JP3044413B2 - Method for producing patterned ceramic molded body - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION The present invention relates to a pavement tile to be laid and fixed on a sidewalk, a roadway or the like, a wall tile and other ceramics, sintered rocks, glass, refractory materials, and structural molded ceramics. Related to manufacturing method.

[0002]

2. Description of the Related Art For example, when a traffic sign pattern such as a pedestrian crossing or a temporary stop is expressed on a part of the surface of a pavement tile, or when a pattern is expressed on the entire surface, it is conventionally necessary to draw the pattern on the surface by transfer, printing, or the like. There was no other way but by inlay.

[0003]

However, the pattern drawn on a part or the entire surface of the pavement tile is rubbed by the bottom of footwear of a person walking on it, or by wheels of a car or the like running on it.
It wears out in a short period of time and needs to be repainted frequently, which is very time-consuming. In addition, the inlay method requires a lot of trouble in manufacturing, and the cost is very high. Accordingly, the present invention provides a method for forming a pattern which is formed on a part or the entire surface of a ceramic molded body by using a pattern layer made of a dried sintered material for a pattern having a predetermined thickness by using a soluble cell dense pair. It was developed to express it in an expression.

[0004]

According to the method of manufacturing a patterned ceramic molded body of the present invention, a cylindrical small section having a constant height is adjacent to a predetermined position inside a mold for molding a base of the ceramic molded body. The densely packed soluble cell dense body is arranged, and a part or the whole of the small section of the soluble densely packed cell contains the dried pattern sintered material and the pattern sintered material inside the mold. The remaining portion not filled is filled with the base layer sintering material and pressurized, or moisture contained in the base layer sintering material or a lubricating binder, or one of the base layer sintering material and the pattern sintering material Or the moisture supplied to both, or plasticity is imparted with a lubricating binder and pressurized to form a base, and the base is removed from the mold and fired to form the base for the pattern-forming sintered material and the base layer. It is characterized by sintering integrally with the sintered material That.

[0005]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the method for producing a patterned ceramic molded body of the present invention will be described below with reference to the drawings. Figure 1,
2 and 3 show a patterned ceramic molded body 1 manufactured according to the present invention, in this case a pavement tile. FIGS. 1 and 2 show a traffic sign pattern, and FIG. 3 shows a pattern pattern.

The tile shown in FIG. 1 comprises a pattern layer 2 and a base layer 3 having the same thickness, and the pattern layer 2 is exposed on a part of the surface of the tile. This tile is filled with the sintering material for the pattern in a part of the subsection of the soluble cell dense body arranged in the formwork as described later, and the sintering material for the base layer is used for the rest of the subsection for the pattern. It was manufactured by filling the same thickness as the sintered material. On the other hand, in the tile of FIG. 2 as well, the pattern layer 2 is exposed on a part of the surface of the tile, but the back surface of the tile is formed only of the base layer 3. That is, the thickness of the base layer 3 is small at the portion lining the pattern layer 2 and thick at the portion exposed on the surface. The tile of FIG. 2 fills a portion of the sub-section of the soluble cell compact with the sintering material for patterning, and includes the remainder of the sub-section, as described below. It was manufactured by filling the entire remaining portion not containing the pattern sintering material with the base layer sintering material. In the tile of FIG. 3, the pattern layer 2 forms the entire front surface, the back surface portion is formed by the base layer 3, and the base layer is not exposed on the tile surface. This tile is filled with the pattern sintering material in all of the subsections of the soluble cell dense body arranged in the form as described later, and the remaining portion of the form inside the form not containing the pattern sintering material. Was filled with a sintered material for a base layer. Note that the order of filling the pattern sintering material and the base layer sintering material is arbitrary in manufacturing any tile.

In the present invention, the base body of the ceramic molded body having the pattern layer 2 exposed on a part of the surface or the entire surface as illustrated in FIGS. A soluble cell dense body 5 in which cylindrical small sections having a height are arranged adjacent to each other is used, and the pattern layer 2 is a dry sintered material for a pattern, and the base layer 3 is pressure-formed with a sintered material for a base layer. Preferably, the cross-sectional shape of the cylindrical small section of the soluble cell dense body is a square or a honeycomb (hexagon) of the same size, and the size is about 1 to 30 mm on one side, The thickness is at least the same as or greater than the thickness of the pattern layer 2 to be formed.

The dried pattern sintering material includes one or more of clay, rock or glass powder or fine particles, powder glaze, or a mixture of these with a pigment or a coloring agent. Even if it contains moisture or a lubricating binder from dry, it is not kneaded with water or a lubricating binder and can be easily loosened and supplied as a sintering material for forming a pattern layer or a sintering material for a base layer. The main component is one or more of powder or fine particles of rock or glass, or a mixture of these and a pigment or colorant. Even if it contains a moisture or a lubricating binder, it is not kneaded with water or a lubricating binder, and even if it is a dry material for a base layer composition that can be easily loosened and supplied, it can be water or a lubricating binder. For the base layer composition It may be a formula material, and it is also possible to mix substances such as crushed and crushed ceramics, powders and grains of metal and other minerals as necessary for both the pattern sintering material and the base layer sintering material, Various lubricants, binders and other additives may be mixed.

Now, in order to manufacture a ceramic molded body according to the present invention, the above-mentioned soluble cell dense body 5 made of oblate and other materials soluble in water or a solvent is used.
This densely packed cell body dissolves and disappears inside the mold, and is not limited to a cylindrical one with an open top and bottom, but may be one with a bottom surface closed at the bottom.

In order to form the base of the ceramic molded body of FIG. 1, as shown in FIG. 5, a densely packed cell body 5 having a solubility substantially equal to the depth of the mold is arranged in the mold 4; For a dry pattern which becomes red when baked inside some of the sub-sections representing the ring of the pattern and a straight line obliquely crossing the inside of the ring during a number of sub-sections of the soluble cell compact. A sintering material 2R, a dried pattern sintering material 2B that turns blue when baked inside some other sub-sections that represent two approximately semicircles inside an annulus separated by an oblique straight line; Outside of the ring, dry type base layer sintered material 3D or kneaded wet type base layer sintered material 3
W is filled by the same thickness (the filling order of each material is arbitrary).

In order to form the green body of the ceramic molded body shown in FIG. 2, as shown in FIG.
5 is filled with the dried pattern sintering material 2R, 2B thinner than the substrate thickness in the same manner as in FIG. 5, and then the remaining subdivisions and the pattern sintering material 2R, 2B 3D dry base material or 3W wet base material
May be filled to obtain a base material having a required thickness, or as shown in FIG.
D, or thinly filled with the wet base layer sintered material 3W, and then the pattern sintered materials 2R and 2B in a small section destined for a part of the soluble cell compact, and likewise the base layer in the remaining small sections. The sintered material 3D or 3W is filled so as to form a base material having a required thickness.

In order to form the green body of the ceramic molded body shown in FIG. 3, as shown in FIG. 8, during the small division of the densely packed soluble cells in the mold, a portion representing snow at the top of the mountain is formed. Is a dried pattern sintering material 2W which is whitened by firing, a dried pattern sintering material 2Br which is also brown in the portion representing the mountain surface, and a dried pattern sintering material which is also blue in the portion representing the sea. 2B, the portion representing the sky is filled with a dried pattern-sintering material 2S, which also becomes a dry sky-blue, in a thickness smaller than the thickness of the base material, and thereafter, the base material having the required thickness is formed over the entire interior of the mold. Is filled with a dry or wet type base layer sintered material 3D or 3W, or, conversely, the entire inside of the mold is first filled with the base layer sintered material 3D or 3W, and then the Pattern grilling for part of a small subdivision of a cell cluster Material 2W, 2Br, 2B, filled similarly 2S.

