JPH0577218A - Production of double layer molded tile - Google Patents

Abstract

PURPOSE:To obtain a tile having both of a three-dimensional appearance and a rich quality appearance by forming embossed patterns to a surface layer composed of flakes having various shapes or sizes by subjecting the flakes laminated to the surface of the raw material of a base material to pressure molding using an elastomer. CONSTITUTION:In the production of a double-layer molded title consisting of a base material and the surface layer laminated thereto, the inorg. raw material of the surface layer is prepared as a composition bondable to the raw material of the base material and granulated to obtain amorphous flakes 5. Next, these flakes 5 are laminated to the surface of the raw material 4 of the base material and all of them are subjected to the press molding by the pressing surface of the elastomer 1a provided to an upper mold 1 to unify the flackes 5 with the raw material 4. Thereafter, the molded one is baked to obtain a desired double-layer molded tile.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a two-layer molded tile in which a surface layer is laminated on the surface of a substrate, pressure-molded and then fired to obtain a product.

[0002]

2. Description of the Related Art A general method for producing a two-layer molded tile is
The upper surface of the base material that is the lower layer is granulated with a base material having the same or similar composition as this base material, and the chips are charged as the upper surface layer, and the chips are embedded in the base material by press molding to be integrated. It was formed and then fired. A mold device is generally used for press molding,
Many products have relatively flat surfaces such that the chips are completely embedded in the substrate. There is also a manufacturing method in which a polishing step is performed in case the chip is not completely buried in the base material.

[0003]

SUMMARY OF THE INVENTION In such a method,
Tile products with various patterns depending on the size of chips and their distribution can be obtained. However, since the chips are integrated and fired in such a state that they melt into the base material, the surface of the finished product ends up being flat. For this reason, the texture is poor, and not only is it lacking in depth and heavyness, but it is also possible to obtain a product with a unique impression of gloss and appearance by complicating the reflection of light by intentionally making the surface uneven. could not.

[0004] The problem to be solved in the present invention is to leave irregular irregularities on the surface of the tile after firing so as to enable the production of a tile having a new feeling with a rich texture.

[0005]

The present invention is a method for producing a two-layer molded tile comprising a base material and a surface layer laminated on the base material, wherein the inorganic raw material of the surface layer is a base material of the base material. And flakes into indefinite flakes by granulation, and these flakes are laminated on the surface of the base material of the base material, and the flakes and the base material of the base material are pressed by a pressing surface of an elastic body. It is characterized in that the flakes and the raw material for raw material are integrated into one body and then fired.

[0006]

By preliminarily forming the flakes of the inorganic raw material of the surface layer and laminating the flakes on the base raw material of the base material, a large number of flakes are complicatedly entangled and stacked. Then, when press-molded by the pressing surface of the elastic body, the pressing surface elastically deforms along the distribution of the thickness of the flake layer, and the flakes are integrated with the base material of the base material without being crushed. Therefore, after pressing, an uneven pattern of flakes is formed on the surface layer, and an irregular striped pattern appears as an uneven surface on the surface by subsequent firing, so that a product is obtained.

[0007]

EXAMPLE The composition of the base material of the tile to be formed is almost the same as the conventional one, and feldspar: 40 parts by weight, clay: 40 parts by weight, porcelain stone: 20 parts by weight, or feldspar: 50 parts by weight.
Parts by weight, clay: 35 parts by weight, porcelain stone: 15 parts by weight.

On the other hand, the flakes forming the surface layer are a combination of kaolin, clay: 15-40 parts by weight, porcelain stone: 10-50 parts by weight, and feldspar 25-60 parts by weight. For example,
Kaolin, clay: 20 parts by weight, porcelain stone: 20 parts by weight, feldspar: 60 parts by weight as an inorganic raw material.

