JPH01139216A - Manufacture of longer tile plate - Google Patents

Abstract

PURPOSE:To form a stepped part for fitting into in a good shape at the time of manufacturing a longer tile plate by forming an upper stepped part on the upper surface side in the green state of tile base simply in the transfer process and also cutting and forming a lower stepped part on the other opposing side at the time of calcination. CONSTITUTION:A couple of music wires P, P for cutting off the longitudinal edge of a tile base 1 are disposed in front of a stainless sheet 8d, an almost L-shaped cutter 11 is provided on the left edge of said stainless sheet 8d. The upper side surface of the left side edge of the tile base 1 fed out in the square direction from said cutter 11 is cut off to form an upper stepped section 1h on the left side edge of the tile base 1. A lower stepped section to be formed on the other section facing to the upper stepped section 1h is cut and formed in accurate dimension and shape by using a grinder or the like after the tile base 1 is calcined, and a continuous ceramic tile 1 can be shaped up in accurate dimension without being affected by the dimension contraction or the like at the time of calcination by forming the lower stepped section in accurate dimension after calcination as above-mentioned.

Description

DETAILED DESCRIPTION OF THE INVENTION (Industrial Application Field) The present invention relates to a method for manufacturing a long tile board, and more particularly, to a manufacturing method for forming a fitting step on a longitudinal end edge of a long tile board. It is something.

(Prior art and its problems) When manufacturing long tile boards to be installed on the exterior walls of buildings, etc., in order to improve the connection state of the long tile boards, it is necessary to Although it has been devised to form a step for fitting on the edge, there is no method for forming a step for fitting well when manufacturing a long tile board.
The emergence of such a manufacturing method was awaited.

(Means for solving the problems) The present invention has been devised in view of the above-mentioned conventional situation, and includes:
The purpose is to provide a method for manufacturing long tile plates that can form fitting steps well while maintaining accurate dimensional accuracy. After cutting into long dimensions, in the process of transporting the tile base in the right angle direction via a pusher, the upper surface side of the edge of one side in the opposite direction of the tile base is cut off to form an upper part for fitting to the tile base. However, after firing the tile base, a lower step portion facing the upper step portion is formed on the lower surface side of the other end edge in the longitudinal direction.

(Function) In the process in which a tile base formed into a long dimension is extruded from an extrusion molding machine and transferred via a pusher,
An upper tier on the upper surface side is formed using a cutting tool or the like on one longitudinal edge of the tile base, and the upper tier is dried and fired with the upper tier formed, and after firing, the longitudinal side of the tile base opposite to this upper tier is removed. A lower step is formed on the lower surface side of the end edge on the other side in the direction by cutting it into a precise size and shape using a grinder or the like, thereby obtaining a long tile board having a fitting step with an accurate size.

In this way, the upper tier on the top side can be easily formed during the transport process of the raw tile base, and since shrinkage occurs in the longitudinal dimension during firing, the lower tier on the opposite side is formed after firing in anticipation of the shrinkage. Since the part is formed by cutting with a grinder etc., the dimensions are accurate, and the glaze surface on the top side has accurate dimensions without any damage, and the glaze surface is well preserved to form the mating step. can complete the section.

(Example) Embodiments of the present invention will be described below based on the drawings.

Figure 1 shows the arrangement of the long ceramic tiles 1 of this example, which are arranged on the exterior wall of a building, in which a large number of long ceramic tiles 1 are arranged horizontally in parallel in the vertical direction. The exterior wall of the building will be well decorated.

Each of these long ceramic tiles 1 is formed in a cross-sectional shape as shown in FIG. In the example 2m
is formed. The front surface 1a of the long ceramic tile 1 is selectively coated with glazes of various colors to form a good decorative surface, and the back surface 1b has a convex portion 1ba projecting outward and a convex surface. A concave groove portion i formed between portions lba
bb are formed alternately. Further, an upper engaging convex portion 1d is integrally formed at the upper end portion in the figure in a protruding manner and continuous with the back surface 1b, and a recessed upper engaging convex portion 1d is formed on the surface 1a side of the upper engaging convex portion 1d. A recessed portion 1e is formed. On the other hand, on the lower surface side, there is a convex portion 1 that protrudes downward in a continuous manner with the surface 1a.
f is integrally formed, and the lower side concave portion 1g is completely formed on the back side of the lower side convex portion 1f. Also, the front side 1a and the back side 1
In this example, four hollow central holes IC are formed in the center part of b in the vertical direction.

