JP3927389B2 - Tile forming mold and tile forming method using this mold - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a mold for forming a tile for forming a handmade tile having a wrinkle pattern formed on its surface, and a method for forming a handmade tile using the mold.
[0002]
[Prior art]
A tile is a square plate-like clay fired product, which is manufactured by molding clay with a molding die, drying it, and baking it in a firing kiln. Commonly used tiles are mass-produced products that are formed by mechanically stuffing clay into molding molds in a certain amount, and various colors are given, and the surface is smoothed, Roughening produces a slightly different color tone and feel, but in any case, such tiles have a smooth surface with no pattern and look very monotonous. Therefore, it gives the user a feeling that it is a mass-produced product.
[0003]
In recent years, hand-made tiles that are molded by hand so as to form a fine wrinkle pattern on the surface instead of tiles with a smooth surface as described above have been very popular and used. Is increasing year by year. In order to mold this handmade tile, a large number of small dumplings of clay are packed in the mold for molding, and after pressing the clay from above the mold, it is removed from the mold. The clay lumps are crushed and stuck to each other on the surface side of the tile press-molded on the bottom surface side of the tile so that the boundary line between the clay lumps forms a fine wrinkle pattern.
[0004]
[Problems to be solved by the invention]
However, in the molding method in which the ridge pattern is formed on the tile surface by the above-described method, it takes a lot of time and labor to pack the clay into the molding die, resulting in high manufacturing costs. . Therefore, the inventor of the present invention has made various studies. Initially, the handmade tile is used as a prototype, and an aluminum mold (female mold) corresponding to the prototype tile is made, and clay is packed into the mold and added. I tried to mold the tiles, but with the aluminum mold, I couldn't reveal the fine wrinkles that were formed on the surface of the handmade tiles. Therefore, as another method, when plaster mold (female mold) is made by pouring plaster on the original handmade tile, and clay is packed in it, and then pressurizing it, the pattern is similar to that of the handmade tile. I was able to express it. However, in this method, since the plaster mold is brittle, when the clay is packed and pressed, it is broken and cannot be used easily.
[0005]
The present invention uses a gypsum mold as described above to form a tile having a wrinkle pattern on the surface of the tile. It is an object of the present invention to provide a mold for forming a tile capable of mass-producing a manufactured handmade feel, that is, a handmade-style tile, and a method for forming a handmade-style tile using the mold.
[0006]
[Means for Solving the Problems]
The tile molding die of the invention according to claim 1 includes a base frame plate 3 having an opening 5 for fitting a tile into which a prototype tile 1 having a ridge pattern a formed on a surface 1a serving as a prototype can be fitted. The mold main body 4 is formed in a substantially box shape by the peripheral wall portion 6 and the upper wall portion 7 and is detachably connected to the base frame plate 3 while being placed on the base frame plate 3. The mold body 4 is provided with a gypsum supply hole 8 and an air vent hole 9 in the upper wall portion 7 of the mold body 4. Are fitted into the mold body 4, and a slurry-like gypsum 18 is put into the gypsum molding chamber 17 formed between the original tile 1, the base frame plate 3, and the mold body 4 from the gypsum supply hole 8. After the gypsum 18 is solidified and the original tile 1 is removed, the mold surface 19 of the ridge pattern a is provided. Characterized in that that tile molding chamber 20 is adapted to be formed.
[0007]
A second aspect of the present invention is the tile mold according to the first aspect, wherein the inner peripheral side surface 10a and the base frame of the mold main body 4 in a state where the mold main body 4 is placed at a fixed position on the base frame plate 3. A gypsum holding step 12 is formed between the upper surface of the plate 3.
[0008]
Claim 3 is the tile mold according to claim 1 or 2, base frame plate 3 is characterized in that it is thin rather than the thickness of the original tile 1.
