JPH0729835B2 - Long ceramic plate manufacturing equipment - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial field of application] The present invention is a natural method in which a raw material mainly composed of clay is planted by spraying an arbitrary pattern on a decorative surface of an extruded product formed by continuous extrusion, An extruded product with a rugged texture is dried in a short time, cut into regular lengths, and fired to produce long ceramic plates of a specified length at a low cost and with a significantly shorter manufacturing time than before. The present invention also relates to a device that can be manufactured without deformation.

[Conventional technology]

Generally, inner and outer wall materials and roof tiles made of clay are extruded in a predetermined shape, and are immediately cut into a short length, for example, a length of 10 to 30 cm, and a drying device having a structure that uses the waste heat of a firing furnace. A device having a structure in which the water content is reduced to 1 to 0% in about 1 to 3 days and then supplied to a trolley type firing furnace was common.

[Problems to be solved by the invention]

In this type of apparatus, it takes several days for the drying and firing steps, and in particular, since it is soft immediately after extrusion, if it is not short, it is greatly deformed and cannot be transported to the drying apparatus, which is the main reason why a long body cannot be formed. Therefore, a vast drying site and warehouse are required. Moreover, once the firing furnace is heated, it is impossible to extinguish the fire due to cost and productivity, and the schedule is 3 shifts for 24 hours. It required three times as many workers, and the energy cost was not as efficient as the productivity. Further, since the conventional apparatus dries with hot air, the dough dries from the surface and is twisted, bent, or cracked, and the maximum length of the dried body is about 60 cm. This is disadvantageous in that the surface layer exposed to the hot air is dried first and further from the end, and deformation, warpage, twisting, cracking and the like occur due to moisture inside. In particular, the deformation of the extrusion-molded product is greatly affected by the water content of about 5 to 10%, so that the drying during this period could not be carried out smoothly and without causing the above-mentioned warpage and cracks.
Furthermore, the firing time is a badge or tunnel dryer structure in which preheating, firing and cooling are completed in 8 to 10 hours according to the temperature curve, and the temperature control is slow in response because of the large size of the furnace and takes a long time as described above. I needed it. In addition, even if the time was shortened by one step among all the steps, it was not a device that brought about a good result in terms of production capacity in the line. Furthermore, the shape of the extruded product in the conventional device is simply determined by the die, and the decorative surface is flat, or the uneven pattern of the same straight line as the extrusion direction, or the embossed pattern according to Japanese Patent Publication No. 61-47683. It could only be formed, and had the disadvantage of lacking the design and natural feel of the ceramic plate.

[Means for solving problems]

In order to eliminate such drawbacks, the present invention smoothly transfers the extrusion-molded product next to the extrusion port of the extrusion-molding machine without causing deformation, twisting, cracking, or shrinking, and at the same time, performing extrusion-molding during the transfer. The same material as the extruded product can be sprayed onto the decorative surface of the body to give a convex pattern, or it can be quickly dried as a cosmetic surface with a natural or three-dimensional effect by pressing down or smoothing. It is sent to the dryer as a continuous body, then the dried extrusion molded body is sent in order of a running cutter, a firing furnace consisting of a roller hearth kiln capable of parallel conveyance, etc.
A long porcelain plate with a length of about 600 to 3000 mm, which can be sent at an arbitrary speed, is dried and fired by a drying process. The present invention provides a long porcelain plate manufacturing apparatus capable of continuously manufacturing in a short time, for example, about 1 to 3 hours.