The method for producing flakes is as follows.
First, the inorganic raw material having the above composition is pulverized by a ball mill or the like into a spray powder having a particle size of about 50 to 500 microns, and dried to a water content of about 7%. Thereafter, the spray powder is granulated with an Erich mixer to a size of about 1 to 10 mm, and water is added to adjust the water content to 10 to 15%.
In addition, at the time of this granulation, a pigment may be added as necessary to color the flakes. Next, the granulated product of the inorganic raw material is rolled by a roller to obtain flat particles of about 0.5 to 2 mm.

The flakes produced in this manner are flat small pieces having a substantially uniform thickness, and their planar shapes vary in size according to the size of the granulated pieces in the granulating process, and their shapes are also different. Different things are obtained for each.

FIG. 1 is a schematic view showing a step of pressing a base material and a surface layer of flakes in the method for producing a double-layer molded tile according to the present invention.

In the figure, an upper die 1, a lower die 2 and a frame die 3 are arranged as a pressing device, and a rubber 1a as an elastic body is attached to the entire lower surface of the upper die 1 as a pressing surface. The rubber 1a has a JIS rubber hardness of 30 to 85, preferably 35 to 65, and a thickness in the rolling direction of about 0.5 to 2.5 mm.

In such a pressing device, a raw material 4 for a base material prepared in advance is filled in the molding space in the lower mold 2 and the frame mold 3, and the upper surface of the raw material 4 is manufactured by the above manufacturing method. The formed flakes 5 are charged and laminated ((b) of FIG. 1).

Here, in order to secure the adhesive strength necessary for integrating the base material 4 and the flakes 5, the water content of the base material 4 is set to 6 to 7%, and the water content of the flakes 5 during pressing is increased. One condition is that the rate is 6 to 14%, preferably 8 to 12%. Further, it is assumed that the composition of the raw material 4 of the base material described above has the same firing characteristics such as fire resistance and firing shrinkage.

After the flakes 5 are laminated on the raw material 4 of the base material, the upper mold 1 is lowered to pressurize the flakes 5 and the raw material 4 ((c) of FIG. 1). The pressing force by the upper mold 1 at this time is
200 to 400 kgf / cm ² , preferably 250 to 3
It is set to about 00 kgf / cm ² . At the time of this pressure molding,
Since the rubber 1a on the lower surface of the upper mold 1 presses down the flakes 5, the rubber 1a elastically deforms according to the laminated state of the flakes 5 and the surface unevenness due to the laminated distribution is left without crushing all the flakes 5. As it is, the flakes 5 are integrated with the raw material 4 of the base material.

Then, the molded body obtained by this pressure molding is charged into a firing furnace, and the firing temperature is 1280 ° C. to 70 to 9 ° C.
Bake for 0 minutes. As a result, a two-layer molded tile composed of the base material 6 and the surface layer 7 shown in FIGS. 2 and 3 is obtained as a final product. A transparent glaze may be applied before firing.

The surface layer 7 is densely distributed over the entire surface of the base material 6 in the pressed state as compared with the state when the flakes 5 are manufactured, and the flakes 5 are laminated as shown in the schematic view of FIG. The indented portions and the edges of the flakes 5 are entangled with each other to form a complicated uneven shape. And this uneven shape is
Unfolded over the entire surface layer 7, the surface of the tile appears as a pattern in which a large number of small pieces are scraped together and packed tightly. Therefore, the unevenness of the surface of the product after firing can provide a tile having a unique surface with rich texture and increased depth.

Here, when the pressing force of the upper die 1 and the hardness of the rubber 1a are appropriately changed during the pressure molding, the force for crushing the flakes 5 also changes variously. Therefore, the degree of the unevenness due to the flakes 5 appearing on the surface can be changed. For example, if the rolling force is reduced or the hardness of the rubber 1a is decreased, a dynamic pattern with the unevenness can be formed.

Further, since the flakes 5 and the raw material 4 of the base material are pressed by utilizing the elastic load of the rubber 1a, the lamination generated at the time of pressure molding can be prevented as compared with the case of using a conventional mold. Can be suppressed. This will be described with reference to FIGS.

