JPH02223404A - Method of casting mold for pottery having patterns - Google Patents

Abstract

PURPOSE:To prevent the occurrence of casting stripes of slurry by casting, and then thickening, pottery slurry for patterning the surface into absorptive molding mold, after that, performing casting and thickening therefor. CONSTITUTION:Pottery slurry for patterning the surface at the amount of forming a thickened layer of the order of approximate 3-5mm is cast uniformly on an upper mold 1 and lower mold 2 comprising a gypsum mold or porous resin mold in a short time, and a thickened layer (a') of the order of approximate 3-5mm is formed on the surface of the lower mold 2. Next, the upper mold 1 is combined with the lower mold 2, and the pottery slurry (b) for a molding body is cast from the casting openings 3 of the upper mold 1, so that the interior of the casting space 5 is filled thereby. After a solid layer (b') is formed within the casting space 5, the upper mold 1 is removed, and the lower mold 2 is set with a wear plate 6. Since the casting of pottery slurry for patterning the surface can be done uniformly in a short period, there may not exist a pattern separation and deviation, and thus, uniform patterns can be formed thereon.

Description

Detailed Description of the Invention (Industrial Field of Application) The present invention applies to ceramics such as toilet bowls, wash basins, counters, tiles, accessories, etc., which have patterns such as stone grain, and tortoise stone and ni [loading amount] using a casting method. Regarding the method of molding etc.

(Conventional technology) Conventionally, the technology to create patterns such as stone grain on the surface of ceramics involves drying a green base formed by a casting method, and applying glaze to the surface of the dried green base. The method used is to create patterns such as stone grain on the surface by combining the pattern and the color of the glaze. Furthermore, in the case of porcelain tiles, etc., a filler that forms a pattern such as a stone grain pattern is mixed with base powder, and the mixture is formed by a dry press method.

(Problem to be Solved by the Invention) However, the above-mentioned method of combining the glaze application pattern and glaze color did not produce a pattern close to that of natural stone, and the texture of the product did not give it a three-dimensional effect.・There was no depth. Furthermore, due to the characteristics of the press method, it is difficult to manufacture products with complicated shapes or products with large dimensions.

The present invention has been made in view of the above-mentioned problems of the prior art, and its purpose is to create ceramics with complex shapes and dimensions that have a three-dimensional effect, a deep stone grain pattern similar to that of natural stone, etc. The purpose is to provide a method by which large-sized ceramics can be manufactured.

(Means for Achieving the Object) In order to achieve the above object, the method for casting ceramics having a pattern according to the present invention takes the following three forms.

The first method is to cast ceramic slurry for surface patterning into a casting mold that has water absorption ability, and after inlaying, further cast ceramic slurry for the main body of the molded product, and after inking, remove the mold and dry it. It is something that makes you

When casting ceramic slurry to create a surface pattern, it is possible to cast only the specified amount from the beginning to achieve the specified inkling, or to cast a larger amount of slurry than the specified inkling amount to achieve the specified inkling. After the completion of the process, the excess slurry may be discharged.The former is suitable for molding a molded product with a simple shape, such as a plate-shaped crystal, and the latter is suitable for molding a molded product with a complex shape.

In the latter case, in order to improve the continuity and adhesion between both the slurry for surface patterning and the molded product body, the ceramic slurry for the molded product body is poured into the ceramic slurry for surface patterning. You may start in the middle of draining the slurry.

In addition, when casting ceramic slurry for the body of a molded product, a solid casting method that does not require a slurry removal process may be used, in order to apply the cast slurry all over the body according to the shape of the molded product. Alternatively, a slurry casting method may be used in which excess slurry is discharged after a predetermined thickness has been deposited.

The second method is to cast ceramic slurry for surface patterning into a casting mold that has water absorption ability, and then remove the mold after inlaying.
It is for drying.

In this method as well, either the solid casting method or the draining slurry casting method may be used for pouring the slurry, as in the first method.