〔Example〕

An embodiment of the apparatus for manufacturing a long porcelain plate according to the present invention will be described in detail below with reference to the drawings. FIG. 1 (a),
(B) is an explanatory view showing a typical example of the above device,
Reference numeral 1 is an extruder for continuously extruding a raw material containing clay as a main material, for example, an extrusion molded body A having a cross-sectional shape shown in FIGS. 2 (a) to (d). Depending on the width, it is about 100 to 2000 mm / min. Clay is a natural mineral, and since the ingredients differ depending on each production area, the advantages and disadvantages of these ingredients can be offset and offset, and other mineral materials can be added as necessary to obtain the prescribed mixed clay. is there. Specific examples thereof include those obtained by crushing pottery stone, feldspar, kaolinite, halosite, metahalosite, kibushi clay, frog eye clay, Shigaraki clay, chamotte, etc. and kneading them with water. If necessary, this clay is used to remove iron with a magnet. Although not shown in the drawing, a die portion 2 has a shape corresponding to the extrusion molded body A, or one having a core interposed in the die portion 2 and extruding the extrusion molded body A having a hollow portion B, or shown in FIG. As shown in FIGS. 4 (a) to 4 (d), one end of a pipe 5 for inhaling or exhausting one gas or a large number of gas is arranged in each core 4 as shown in FIGS. It is connected to the lattice 4a, and the required gas is supplied to and discharged from the hollow portion B from the other end of the pipe 5. Reference numeral 6 denotes a conveyer, which is, for example, a free roller 7, or a transfer portion 9 including at least one kind of drive belt conveyor 8 synchronized with the extrusion speed, and an ejector 10 for forming an arbitrary convex pattern on the decorative surface of the extrusion molded body A. It was formed from and. In particular, the transfer unit 9 is for smoothly feeding the extruded product A at the extrusion speed without deformation in the next step, and the fli roller 7 transfers the extruded product A in a state of being extruded without static friction resistance. The drive belt conveyor 8 is somewhat harder than when the extruded product A is extruded at a position about 0.5 to 2 m away from the outlet, and the force at the time of extruding is the weight of the extruded portion extruded first. This is useful for continuously transferring the extruded product A to the next step at substantially the same speed as when it is extruded in order to prevent the product from being compressed without being fully resisted and shrinking. Also, the discharger 10 is shown in FIG.
As shown in (b), the clay of the same quality as the extruded product A is applied to the decorative surface A ′ of the extruded product A by a spray gun, a stirrer or the like.
In 11, the convex pattern C of arbitrary size and lumps is discharged at an arbitrary density. This is effective in producing a natural and three-dimensional effect, and cannot be formed by the conventional extrusion line. A specific example is as shown in FIGS. 6 (a) to 6 (c). 12 is a dryer for microwave heating 13,
At least two or more of the far-infrared heater 24 and the waste heat utilization unit 28 change the arrangement of each machine according to the purpose. To further explain, the microwave heater 13 has a continuous oven structure and mainly permeates into the inside of the extruded body A to convert the microwave D into heat energy with almost no time required for heat conduction. It heats up in a few minutes and
It is for evaporating 1/3, for example, 5 to 10% (weight%). In addition, the water content in the extruded product A is a weight ratio.
It is contained in about 22 to 15%, of which 5 to 10% can be evaporated. In particular, this type of extruded product A has a large volume contraction until the water content becomes about 5 to 8%, but when the water content is less than that, the volume contraction hardly occurs. Therefore, the microwave heater 13 will be described in detail. A waveguide 14 that guides the microwave D oscillated from a microwave oscillator (not shown) to a required location and a reflector 15 that reflects the guided microwave D. A rotary blade 16 that stirs the reflected microwave D, and a fli roller 17 that moves the extrusion-molded body A at the extrusion speed and irradiates the microwave D from the back surface of the extrusion-molded body A. Introducing the transfer section 18 and the inlets and outlets of the extruded body A, and the filter sections 19 and 20 for attenuating the microwave D so as not to leak to the outside and the air E or the like supplied as necessary to the heated space 21. Mouth 22 and microwave D are heated spaces
It is composed of an enclosure 23 surrounded by 21 so as not to leak outside. In addition, the heated space 21 of the extruded body A
The size of is different depending on the purpose, but is, for example, about 1 to 5 m. Furthermore, since the volume of the extruded product A contracts by about 10% during the drying process, the conveying unit 18 absorbs this with the free rollers 17 without difficulty. Further, the inlet 22 discharges a large amount of water vapor in a short time by heating the microwave D to the outside through the inlets and outlets 19a and 20a, and the surface of the extrusion molded body A and the inner wall of the enclosure 23. To prevent dew condensation on the surface of the extrusion-molded product A by the wind to prevent adverse effects (cracks, explosions) during drying.
It helps to blow off and shorten the drying time. A far-infrared heater device 24 is a heater that uses far-infrared rays as a heat source, and raises the temperature of the extruded product A to 130 ° C. or more in order to reduce the water content of the extruded product A to 1 to 0%. The configuration is composed of a transport mechanism 25 including a fli roller and a drive belt, a far infrared heater 26, and a heat insulation box 27.
The heating zone is about 2-5 m. Of course, the heating zone differs depending on the thickness, width, size, and conveyance speed of the extruded product A that has become a semi-dried product. Reference numeral 28 denotes a waste heat utilization unit for supplying waste heat of a firing furnace 31 described later to an arbitrary portion of the dryer 12 . Reference numeral 29 denotes a traveling cutter, which cuts the dried continuous extruded product A into a predetermined size during traveling. 30 is a take-out structure, Blank dry plates A "drive roller which is cut into standard length, a belt or the like, is intended to feed the next step faster than the speed sent from the extruder 1 speed. 31 is fired The furnace consists of one type of roller hearth kiln and tunnel type firing furnace, and its configuration has a mountain-shaped temperature distribution from the inlet 31a to the outlet 31b, and the preheating region 32, the firing region 33,
The cooling area 34 is temporarily divided and configured, the temperature of the preheating area 32 is 150 to 700 ° C, the baking area 33 is 300 to 1300 ° C, and the cooling area 3
No. 4 is about 600 to 100 ° C. Of course, the crystal transformation point also differs depending on the type and composition of clay,
The temperature setting between the regions is different, and the temperature and the transportation speed can be arbitrarily changed in each section. In addition,
The temperature between the above regions is not a clear division, but is a temporary division during continuous firing. Further the baking furnace 31 will be described, the firing furnace 31 Ka燃gas, for example by burning LPG gas and is then burned Blank dry plates A ", each region sequences burner therefor (not shown) those provided corresponding to. Moreover, the mesh belt as conveying means Blank dry plates a "in the firing furnace 31, the metal roller,
A ceramic roller, an alumina roller, or the like is used, but since the temperature rises up to about 1300 ° C., especially in the range of the firing region 33, for example, as shown in FIGS.
Alumina roller 37 is placed between 35 and 36 to convey the heat conduction without transmitting the heat conduction to the drive source. Incidentally, the firing area 33 of the firing furnace 31 forms a furnace with refractory bricks, etc., and is to linearly and continuously pass through it, each device,
An exhaust damper (not shown) is arranged between the regions.

