JP2949868B2 - Production of patterned inorganic products - 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 a patterned inorganic product on which a pattern such as marble is formed.

[0002]

2. Description of the Related Art Recently, large-sized colored ceramic plates are attached to inner and outer walls and floors to enhance the appearance of buildings.

[0003] Such a large-sized ceramic plate with a color pattern is conventionally produced by a dry press molding method. That is, a mixed powder of a base slurry raw material and a coloring raw material (pigment) is raised and filled in a lower mold for press molding, and pressed to form a multicolored ceramic plate. However, according to this method, since both raw materials are composed of particles, only a spot pattern is formed, and the degree of freedom of pattern formation is reduced. Also, recently, a casting method has been proposed and partially put into practical use. In this method, about 30% of water is added to and mixed with a base slurry and a colored slurry in a mixing device to form a mixed slurry, which is passed through a pipe communicating the mixing device and the casting mold in the casting mold. And molded by casting in a molding die, and then the molded article is demolded and fired to form a colored ceramic plate. According to this method, the mixed slurry produced by the mixing device can be directly injected into the molding die through a pipe line, and the mixed powder is filled in the lower die for press molding as in the dry press molding method described above. There is an advantage that work is quick and easy without taking time, and continuous operation is also possible. However, this casting method has a disadvantage that the base slurry and the colored slurry are uniformly mixed during the mixing in the mixing device, so that the whole becomes a uniform color and the pattern cannot be formed. However, continuous operation is possible,
In addition, if a method of producing a patterned inorganic product having a high degree of freedom in pattern formation is developed, a ceramic plate having various color patterns can be efficiently manufactured.

The present invention has been made in view of such circumstances, and an object of the present invention is to provide a method for producing a patterned inorganic product which can be operated continuously and has a high degree of freedom in pattern formation.

[0005]

In order to achieve the above object, a method for producing a patterned inorganic product according to the present invention comprises a step of intermittently mixing a colored slurry into a first base slurry, (1) A step of press-fitting the base slurry into a molding recess of a mold having water permeability from a plurality of horizontal casting holes formed in the side surface of the lower mold at predetermined intervals in a lateral direction, and the intermittent coloring in the molding recess. After filling a predetermined amount of the first base slurry in a predetermined shape, the second base slurry is cast from a central casting port formed upward on the bottom surface of the lower mold, and the intermittently colored first base slurry is cast therein. Pressing the mold against the mold surface with pressure and dewatering and molding using the water permeability of the mold,
And a step of removing the molded product.

[0006]

According to the method of manufacturing a patterned inorganic product of the present invention, a colored slurry is intermittently mixed into a first base slurry, and the intermittently colored first base slurry is laterally spaced apart from the lower mold by a predetermined distance. Are press-fitted into the molding recesses of the mold having water permeability from the plurality of horizontal casting holes formed by the above. Therefore, in the forming concave portion, a plurality of strip-shaped intermittent colored patterns extending from each horizontal casting port are formed at predetermined intervals by the intermittent colored first base slurry press-fitted from the plurality of horizontal casting ports. (Same number as horizontal casting port). In addition, since the streak-shaped intermittently colored pattern is formed along the press-fitting direction when the intermittently colored first base slurry is press-fitted into the molding recess, the reproducibility is directional, and When mixing colored slurry into one base slurry, the pattern shape can be freely changed by changing the amount and mixing interval. In addition, the intermittent colored first
After filling a predetermined amount of base slurry, lower the second base slurry
By casting the intermittently colored first base slurry onto the mold surface with the casting pressure and dewatering the mold using the water permeability of the mold. I have. Accordingly, the intermittently colored first base slurry filled in the molding recess is pushed upward as it is without being deformed by the second base slurry. While the first base slurry and the second base slurry are tightly integrated,
The intermittently colored first base slurry is uniformly pressed against the mold surface by the casting pressure of the base slurry, and at the same time, depressurized and dewatered using the water permeability of the mold. Therefore, at the time of the pressure dehydration, the streak-shaped intermittently colored pattern formed in the molding recess does not deform and appears as a streak-like intermittently colored pattern in the obtained molded article.

Next, the present invention will be described in detail based on embodiments.

[0008]

FIG. 1 shows an example of an apparatus for producing a patterned ceramic plate used in the method of the present invention. In the figure, 4, 5, 6
Is a rotary displacement type single-shaft eccentric screw pump. A colorless first base slurry 1 flows into the first pump 4 through the suction pipe 4a, and after the flow, the first pump 4 is moved from the first pump 4 to the first main pipe 7 by a pumping action. To be pumped. The second pump 5
The colored slurry 2 flows into the inside through the suction pipe 5a, and after the inflow, the second pump 5 and the first pump 4
Is fed to the connecting pipe 8 at a pumping pressure higher than the pumping pressure. Further, the second base slurry 3 flowing into the third pump 6 through the suction pipe 6a is pumped from the third pump 6 to the second main pipe 9 by a pump action.

