JPH0272904A - Molding method of wall material and the like - Google Patents

Abstract

PURPOSE:To contrive an improvement in workability in molding of a wall material and the like, by a method wherein a molding material is fed on a lower side belt under a state where an upper and the lower belts are moved continuously and the material is pressurized and molded continuously in accordance with movements of the upper and lower belts. CONSTITUTION:Belts 5, 9 in each conveyor are moved continuously at the fixed same speed. A patterning material 31 is fed onto a main body part 5b of the belt from each feed element 22 in a feed device 21 through its feed port 22a. Then a main molding material 32 is fed from a feed device 23 through a feed port 23a so that the molding material 32 covers the patterning material 31 continuously. Then a levelling plate 24 is interposed between lateral walls 5a and the top of a loaded material is levelled flat with its lower fringe 24a. The material whose surface is levelled arrives at a confronting part between the belts 5, 9 according to a movement of the belt 5 and pressurized gradually on both sides. Molding is performed continuously according to the movement of the belts 5, 9. In addition, the lateral walls 5a on both the right and left sides of the belt 5 prevent reliably an overflow of the molding material from the upper part of the belt 5.

Description

[Detailed Description of the Invention] [Field of Industrial Application] The present invention relates to a method for forming wall materials such as interior wall materials and exterior wall materials, or floor materials (collectively referred to as wall materials, etc. in this specification). It is something.

[Conventional technology]

With two endless belt conveyors arranged vertically and continuously moving in the same direction, molding material is continuously supplied onto the belt of the lower conveyor, and the supplied material is transferred to the upper and lower belts. Continuous pressure molding is carried out in between.

Furthermore, in order to prevent the molding material supplied onto the belt from spilling on both sides of the belt, endless belts are provided on both sides of the molding material supplied onto the belt to prevent spillage. Such techniques are known. (See, for example, Japanese Patent Application Laid-Open No. 63-62706.) [Problem to be Solved by the Invention] However, in the above technique, the lower belt is easily bent due to the heald, creating a gap between it and the spill prevention belt. When a gap is created, molding material spills out and adheres to the belt drive part, roller, belt, etc., or even gets into the gap, increasing friction, accelerating wear, and causing damage. was there.

The present invention has been made in view of the above points, and its purpose is to provide a method for molding wall materials, etc., which allows molding to be performed while completely preventing spillage of the molding material. That is.

The configuration of the present invention is as follows.

[Means to solve problems]

In order to achieve the above object, the present invention takes the measures as described in the claims above, and its effects are as follows.

[Effect]

The upper and lower conveyor belts are continuously moved in the same direction. In this state, the material supply device continuously supplies molding material onto the belt of the lower conveyor. The supplied material is continuously pressure-formed between the upper and lower belts that face each other as the belt moves. In the above process, the lateral walls of the lower belt prevent spillage of molding material. Furthermore, since these side walls can be elastically compressed by the upper and lower belts, they do not interfere with the molding of the molding material.

〔Example〕

The drawings showing the embodiments of the present application will be described below.

In FIGS. 1 to 7, 1 indicates a roll forming machine.

In this case, reference numeral 2 denotes a lower endless belt conveyor, which is composed of drive rollers 3.4 which are rotationally driven in the direction of the arrow through a well-known electric motor and speed reducer (not shown), and an endless belt 5 passed around them. 6 is the upper endless belt conveyor,
Like the conveyor 2 described above, it is composed of drive rollers 7.8 and an endless belt 9. These conveyors 2.6 are arranged side by side as shown in the figure, with each portion of the surface of the belt 5.9 facing each other vertically at a predetermined interval.