The third method is to apply ceramic slurry to create a surface pattern on the molding surface of an intrusion mold that has water absorption ability, and after application, ceramic slurry for the main body of the molded product is cast, and after completion of inlaying, the mold is removed. ,
It is for drying.

Also in this method, the above-mentioned 1. Similar to the second method, the ceramic slurry for the molded product body may be cast by either the solid casting method or the draining mud casting method.

Furthermore, the method of applying ceramic slurry to create a surface pattern is not particularly limited, and may include spraying, brushing,
Dipping etc. can be used.

Note that the sludge casting method mentioned in the description of each method above includes not only the case where sludge casting is carried out over the entire molded product, but also the case where there is a partial solid casting part.

Ceramic slurries used to create surface patterns include those that contain pigments to create patterns in various colors, and those that contain fillers to create patterns such as the stone grain of natural stones. When using a slurry containing a filler, if the filler used is of a ceramic base material similar to the ceramic slurry used for surface patterning, the filler and base matrix will exhibit approximately the same firing yield. Cracks are less likely to occur. Examples of methods for producing this ceramic filler include a method in which a ceramic base slurry to which a binder and pigment are added is dried, then crushed and sieved, or formed into granules using a spray dryer method, etc. .

Also, 1st. In the third method, ordinary casting slurry can be used as the ceramic slurry for the body of the molded product, but drilling is a process or cutting process. The patterned portion of the layer and the unpatterned portion of the internal layer constituting the molded product body may be unnaturally discontinuous, which may be inconvenient in terms of appearance. In such a case, the same ceramic slurry for forming the surface pattern may be used as the ceramic slurry for the molded product body.

Also, 1st. In the third method, the thickness of the ceramic slurry applied or applied to create the surface pattern is not particularly limited, but is preferably 0.2 to 5M, and the thicker the better to create a deep pattern. However, in order to prevent cracks from occurring during drying and firing, the thinner the material, the better.

Note that if the surface smoothness of the molded product after demolding is not -E, the surface of the molded product can be polished after drying. In particular, if the ceramic slurry used to pattern the surface contains filler, depending on the viscosity of the slurry and the amount of filler, the filler may not come out sufficiently to the surface, or conversely, a portion of the filler may protrude from the coated surface. In such cases, it is also necessary to polish the surface after drying to expose the filler or to make the surface smooth.

In this case, polishing is easier if the filler is made of ceramic material.

(Function) According to the first method, the ceramic slurry used to create surface patterns does not have time to form a molding box, which occurs when the viscosity is high, and also prevents separation of patterns, which occurs when the viscosity is low. Before any deviation occurs, ink builds up on the lower mold, and the pattern on the mold surface becomes fixed and does not move.

According to the second method, for example, in a mold with a small casting space, during the casting process, the mold is coated and the pattern is formed before the sludge that occurs when the viscosity is high or the separation or unevenness of the pattern occurs when the viscosity is low. Fixed without moving.

According to the third method, the ceramic slurry for surface patterning is sprayed with a gun, so that even if the shape is complex, the ceramic slurry for surface patterning is fixed to the mold surface with a uniform thickness.

(Example) Hereinafter, the present invention will be specifically explained based on Examples.

(Example 1) In this example, a large ceramic plate is molded, and the molding process is as shown in Figures 1 to 4. Prepare an upper mold (1) and an F mold (2), and place the lower mold (2) into the lower mold (2).
2) Apply a uniform amount of ceramic slurry to create a surface pattern, in this case filler-containing slurry (a) that forms a stone-like pattern, to form an ink layer of about 3 to 5 #I#l on the surface. The mold is poured in a short period of time to form an ink layer (a') of about 3 to 5M on the surface of the lower mold (2). (Fig. 1) ■ Assemble the upper mold (1) with the lower mold (2), set the head tank (4) for slurry replenishment in the casting port (3) of the upper mold (1), and ) as a ceramic slurry for the molded product body, a filler-containing slurry similar to the ceramic slurry for forming the surface pattern or a slurry other than the filler-containing slurry (b) is cast to fill the casting space (5). (Fig. 2) ■ After forming the solid 11(b') in the casting space (5), remove the upper mold (1) and set the receiving plate (6) in the lower mold (2). (Fig. 3) ■ Next, the lower mold (2) and the receiving plate (6) are turned over 180 degrees, the lower mold (2) is removed, and the molded product (A) is obtained on the receiving plate (6).

■ After that, dry the molded product (A). ■ Finally, use paper etc. to dry the molded product (A).
) is polished to expose the filler.

(Example 2) In this example, a small item such as a soap holder is molded, and the molding process is as shown in Figures 5 to 7. 7).

Prepare the outer mold (8), shape it to form a casting space (5), set the head tank (4) for slurry replenishment in the casting opening (3) of the medium mold (7), and A filler-containing slurry (a), which is a ceramic slurry for patterning the surface, is poured into the pot from ) to fill the casting space (5).

(Fig. 5) ■ After forming the solid layer (a'') in the casting space (5), remove the middle mold (7) and outer mold (8) (Fig. 6), and place the molded product (A) on the receiving plate. obtain.

■ Dry the molded product (A), ■ Finally, use paper etc. to dry the molded product (A).
> surface (pattern side) is polished to expose the filler (C). (Fig. 7) (Example 3) In this example, a product is molded with mud removal, and the molding process is as shown in Figs. 8 to 12. , an upper mold (1) and a lower mold (2) made of a plaster mold or a porous resin mold are prepared, and the mold surfaces forming the casting space (5) of each of the upper mold (1) and the lower mold (2) are prepared. ,
Filler-containing slurry (a) is sprayed as a ceramic slurry for surface patterning using a mortar gun (9). (thickness:
Approximately 2 to 3 #111) (Fig. 8) ■ Assemble the upper mold (1) and lower mold (2), and insert the head tank (4) for slurry replenishment into the casting port (3) of the upper mold (1). A filler-containing slurry similar to the slurry for forming the surface pattern or a slurry other than the filler-containing slurry (b) is cast from the head tank (4) as a ceramic slurry for the molded product body, and a slurry (b) other than the filler-containing slurry is poured into the casting space (5). ) to fill the inside. (
(Fig. 9) ■ After the specified thickness is completed, the excess slurry in the casting space (5) is drained out of the mold, and the upper mold (1) is removed (Fig. 10) ■ The lower mold (2) is After setting the receiving plate (6), lower mold (2)
) and the receiving plate (6) are reversed 180 degrees, the lower mold (2) is removed, and the molded product (A) is obtained on the receiving plate (6).

■ Dry the molded product (A), ■ Finally, use paper etc. to dry the molded product (A).
> surface (pattern side) is polished to expose the filler (C).

(Example 4) In this example, a product with the same shape as in Example 3 was molded, and the molding process was as shown in Figures 13 to 16. A lower mold (2) made of a resin mold is prepared, and the lower mold (2) is surrounded by a temporary casting case (10).

■ Cast filler-containing slurry (a) as a ceramic slurry for surface patterning inside the temporary casting case (10) (Fig. 13) to form an ink layer (a') of approximately 2 to 4 mm. let

(2) Tilt the lower die (2) to discharge the excess filler-containing slurry (a) from the slurry drainage hole (11) numbered in the temporary casting case (10). (Fig. 14) ■ Remove the temporary casting case (10) and set the upper mold (1) in the lower mold (2>).

■ A head tank (4) for replenishing slurry is set in the casting hole (3) of the upper mold (1), and from the head tank (4) the slurry for creating the surface pattern is supplied as ceramic slurry for the main body of the molded product. The same filler-containing slurry or a slurry (b) other than the filler-containing slurry is poured to fill the casting space (5). (Fig. 15) (1) After forming an ink layer (b') of about 7 to 9 mm, excess slurry in the casting space (5) is discharged outside the mold.

