JPH0345551A - Production of dry type molded roof tile - Google Patents

Abstract

PURPOSE:To prevent shrinkage and strain with drying and improve yield of a product by blending a specific aggregate crushed and granulated with a binder, molding the blend under pressure and then applying coloring to the molded article and burning the molded article. CONSTITUTION:At least one kind of raw material selected from a defective or broken article of ceramic burned article, mixed and burned article of burned ash of general waste and clay and melted and cooled product of burned ash of general waste is crushed and selected to afford an aggregate having 2-3mm particle size. Then the aggregate is blended with a hinder consisting of ordinary temperature type binder such as bentonite and heating type binder such as frit at a weight ratio of 7-9:3-1 and the blend is subjected to high pressure press molding to provide the molded roof tile. Then as necessary, coloring is applied to the roof tile and the colored roof tile is smoked by subjecting the roof tile to reduction burning at about 1000 deg.C or blocking oxygen and then as necessary resin is impregnated into the roof tile.

Description

Detailed Description of the Invention (Industrial Field of Application) The present invention relates to a method for manufacturing molded roof tiles, in particular using crushed ceramic fired products including defective products, fired crushed waste, etc. as aggregate;
This invention relates to a method for manufacturing so-called dry-formed roof tiles that do not involve adding water or mixing during the molding of roof tiles.

(Prior Art) As shown in Fig. 2, conventional molded roof tiles are manufactured through a mixing process (1) in which the raw material is clay, which is kneaded and crushed, and then mixed with water. The molding process included a molding step 2 in which the mixture was molded and then dried, and a firing step 3 in which it was fired in a kiln.

(Problems to be Solved by the Invention) The above prior art requires the drying step 2 because the JM material has clay as its main component.

Shrinkage and distortion occur as a result of drying, resulting in lower product yields, and improvements from the viewpoint of cost reduction and energy conservation have also become major issues. It is an object of the present invention to solve the above-mentioned problems of the prior art and to provide a method for manufacturing dry-formed roof tiles with low cost and excellent quality.

(Means for solving the problem) The above purpose is to use a ceramic fired product, a mixed fired product of waste incinerated ash and clay, or a molten and cooled product of waste incinerated ash as a raw material instead of clay, and crush the raw material. a pulverization step of pulverizing the raw material into fine particles, using at least one of the pulverized raw materials as aggregate, adding a binder thereto, and adjusting the component weight ratio of the aggregate and binder to 7 to 7;
It is distantly related to a manufacturing method comprising a blending step of mixing at a ratio of 9:3 to 1, a molding step of press-molding the blended product and then applying it, and a firing step of heating in a kiln.

Further, after the above-mentioned molding, the process may be omitted, and the oxygen supply may be reduced during the high temperature of the above-mentioned sintering to reduce the oxygen supply, or oxygen may be cut off and oxidized, and a process of infiltrating the resin after cooling the sintered product may be added. It may be a manufacturing method.

(Function) According to the manufacturing method having the above configuration, clay is not used as a raw material for forming tiles, and crushed products obtained by crushing defective or damaged ceramic fired products such as roof tiles, bricks, and ceramics, and general waste are incinerated. The fired and crushed mixture of ash and clay or the fused and crushed mixture of general waste can be reused as aggregate, and it can be molded without adding or mixing water, thereby omitting the drying process and improving product yield. It becomes possible to fire so-called dry-formed roof tiles that contribute to energy savings.

(Example) An example of the present invention will be described with reference to the drawings. FIG. 1 is a process diagram showing an embodiment of the method for manufacturing a dry-fired tile according to the present invention.

<Crushing process 11> One of the characteristics of this example is that the raw materials are roof tiles and bricks.

Ceramic fired products such as ceramics, industrial waste, and general waste including household waste are produced by incineration, with clay added and mixed, and the mixture is heated to high temperature and fired, or the above waste is once melted. The product obtained is then cooled and used. These raw materials are crushed to a particle size of 2 to 3 fffl using a show crusher or an impact crusher, and then passed through a sieve to form aggregate.