In the figure, the size of the soluble cell dense body is adjusted to the inner shape of the mold, but it is sufficient that the size is slightly larger than the outer shape of the pattern to be expressed, and it is not always necessary to match the inner shape of the mold. There is no. Filling of each pattern sintered material into a small section of a soluble cell dense body can be performed manually or by a robot in the form of dots. However, for accurate and rapid filling, a soluble cell dense material is required. It is preferable to use a closed mask that is the same size as the aggregate and has an opening corresponding to the pattern, and other than this opening.
Since the pattern of the molded body of FIGS. 1 and 2 is composed of a red pattern and a blue pattern, as shown in FIG. 4, a mask MR having an opening R corresponding to the red pattern and an opening corresponding to the blue pattern Part B
Is used. Both masks have the same outer shape as the soluble cell compact 5 and the soluble cell compact 5
The openings R and B can express the respective patterns of red and blue when they are accurately overlapped on the top. Therefore, one of the masks, for example, the MR is first superimposed on the dissolvable cell mass, and the pattern-forming sintered material 2R which becomes red upon firing through the opening R is filled in a required small section. MR
, The mask MB is overlaid on the soluble cell mass,
It is only necessary to fill the other necessary small sections with the pattern sintering material 2B that becomes blue through the opening B and remove the mask MB.

In the case where the dry base material 3D is to be filled, the sintering material necessary for press-molding the base material with respect to the entire amount of the base material sintering material and each pattern sintering material is used. Water or lubricating binder is supplied in an appropriate amount to the entire inside of the mold so that the ratio or lubricating binder ratio is reached. May be supplied.

Further, the material to be filled is a wet base layer sintered material 3.
In the case of W, when the base layer sintered material 3W has an unnecessarily high water content or lubricating binder ratio, the water or the lubricating binder is supplied to the dried pattern sintering material. Of course, when the water or lubricating binder contained in the base layer sintering material and the pattern sintering material is insufficient, it is additionally supplied.

When the sintered material for a pattern and the sintered material for a base layer have a water content or a lubricating binder content required for pressure molding in this way, both materials in the mold are pressed to form a ceramic molded body. The base material is molded, removed from the mold and fired, and both materials are integrally sintered to form a ceramic molded body. Of course, after demolding, if necessary, before sintering, the substrate is dried so that the water content or the lubricating binder content of both materials becomes a predetermined value,
Glaze the substrate.

In the embodiment of the present invention for manufacturing the ceramic molded body shown in FIGS. 1, 2 and 3, since the soluble dense cell body is soluble, the step of removing it from the mold is unnecessary. Become. The traces of the dissolved and disappeared soluble cell dense bodies are filled with the pattern-forming sintered material in contact with the small partition walls and the pattern-forming sintered material and the base layer-sintering material. Vibration or pressure may be applied to promote collapse.

When it is desired to dissolve and dissolve the soluble cell dense body as soon as possible, water or a lubricating binder is supplied after all of the dried sintering materials for each pattern are filled, and then the firing for the base layer is performed. A binding material may be filled. In this case, the supply amount of water and the lubricating binder thereafter to the dry-type base layer sintered material 3D is reduced, and the water content or the lubricated binder ratio of the wet-type base layer sintered material 3W is reduced. Put. Further, if the wet base layer sintered material 3W is filled before the pattern sintered material, the soluble cell dense body may be dissolved before the pattern sintered material is filled. As the soluble cell mass, use is made of one which is soluble but requires time for dissolution. Then, since the soluble cell dense body dissolves and does not need to be taken out from the mold, it may have a depth equal to the filling thickness of the pattern sintering material, and is protruded upward from the upper surface of the mold. It is not necessary.

In the above-described manufacturing method of the present invention, when the mold is placed on the table vibrator and vibration is applied when filling the sintering material for each pattern and the sintering material for the base layer, the density of each material is reduced. It can be densely packed.

As shown in FIG. 9, a water-absorbing or oil-absorbing mat 6, for example, a non-woven fabric is laid on the inner surface of the bottom of the mold frame 4, and a soluble cell dense body 5 is placed thereon. Filling the material absorbs excess water and lubricating binder, distributes the water and lubricating binder uniformly to each material, and helps degassing from the material during pressurization. The mold gets better. FIG. 9 corresponds to the embodiment of FIG. 5, but the same applies to the embodiments of FIG. 6 and FIG. In FIG. 7, since the base layer sintered material 3D or 3W is filled first, and the pattern sintered material is filled thereon, the water-absorbing or oil-absorbing mat is formed on the surface of the base material or the inner surface of the bottom of the mold. When laying is placed, moisture and a lubricating binder are uniformly distributed as described above, and deaeration is assisted during pressurization, so that molding and demolding are improved.

