JPH01141864A - Continuous-length extrusion molded pottery plate - Google Patents

Abstract

PURPOSE:To obtain the title pottery plate capable of being excellently shaped while maintaining extrusion molding properties of a basis material by utilizing raw material soil in which chamotte is mixed with natural soil incorporating clay mineral as a main component and extrusion-molding it to continuous length and shaping it. CONSTITUTION:A pottery plate is obtained by using raw material soil in which chamotte, agalmatolite and pottery stone etc., are mixed with natural soil incorporating clay mineral as a main component at 25-35wt.% and extrusion-molding the mixture to continuous length and shaping it. In this pottery plate, e.g. as natural soil, 65.9wt.% SiO2, 19.0wt.% Al2O3, 2.4wt.% K2O and 6.1wt.% ignition loss can be made to be a main component and a compound in which about 30% clay mineral such as kaolinite, sericite and montmorillonite is incorporated into 50% feldspar can be utilized besides it. The raw material soil can be obtained by mixing chamotte, agalmatolite or pottery stone is which a calcined material such as a brick, a tile and a tableware is crushed and made powdery with the natural soil at 25-35wt.%.

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) This invention relates to a ceramic plate that is extruded and shaped into a long length.

(Prior art and its problems) - Conventionally, in order to improve the aesthetic appearance of the exterior wall of a building, long cement boards are sometimes placed on the exterior wall of a building. Since the firing temperature of cement boards is lower than that of ordinary ceramics, there is a problem that the type of glaze that can be applied to the surface is limited and there is a lack of variety in surface color. There was a problem in that it was expensive.

(Means for Solving the Problems) The present invention was devised in view of the above-mentioned conventional problems, and its purpose is to obtain long ceramic plates using inexpensive natural soil. The gist is that raw material soil, which is made by mixing 25 to 35% by weight of cymot, Rouseki, pottery stone, etc. into natural soil mainly composed of clay minerals, is extruded into a long length and shaped.

(Function) When extrusion molding and shaping a long ceramic plate, natural soil containing clay minerals as the main component is used as the raw material, so the raw material soil can be obtained at low cost, making the entire product inexpensive. It can be shaped. Also, in this natural soil 25
Since the raw material soil is mixed with ~35% by weight of chamotte, Rouseki, pottery stone, etc., the extrusion moldability of the base material is maintained, and cracks do not occur during the drying and firing process, making it possible to create long pieces. Ceramic plates can be shaped well.

(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 according to this example, which can be placed 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 can 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 l formed between the parts 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 1c is formed. On the other hand, on the lower surface side, there is a lower engagement convex portion 1 that protrudes downward in a continuous manner with the surface 1a.
f is integrally formed, and a lower engagement recess 1g is formed on the back side of the lower engagement protrusion 1f'. Further, in this example, four hollow central holes 1c are formed in the center of the front surface 1a and the back surface 1b 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 1f 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 quill 1 has a long longitudinal dimension of approximately 2 m, extrusion molding using raw material soil made of natural soil without added chamotte may cause twisting 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 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, S1Ot65.9% by weight, A1.
0.19.0% by weight, 102.4% by weight, Igros 6
．． It is possible to use raw materials with a product content of 1% by weight,
In addition, a mixture containing about 30% of clay minerals such as kaolinite, sericite, and montmorillonite in 50% of feldspar 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 less than 20%, cracks and warping occurred during drying and firing when used as a long tile base. Furthermore, when the amount of chamotte mixed in is about 40% by weight, the 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 punching holes 4 are horizontally arranged in the center, and the central hole 1c of the long ceramic tile 1 is formed by the punching holes 4. Further, sub-extrusion spaces 2b are formed on the outer periphery of the protrusion space corresponding to the upper engagement protrusion 1d and the lower engagement protrusion 1f in FIG. 1 of the main extrusion space 2a. Partition plates 3a and 3b are disposed between the main extrusion space 2a and the sub-extrusion spaces 2b, 2b, and the tile base extruded from the main extrusion space 2a and the sub-extrusion spaces 2b, 2b is The partition plates 3a and 3b extrude them into separate pieces.

In this way, following the outer circumference of the main extrusion space 2a, the extrusion space 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 almost symmetrical in the horizontal and vertical directions, the secondary extrusion spaces 2bl, 2b
! are formed, and the main extrusion space 2a and the sub-extrusion spaces 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 space 2bl,
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 portion extruded at the same time can also be used for supporting the protrusion corresponding to the lower engagement convex portion 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 into a long shape onto the stainless steel plate 8 on the front side.