[0009]
A tile molding method according to a fourth aspect of the present invention is a tile molding method using the tile mold according to any one of the first to third aspects, wherein the tile fitting opening 5 of the mold 2 is used. The prototype tile 1 having the ridge pattern a formed on the surface of the prototype is fitted into the mold body 4 with the ridge pattern surface 1a facing the mold body 4, and the prototype tile 1 and the mold 2 are connected to the horizontal plane P. After being placed on, the slurry-like gypsum 18 is poured into the gypsum molding chamber 17 inside the gypsum supply hole 8 of the mold 2, and after the gypsum 18 is solidified, the original tile 1 is passed through the tile fitting opening 5. The mold 2 is reversed and the tile 21 is filled with the clay 21 in the tile forming chamber 20 where the ridge pattern a is formed in the tile fitting opening 5 from which the original tile 1 is extracted. By pressing the clay 21 through the pressure plate 22 It is characterized in that so as to mold the tile 1 a wrinkle pattern a is formed.
[0010]
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1A is a handmade prototype tile 1 in which a ridge pattern a is formed on the surface 1a, and is a perspective view of the tile 30 as a product viewed from the surface 1a side, and FIG. It is the perspective view which looked at a certain tile 30 from the back surface 1b side. FIG. 2 is an exploded perspective view showing the tile molding die 2 of the present invention used for molding the tile 30 having the ridge pattern a formed on the surface 1a shown in FIG. 3A is a longitudinal sectional view of the mold 2, and FIG. 3B is a transverse sectional view of the mold 2. FIG. The original tile 1 shown in FIG. 1 is a handmade tile made entirely by hand, and also shows a handmade tile 30 produced by molding with the mold 2 for forming a tile according to the present invention. To do.
[0011]
As shown in FIG. 1, the tile forming mold 2 is made of a rectangular frame-shaped aluminum alloy in which a tile fitting opening portion 5 into which a tile 1 as a prototype having a ridge pattern a formed on the surface can be fitted is formed. The base frame plate 3 and the same aluminum alloy as the base frame plate 3 are formed in a substantially box shape composed of the peripheral side wall portion 6 and the upper wall portion 7. The mold body 4 is detachably connected to the frame plate 3, and a gypsum supply hole 8 and an air vent hole 9 are provided in the upper wall portion 7 of the mold body 4. The peripheral side wall portion 6 of the mold body 4 includes front and rear side wall portions 10 and 10 and left and right side wall portions 11 and 11. In this embodiment, the aluminum alloy plate or aluminum alloy casting is used. However, the present invention is not limited to this, and may be formed of an iron plate, a steel plate, or a casting thereof.
[0012]
The tile fitting opening 5 of the base frame plate 3 has vertical and horizontal dimensions La, slightly larger than the vertical and horizontal dimensions L and W of the original tile 1 so that the original tile 1 can be fitted and detached in a posture parallel to the base frame plate 3. Opened to Wa. The vertical and horizontal internal dimensions Lb and Wb of the mold body 4 are formed sufficiently larger than the vertical and horizontal dimensions La and Wa of the tile fitting opening 5 of the base frame plate 3, respectively. As can be seen from B), the inner peripheral side surfaces 10a, 10a, 11a, 11a of the mold main body 4 and the upper surface of the base frame plate 3 in a state where the mold main body 4 is placed at a fixed position on the base frame plate 3. The gypsum holding step 12 is formed over the entire circumferential direction. The outer dimensions of the base frame plate 3 and the mold body 4 are the same (see FIGS. 3 and 7).
[0013]
The base frame plate 3 is formed thinner than the thickness T of the original tile 1. That is, the original tile 1 is in a state in which the peripheral edge portion of the surface 1a is rounded and chamfered, the thickness of the chamfered portion R is α (see (2) in FIGS. 1 and 4), and the base frame plate If the thickness of 3 is t, the relationship between the thickness T of the original tile 1, the thickness α of the chamfered portion thereof, and the thickness t of the base frame plate 3 is approximately T−α = t. When the prototype tile 1 is fitted in the tile fitting opening 5 of the base frame plate 3 with the surface 1a on which the ridge pattern a is formed facing the mold body 4, the prototype tile 1 is shown in FIG. As indicated by 2 ▼, the base plate 3 rushes into the mold body 4 by the thickness α of the chamfered portion R from the upper surface.