In the manufacturing method of the present invention, FIG.
As shown in FIG. 11 or FIG. 11, a plate or sheet 7 having pins or small pieces planted thereon or a sheet 8 having flocked, brushed, bristled, or linac (pile, loop, etc.) is previously laid on the inner surface of the bottom of the formwork. Then, the soluble cell dense body 5 is placed thereon, and the filled dry pattern sintering material or the base layer sintering material 3D or 3W is filled with pins or small pieces 7 ', flocking, napping, bristle, 8 '. This can prevent the materials from moving due to vibrations or the like until the respective materials are pressed and formed. The boundaries between the differently colored sintering materials for pattern, the sintering material for pattern and the sintering material for base layer 3D
Alternatively, the boundary of 3 W can be clearly expressed. The above pins, small pieces,
If the flocking, brushing, bristles, and rina are made soluble for each sheet or plate, they dissolve and disappear before baking, eliminating the need to peel off from the substrate, but make them soluble. It is desirable to make it insoluble depending on the required holding state.

Further, in the manufacturing method of the present invention, a part or the whole of the mold 4 is made of a deformable material, and the mold is filled with the pattern sintering material and the base layer sintering material 3D or 3W. It is also possible to produce a molded body other than a tile by deforming and pressing the green body, which will be described below.
A case of manufacturing a ceramic molded body having a pattern layer 2 similar to that shown in FIG. 1 on the surface will be described.

FIGS. 12 to 14 show an embodiment for producing a cylindrical molded body, in which a mold frame 10 is made of a deformable peripheral frame 11 made of urethane rubber or the like, and a metal for mounting the peripheral frame 11 thereon. It is composed of a rollable bottom sheet 12 such as a thin plate, a plastic sheet, paper, a nonwoven fabric, a woven or woven fabric, and a rubber sheet.
1. A soluble cell dense body is arranged at a predetermined position in the interior surrounded by 1 and dried as described above.
And a dry or wet base layer sintered material 3D or 3W (FIG. 12). After supplying water and a lubricating binder as needed, the surrounding frame 11 is covered with a rollable auxiliary sheet 13 similar to the bottom sheet 12 (FIG. 13).
The two surrounding sintered materials surrounded by 1 are supported between the bottom sheet 12 and the auxiliary sheet 13 and are rounded together with the peripheral frame 11 (FIG. 14), and are kept in a rolled state until they are press-formed. Can be formed at the required position.

FIG. 15 shows a mold 14 corresponding to the inner shape of a cylindrical ceramic molded body to be manufactured after filling the pattern sintered material and the base layer sintered material as shown in FIG. (In the case of a cylindrical shape, a cylindrical shape), and press-mold both sintered materials to form a green body of a cylindrical molded body. In this case, since the surfaces of the two sintered materials 2R, 2B and 3D or 3W exposed on the open upper surface of the peripheral frame 11 contact the outer surface of the mold 14, the auxiliary sheet 13 can be omitted, and A body having a polygonal cross section can be formed using a polygon. When the substrate is rolled or rolled by the manufacturing method of FIGS. 14 and 15 described above, if two side edges of the peripheral frame 11 are adjacent to each other, a seam of space occurs between the side edges of the base layer sintered material. Both side edges are overlapped and slightly overlapped inside and outside, and the base layer sintered material is doubled inside and outside at the seam, or each side edge of the surrounding frame 11 is cut off and exposed to each side edge. The materials are butted so that no space is created at the seam.

Similarly, after filling the sintering material for the pattern and the sintering material for the base layer as shown in FIG.
As shown in the figure, the peripheral frame 11 is removed to correspond to the inner shape of the cylindrical ceramic molded body to be manufactured.
It is also possible to wrap it together with the bottom sheet 12 on the outside of a mold 15 having a 15 'and to keep both sintered materials in that state (see Fig. 17) to form a cylindrical body. As a matter of course, the width of the inner shape of the peripheral frame 11 is set in accordance with the length of one circumference of the outer periphery of the mold 15 as in the case of FIG. 15, and the length is made equal to the interval between the flanges 15 ', 15'. Also in this case, the auxiliary sheet 13 can be omitted, and a cylindrical body having a polygonal cross section other than the cylindrical shape can be formed by using a polygonal one for the mold 15.