As shown in Fig. 1, the distance between the belts 5.9 and 9 is made smaller at the end of the belt in the direction of movement, so that the molding material described later is gradually pressurized as the belt moves. It's Nishide. As the upper belt 9, a stainless steel belt is used because the belt elongates and deforms little, has high hardness, and is resistant to rust. Its width is, for example, about 600 tm (and 15
Belt 5 on the lower side (sometimes up to about 00 Tsuru)
has a cross-sectional shape as shown in FIG. 3, with horizontal walls 5a on both sides.
, 5-a. Such a box-like shape has horizontal walls 5 on both side edges of the belt main body portion 5b.
a, 5a are continuously attached over the entire length of the main body portion 5b. The main body portion 5b has the same width as the upper belt 9 and is made of the same material. However, they may also use other belt materials,
The side walls 5a, 5a are made of an elastic material, such as foamed chloroprene rubber. Furthermore, the material is
Foams such as butyl rubber, EPR, and EPT may also be used. The cross-sectional shape of the horizontal walls 5a, 5a is, for example, a square, but it may be a vertically long or horizontally long rectangle. , for 9fi, it will be about 25 dragons, and for 15 cranes, it will be about 45 ko. In other words, the attachment of the side wall 5a to the main body portion 5b, which has a height (thickness) approximately three times the thickness of the molded body, is as follows:
This is done by attaching both sides with, for example, double-sided adhesive tape so that the side wall 5a can be attached or detached. The above-mentioned horizontal walls 5a are prepared in various heights, and one is selected according to the thickness of the molded body, and is attached to the main body part 5b. The above installation is called Velcro.
This may be done by using a pair of connecting elements that are detachable from each other, or when the thickness of the molded body is not changed, the side wall 5a may be permanently fixed to the main body 5b. Reference numerals 11 and 12 denote pressure rollers exemplified as pressure means, which are attached to the back sides of mutually opposing portions of the belts 5.9 in each of the above-mentioned conveyors 2.6. These pressure means may be pressure plates that contact the back surface of each belt with little friction. The pressure roller 11. is wider than the width of the belt 5.9 mentioned above. The width of the peripheral surfaces 11a and 12a at +2 is slightly larger. The arrangement pitch of the upper and lower pressure rollers 11 and 12 is made smaller toward the end in the direction of movement of the belt, so that the pressure applied from these rollers to the molding material via the belt 59 increases sequentially. It has become. 13 is a heating means that heats the molding material at a constant temperature (60 to 80°C) via a belt 5.9.
It is designed for heating.

Such heating promotes pressure forming of the molding material (activates the binder aluminum phosphate in the molding material). As the heating means, a far-infrared heater, an infrared heater, or the like is used.

Next, 21 is a pattern material supply device, which in this example consists of a plurality of supply elements 22, 22, etc. arranged in the width direction of the belt 5 as shown in FIG. , over the entire width of the belt 5, the main molding material (also referred to as main material or simply molding material in this specification) -
It is configured so that it can be supplied in various ways. Reference numeral 24 denotes a scraping plate, which is configured so that the molding material supplied onto the belt 5 from the supply device 23 can be made to have a uniform thickness over its entire width. It also has the ability to move up and down. Reference numeral 25 indicates a cutter for the molded product that has been press-molded, and reference numeral 626 indicates a conveyor for carrying out the molded product, and an arbitrary conveyor such as a belt or a roller conveyor can be used.

Next, the molding material and pattern material used in the roll forming machine 1 will be explained.

Examples of molding materials include glass cullet, 50 to 80 parts by weight, aluminum oxide, 10 to 40 parts by weight, bentonite. 3 to 30 parts by weight colorant (
metal oxide)...0 to 20 parts by weight binder (
PVA) ・・・・・・・・・1 to 2 parts by weight is basically used. After pulverizing and mixing these in a ball mill, an appropriate amount of water is added to the mixture to form a slurry, and then a spray dryer is used. by 125~25
Make into granules with a size of 0μ. Since the molding material that has passed through the spray dryer is in a dry state, when it is used, the molding material is hydrated by spraying so that the moisture content becomes 3 to 6 parts by weight.

In addition, when the molding material is not made into granules and is used as a powder, the above-mentioned step using a spray dryer is omitted.

The pattern material consists, for example, of a composition similar to that described above, with the addition of 5% by weight of a coloring agent (metal oxide or a metal compound that converts into an oxide upon heating, such as a carbonate). A mixture having such a composition is granulated by a method similar to that described above.

Next, examples of the relationship between the types and colors of the colorants used as the above-mentioned colorants are as follows.

Red (FazOi)...Red (brick color),
Chromium oxide: green, titanium oxide: yellowish white, cobalt oxide: blue, iron oxide (PesOn): black In other words, one type or a mixture of several types of these can be used. However, metal oxides not exemplified here can also be used as colorants.

Regarding the material used as the molding material, in 1 above, we explained a composition that does not contain a coloring agent, but for example, when making a wall material with a red color, red iron oxide (Fezes) may be used as a coloring agent. Will be using it. Therefore, the pattern material to be used in conjunction with this is a material of a different color, that is, a material that is a mixture of different types of metal oxides used as colorants.