[0014]
As shown in FIG. 3, the base frame plate 3 and the mold body 4 are detachably connected by bolts 13 and nuts 14. That is, bolt insertion holes 15 are provided in the four corners and intermediate required portions of the base frame plate 3, respectively, and bolt insertion holes 16 are provided in the mold body 4 at positions corresponding to the bolt insertion holes 15 of the base frame plate 3. The base frame plate 3 and the mold body 4 can be integrally connected by tightening the bolt 13 through the bolt insertion holes 15 and 16 with the nut 14.
[0015]
Next, a method of forming a tile using the tile forming mold 2 having the above-described configuration will be described with reference to FIGS.
[0016]
First, a handmade tile 1 as shown in FIG. 1 in which a tile pattern 1a is formed on the tile surface 1a is used as a prototype, and the prototype tile 1 is obtained as shown in (1) and (2) in FIG. The surface 1a is fitted into the mold body 4 of the tile forming mold 2, and the original tile 1 and the mold 2 are placed on a horizontal plane P such as a base plate in this state. At this time, as shown in (2) in FIG. 4, the original tile 1 has entered the mold body 4 by the thickness α of the chamfered portion R, and the original mold 1 is placed inside the tile forming mold 2. A gypsum molding chamber 17 is formed between the tile 1, the base frame plate 3, and the mold body 4.
[0017]
Slurry gypsum 18 is poured from the gypsum supply hole 8 of the mold body 4 into the gypsum molding chamber 17 formed in the mold 2 in this way, and the state shown in (3) in FIG. Leave the plaster 18 for a while until it solidifies. Note that when the slurry-like gypsum 18 is poured into the gypsum molding chamber 17 from the gypsum supply hole 8, the air in the gypsum molding chamber 17 escapes from the air vent hole 9, so that the gypsum 18 is accurately supplied to the gypsum molding chamber 17. Can do.
[0018]
When the gypsum 18 is solidified, the original tile 1 is extracted from the tile fitting opening 5 of the base frame plate 3, and the mold 5 is repeatedly reversed as shown in (1) of FIG. By extracting the original tile 1 from the tile fitting opening 5, a tile forming chamber having a mold surface 19 in which a wrinkle pattern similar to the original tile 1 is formed on the solidified gypsum 18 side in the tile fitting opening 5. 20 is formed. Further, a chamfering mold surface portion 19r is formed on the peripheral edge portion of the mold surface 19.
[0019]
In the gypsum molding chamber 17, the gypsum holding step 12 is formed between the inner peripheral side surfaces 10 a to 11 a of the mold body 4 and the upper surface of the base frame plate 3. When the original tile 1 is extracted from the tile fitting opening 5 and the mold 5 is repeated in the opposite direction, the solidified gypsum 18 does not come out together with the original tile 1. Further, since the gypsum holding step 12 is formed in the entire circumferential direction of the mold body 4, the chamfering mold surface 19 r is accurately formed on the peripheral edge of the mold surface 19.
[0020]
In this manner, the tile forming chamber 20 formed in the tile fitting opening 5 of the base frame plate 3 is filled with clay 21 for one tile as shown in (1) and (2) of FIG. Is pressed through the pressurizing plate 22 by using an appropriate pressurizing means such as a hydraulic cylinder or the like, thereby coming into contact with the ridge pattern mold surface 19 of the tile forming chamber 20 as shown in (3) of FIG. On the surface of the clay 21, the same ridge pattern a as the ridge pattern formed on the ridge pattern mold surface 19 is formed. At this time, even if the clay 21 packed in the tile forming chamber 20 is strongly pressed by the pressing means as described above, the gypsum 18 forming the tile pattern surface 19 of the tile forming chamber 20 is Since the outer peripheral portion is reinforced by the mold body 4, there is no cracking or cracking.