In this example, a cutting conveyor 5 is placed on the exit side of the extrusion mold 2.
is disposed, and when the cutting conveyor 5 is rotated, the portion (upper cut portion) 1b of the tile base extruded from the extrusion mold 2 that is pushed out from the secondary extrusion space 2bl is removed and removed from the outside. The discharged upper cut portion 1b 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 , 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 2bt is extruded while remaining in contact with the lower surface side of the tile base 1.

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

Further, in this example, a plurality of rollers 7.7.7. '/ is completely disposed, and this roller 7 comes into contact with the side edge of the tile base 1 to be extruded and assists the straightness of the tile base 1. Accordingly, a plurality of rollers 7.7, 7.
The tile base 1 is extruded from the extrusion mold 2 in a straight line on the stainless steel plate 8 while being guided by the extrusion mold 7, and warpage and the like are effectively prevented.

Further, in this example, a primary cutting machine 9 is installed approximately 2 m in front of the eaves from the exit of the extrusion mold 2, and the tile base 1 extruded by this military cutting machine 9 can be primarily cut. 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 cutting machine 9.

In addition, in the past, this buko cutting machine 9 is an extrusion mold 2.
The tile base 1 was to 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 material that is completely 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 flopped outward. This preforming is not a big 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 preformed, 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,
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 is obtained by the accompanying force of the preceding tile base 1 that has already been pushed out onto the stain plate 8a, and furthermore, the straightness is assisted by the roller 7.
The frictional resistance is large at the top, and especially in the case of a long object like the one in this example, the frictional resistance in the lateral direction increases to avoid lateral play, resulting in good straightness and preventing side warping. 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. Therefore, 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.
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 upper part is pushed out in a straight line, and side warping etc. are well prevented.

It should be noted that - the distance between the buko cutter 9 and the extrusion mold 2 is not limited to 2 m, and as mentioned above, there is an accompanying 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 military cutter 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 during the formation of 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 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 with respect to a horizontal surface.
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 engagement protrusion 1f of the tile base 1 is locked to the lower end of the inclined plate 13 during drying, gravity acts on the lower engagement protrusion 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 warping. Furthermore, this inclined plate 1
The support stand 14 that supports No. 3 from the bottom side is, for example, No. 513.
A dimension shown in 0 is 279mm 11.33 dimension is 150m
The inclined plate 13 can be supported at an inclined angle of about 1 l.

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 and fired in a roller hearth kiln. 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 l 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 continuously moving on the rollers 15 in the roller hearth kiln as in this example, the tile base 1 is moved in line contact with the rollers 15, so the firing process When the tile base 1 contracts in the horizontal direction, there is no frictional resistance 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 a large number of rollers 15 arranged in a row in the roller hearth kiln are arranged at an angle 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 can be effectively prevented. be able to.

(Effects of the Invention) The long extrusion-molded ceramic plate of the present invention is extruded into a long length using raw material soil made by mixing 25 to 35% by weight of chamotte, Rouseki, pottery stone, etc. to natural soil mainly composed of clay minerals. By molding and shaping, it can be mass-produced at low cost using inexpensive natural soil, and has the effect of being able to be formed into a long shape with good moldability and less warping when drying. have

[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
1f...Lower engagement convex part 1h...Upper stage part
11...Lower section 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...Rolled...Long ceramic tile (tile base) 1a/Surface
1b...Back surface 1d...Top engaging convex portion 1
f...Lower engagement convex portion 1h...Upper section II/Lower section 2...Extrusion mold 2@...Main extrusion spaces 2b+, 2b+ -Subextrusion spaces 3a, 3b...Partition plate 4... Extraction 7...Roller 9...-Notch cutter 10/Bun 7 Yaar plate 11...Cutter 13...-Slanted plate
14...Support stand 15 -Roller Fig. 15

Claims (2)

[Claims] (1) Long extrusion molding characterized by extrusion molding into a long length using raw material soil made by mixing 25 to 35% by weight of chamotte, Rouseki, pottery stone, etc. into natural soil mainly composed of clay minerals. Ceramic board. (2) The elongated extrusion-molded ceramic plate according to claim 1, having a longitudinal length of 600 mm or more.