When the long ceramic tiles 1 formed in this way are arranged side by side on the wall surface of a building, the long ceramic tiles 1 arranged on the upper side are attached to the engaging protrusions 1d of the long ceramic tiles 1 arranged on the lower side. The engagement recesses 1g of the ceramic tiles 1 are engaged, and the lower engagement protrusions 1r on the upper side are superimposed on the surface side of the engagement protrusions 1d on the lower side, and the elongated ceramic tiles 1 are successively arranged upward. can be set.

In order to shape the long ceramic tile 1 described above, a tile base is first formed by extrusion using an extrusion molding machine, and this tile base is dried and fired. Since the tile 1 is long, with a longitudinal dimension of approximately 2 m, extrusion molding on a raw material made of natural soil to which no chamotte or other additives are added may cause torsional deformation, cracks, etc. Ingenuity has been added to the mold.

That is, in this example, inexpensively available natural soil is used as the raw material, and this natural soil is mixed with powder or pulverized materials such as chamotte, Rouseki, pottery stone, etc.

For example, as natural soil, S s 0165.9% by weight, At
zost9. It is possible to use raw materials containing 50% feldspar and 30% clay minerals such as kaolinite, sericite, and montmorillonite. % can also be used.

As mentioned above, it is possible to mix 25% to 35% by weight of chamotte, Rouseki, pottery stone, etc., which are made into powder by crushing fired materials such as bricks, tiles, tableware, etc., into these natural soils and use it as a raw material. can.

That is, according to the inventor's experimental data, 10% by weight and 20% by weight of chamotte were added to the above-mentioned natural soil.

When chamotte was mixed in amounts of 30% and 40% by weight and its formability was evaluated, it was found that when the amount of chamotte mixed in was less than 20% by weight, cracks and warping occurred during drying and firing when used as a long tile base. Furthermore, when the amount of chamotte mixed is about 40% by weight, the moldability and surface smoothness are deteriorated. Therefore, the optimum amount of chamotte etc. to be mixed is 25 to 35% by weight.

When extrusion molding a tile base using such a raw material, an extrusion mold 2 as shown in FIG. 2 is used in this example.

This extrusion mold 2 is installed at the tip of the extruder and has a front shape as shown in FIG. That is, in the central part of the extrusion mold 2, a main extrusion space 2a having a spatial shape corresponding to the cross-sectional shape of the elongated ceramic tile 1 in FIG. 1 described above is formed in the lateral direction. Four punching holes 4 are arranged horizontally in the center of the tile, and the central hole 1c of the long ceramic tile 1 is formed by the punching holes 4. Further, sub-extrusion spaces 2b and 2b are formed on the outer periphery of the protrusion space corresponding to the upper engagement convex portion 1d and the lower engagement convex portion 1f'' in FIG. 1 of the main extrusion space 2a. Partition plates 3a and 3b are arranged between the main extrusion space 2a and the sub-extrusion spaces 2b, 2b, and the main extrusion space 2a
The tile base extruded from the secondary extrusion spaces 2b and 2b is extruded separately by the partition plates 3a and 3b.

In this way, the outer circumference of the main extrusion space 2a is followed by the extrusion spaces 2b, .
2b was formed because when the tile base is extruded only from the main extrusion space 2a, the density distribution of the protrusions corresponding to the upper engaging convex portion 1d and the lower engaging convex portion 1f of the extruded tile base is dense. As a result, the density distribution in the central part becomes rough and the overall filling density distribution becomes uneven. In order to make the shape substantially symmetrical in the horizontal and vertical directions, the secondary extrusion spaces 2b, 2b
, a main extrusion space 2a and a sub-extrusion space 2b, 2
b) The whole structure was made to have a rectangular shape.

In this way, the outer circumference of the main extrusion space 2a is followed by the extrusion spaces 2b, .
By forming 2b, the filling density distribution of the tile base becomes uniform and it can be extruded, and as a result, the shrinkage during the subsequent shrinkage process during drying, firing, etc. is made uniform, and cracks, twists, warping, etc. occurrence is avoided. Also, a secondary extrusion space 2b.

The tile base part extruded at the same time can also be used for supporting the protrusion corresponding to the lower part convex part 1f, and can also serve as a support while the tile base is soft.