[0021]
After the product tile 30 having the ridge pattern a formed on the surface 1a is formed in the tile forming chamber 20 in the tile forming mold 2 as described above, as indicated by the arrow (1) in FIG. Then, the tile 30 is taken out from the mold 20 by a take-out tool (not shown) such as an adsorber, and then, as shown in (2) of FIG. 6, a groove forming tool 23 is formed on the back surface 1b of the formed tile 30. Thus, a non-slip groove b as shown in FIG. 1B is formed. In this groove forming tool 23, a metal wire material 26 such as a nail is projected in a row at regular intervals on a base frame 25 with a handle 24. The wire forming device 26 is held by the handle 24 and the wire material 26 is shown in FIG. What is necessary is just to press on the back surface 1b of the tile 1 shape | molded in the state as shown in, and to move from the one end side to the other end side.
[0022]
After the formation of the anti-slip groove b on the tile back surface 1b as described above, as shown in (3) in FIG. A claw pattern a similar to the pattern is formed, and a chamfered portion R formed on the peripheral portion of the handmade tile surface is formed on the peripheral portion of the tile surface 1a. A wrinkle pattern a is formed, and thus the molded tile 30 is almost the same as a handmade tile.
[0023]
The tile 30 molded and taken out as described above is dried for a required time, and then placed in a firing kiln and fired to obtain a final tile product.
[0024]
In the tile molding die 2 used in the tile molding method, the gypsum 18 forming the ridge pattern mold surface 19 of the tile molding chamber 20 is reinforced by the mold body 4 at the bottom and outer periphery thereof. Even if the clay 21 packed in the chamber 20 is strongly pressed, the gypsum 18 is not cracked or cracked. Thus, the gypsum 18 once molded in the gypsum molding chamber 17 in the mold 2 can be repeatedly used without re-molding, and a handmade tile can be molded. Incidentally, in the implementation by the inventors of the present invention, about 2000 tiles 1 could be repeatedly formed with the gypsum 18 once formed.
[0025]
Further, in forming the tile 30 by the above forming method, the clay 21 to be packed in the tile forming chamber 20 formed in the tile forming mold 2 as shown in (1) of FIG. 5 is, for example, as shown in FIG. The tile clay molding machine 27 molds each tile into a rectangular plate.
[0026]
Further, in the above-described tile forming method, the tile 1 as a prototype in which the surface pattern 1a is formed on the surface 1a for fitting into the tile fitting opening 5 of the mold base frame plate 3, is preferably completely Although the handmade tile product formed by the above-mentioned manual work is preferable, the tile product formed by the above-described tile forming method may be used.
[0027]
【The invention's effect】
The mold for forming a tile according to the first aspect of the present invention is formed in a substantially box shape with a base frame plate having an opening into which a tile to be a prototype with a ridge pattern formed on the surface can be fitted. It consists of a mold body that can be detached from the base frame plate while it is placed on the frame plate, with the original tile facing the tile fitting opening of the base frame plate, and the surface of the tile pattern facing the mold body The slurry-like gypsum is supplied to the gypsum molding chamber formed between the original tile, the base frame plate, and the mold main body, and the original tile is extracted after the gypsum is solidified, thereby forming a wrinkled pattern. Since a tile molding room with a mold surface is formed, when molding a tile using this mold, the plaster that forms the tile pattern mold surface of the tile molding room is reinforced by the mold body Therefore, even if the clay packed in the tile forming room is strongly pressed, Without such cracking, once molded gypsum plaster molding chamber of the mold, and can be used repeatedly many times, it is possible to easily easily molded tiles handmade style.
[0028]
The gypsum holding step portion between the inner peripheral side surface of the mold main body and the upper surface of the base frame plate in a state where the mold main body is placed at a fixed position on the base frame plate. Therefore, when the original tile is extracted from the tile fitting opening of the base frame plate, the solidified gypsum can be prevented from coming out together with the tile.
[0029]
As described in claim 3, since the base frame plate is formed rather thin than the thickness of the original tile, when in the state in which the peripheral surfaces of the original tile is rounded, wrinkle pattern prototype tile If the surface is fitted into the mold body and the original tile and the mold are placed on a horizontal surface, the gypsum is poured into the gypsum molding chamber. The chamfering mold surface is formed on the periphery of the ridge pattern mold surface, and the tile formed by this tile forming chamber has a rounded chamfered surface like the original tile, giving it a handmade feel. It can be further enhanced.