The cylindrical body thus formed is dried, glazed, fired and sintered into a ceramic molded body as required.

The above is a method of manufacturing a cylindrical ceramic molded body, but a ceramic molded body other than a cylindrical one can also be manufactured by partially or entirely deforming a mold.

For example, as shown in FIG. 12, a mold 10 is filled with a pattern sintering material and a base layer sintering material, and this is filled with a concave portion 16 on the upper surface as shown in FIG. 17
Is placed on a lower mold 18 that satisfies the above conditions, and is pressed from above with an upper mold 20 having a convex portion 19 corresponding to the concave portion 16 (FIG. 19).
As a result, the upper surface is pressed by the convex portion 19 to be dented, and the lower surface is pressed into the concave portion 16 to form the base body of the molded body which swells downward. In this case, it is not necessary that the peripheral frame 11 be deformable because the part deformed by the mold is a part of the bottom sheet 12. Further, the gel 17 filled in the concave portion is the upper mold 20.
This is for keeping the portion of the bottom sheet located on the concave portion 16 flat until it is pressurized by the press, and when the pressing of the upper mold 20 starts, the bottom sheet pushed into the concave portion and the material thereover It overflows from the upper edge of the recess. The lower mold 18
May be made of a plastic material such as a viscous material. In this case, since the upper surface of the lower mold made of the plastic material is depressed by pressing the upper die, the recess 16
And filling the gel 17 therein can be omitted.

Further, as shown in FIG. 12, after filling the pattern sintering material and the base layer sintering material into the mold 10 as shown in FIG. (FIG. 21), thereby deforming the mold 10 and the two sintered materials filled therein assuming the uneven upper surface of the lower mold 21, thereby forming a tile-shaped, A base such as a shape can also be formed. The mold 10 in this case may be constituted by the deformable peripheral frame 11 described above and a bottom sheet 12 laid under the bottom thereof, but the bottom surface of the deformable peripheral frame is formed by a deformable bottom wall. It may have a closed bottom.

The green body thus formed is dried if necessary, glazed, fired and sintered into a ceramic molded body.

As described above, when the base is formed by partially or entirely deforming the mold, the mold may be deformed after the cell dense body starts melting. In order to make the fusible cell cluster deformable, for example, the fusible cell cluster is made of a deformable material, or a cut is made from above or below a partition wall that separates a single cylindrical subsection. Then, each partition wall may be partly addressed or cut off.

[0032]

According to the present invention, it is possible to easily manufacture a ceramics molded body in which the pattern layer is exposed partially or entirely on the surface in a Kintaro candy style to express the pattern. And even if the surface of the pattern layer is worn, the expressed pattern does not disappear or become unsightly.

Further, since the pattern layer is formed of a dried pattern-forming sintered material filled in the small section of the soluble cell dense body, the pattern layer can be filled with a gap without any gaps, and the soluble cell which has been dissolved and disappeared is formed. Since the traces of the dense body are filled by the collapse of the pattern sintering material and the base layer sintering material, the boundary between the pattern layer and the base layer can be expressed finely, and a ceramic molded body having a very clear pattern can be obtained.

Furthermore, since the pattern sintering material is dry, if it is erroneously filled, it can be easily removed by suction using a vacuum cleaner-type tool and can be repaired.

After filling the dried sintering material for each pattern,
Alternatively, after filling the dried sintering material for each pattern and the dried sintering material for the base layer, a unique pattern having a texture of marble or other various natural stones can be obtained by disturbing a boundary portion or the whole of each material. Can be expressed.