The state of extrusion molding using the extrusion mold 2 having such a shape is shown in FIG. 3 and will be described.

In FIG. 3, the above-mentioned extrusion mold 2 is attached to the tip of the extrusion molding machine, and the above-mentioned raw material is extruded into a long shape from the extrusion mold 2 onto the stainless steel plate 8 on the front side. .

In this example, a cut con hair 5 is provided on the exit side of the extrusion mold 2.
is disposed, and by rotating this cutting conveyor 5, the secondary extrusion space 2b of the tile base extruded from the extrusion mold 2 and the portion (upper excision portion) 1b that is extruded further are removed. It is discharged to the outside, and the discharged upper cut portion 1bx is again circulated over the raw material and reused.

Therefore, the tile base 1 (
(The same reference numeral is used because it is in the same shape as the long pottery tile 1 in the molding process) is the above-mentioned upper cutout part 1b.
By removing , the upper engagement protrusion 1d and the upper engagement recess 1e are formed and pushed out. Further, the tile base (lower cutout portion 6) extruded from the aforementioned secondary extrusion space 2b+ is extruded while remaining in contact with the lower surface side of the tile base 1.

At the time of this extrusion, a release agent is injected between the lower cutout 6 and the tile base 1 using a spray nozzle (not shown), so that the lower cutout 6 can be easily removed later.

Further, in this example, a plurality of rollers 7° 7, 7, 7 are arranged on the sides of the stainless steel plate 8a from which the tile base 1 is extruded, and these rollers 7 move the side edges of the tile base 1 to be extruded. This is to assist the straightness of the tile base 1 by coming into contact with the tile base 1. Therefore, a plurality of rollers 7.7, 7.7
The tile base 1 is extruded from the extrusion mold 2 in a straight line on the stainless plate 8 while being guided by the extrusion mold 2, and warpage and the like are effectively prevented.

Further, in this example, a primary cutting machine 9 is installed approximately 2 m forward from the exit of the extrusion mold 2, and the extruded tile base 1 is primarily cut by this success cutting machine 9. Therefore, the tile base 1 which has already been extruded onto the stainless steel plate 8b on the further front side can be cut into a predetermined length (2 m) by this success cutting machine 9.

Incidentally, in the past, this -success cutting machine 9 was used as an extrusion mold 2.
The tile base 1 can be primarily cut near the exit side of the extrusion mold 2.

Therefore, an outward diffusion force released from the pressing force acts on the tile base extruded from the exit of the extrusion mold 2.
The tip of the tile base was first cut near the exit side and became a free end, so it sometimes lost its direction and swayed outward. This wobbling is not as much of a problem when the tile base is short, but it becomes a big problem when the tile base is long like this example, and if the tile base is shaken, it will cause side warping (
(Warpage in the lateral direction of the tile base shown in the plan view in Figure 7)
It was the cause of.

However, in this example, as mentioned above, - Successful disconnection 9
Since the distance between the tile base 1 and the exit side of the extrusion mold 2 was secured at about 2 m, the tile base 1 extruded from the exit of the extrusion mold 2 has already been extruded for a considerable length onto the stainless plate 8a.
In addition, since the straightness is assisted by the roller 7, the straightness can be obtained by the accompanying force of the preceding tile base 1 which has already been pushed out onto the stain plate 8a, and furthermore,
The frictional resistance is large at the top, and especially in the case of a long object like this example, the frictional resistance in the lateral direction increases, avoiding lateral wobbling, achieving good straightness and preventing side warpage. As the tile base 1 is extruded into a long length, the extrusion resistance gradually increases, and the extruded tile base 1 applies a counter-extrusion force to the extrusion mold 2, so that the tile base 1 extruded from the extrusion mold 2 A central concentrated extrusion force counteracting the counter-extrusion force acts, and on the exit side of the extrusion mold 2, an action that concentrates in the center direction and tries to extrude the tile base 1 acts, and the tile base 1
The straightness of the vehicle will be improved.

Therefore, the tile base 1 extruded from the extrusion mold 2
, between the linear movement assisting action of the roller 7 and the stainless steel plate 8a
The top is pushed out in a straight line, effectively preventing side warping.

Note that the distance between the -successful cutter 9 and the extrusion mold 2 is not limited to 2 m, and as described above, there is a concomitant force on the exit side of the extrusion mold 2, a frictional resistance that restricts lateral wobbling, and a centrally concentrated extrusion. It can be set to a distance of at least about 1 m or more, which is enough for output and the like to be applied.

In this way, the tile base 1 which has been completely cut by the successful cutter 9 and formed into approximately long dimensions is subjected to the operating force of the pusher plate 10 that presses the tile base 1 at right angles on the stainless steel plate 8b. Sten board 8 located in the right angle direction
C and further guided onto the stainless steel plate 8d.

A pair of piano wires P and P are arranged in front of the stain plate 8d for cutting the longitudinal edge of the tile base 1, and in this example, a pair of piano wires P and P are provided on the left side edge of the stain plate 8d as shown in the figure. An L-shaped cutter 11 is installed, and this cutter 11
As a result, the upper surface side of the left edge of the tile base 1 that is sent out in the right angle direction is cut off, and an upper step 1h is completely formed on the left side edge of the tile base 1. The cut portion 12 cut out by the cutter 11 when forming the upper step portion 1h is reduced to a raw material by appropriate means and reused.

The reason why the upper part 1h is formed on the side edge of the tile base 1 in this way is because a plurality of completed long ceramic tiles 1 are placed on the wall of a building, as shown in FIGS. This is to provide the long ceramic tile 1 with a fitting function in the horizontal direction as well as a fitting function in the vertical direction when installed in the tile 1, as shown in an enlarged view in FIG. 4 (b). The upper step part 1 is formed on the longitudinal side edge of the tile base 1 as described above.
h can be fitted with a lower part 11 formed on the back side of the other end edge in the longitudinal direction of the tile base 1, and by overlapping the lower part 11 on the upper surface side of this upper part 1h, installation is possible. This allows the long ceramic tiles 1 to be connected in a good manner in the left and right direction.

As explained in FIG. 3, the upper part 1h is formed by cutting when the tile base 1 is in a soft state.
The lower step part 11 formed on the other edge opposite to the upper step part 1h is cut into an accurate size and shape using a grinder or the like after the tile base 1 is fired. By forming the lower step portion 11 into an accurate size and shape after firing, the long ceramic tile 1 can be shaped into an accurate size without being affected by dimensional shrinkage during firing.

Next, FIG. 5 shows a side view of the tile base 1 formed as shown in FIG. 3 in the process of drying.

In this example, the tile base 1 is placed in an inclined manner on an inclined plate 13 which is installed in an inclined manner than a horizontal plane, and
The tile is dried in a drying oven at 5°C for about 48 hours, and by drying the tile base 1 in an inclined manner in this way, it is possible to dry while effectively preventing side warping that occurs during drying. can. That is, since the lower end portion 1r of the tile base 1 is locked to the lower end portion of the inclined plate 13 during drying, gravity acts on the lower end holding portion 1f side, causing the inclined plate 13 to
Since the tile substrate 1 is dried while being held at the lower end, gravity always presses the tile substrate 1 against the lower edge of the inclined plate 13 during drying to prevent side warpage. Furthermore, this inclined plate 1
For example, the support stand 14 that supports 3 from the bottom side has an A dimension of 27Qlllllll and an 8 dimension of 15011 shown in FIG.
The inclined plate 13 can be supported at an inclination angle of about 111 degrees.

Next, FIG. 6 shows a schematic diagram of the drying process.

The tile base 1, which has been completely dried while preventing side warping in the state shown in FIG. 5, is heated to about 1250° C. and fired in a roller hearth kiln. Incidentally, after the drying process shown in FIG. 5, a glaze of a predetermined color tone is applied to the surface 1a of the tile base 1.

The tile base 1 that has been completely glazed in this way is rolled by rollers 15.1 arranged horizontally in a roller hearth kiln.
5.15, and is continuously transferred within the roller hearth kiln as each o-roller 15 rotates.

During this transfer, heat is applied from the front and back sides of the tile base 1 to ensure good firing.

In the past, the tile base 1 was placed on a base plate, loaded onto a trolley, and the trolley was passed through a firing furnace to be fired, but this method of placing the entire surface of the tile base 1 on the base plate is , it is difficult to make a flat floor plate on which to place a long tile base 1 like in this example from a single board, and the floor plate may warp, or two or more boards may be joined together. When making a tile base board, there is a problem in that the joints shift and the flatness is lost. Even if a flat tile board could be made from a single board, the tile base 1 is placed on the base board and the cart is moved. In the process of loading the tile into the tile and passing the trolley through the firing furnace to fire, the tile base 1 shrinks due to firing, and when it contracts, the shrinkage becomes partially uneven due to the frictional resistance caused by the surface contact with the floor plate, resulting in surface warping (8th Warping (as shown in the side view) or cracking (cracks) may occur, especially on long tile substrates like the one in this example.
When fired, surface warping and sharpness occur frequently.