The connecting pipe 8 is connected to the first main pipe 7, and the first switching valve 10 provided in the connecting pipe 8 is connected to the first return pipe 17. The first switching valve 10 periodically (for example, every 10 seconds)
It can be switched. That is, the upstream portion 8a and the downstream portion 8 of the first switching valve 10 of the connecting pipe 8
b and the upstream portion 8a of the connecting pipe 8 and the first
A slurry communication state in which the return pipe 17 is shielded, and a return in which the upstream part 8a and the downstream part 8b of the connection pipe 8 are shielded and the upstream part 8a of the connection pipe 8 communicates with the first return pipe 17. State and the first switching valve 10
Is switched.

A pressure gauge 12 and a second switching valve 11 controlled by a first solenoid valve 26 connected to the pressure gauge 12 are provided at the distal end of the first main pipe 7. 11 is connected to the discharge pipe 13. Also,
A branch pipe 14 is connected to the end of the first main pipe 7, and this branch pipe 14, as shown in FIG.
On the way, it branches into five pipe sections 14a to 14e (the same number as the five horizontal casting ports 22 provided in the lower mold 20 of the molding die 24), and each branched pipe section 14a to 14e is a side of the lower mold 20 respectively. It is connected to the casting port 22. Then, the pressure gauge 12 detects a pressure increase in the molding recess of the molding die 24, and when the indicated value of the pressure gauge 12 reaches a certain value, activates the first solenoid valve 26 and switches the second switching valve 11. It is like that. That is, a fluid communication state in which the upstream portion 7a and the downstream portion 7b of the second switching valve 11 of the first main pipe 7 communicate with each other to shield the upstream portion 7a of the first main pipe 7 from the discharge pipe 13 is provided. The second switching valve 11 is set in a discharge state in which the upstream portion 7a and the downstream portion 7b of the first main pipe 7 are shielded and the upstream portion 7a of the first main pipe 7 communicates with the discharge pipe 13. Is switched.

A pressure gauge 16 is provided at a tip end of the second main pipe 9 and a second solenoid valve 2 connected to the pressure gauge 16.
A third switching valve 15 controlled by the control unit 7 is provided,
This third switching valve 15 is connected to the second return pipe 18. A connecting hose 19 is connected to the end of the second main pipe 9, and the connecting hose 19 is formed at the center of the bottom surface of the lower mold 20 through a passage 28 a opened in the lower fixing stand 28. 23. The pressure gauge 16 also detects a pressure increase in the molding recess of the molding die 24, and when the indicated value of the pressure gauge 16 reaches a certain value, activates the second solenoid valve 27 and switches the third switching valve 15. It is like that. That is, the second main pipe 9 communicates between the upstream portion 9a and the downstream portion 9b of the third switching valve 15 and the second main pipe 9 communicates with the upstream portion 9a and the second portion 9b.
A slurry communication state that shields between return pipes 18 and a second state
The upstream portion 9a and the downstream portion 9b of the main pipe 9
The third switching valve 15 can be switched to a return state in which the space is cut off and communication between the upstream portion 9a of the second main pipe 9 and the second return pipe 18 is established.

The mold is made of a water-permeable resin mold.
As described above, the lower die 20 is provided with five horizontal casting holes 22 on one side surface and a center casting hole 23 at the center of the bottom surface. 21 is an upper die, 29a-29e are flow control valves.

The colored ceramic plate is manufactured using the above-described apparatus, for example, as follows. That is, first, the first base slurry 1 is supplied from the first pump 4 to the first main pipe 7.
To be pumped. On the other hand, the colored slurry 2 is pumped from the second pump 5 to the connecting pipe 8. The first switching valve 10 disposed on the connecting pipe 8 is periodically switched between a sludge passing state and a return state.
Is forcibly fed into the first base slurry 1 in the first main pipe 7 (the pumping pressure of the second pump 5 is higher than the pumping pressure of the first pump 4). Then, it is returned to the second pump 5. Thereby, the colored slurry 2 is intermittently fed into the first base slurry 1. In FIG. 1, the first base slurry 1 in the first main pipe 7 and the branch pipe 14 is indicated by a chain line (internal blank), and the connecting pipe 8, the colored slurry 2 in the first main pipe 7 and the branch pipe 14 are indicated by a chain line ( (Internal diagonal lines). At this time, the second switching valve 11 is in the sludge passing state, the third switching valve 15 is in the returning state, and the flow control valve 29
a to 29e are fully open. Accordingly, only the intermittently colored first base slurry 1 in which the coloring slurry 2 is intermittently mixed into the first base slurry 1 is pressed into the molding recess from each horizontal casting opening 22 of the lower die 20. Then, as shown in FIG. 3, intermittent colored patterns of five stripes are formed in the molding recesses.

A predetermined amount is filled in the molding recess,
When the internal pressure rises and exceeds a certain value, the pressure gauges 12 and 16 detect this, and the second switching valve 11 is set in the discharge state,
The third switching valve 15 switches to the sludge passing state. As a result, the intermittently colored first base slurry 1 in the first main pipe 7 is sent to the storage tank 25 via the discharge pipe 13, and only the second base slurry 3 is formed from the central casting port 23 of the lower mold 20. Press-fit into the recess.