Next, a procedure for manufacturing wall materials and the like using the above-mentioned molding machine and materials will be explained. First, the belt 5.9 on each conveyor
are continuously moved at the same predetermined speed. The speed is appropriately set, for example, within the range of 5 to 30-7 hours. In this case, when molding a thick wall material, etc., it is preferable to slow down the feed rate so that sufficient pressure is applied to the molding material. In the above state, the pattern material 31 is supplied from each supply element 22 in the supply device 21 through its supply port 22a onto the belt main body portion 5b as shown in FIG. 6(A). As shown in b), the main molding material 32 is passed from the supply device 23 through the supply port 23a.
is continuously supplied so as to cover the pattern material 31. Next, as shown in FIG. 6(c), the side wall 5a
, A pickpocket board 24 is interposed between Sa, and its lower edge 2
Smooth the top surface of the official material using step 4a.

In this case, if you want to make the thickness of the molded wall material even thinner, that is, if you want to mold a thin plate, you can use the slotted board 24.
This can be dealt with by moving it further downward. In other words, the lower edge 24a of the pickpocket plate 24 and the belt main body portion 5b
By narrowing the interval (distance) between the top surface and the top surface, the thickness of the loaded material can be reduced by that amount. As the belt 5 moves, the material whose surface has been smoothed as described above reaches a portion where the belts 5 and 9 face each other, where it is gradually pressurized from above and below. And the final stage pressure roller ll', 12"
Pressure molded to a predetermined thickness. The above-described forming is performed continuously as the belts 5 and 9 move. Incidentally, the molding pressure is set to, for example, 600 kg/cm2 at the pressure rollers 11' and 12' at the final stage.

As described above, in the process from when the molding material is supplied onto the lower belt 5 until it is pressure-molded, the horizontal walls 5a on both the left and right sides of the belt 5.

5a reliably prevents the molding material from spilling over the belt 5. That is, since the lower surface of the horizontal wall 5a is fixed to the upper surface of the main body part 5b, even if the main body part 5b is bent and deformed up and down to some extent by passing alternately between the places where the pressure roller 11 is present and the places where the pressure roller 11 is not present, the side wall 5a It similarly transforms accordingly. (That is, there is no gap between the two.) Therefore, no molding material spills.

In addition, when the above molding material is pressurized between the upper and lower belts,
The horizontal wall 5a is elastically compressed from above and below as shown in FIG. 3-3, and its height decreases in response to the decrease in thickness accompanying the compression of the molding material. Therefore, regardless of the presence of the side wall 5a, the molding material can be properly pressurized from above and below. Not only that, but in this case, the horizontal wall 5 compressed from above and below
a is as shown by arrow A in Figure 3-3. It is pressurized in almost the same way, and the entire width is pressurized to an approximately uniform density.This helps to prevent sharpness and deformation (warping and curling) during firing due to uneven pressure that conventionally occurs. .

After the above-mentioned pressure forming, the horizontal wall 5a released from the pressure by the upper belt 9 restores itself due to its high restoring force (elastic force), and reaches the material supply device again by the rotation of the belt 5.

Next, the molded product is cut into a predetermined size using a guillotine-type canter 25 or a well-known cutting saw to form a wall material 33 as shown in FIG.

The wall materials and the like are transferred to the next firing process by a roller conveyor 26 for conveyance. In the firing process, the wall materials etc. 33
For example, it is put into a firing furnace such as the Barola hearth kiln,
For example, it is baked at a temperature of 800 to 900° C. for about 30 minutes.

The wall material 33 fired as described above is the molding material 3
Since the pattern material 2 and the pattern material 31 are of the same quality, they are made into porcelain in an integrated state. That is, the fired wall material is densified in the same way as the molding material even in the areas where the pattern material is present. Therefore, the wall materials, etc. maintain the original excellent properties of the material, such as hygroscopicity and mechanical strength, over the entire area.

The wall material 33 fired as described above is rough-finished or cut with a chip saw or the like as needed to give a suitable finish, and then transferred to the final polishing process to reveal the pattern. The surface is polished to give a glossy finish to the finished product.

In the above manufacturing process, pattern materials of the same color or different colors may be supplied from each supply element 22, and by continuously supplying pattern materials from each supply element 22, A striped pattern is formed on the finished wall material, etc., and a dotted pattern is formed on the wall material, etc. by intermittently supplying the pattern material from each supply element 22. Furthermore, by supplying the pattern material while repeatedly moving each supply element 22 in the width direction of the belt 5,
A wavy pattern is formed on wall materials, etc. The intermittent supply of pattern material or the movement of the supply element 22 in the width direction as described above may be controlled manually by an operator or automatically by a control device such as a computer.

