit, and the divided tile bodies of each unit are directly stacked in a plurality of stages as they are and sent to the firing step. The method for producing a tile according to claim 3 or 4 , wherein the tile is adapted to be used.