[0030]
In the tile forming method of the invention according to claim 4, in the state where the original tile is fitted into the opening for fitting the tile of the mold and the surface side thereof is fitted into the mold body, the original tile and the mold are combined. After placing on a horizontal surface, pour slurry gypsum into the gypsum molding chamber inside the mold, and after solidifying this gypsum, pull out the original tile from the tile fitting opening and reverse the mold, This is a method in which clay for one tile is packed in a tile forming chamber where a cocoon pattern is formed in the extracted opening for mating, and this clay is pressed through a pressure plate, so that a cocoon pattern is formed on the surface. The handmade tiles can be formed mechanically and efficiently, thereby enabling mass production of handmade tiles and reducing the cost.
[Brief description of the drawings]
FIG. 1A is a perspective view of a tile having a wrinkle pattern formed on its surface as viewed from the front side, and FIG. 1B is a perspective view of the tile as viewed from its back side.
FIG. 2 is an exploded perspective view showing a tile forming mold of the present invention used for forming a tile having a ridge pattern formed on the surface shown in FIG. 1;
3A is a longitudinal sectional view of a mold, and FIG. 3B is a transverse sectional view of the mold.
FIGS. 4A to 4C are cross-sectional views illustrating the first stage of the molding process of the tile molding method according to the present invention.
5 are sectional views for explaining the next stage of the molding method.
FIGS. 6A and 6B are cross-sectional views illustrating the final stage of the molding method.
FIG. 7 is a perspective view showing an appearance of a mold for forming a tile and an appearance of a clay molding machine for forming a rectangular plate-shaped clay.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Prototype tile with a wrinkle pattern formed on the surface 1a The surface of the tile 1b The back surface of the tile a The wrinkle pattern formed on the tile surface b The anti-slip groove R formed on the back surface of the tile R Chamfer 2 Tile mold 3 Base frame 4 Mold body 5 Tile fitting opening 6 Peripheral side wall 7 of mold body Upper wall 8 of mold body Gypsum supply hole 9 Air vent hole 12 Gypsum holding step Part 17 Gypsum molding chamber 18 Gypsum 19 Mold surface 19r with crest pattern Chamfering mold surface 20 Tile molding chamber 21 Clay 30 Tile as product

Claims (4)

  It is formed in a substantially box shape by a base frame plate having an opening for tile fitting into which a prototype tile with a ridge pattern formed on the surface to be a prototype can be fitted, and a peripheral side wall portion and an upper wall portion, The mold body is detachably connected to the base frame plate in a state of being placed on the base frame plate, and a gypsum supply hole and an air vent hole are provided in the upper wall portion of the mold body, Placing the original tile into the tile fitting opening of the base frame plate with its ridge pattern surface facing into the mold body, and forming the plaster molding between the original tile, the base frame plate and the mold body A tile mold in which a tile molding chamber having a mold pattern surface is formed by supplying slurry-like gypsum to the chamber from the gypsum supply hole and extracting the original tile after the gypsum is solidified .   With the mold body placed at a fixed position on the base frame plate, a gypsum holding step is formed between the inner peripheral side surface of the mold body and the upper surface of the base frame plate. The tile mold according to claim 1. Base frame plate, a tile mold according to claim 1 or 2 is thin rather than the thickness of the original tile.   A method for forming a tile using the tile mold according to any one of claims 1 to 3, wherein an original tile in which a ridge pattern is formed on a surface serving as a prototype in a tile fitting opening of the mold. After placing the mold tile and the mold on a horizontal surface in a state where the surface of the wrinkle pattern is fitted into the mold body, the gypsum supply hole of the mold enters the gypsum molding chamber inside the mold. Slurry gypsum is poured, and after the plaster is solidified, the original tile is extracted from the tile fitting opening to reverse the mold, and a wrinkle pattern is formed in the tile fitting opening from which the original tile has been extracted. A tile forming method in which a tile forming chamber is filled with clay for one tile and the clay is pressed through a pressure plate to form a tile having a ridge pattern formed on the surface.

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