Next, the operation will be described.

First, a clay consisting of Shigaraki clay, chamotte, a water reducing agent and water is prepared as a raw material. The weight% is, for example, Shigaraki clay 61.5%, chamotte 18%, water reducing agent 0.5% (trade name:
Cell Flow, manufactured by Dai-ichi Kogyo Seiyaku Co., Ltd., water 20% clay mixer (MP
-100 type manufactured by Miyazaki Tekko Co., Ltd.). Also, the extrusion molding machine 1 has a model name MV with an extrusion capacity of 100 to 150 l / hr.
-FM-A-1 type (manufactured by Miyazaki Tekko Co., Ltd.) is used, the mouthpiece 3 has the shape shown in FIG. 3, the shape shown in FIG. 2 (a) is used, and dry air is used as the pipe 5. Suppose it is sent. Further, the fry roller 7 and the driving belt conveyor 8 are arranged in this order as the carrier 6 , and the cosmetic surface immediately after the same material as the extruded product A is extruded through the discharge tool 11 composed of a spray gun as the discharge machine 10. It is distributed in A'in arbitrary masses and densities, and has the shape shown in FIG. 6 (a). The microwave heater 13 has a frequency of 2450 MHZ and an output of 5
The length of KW and heated space 21 is 3m, and air E
Is sent to the heated space 21 from one wall surface of the enclosure 23 in large quantities, and the steam generated during heating is discharged from the inlets and outlets 19a, 20a to the outside to reduce the steam pressure in the heated space 21, The heating object and the inner wall of the enclosure 23 are configured to prevent the generation of dew condensation water, and the transport unit 18 is a flea roller made of a Teflon pipe. In addition, far infrared heater device
Reference numeral 24 designates a plurality of far-infrared heaters 26 arranged in a zone of about 3 to 10 m, and its output is set to 20 KW, for example.
In the microwave heater 13, the moisture content of the extruded product A was 18%.
(% By weight) was evaporated to 5% (% by weight), and the remaining water was set to 1% (% by weight) or less by the far infrared heater device 24. Further, the extrusion speed of the extruder 1 is 300 to 1000 mm / min, and here it is 400 mm / min.
In addition, extrusion molded product A (here, it is a continuous molded product)
And the extrusion line of the extrusion molding machine 1 is fed to the microwave heating machine 13 via the transfer section 9 as it is, and the conveying section 18 in the microwave heating machine 13 is supplied.
The fli roller 17 is configured to absorb the difference in speed due to the volume contraction due to the evaporation of water. The traveling cutter 29 is synchronized with the extrusion speed, cut with a rotary blade etc. without stopping the line,
It is for supplying to the take-out mechanism 30. The take-out mechanism 30 rotates at a speed at which the standard-size drying plate A ″ cut by the running cutter 29 can be separated from the running-cutter 29, that is, a speed slightly higher than the so-called extrusion speed, so that the wood edges of the standard-size drying plates A ″ are separated from each other. It was designed to prevent collisions. Also, the firing furnace 31
The preheating zone 32 raises the temperature from 150 to 800 ° C in 10 m, the firing zone 33 rises from 800 to 1300 ° C in 5 m, and the cooling zone 34
It is a structure that decreases from 130 to 100 ℃ in 10m. The conveying speed can be variously set, but is, for example, about 300 to 30 mm / min. Therefore, when the clay supplied to the extruder 1 is sent out from its outlet in a continuous body having a cross section shown in FIG. 2 (a), and is sent to the next step on the decorative surface A'shown in FIG. 6 (a). I assume. Then, the extruded product A sent out is sent to the microwave heating device 13 of the dryer 12 via the carrier 6 , and the extruded product A is passing through the heated space 21 of the microwave heating device 13.
Water content is reduced to an average of 5% (wt%) in 5 minutes and is fed from the outlet to the far infrared heater device 26, and the far infrared heater device 26 reduces the water content to 1% (wt%) or less for about 10 minutes. Evaporated to dryness. As a result, the extruded product A having a continuous band from the exit of the extruder 1 to the far infrared heater device 24 is fed to the traveling cutter 29 as a dried product in about 15 to 20 minutes,
It is cut into a predetermined size to obtain a standard size dry plate A ″, and this is sent to a baking furnace 31 by a take-out mechanism 30. In the baking furnace 31 , preheating → baking → cooling is performed, and as a long ceramic plate A from the outlet 31b, for example, 300 mm / The firing time is 1 hour and the maximum humidity during firing is 1150 ° C.