Furthermore, when molding wall materials or the like as described above, the front and rear positions of the pattern material supply device 21 and the main material supply device 23 may be interchanged. In this case, the wall material or the like can be molded with the pattern exposed on the side facing the belt 9. In that case, in the molding material supplied from the supply device 23, a groove is formed at a position corresponding to the position where the pattern material is supplied, and by supplying the pattern material to the groove, the upper and lower belts are The thickness of the entire material between 9 and 5 can be made approximately equal.

Furthermore, when molding a wall material or the like as described above, the thickness of the pattern may be arbitrary. If necessary, the thickness may extend from the upper surface to the lower surface of the wall material 33.

If only a plain molded body without a pattern is to be formed, the supply of material from the pattern material supply device 121 may be stopped or the device may be omitted.

Next, FIGS. 8 to 11 showing different embodiments of the present application will be described. This example shows an example in which the striped pattern can be formed by a pattern forming plate after the pattern material is supplied over the entire width of the belt. In the figure, the pattern material supply device 21e is configured to be able to supply pattern material across the entire width of the upper surface of the belt main body portion 5be. 35 is a patterned plate with many comb-shaped teeth 3 on the lower edge.
5a. This pattern forming plate is provided on the rear side of the pattern material supplying device 21e, as shown in FIG. In addition, the above-mentioned large number of @35a may each be made to have a different arbitrary shape, or the mutual spacing may be made to be variously different.Furthermore, the pattern forming plate 35 may be moved back and forth in the width direction of the heald 5e. .

In the case of such a structure, the pattern material 31e is placed approximately on the main body portion 5be as shown in FIG.
After the pattern forming plate 3 is fed as shown in (b),
The pattern material 31e is formed into a plurality of strips by the teeth 35a. Thereafter, as shown in (c) and (d), the supply of molding material and the smoothing of the surface are performed in the same manner as in the previous embodiment, and further pressure molding is performed, resulting in a wall material as shown in Fig. 11. Etc. 33e is obtained.

It should be noted that parts that are considered to have the same or equivalent structure as those in the previous figure in terms of function are given the same reference numerals as in the previous figure with the letter e, and redundant explanations are omitted.

(Furthermore, the same concept will be used in the next and subsequent versions, and the alphabetical letters "flg" will be added in order to omit duplicate explanations.) Next, FIGS. 12 to 14 show further different embodiments of the present application. This is an example of a product in which the surface of a wall material or the like is provided with transparent glass and a pattern with a three-dimensional effect can be formed by the method of the present invention. In the figure, numeral 37 denotes a glass material supplying device which can supply glass powder (glass current) 39 made of the same material as the glass prize component contained in the molding material onto the belt main body portion 5bf over its entire width. ing. The 3rd is a Surikiri board.

In the structure described above, as the belts 5f and 9f move, wall materials, etc. are formed in the order shown in FIGS. 13(a) to 13(f). That is, first, as shown in (A)D, the glass material 39 is supplied onto the belt 5f from the glass material supply device 37. Next, as shown in (b), the glass material 39 is smoothed to a thickness of - by using a scraping plate 38. Next, as shown in (c), a pattern material 31f is supplied thereon, and then, as shown in (d), a linear pattern of the pattern material 31f is formed by a pattern forming plate 35f. In this case, the lowering position of the pattern forming plate 35 is preferably such that the pattern material 31f forms a linear pattern and the glass material 39 does not collapse significantly. Next, as in the previous case, the molding material 32f is supplied as shown in (e), and the surface is smoothed with a scouring plate 24f as shown in (f). Thereafter, pressure forming is performed in the same manner as described above, and a wall material 33f as shown in FIG. 14 is obtained. When such a wall material or the like is fired, the glass material 39 on the surface thereof is melted and becomes glass-like.

Next, FIGS. 15 and 16 show further different embodiments of the present application. In the figure, reference numeral 41 denotes an adhesive applicator which applies an adhesive or pressure-sensitive adhesive to the surface of the belt main body 5bg at a position corresponding to a pattern to be formed. A nozzle is used that sprays the adhesive onto the belt main body portion 5bg.

42 indicates an air nozzle.

With such a configuration, during the movement process of the belt 5g, the adhesive or adhesive is applied to the surface of the main body portion sbg at a location corresponding to the pattern to be formed by the adhesive applicator 41. be done.