Furthermore, by selecting the particle size of the dried sintered material for each pattern, the pattern layer can be made porous and water-permeable,
By selecting the particle size of the sintered material for the base layer, the base layer can be made porous and water-permeable, or by performing both of them, the whole ceramic molded body can be made porous and water-permeable. In the case of FIG. 5 and the like, a ceramic molded body having a translucent pattern can be easily obtained by using a translucent pattern sintering material for the pattern layer.

[Brief description of the drawings]

FIG. 1 is a perspective view of an example of a patterned ceramic molded body molded according to the present invention.

FIG. 2 is a perspective view of another example of a patterned ceramic molded body molded according to the present invention.

FIG. 3 is a perspective view of another patterned ceramic molded body manufactured according to the present invention.

FIG. 4 is an enlarged perspective view of a mold for forming a base of the ceramic molded body of FIG. 1, a soluble cell dense body, and a part of the soluble cell dense body;

FIG. 5 is a sectional view showing a state of manufacturing a green body of the molded body of FIG. 1;

FIG. 6 is a sectional view showing a state of manufacturing a green body of the molded body of FIG. 2;

FIG. 7 is a cross-sectional view showing another manufacturing state of the green body of the molded body of FIG. 2;

FIG. 8 is a cross-sectional view showing a state of manufacturing a green body of the molded body of FIG. 3;

FIG. 9 is a cross-sectional view showing another manufacturing state of the green body of the molded body of FIG. 1;

FIG. 10 is a cross-sectional view showing another manufacturing state of the green body of the molded body of FIG. 1;

FIG. 11 is a sectional view showing another state of manufacturing the green body of the molded body of FIG. 1;

FIG. 12 is a perspective view of a first stage of a production state of the base body of the tubular forming body.

FIG. 13 is a second view showing a state in which the green body of the cylinder forming body of FIG.
It is a perspective view of a stage.

FIG. 14 is a perspective view of a final stage of a manufacturing state of the base body of the tubular forming body of FIG. 12;

FIG. 15 is a perspective view showing another manufacturing state of the tubular forming body.

FIG. 16 is a perspective view of a first stage in a manufacturing state of another tubular forming body.

FIG. 17 is a perspective view of a final stage of a manufacturing state of the tubular forming body of FIG. 16;

FIG. 18 is a perspective view showing a state of manufacturing a green body of another molded body.

19 is a cross-sectional view of the molding state of FIG.

FIG. 20 is a perspective view showing a state of manufacturing a green body of another molded body.

21 is a cross-sectional view of the molding state of FIG.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Molded body 2 Pattern layer 2R Pattern sintering material 2B Pattern sintering material 2S Pattern sintering material 2Br Pattern sintering material 3W Pattern sintering material 3 Base layer 3D Dried base layer sintering material 3W Watered base layer Sintered material for use 4 Formwork 5 Soluble cell dense body 6 Water-absorbing or oil-absorbing mat 7 Board or sheet 8 Board or sheet 10 Formwork 11 Formwork surrounding frame 12 Bottom sheet 13 Auxiliary sheet 14 Cylindrical Mold 15 Cylindrical mold 18 Lower mold 19 Convex mold 20 Upper mold 21 Lower mold 22 Elastic plate MR mask MB mask

Continuation of front page (56) References JP-A-48-5811 (JP, A) JP-A-62-288036 (JP, A) JP-A-5-84714 (JP, A) JP-A-5-38707 (JP) , A) JP-A-4-140104 (JP, A) (58) Fields investigated (Int. Cl. ⁷ , DB name) B28B 1/14 B28B 1/16

Claims (1)

(57) [Claims] A dissolvable cell dense body in which cylindrical small sections of a certain height are arranged adjacent to each other at a predetermined position inside a mold for molding a base body of a ceramic molded body. A part of or all of the small section of the cell densely packed body is filled with the dried pattern sintering material, and the remaining part of the inside of the mold without the pattern sintering material is filled with the base layer sintering material. Pressurizing or adding plasticity with moisture contained in the base layer sintering material or lubricating binder, or moisture supplied to one or both of the base layer sintering material and the pattern sintering material, or lubricating binder. Forming a base by pressing, removing the base from the mold, and sintering the sintering material for the base and the sintering material for the base layer integrally by firing the base; Manufacturing method of ceramic molded body.