When the second base slurry is press-fitted from the central casting port 23 of the lower mold 20, the intermittently colored first base slurry 1 is pressed against the mold surface of the molding die 24 at the casting pressure and formed. Pressure dehydration is performed using the water permeability of the mold 24. Thereafter, the third switching valve 15 is switched to the return state, and the second base slurry 3 is returned to the second return pipe 18.
And is returned to the third pump 6. The molded article obtained in this manner is removed from the mold and fired to produce the desired colored ceramic plate.

According to the above arrangement, a marble pattern is formed on the ceramic plate in a vivid manner. In addition, the color pattern can be changed by changing the amount of the colored slurry 2 mixed into the first base slurry 1 and the mixing interval, and by adjusting the amount of press-fit from each horizontal casting port 22.
The pattern shape can be freely changed by changing the press-fitting speed. Moreover, after a predetermined amount of the intermittently colored first base slurry 1 is filled in the molding recess, the second base slurry 3 is pressed into the molding recess from the central casting port 23 to perform pressure dehydration. Therefore, the intermittently colored pattern formed in the molding recess by the intermittently colored first base slurry 1 does not collapse during pressure dehydration.

In the above embodiment, the flow control valve 29a
To 29e are fully open, but the invention is not limited to this. For example, the flow control valve 29a may be half-open and the flow control valve 29e may be fully open. In this case, the momentum of the intermittent colored first base slurry 1e press-fitted from the horizontal casting port 22e exceeds the momentum of the intermittent colored first base slurry 1a press-fitted from the horizontal casting port 22a, and FIG. As shown, the formed flow pattern is inclined. Further, in addition to this, the flow control valves 29b and 29d may be temporarily stopped. In this case, the intermittently colored first base slurry 1b press-fit from the horizontal casting port 22b.
In addition, the pattern of the intermittently colored first base slurry 1d press-fitted from the horizontal casting port 22d is interrupted on the way, and as shown in FIG. 5, the formed flow pattern is interrupted on the way. Further, in the above embodiment, one first pump 4 and one second pump 5 are used, and these are communicated with the plurality of horizontal casting ports 22 of the lower die 20 via one first main pipe 7 and one branch pipe 14. However, the present invention is not limited to this.
Each of the pumps 5 and the first main pipe 7 may be connected to the plurality of horizontal casting ports 22 of the lower mold 20.

In the above embodiment, the colorless first base slurry 1 is used. However, the present invention is not limited to this.
The colored first base slurry 1 may be used. In this case, the colored slurry 2 is colored in a different color from the first base slurry 1. Further, a reinforcing material made of glass fiber may be mixed with the second base slurry 3 to improve the mechanical strength of the obtained patterned ceramic plate.

[0019]

As described above, according to the method for producing a patterned inorganic product of the present invention, an intermittent colored shape press-fitted from the plurality of horizontal casting holes in the molding recess of the water-permeable molding die. By the first base slurry, a plurality of strip-shaped intermittent colored patterns extending from each horizontal casting port are formed at predetermined intervals. The streak-shaped intermittently colored pattern is formed along the press-fitting direction when the intermittently colored first base slurry is press-fitted into the molding recess, so that the directionality is reproducible, and 1
When the colored slurry is mixed into the base slurry, the pattern shape can be freely changed by changing the amount and the mixing interval. In addition, after filling a predetermined amount of the intermittently colored first base slurry into the molding recess, the second base slurry is cast from a central casting hole formed upward on the bottom surface of the lower mold to form the intermittently colored slurry. The first base slurry is pressed against the mold surface by the casting pressure and dewatered by utilizing the water permeability of the mold. Therefore, during the pressure dehydration, the streak-shaped intermittent colored pattern formed in the molding recess does not deform, and appears as a streak-shaped intermittent color pattern in the obtained molded product.

[0020]

[Brief description of the drawings]

FIG. 1 is an explanatory view of an apparatus for producing a patterned ceramic plate used in the present invention.

FIG. 2 is an explanatory view of a lower mold of a molding die used in the above-mentioned apparatus.

FIG. 3 is an explanatory view of a pattern formed in the molding.

FIG. 4 is an explanatory view showing a modification of a pattern formed in the molding.

FIG. 5 is an explanatory view showing a further modification of the pattern formed in the molding.

Claims (1)

(57) [Claims] 1. A step of intermittently mixing a colored slurry into a first base slurry, and a plurality of horizontal casting holes formed at predetermined intervals in a lateral direction of the intermittently colored first base slurry on a side surface of a lower mold. Press-fitting into a molding recess of a mold having water permeability from above, and filling the molding recess with a predetermined amount of the intermittently colored first base slurry, and then inserting the second base slurry into the lower mold.
Casting from the central casting hole formed upward on the bottom surface, pressing the intermittently colored first base slurry against the mold surface at the casting pressure, and dewatering and molding using the water permeability of the mold. And a step of removing the molded product from the mold.