<Blending Step 12> At least one of the above aggregates is selected, and bentonite and frit are mixed therein as a binder. The composition weight ratio of the fired pulverized product and the binder is appropriately selected depending on the shape of the intended shaped tile.
4% by weight and 11% by weight in the free placement part, and mix them in a mixer. In addition to the above examples, binders used in the present invention include so-called room-temperature binders that have a bonding strength with raw materials at room temperature, such as clay and bentonite, and water glass, frit, and glass powder. A mixed binder is used in which a so-called heating type binder is mixed with a so-called heating type binder which has a bonding force with the raw material under heating.

<Forming step 13> This is a coloring step in which the above mixture is dry-molded into a predetermined tile shape using a high-pressure molding press, and sprayed using an ordinary powder when necessary. The shape of the molded tile in this example is suitable for molding tiles with a relatively simple shape, and the above composition is suitable for molding roof tiles (there are noshi tiles, round tiles, crown tiles, etc.). suitable.

Firing process 14> It is packed in a kiln and fired in a kiln at a temperature of around 100°C.

During the cooling process from high temperature in the kiln, the amount of air supplied is reduced and only fuel is supplied to fire reduced tiles in an oxygen-deficient state, or oxidized tiles are fired with air (therefore oxygen) cut off. is also possible. When firing reduced tiles and oxidized tiles, pre-painting is omitted6. <Finishing work 815> A resin agent such as silicone resin is infiltrated into the fired tiles taken out of the kiln after completing the firing process 14 to impart waterproofness. This step can be omitted for product tiles that do not require waterproofness.

The molded tile of this example has superior dimensional and shape stability as a product compared to molded tiles made by normal manufacturing methods, and is suitable for relatively thin and lightweight tiles, and is particularly suitable as a ridge tile, and is suitable as a roof tile. Experiments conducted by the inventors have revealed that it can be used in a wide range of applications in combination with ordinary molded roof tiles, has sufficient room-temperature strength and low-temperature strength, and is free from frost damage.

In addition to the above-mentioned examples, the composition of the present invention is such that the mixing ratio of the aggregate and the binder is 7 to 9:3 to 1 by weight, including cases where fired products and molten and cooled products are used as raw materials. It is possible.

(Effects of the Invention) By implementing the present invention, it is possible to achieve an energy saving effect by eliminating the drying process, a reduction in product cost by obtaining the main material of molded tiles at a low cost, and shrinkage due to drying of molded tiles. and distortion was prevented and product yield was improved. In addition, a remarkable secondary effect can be obtained in that a large amount of industrial waste as well as general waste can be reused.

[Brief explanation of drawings]

FIG. 1 is a process diagram of an embodiment of the method for manufacturing dry-formed roof tiles according to the present invention, and FIG. 2 is a process diagram of a conventional method for manufacturing conventional molded roof tiles. 11...Crushing process 12...Blending process 3.
...Molding process 14...Baking process 15...Finishing process

Claims (4)

[Claims] 1. A pulverizing step 11 in which a ceramic fired product, a mixed fired product of waste incinerated ash and clay, or a melted and cooled product of waste incinerated ash is used as a raw material, and the raw material is pulverized into fine particles, and at least one of the pulverized raw materials a blending step 12 in which one is used as aggregate, a binder is added thereto, and the component weight ratio of the aggregate and the binder is mixed in a ratio of 7 to 9:3 to 1; A method for manufacturing a dry-formed tile, which comprises a forming step 13 of dry forming and a firing step 14 of heating in a kiln. 2. 2. The method of manufacturing a dry-formed tile according to claim 1, wherein the binder is a mixture of a room-temperature binder and a heating binder. 3. Claim 1, wherein the molding step 13 is not performed, and the firing step 14 is characterized in that at high temperature, oxygen supply is reduced to perform reduction, or oxygen is cut off and oxidized.
The method for manufacturing the dry-formed tiles described. 4. 2. A method for manufacturing a dry-formed tile according to claim 1, further comprising a finishing step 15 of infiltrating a resin into the fired product after cooling the fired product following the firing step 14 of claim 1.