Next, the pattern material 31g on the main body part Sbg is blown off by the air blown out from the zero-order nozzle 42, which is supplied over the entire width of the pattern material 31g on the main body part Sbg. As a result, on the surface of the main body portion 5bg, the pattern material 31g remains only in the areas where the adhesive or pressure-sensitive adhesive was applied. After that, the molding material was supplied and pressure molded in the same manner as above, and 33g of wall material etc. as shown in Fig. 16 was produced.
is obtained.

According to the method described above, the pattern material 31g on the belt 5g does not shift in position during any of the feeding process of the molding material 32g, the leveling process of the surface, and the pressure forming process, and the outline is clearly defined. It becomes possible to make wall materials etc. with a pattern.

The adhesive or pressure-sensitive adhesive is one that does not leave part of the molding material or pattern material attached to 5g of the belt during pressure molding, or does not remain as carbon after the molded body is fired. It is preferable to use a common synthetic resin adhesive or pressure-sensitive adhesive.

The thickness of the pattern on wall materials etc. formed in the above manner is sufficiently thicker than that of conventional glazes, so that even if the surface on which the pattern is exposed is polished as described above, the pattern will not disappear. There's nothing wrong with that. In this specification, such a thickness will be referred to as a large thickness.

〔Effect of the invention〕

As described above, in the present invention, when molding the wall material 33, the upper and lower belts 5 and 9 are continuously moved, and in this state, the molding material 32 is continuously supplied onto the lower belt 5. The material can be press-molded continuously as the belt 5.9 moves, and the wall material etc. can be formed with extremely high workability.

Furthermore, in the above process, the molding material supplied onto the lower belt 5 has the advantage that it can be completely stopped by the belt 5 having a box-shaped cross section. This reliably prevents the molding material from spilling over the belt 5, and has the effect of preventing the abrasion and damage to the machine that would otherwise be caused by the molding material spilling as in the prior art.

Moreover, even though the lower belt 5 is box-shaped as described above,
When the supplied molding material is pressed by the upper and lower belts 9.5, the heights of the elastic horizontal walls 5a, 5a of the lower belt 5 change correspondingly as the molding material is compressed. It has the advantage that the molding material can be compressed appropriately.

[Brief explanation of the drawing]

The drawings show an embodiment of the present application, and FIG. 1 is a vertical cross-sectional partial view of the roll forming machine, FIG. 2 is a plan view of the roll forming machine with the upper conveyor removed, and FIG. 3 is a partial vertical section view of the roll forming machine. Fig. 3-2 is an enlarged sectional view of the ■° section in Fig. 3, Fig. 3-3 is a similar view to Fig. 3-2 in the ■'' section of Fig. 2, Fig. 4 The figure is a side view showing the relationship between the lower conveyor and the pattern material supply device, and Figure 5 is a perspective view of the pickpocket board.
Fig. 6 is a diagram schematically showing the forming process for wall materials, etc., Fig. 7 is a perspective view of the wall material, etc., Fig. 8 is a vertical cross-sectional partial view showing a different embodiment, and Fig. 9 is a diagram of a pattern forming plate. A perspective view, and FIG.
1 is a perspective view of a wall material, etc., FIG. 12 is a longitudinal cross-sectional partial view showing a further different embodiment, FIG. 13 is a diagram schematically showing the process of forming wall material, etc. using the apparatus shown in FIG. 12, and FIG. The figure is a perspective view of the same wall material, etc., FIG. 15 is a vertical cross-sectional partial view showing a further different embodiment, and FIG. 16 is a perspective view of the wall material, etc. formed by the apparatus shown in FIG. 15. 2.6...Endless belt conveyor, 5.9...Belt,
11.12... Pressure roller, 23... Material supply device, 32... Molding material. Figure 3-2 Figure 3-3

Claims (1)

[Claims] 1. Two endless belt conveyors are arranged side by side in such a way that each part of the surface of the belt in each conveyor is vertically opposed to each other with a predetermined interval apart, and the belt on the lower conveyor is The cross-sectional shape is box-shaped with erect horizontal walls on both sides, and both horizontal walls have elasticity in the vertical direction, and the mutually opposing portions of the belt in each of the conveyors are A pressurizing means is attached to the back side of each of the belts, and a material supply device is provided to continuously supply molding material to the belt of the lower conveyor. A wall material, etc., characterized in that the belts are continuously transferred in the same direction, and the supplied material is continuously pressure-formed between the upper and lower belts facing each other as the belts move. molding method. 2. The method for forming wall materials, etc. according to claim 1, wherein the belt in the lower belt conveyor comprises a belt-shaped belt main body and horizontal walls detachably installed on both side edges of the belt main body.