JPH01139217A - Manufacture of longer tile plate - Google Patents

Abstract

PURPOSE:To increase frictional resistance in the horizontal direction particularly for a longer material to avoid horizontal vibration, good straightness and prevent side warp by disposing a cutter at a substantial distance from an outlet of mold and extraction molding a tile base straight forward from the mold. CONSTITUTION:A tile base 1 extruded out of the outlet of an extrusion mold 2 extruded by a substantial length on a stainless sheet 8a in order to secure the distance between a primary cutter 9 and the outlet side of an extrusion mold 2 by approximately 2m. As straightness is assisted by a roller 7, straightness is obtained by the accompanying force of the foregoing tile base 1 already extruded on the stainless sheet 8a, and as frictional resistance is large on the stainless sheet 8a, particularly friction resistance is increased in the horizontal direction for a longer material to avoid horizontal vibration, and good straightness can be obtained to prevent side warp. Further, as the material is extruded continuously, so extrusion resistance is increased gradually and central concentrated force to compete anti-extrusion force is actuated, and the action of extruding the tile base 1 is effected to make straightness better.

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) The present invention relates to a method of manufacturing a long tile board.

(Prior art and its problems) Conventionally, when extruding raw soil from an extruder to form a tile base, a cutting machine was installed near the exit side of the mold at the tip of the extruder, and the primary cutting was performed near the mold. If the tile substrate is short in size, there is no problem in making the primary cut near the mold, but this is especially true when the tile board extruded from the mold is long. However, if the primary cutting is done near the molding machine as in the past, the tile base extruded from the mold will not have any directionality, and the long tile base will warp.

(Means for Solving the Problems) The present invention has been devised in view of the above-mentioned conventional problems, and is a manufacturing method capable of obtaining a tile base without warping when extruding a long tile base. The purpose is to provide a method for producing long tile plates, the gist of which is to extrude raw material soil from a mold installed in an extruder and cut it with a cutting machine to form a long tile board, which method comprises: A cutting machine is placed at a considerable distance from the exit of the mold, and the tile base is extruded in a straight line from the mold by the action of the accompanying force of the tile base being pushed out to the cutting position of the cutting machine. be.

(Function) The cutting machine is placed at a considerable distance from the exit of the extrusion mold, and instead of performing the primary cutting near the mold as in the past, the cutting machine is placed at a considerable distance from the mold. Since we decided to perform primary cutting, as the size of the tile base extruded from the mold gradually increases, straightness is obtained due to the accompanying force of the previous tile base that has already been extruded onto the stainless steel plate, etc. Frictional resistance is large on stainless steel plates, and especially in the case of long objects, the frictional resistance in the lateral direction increases, avoiding lateral wobbling, achieving good straightness and preventing side warping. The extrusion resistance gradually increases as it is further extruded into a longer length, and the extruded tile base applies a counter-extrusion force to the extrusion mold. An opposing central concentrated extrusion force acts, and on the exit side of the extrusion mold, an action that tries to extrude the tile base concentrates toward the center, improving the straightness of the tile base. . Therefore, warping of the tile base material does not occur, and a long tile base material can be molded without warping.

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

Figure 1 shows how the long ceramic tiles 1 of this example are arranged on the exterior wall of a building. 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. Then 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 l 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 la 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 a lower side concave portion 1g is 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 1c are formed in the central 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 retaining concave portions 1g of the ceramic tiles 1 are engaged, and the lower mating convex portions 1f on the upper side are superimposed on the surface side of the lower engaging convex portions 1d, and the elongated ceramic tiles 1 are placed one after another 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 using raw material soil made of natural soil such as chamotte may cause twisting deformation, cracks, etc. Ingenuity has been added to the extrusion mold.

That is, in this example, inexpensively available natural soil is used as the raw material soil, and this natural soil is mixed with powdered or crushed materials such as chamotte, Rouseki, potter's stone, etc.

For example, as natural soil, 810165.9% by weight, Alzo
s19.0% by weight, 02.4% by weight, Igros 6.
A raw material containing 1% by weight as a main component can be used, and a mixture containing 50% feldspar and about 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 to obtain raw material soil. 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 20% by weight or less, cracks and warping occurred during drying and firing when used as a long tile base. Further, when the amount of chamotte mixed in is about 40% by weight, it has been found that moldability and surface smoothness deteriorate. Therefore, the optimum amount of chamotte etc. to be mixed is 25 to 35% by weight.

When extrusion molding a tile base using such raw material soil, 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 center of the extrusion mold 2, a main extrusion space 2a is formed in the horizontal direction, and the space shape corresponds to the cross-sectional shape of the long ceramic tile 1 in FIG. Four wood cuttings 4 are arranged horizontally in the center, and the central hole 1c of the long ceramic tile 1 is formed by these cuttings 4. Further, sub-extrusion spaces 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 tile base extruded from the main extrusion space 2a, the sub-extrusion spaces 2b and 2bt is They are extruded and separated by partition plates 3a and 3b.

In this way, the outer circumference of the main extrusion space 2a is followed by the extrusion space 2b+,
2b- is 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 1r 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
2 to form a main extrusion space 2a and a sub-extrusion space 2b, 2.
The entire bl 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 is made uniform and 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 soil is extruded from this extrusion mold 2 onto the stainless plate 8 on the front side in a diagonal shape.

In this example, a cutting conveyor 5 is placed on the exit side of the extrusion mold 2.
is disposed, and as the cutting conveyor 5 rotates, the portion (upper cutting portion) 1b of the tile base extruded from the extrusion mold 2 that is pushed out from the secondary extrusion space 2bz is removed and removed from the outside. The discharged upper cut portion 1bz is again circulated as raw material soil and reused.