■ After removing the upper mold (Fig. 16), ■ ~ of Example 3 above.
Perform the same operation as ■.

In Examples 1 to 4 above, filler-containing slurries having the following composition were used.

55 parts by weight of pottery stone, 25 parts by weight of clay, 20 parts by weight of feldspar, 20 parts by weight of filler, 100 parts by weight of water, 0.3 parts by weight of pigment 10 times suspended water glass, 0.3 parts by weight of CHC (pine 'j-)
Parts by weight Among the above compositions, the filler used was a ceramic filler having the following composition.

55 parts by weight of pottery stone, 25 parts by weight of clay, 20 parts by weight of feldspar.

10 parts by weight of zircon, 5 parts by weight of pigment. In addition, in Examples 1 and 3.4, whether to use "filler-containing slurry" or "sludge other than filler-containing slurry" as the ceramic slurry for the molded product body is determined by the open hole. Hole drilling is a product that requires a process or cutting process, and the cross section in the inking direction is exposed, and the part with the pattern on the surface layer and the pattern on the internal layer are exposed. If the missing part becomes unnaturally discontinuous and is not convenient for the appearance, use the same filler-containing slurry as the ceramic slurry used to create the surface pattern, otherwise use a slurry other than the filler-containing slurry. .

The slurry other than the filler-containing slurry is one that is used as a normal casting slurry, and is, for example, a human rare china slurry having the following composition.

59 parts by weight of pottery stone, 25 parts by weight of clay, 16 parts by weight of feldspar.

To explain the correspondence between the examples and claims of 43 parts by weight of water and 0.3 parts by weight of water glass, and the respective methods shown in <Means for achieving the object>, Example 1 corresponds to Claim 2. Corresponds to the first method, Example 2
Example 3 corresponds to claim 6 and the second method, Example 3 corresponds to claim 9 and the third method, and Example 4 corresponds to claim 3 and the first method.

In addition, claims 1, 4, 7.8. The only difference is the presence or absence of a discharge process for the ceramic slurry for patterning and for the slurry for the molded product body, so a description of the examples will be omitted.

(Effects) Since the present invention is configured as described above, it produces the effects described below.

In the first method, if the ceramic slurry for surface patterning is uniformly cast in a short time, there will be no casting streaks that occur when the slurry is highly viscous, and when the viscosity is low. Ink is applied to the lower mold before the pattern separation or deviation occurs.

As a result, the pattern on the mold surface is fixed and does not move, making it possible to produce a uniform pattern.

According to this method, even large ceramics such as large ceramic plates such as counters can be easily molded to have a uniform pattern.

The second method is suitable when the intrusion space is small, and the mold is inked before the slurry stripes that occur when the viscosity is high during casting or the pattern separation and unevenness that occur when the viscosity is low occur.

As a result, the pattern is fixed without moving, making it possible to produce a uniform pattern.

This method can easily mold small articles such as soap trays, towel racks, and other accessories.

In the third method, the surface layer is sprayed with a gun, so the ceramic slurry for creating the surface pattern can be fixed to the surface of the mold with a uniform thickness with a uniform thickness, making it possible to create a uniform pattern. can.

Further, the ceramic slurry to be cast after fixing the pattern may be any slurry other than the ceramic slurry for surface patterning, and since the viscosity is low, it can be easily drained. Therefore, this method can facilitate the molding of complex-shaped ceramics that require mud removal, such as toilet bowls and wash basins.

In addition, in any of the first to third methods described above, the molded product obtained by the method can exhibit a pattern such as a deep stone grain pattern similar to that of natural stone after firing.

Furthermore, by combining the first to third methods described above, it is possible to create patterns such as stone grain on ceramics of various shapes.