FIG. 5 shows the lower layer 10 (corresponding to the base material 4).
FIG. 3 is a schematic diagram for explaining a case where granulated powder 11 (corresponding to flakes 5) is laminated on the surface of and the press molding is performed by a mold.

When the laminated granulated powders 11 are stacked on each other as shown in FIG. 5A, the lower surface of the mold is flat and is not deformed when pressed by the mold, so that the granulated powders 11 are placed on top. The granulated powder 11 is pressed down so as to enter the gap between the granulated powder 11 below. For this reason, air is often left in the gap portion, and the granulated powder 11 laminated on the surface layer 12 having a mesh-like hatching as shown in FIG. The surface layer 12 has a higher density than the other parts. In this way, if air remains between the lower layer 10 and the surface layer 12 after pressing, or if there is a dense or sparse portion in the packing degree of the granulated powder 11, deformation or lamination of the molded tile after firing may occur. It is likely to result.

On the other hand, FIG. 6 shows the case of pressure molding by the upper mold 1 used in the manufacturing method of the present invention.

When the rubber 1a of the upper die 1 pressurizes the granulated powder 11, the portion where the granulated powder 11 overlaps is greatly contracted and deformed ((a) in the figure).
Pressurize according to a filling degree of 1. Therefore, (b) in the figure
As described above, the formed surface layer 12 does not become flat, but the density in the thickness direction does not become uneven, and the granulated powder 11 is gently deformed, so that air can easily escape during this time. There is no air left.
Therefore, there is no occurrence of lamination after firing and deformation of the molded body, and it is possible to obtain a molded body with stable quality even after demolding.

As described above, by utilizing the elastic reduction by the rubber 1a, not only the appearance of the uneven pattern due to the flakes 5 but also the deformation after firing can be suppressed and the dimensional accuracy can be improved.

[0025]

In the present invention, the flakes laminated on the surface of the base material of the base material are pressure-molded by the elastic body, so that they can be left as irregularities on the surface of the base material without crushing all the flakes. it can. Therefore, it is possible to create a complicated uneven pattern on the surface by flakes of various shapes and sizes, and it is possible to obtain a tile with a completely new feeling that has a three-dimensional effect and is rich in texture.

Further, the degree of unevenness of the flakes can be freely changed by changing the pressing force during pressing and the hardness of the elastic body on the pressing surface. For this reason, it is possible to perform sufficiently good molding without strictly setting the composition and water content of the flakes, which improves the degree of freedom in processing and allows various products to be formed by gradually increasing or decreasing the unevenness of the surface. The one with the specifications can be easily manufactured.

[Brief description of drawings]

FIG. 1 is a schematic view showing a manufacturing process of a double-layer molded tile of the present invention.

FIG. 2 is a schematic plan view of the obtained two-layer molded tile.

3 is a schematic vertical cross-sectional view of the two-layer molded tile of FIG.

FIG. 4 is a diagram showing a state of surface irregularities due to flakes after molding.

FIG. 5 is a schematic vertical cross-sectional view showing the rolling deformation of the granulated powder in the case of press processing using a conventional die.

FIG. 6 is a schematic vertical cross-sectional view showing the deformation of the granulated powder under pressure by a rubber press.

[Explanation of symbols]

 1 Upper Mold 1a Rubber (Elastic Body) 2 Lower Mold 3 Frame Mold 4 Raw Material (of Base Material) 5 Flakes 6 Base Material 7 Surface Layer

Claims (1)

[Claims] 1. A method for producing a two-layer molded tile comprising a base material and a surface layer laminated on the base material, wherein the inorganic raw material of the surface layer has a composition capable of being bonded to the base raw material of the base material. Amorphous flakes by granulation, these flakes are laminated on the surface of the base material of the base material, the flakes and the base material of the base material are press-molded by the pressing surface of the elastic body to form flakes and the base material. The method for producing a two-layer molded tile, comprising: