JPH01141878A - Production of long-sized tile - Google Patents

Abstract

PURPOSE:To produce a title long-sized tile free of warpage by transferring the dried long-sized tile material in the roller-hearth kiln while inclining the material, and simultaneously firing the material. CONSTITUTION:The tile material 1 is extruded from the forming die 2 of an extruder, and the upper part 1b2 is cut off by a cutting conveyor 5. The material 1 is then placed on a stainless steel sheet 8a, rectilinearly transferred by the plural rollers 7 arranged by the sheet 8a, longitudinally cut by a primary cutter 9, transferred onto a stainless steel sheet 8b, and orthogonally sent by a pressure plate 10 onto a stainless steel sheet 8c. The longitudinal edges are cut off by a couple of piano wires P and P, the upper surface side of the left edge is cut off by an L-shaped cutter 11, and the material 1 is placed on a stainless steel sheet 8d. The material 1 is placed on an inclined sheet 13, dried, then transferred into the roller-hearth kiln, placed on orthogonally arranged rollers 15a and 15b, obliquely transferred, and simultaneously fired.

Description

Detailed Description of the Invention (Industrial Application Field) The present invention relates to a method for manufacturing a tile board formed into a long size, and more specifically, a method for manufacturing a long tile board while effectively preventing warping during firing. It is about the method.

(Prior art and its problems) Conventionally, in the step of drying and firing the tile base extruded from an extrusion molding machine, shrinkage occurs during firing, and especially in long tile bases, warping due to the shrinkage occurs. There was a problem in that this was noticeable and manufacturing was difficult.

Conventionally, the tile base is placed on a floor plate, placed on a trolley, and fired in a firing furnace, so when the tile base shrinks during firing, frictional resistance occurs between the tile base and the base plate, and this frictional resistance increases. There is a problem in that shrinkage stress remains in the tile base and warpage occurs due to the shrinkage stress, and the current situation is that it is difficult to prevent warpage.

(Means for Solving the Problems) The present invention has been devised in view of the above-mentioned conventional problems, and its purpose is to provide a firing method that can perform firing while preventing warpage. is a method for manufacturing long tiles in which a tile base is extruded from an extrusion molding machine, cut into long dimensions, dried and fired, and in the process of firing the tile base after drying, the tile base is tilted from the horizontal plane. The object of the present invention is to carry out firing in a roller hearth kiln equipped with a large number of rollers, while preventing warping while conveying the material at an angle through the rollers.

(Function) A roller hearth kiln is used to fire the tile base after drying, and a large number of inclined rollers are arranged in the roller hearth kiln, and the tile base is transferred in an inclined manner on the inclined rollers. By firing, the weight of the tile base itself is applied to the lower surface of the tile base, and even if shrinkage stress occurs within the tile base, the shrinkage stress is corrected by the weight of the tile base itself, preventing warping in the longitudinal direction. be done.

In addition, since the tile substrate is not placed on the floor plate and fired as in the past, when the tile substrate shrinks, the contact between the tile substrate and the roller is a line contact, so the contact between the tile substrate and the roller when it shrinks is There is little frictional resistance between
Therefore, the shrinkage stress is reduced and the occurrence of warping can be better prevented, and since the heating and firing are done evenly within the roller hearth kiln, the firing is done evenly and the occurrence of shrinkage stress is less. Warpage is effectively prevented.

(Example) Embodiments of the present invention will be described below based on FIG. 1.

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 l formed between portions lba
The bbs 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. The recess 1e has been completely 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. 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 are placed on the upper side of the engaging convex portion 1d of the long ceramic tile 1 that is completely placed on the lower side. Engage the engagement recesses 1g of the ceramic tiles 1, overlap the lower engagement protrusions 1f on the upper side with the surface side of the lower engagement protrusions 1d, and move the long ceramic tiles 1 upward one after another. can be placed.

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 chamotte is added to this natural soil! A mixture of powdered or crushed materials such as stone and pottery stone is used.

For example, as natural soil, 5iOa65.9% by weight, A1, o
, 19.0% by weight, 02° 4% by weight, Igros 6.
A raw material containing 1% by weight as a product 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 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 the moldability was determined by mixing 30% by weight and 940% by weight, 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. It has been found that 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 a raw material, an extrusion mold 2 as shown in FIG. 2 can be 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.

It is. The main extrusion space 2a and this sub-extrusion space 2b,
, 2b, and partition plates 3a and 3b are disposed between them,
The tile bases extruded from the main extrusion space 2a and the secondary extrusion spaces 2b and 2b are 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 protrusions 1d and the lower engaging protrusions 1f of the extruded tile base is The density distribution becomes denser and the density distribution in the central part becomes coarser, making the overall filling density distribution uneven. In order to make the overall shape substantially symmetrical in the horizontal and vertical directions, the secondary extrusion spaces 2111, .
2b, a main extrusion space 2a and a sub-extrusion space 2b,
, 2b, was made to have a rectangular shape as a whole.