In addition, by using filler for ceramic base material as a filler to create surface patterns, when processing the green base material after demolding, the filler itself exhibits the same characteristics as the green base material, so processing such as cutting of the green base material can be performed as usual. It can be done in the same way as base material processing, and there are fewer defects such as warping and cutting after firing.

[Brief explanation of the drawing]

The drawings are explanatory drawings for explaining the steps of the casting method for ceramics having a pattern of the present invention, and FIGS. 1 to 4 show the method of Example 1, and FIGS. , FIGS. 8 to 12 show the method of Example 3, and FIGS. 13 to 16 show the method of Example 3.
The figures show the method of Example 4, respectively. 1.2.7.8: Casting mold 5: Casting space 9 Varnish spray gun 10: Temporary casting case 11: Ceramic slurry for creating a pattern on the two surfaces of drainage holes: Patent application for slurry for molded product body Jinto Toki Co., Ltd.

Claims (13)

[Claims] (1) After pouring ceramic slurry for surface patterning into a casting mold with water absorption ability and depositing it to a predetermined thickness,
A method for casting and molding ceramics having a pattern, which comprises discharging excess slurry, further casting ceramic slurry for the main body of the molded product, and removing and drying the mold after completion of inlaying. (2) Pour the specified amount of ceramic slurry for surface patterning into a casting mold that has water absorption ability, and after finishing the coating, pour the ceramic slurry for the main body of the molded product, and after finishing the coating. A method for casting and molding ceramics having a pattern, which is characterized by removing the mold and drying it. (3) After pouring ceramic slurry for surface patterning into a casting mold with water absorption ability and depositing it to a predetermined thickness,
Excess slurry is discharged, ceramic slurry for the main body of the molded product is further cast, and after a predetermined thickness has been deposited, the surplus slurry is discharged, followed by demolding and drying. Casting method. (4) A predetermined amount of ceramic slurry for creating a surface pattern is poured into a casting mold that has water absorption ability, and after the deposition is completed, another ceramic slurry for the body of the molded product is cast, and this completes the deposition. A method for casting and molding ceramics having a pattern, which is characterized by draining excess slurry, followed by demolding and drying. (5) Casting of ceramics having a pattern according to claim (1) or (3), characterized in that the casting of the ceramic slurry for the main body of the molded article is started while the ceramic slurry for forming the surface pattern is being discharged. Molding method. (6) A method for casting ceramics with a pattern, which comprises: casting a ceramic slurry for forming a surface pattern into a casting mold having water absorption ability, and removing the mold and drying it after the coating is completed. (7) A pattern characterized by pouring ceramic slurry to create a surface pattern into a casting mold with water absorption ability, draining the excess slurry after a predetermined thickness has been applied, and then removing the mold and drying it. A method of casting and molding ceramics. (8) Applying ceramic slurry to create a surface pattern on the molding surface of a casting mold with water absorption ability, and after application, pouring ceramic slurry for the body of the molded product, and after inking, remove the mold and dry it. A casting method for ceramics having a pattern characterized by: (9) Apply ceramic slurry to create a surface pattern on the molding surface of a casting mold that has water absorption ability, and after coating, pour in ceramic slurry for the body of the molded product.After the specified thickness has been deposited, remove the excess slurry. A method for casting and molding ceramics having a pattern, which is characterized by discharging and then removing and drying the mold. (10) Claims (1) to (9) characterized in that the ceramic slurry for surface patterning contains a filler.
) A method for casting and molding ceramics having a pattern described in any of the above. (11) The method for casting ceramics having a pattern according to claim (10), wherein the filler is made of ceramic material. (12) The method for casting ceramics having a pattern according to claim (11), wherein the filler is formed into granules from a slurry mainly composed of a ceramic base to which a binder and a pigment are added. (13) A method for casting ceramics having a pattern according to any one of claims (1) to (12), characterized in that the surface of the molded product is polished after drying.