Therefore, if the tile base 1 is fired in the process of being continuously moved on the rollers 15 in a roller hearth kiln as in this example, the tile base 1 is moved by the rollers 15 in line contact, so the tile base 1 is moved during the firing process. There is no frictional resistance when the substrate 1 contracts in the horizontal direction due to the linear contact with the roller 15, and the linear resistance is reduced accordingly, so that surface warping and sharpness are effectively prevented. Furthermore, since the height of each roller 15 can be adjusted as appropriate, it is easy to align each roller 15 on the same plane, and warpage can be better prevented.

Incidentally, if the large number of rollers 15 arranged in a row in the roller hearth kiln are allowed to be arranged in an inclined manner as shown in FIG. can. In this case, by arranging the rollers 15 in the roller hearth kiln so as to be inclined in an intersecting manner, the tile substrate 1 can be transferred better, and side warping on nine sides can be effectively prevented. be able to.

(Effects of the Invention) In the method for manufacturing a long tile board of the present invention, a tile base is extruded from an extrusion molding machine, cut into long dimensions, and then transferred in a perpendicular direction via pushers. An upper part for fitting is formed on the tile base by cutting off the upper surface side of one end edge in the longitudinal direction of the tile base, and after firing the tile base, the upper part and the upper part are cut off on the lower surface side of the other end edge in the longitudinal direction. By forming opposing lower tiers, the upper tier can be easily formed in the raw state of the tile base, and after firing,
The lower part on the other side can be formed with accurate dimensions,
This has the effect that it is possible to obtain a stepped portion for accurate fitting while maintaining the dimensions of the tile board accurately and also keeping the glazed surface well preserved.

[Brief explanation of the drawing]

The figures show an embodiment of the present invention. Figure 1 is a perspective view of the main part showing the arrangement state when the long ceramic tile of this example is installed on the wall of a building, and Figure 2 is a long view of the long ceramic tile of the present invention A front view of an extrusion mold for extrusion molding ceramic tiles, Figure 3 is a schematic perspective view of the configuration when extrusion molding a tile base, and Figures 4 (a) and (b) are rows of long ceramic tiles. Fig. 5 is a side view of the arrangement in the process of drying the tile base; Fig. 6 is a perspective view of the arrangement of the tile base during firing in a roller hearth kiln; FIG. 7 is a plan view of the tile base showing a warped state, and FIG. 8 is a side view of the tile base showing a warped state. 1...Long ceramic tile (tile base) 1a...Surface 1b...Back surface 1d...Top engaging convex portion
1f...Lower convex part 1h...Upper part
11...Lower section 2...Extrusion mold 2a...
・Main extrusion space 2bz, 2bt...Subextrusion space 3a, 3b...Partition plate 4...Ejecting 7...Roller 9...-Cut cutter 10...Pusher plate 11... Cutter 13... inclined plate
14...Support stand 15...Roller patent applicant Inax Co., Ltd. agent
Patent Attorney Yoshihisa Shimizu 1...Long ceramic tile (tile base) 1a...Surface 1
b...Back surface 1d...Upper engagement convex portion 1f...Lower engagement convex portion 1h...Upper section 11.Lower section 2.
...Extrusion mold 2a...Main extrusion space 2b,
2b,...Sub-extrusion space 3a, 3b...Partition plate 4...Ejecting 7...Roller 9...-Cutter 10...Pusher plate 11...Cutter 13...Incline plate
14...Support stand 15...Roller Fig. 11

Claims (1)

[Claims] After extrusion-molding the tile base using an extrusion molding machine and cutting it into long dimensions, in the process of transporting the tile base in the right angle direction via a pusher, the upper surface side of one longitudinal edge of the tile base is cut off to form the tile base. A method for producing a long tile board, comprising: forming an upper part for fitting in the tile base, and after firing the tile base, forming a lower part facing the upper part on the lower surface side of the other end edge in the longitudinal direction. .