In this way, the outer circumference of the main extrusion space 2a is followed by the extrusion spaces 2b, .
By forming 2BL, the filling density distribution of the tile base becomes uniform and it is extruded, and as a result, the shrinkage becomes uniform during the subsequent shrinkage process during drying, firing, etc., causing cracks, twisting, warping, etc. This will be avoided. Furthermore, the tile base portion extruded from the secondary extrusion space 2bt at the same time can also be used to support 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 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 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 1bz is again circulated over the raw material and can be 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 , 1. It is pushed out with the upper engagement protrusion 1d and the upper engagement recess 1e formed. In addition, the tile base (lower cutout 6) that is extruded from the secondary extrusion space 2b described above
is pushed out 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 disposed on the side of the stainless plate 8a from which the tile base 1 is completely extruded, and these rollers 7 are arranged at 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 tile base 1 extruded by this military cutting machine 9 is primarily cut. Therefore, the tile base 1 which has already been extruded onto the stainless plate 8b on the further front side 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 is primarily cut near the exit of the extrusion mold 2.

Therefore, an outward diffusion force acts on the tile base extruded from the exit of the extrusion mold 2, which is released from the pressing force.
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 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 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,
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 to 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.

In addition, the distance between the buko cutter 9 and the extrusion mold 2 is not limited to 2 m, and as described above, there is an accompanying force on the exit side of the extrusion mold 2, frictional resistance that restricts lateral play, and center concentration. It can be set at a distance of at least 1 m or more, which is sufficient to apply a pushing 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 when forming the upper step portion 1h is returned to the 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 pot 1 with a fitting function in the horizontal direction as well as a fitting function in the vertical direction when installed in the long ceramic pot 1, as shown in an enlarged view in Fig. 4 (b). , an upper step portion 1 formed as described above on the longitudinal side edge of the tile base 1;
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 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 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 27Qmn and 8 dimension of about 150 m11 shown in FIG.

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

The tile base 1 dried in the state shown in FIG. 5 while preventing side warping 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 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 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. Moreover, since the height of each roller 15 can be adjusted as appropriate, it is easy to align each roller 15 to the same level, and it is possible to better prevent surface warping.

Incidentally, by arranging a large number of rollers 15 that can be moved in rows in a roller hearth kiln at an angle, side warping can be effectively prevented during the firing process.

In that case, as shown in FIG. 9, the rollers in the roller hearth kiln are crossed rollers 15a and 15b, and roller 15a.

If the tile base 1 is to be transferred obliquely through the rollers 15b, the gravity of the tile base 1 will act on the lower end side while the tile base 1 is being transferred, and the tile base 1 will be transferred to either side of the rollers 15a or 15b. Since firing is performed while pressing the lower end of the sheet, side warping and two-sided warping 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 in which a tile base is extruded from an extrusion molding machine, cut into long dimensions, dried and fired, During the firing process of the dried tile base, the tile base is transported in a roller hearth kiln equipped with a large number of rollers arranged at an angle from the horizontal plane, and is fired while preventing warping while transporting the tile base through the rollers at an angle. Therefore, even if shrinkage stress is generated within the tile base during firing, the weight of the tile base itself acts downward along the inclined surface of the roller, so the shrinkage stress is alleviated by this weight and warping is effectively prevented. be done.

In addition, since the contact between the rollers is a line contact when the tile base shrinks during firing, there is less frictional resistance, and as a result, no shrinkage stress is generated within the tile base, and warping is better prevented. This has the effect of making it possible to obtain a long tile board with less warpage.

[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; Figure 7 is a plan view of the tile base showing a warped state, Figure 8 is a side view of the tile base showing a warped state, and Figure 9 is a view of the tile base during firing when the rollers in a roller hearth kiln are arranged in an intersecting manner. FIG. 2 is a perspective view of the arrangement of tile bases. 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... - Large cutting machine 10... Butcher plate 11 ... Cutter 13 ... Inclined plate
14... Support stand 15.15a, 15. b・-o
−Ra patent applicant Inax Co., Ltd. agent
Patent Attorney Yoshihisa Shimizu Figure 7 Figure S 1...Long ceramic tile (tile base) la...Surface 1b...Back surface 1d...Top engaging convex portion
1t...Lower engagement convex part 1h...Upper stage part
II...Lower section 2...Extrusion mold 2a...
-Main extrusion spaces 2b+, 2b1...Sub-extrusion spaces 3a, 3b...Partition plate 4...Drawing 7...Roller 9...-Large cutting machine 10...Butcher plate 11...Cutter 13... Inclined plate
14...Support stand 15.15, 15b...Roller Figure 1

Claims (1)

[Claims] A method for manufacturing long tiles, in which a tile base is extruded from an extrusion molding machine, cut into long dimensions, dried and fired, and in the process of firing the tile base after drying, a large number of tiles are tilted from a horizontal plane. A method for producing a long tile board, characterized in that firing is carried out in a roller hearth kiln equipped with rollers, which is transported through the rollers at an angle while preventing warping.