Therefore, the tile base 1 (
(The same reference numerals are used because it is in the same shape as the long pottery tile 1 in the molding process) is the above-mentioned upper cutout portion 1b.
By removing a, the upper engagement protrusion 1d and the upper engagement recess 1e can be pushed out in a state where they are formed. Further, the tile base (lower cutout portion 6) that is extruded from the secondary extrusion space 2b described above 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 further forward is 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 is primarily cut near the exit 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 cut off near the exit side and became a free end, which caused it to lose its direction and sometimes wobble 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, -truncated a9
Since the distance between the tile base 1 and the exit side of the extrusion mold 2 was secured at 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 steel 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 further extruded into a longer length, the extrusion resistance gradually increases, and the extruded tile base 1 applies a counter-extrusion force to 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.

It should be noted that the distance between the success cutting machine 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 center concentration. It can be set to a distance of at least about 1 m or more, which is enough to apply an extrusion force or the like.

In this way, the tile base 1 cut by the success cutting machine 9 and formed into approximately long dimensions is subjected to the operating force of the butcher plate 10 that presses the tile base 1 at right angles on the stainless steel plate 8b. , stainless steel plate 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
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 portion 1h is 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 raw material soil 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 the lower step part 11 formed on the back surface side at the other end edge in the longitudinal direction of the tile base 1, and by overlapping the lower step part 11 on the upper surface side of this upper step part 1h, This allows the long ceramic tiles 1 to be installed to be well connected 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 part 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 with respect to a horizontal surface.
It is dried for about 48 hours in a drying oven at 5°C.
By drying the tile base 1 by rolling it in an inclined manner in this manner, it is possible to dry the tile base 1 while effectively preventing side warping that occurs during drying. That is, since the lower end portion 1r of the tile base 1 is locked to the lower end of the inclined plate 13 during drying, gravity acts on the lower end portion lf side of the lower end portion of the inclined plate 13.
Since drying is carried out while holding the tile base 1 at the lower end, gravity always presses the tile base 1 against the lower end edge of the inclined plate 13 during drying to prevent side warping. Furthermore, this inclined plate 1
The support stand 14 that supports the tilt plate 13 from the bottom side is capable of supporting the inclined plate 13 at an inclination angle of, for example, A dimension of about 270 m'n and B dimension of about 1508 mm as shown in FIG.

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

The tile base 1, which has been dried while preventing side warping in the state shown in Figure 5, is heated to about 1250''C in a roller hearth kiln and fired. A glaze of a predetermined color tone is applied to the surface 1a side.

The tile base 1 glazed in this way is moved by a large number of rollers 15.15 arranged horizontally in a roller hearth kiln.
．． 15, and is continuously transported within the roller hearth kiln as each 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 that 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 that case, if the rollers 15 in the roller hearth kiln are arranged in an intersecting manner,
The tile base 1 can be transferred better, and side curvature on one side can be effectively prevented.

(Effects of the Invention) The method for manufacturing a long tile board of the present invention is a method for manufacturing a long tile board in which raw material soil is extruded from a mold installed in an extruder and cut by a cutting machine. Then, a cutting machine is placed at a considerable distance from the outlet of the mold, and the tile base is extruded in a straight line from the mold by the action of the accompanying force of the tile base being pushed out to the cutting position of the cutting machine. By doing so, as the size of the tile base extruded from the mold gradually increases, straightness is obtained due to the accompanying force of the previous tile base that has already been extruded, and the frictional resistance gradually increases. In the case of long tiles, the frictional resistance in the lateral direction increases and lateral wobbling is avoided, good straightness is achieved and side warping is prevented, and even when the tile base is long, good directionality is imparted. This has the effect of preventing warping.

[Brief explanation of the drawing]

The figures show an embodiment of the present invention, and Fig. 1 is a perspective view of the main part showing the arrangement state when the long ceramic tile of this example is arranged on the wall of a building. 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
1r...Lower convex part 1h...Upper part
11...Lower steamed bun part 2...Extrusion mold 2a...
・Main extrusion spaces 2b, 2b,... Sub-extrusion spaces 3a, 3b... Partition plate 4... Extraction 7... Roller 9... - Cutting machine 10... Butcher plate 11 ... Cutter 13 ... Inclined plate
14...Support stand 15...Roller patent applicant Inax Co., Ltd. agent
Patent attorney Yoshimizu Shimizu No drawings available Fig. 7 Fig. S Fig. 1...Long ceramic tile (tile base) 1a...Surface 1b...Back surface 1d...Top engaging convex portion
1"...Lower convex part 1h...Upper part
1i...lower section 2...extrusion mold 2a...
・Main extrusion space 2b+, 2bm...Sub-extrusion space 3a, 3b...Partition plate 4...Ejecting 7...Roller 9...-Bugou cutting machine 10...Butcher plate 11...・Cutter 13... Inclined plate
14...Support stand 15...Roller Fig. 1

Claims (2)

[Claims] (1) A method for manufacturing a long tile plate in which raw soil is extruded from a mold installed in an extruder and cut by a cutting machine, the material being cut at a considerable distance from the exit of the mold. A method for manufacturing a long tile board, which comprises arranging a machine and extruding the tile base straight from the mold by the action of the accompanying force of the tile base extruded to the cutting position of the cutting machine. (2) A long tile board according to claim 1, characterized in that a roller is disposed on the side edge of the tile base in the extrusion direction, and the tile base extruded by the roller is given straightness. Production method.