What has been described above is only one example of the apparatus for manufacturing a long porcelain plate according to the present invention, and it is possible to more efficiently dry the waste heat of the firing furnace 31, or to use a plurality of firing furnaces after the traveling cutter 29.
31 may be formed of, or running cutter 29 and not in series may be installed sintering furnace 31 via a directional converter, not shown separately direction. Further, a glaze machine may be provided in front of the firing furnace 31 as shown by a chain double-dashed line. Further, the porcelain plate may have a cross section having a shape shown in FIGS. 8 (a) to (n).

[Effects of the Invention] As described above, according to the apparatus for producing long length ceramics according to the present invention, a clay extruded body containing 22 to 15% (wt%) of water (short length, long length, continuous body) ) Microwave heating machine that evaporates 1/3 of the water on average to dry without distortion and the remaining 2/3
There are no cracks, explosions, twists, or warps due to the heating of the two-stage dryer of the far-infrared heater device that can efficiently increase the water content of microwaves to higher heat than microwaves.
The drying time was shortened to the 00th position to form a long body and a continuous body of dried body, and then the ceramic plate was manufactured by shortening it to 1/3 to 1/10 of the time to burn this dried body. There is a feature that can be done.
Further, the volume of the extruded product shrinks by 10% or more as compared with the extruded product, but the adverse effect on the transport speed caused by the shrinkage can be absorbed by the fli roller or the like and fed to the traveling cutter. Further, the drying step and the firing step have a feature that they can be performed as a long body because of the structure using rollers. In addition, unlike conventional badges and tunnel dryers, the firing furnace allows the temperature and transport speed to be changed arbitrarily and in a short time, so the firing time
It has a feature that it can be shortened to 1/8 to 1/10, and the entire production process can be shortened to about 1/50 to 1/400 as compared with the previous one. Further, since the decorative surface can form a lump having a convex pattern or an arbitrary shape, there is a feature that a ceramic plate having a three-dimensional effect and a natural feeling can be obtained.

[Brief description of drawings]

1 (a) and 1 (b) are schematic configuration diagrams showing an embodiment of an apparatus for producing a long porcelain plate according to the present invention and a sectional view taken along the line ii, and FIGS. 2 (a) to 2 (d) are extrusions. Explanatory view showing a cross section of the molded body,
FIG. 3 is an explanatory view showing a cap portion, FIGS. 4 (a) to 4 (d) are explanatory views showing an example of a core, and FIGS. 5 (a) and 5 (b) are explanatory views showing an example of a carrier. 6 (a) to 6 (c) are perspective views showing an example of a convex pattern and a lump, FIGS. 7 (a) and 7 (b) are perspective views showing an example of a firing furnace, and FIGS. (N) is sectional drawing which shows another example of a ceramic board. 1 ... Extruder, 6 ... Conveyor, 12 ... Dryer, 13 ...
… Microwave heater, 24… Far infrared heater device, 29…
… Running cutter, 31 …… Baking furnace.

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification code Internal reference number FI Technical indication C04B 33/30 L 33/32 L

Claims (1)

[Claims] 1. An extrusion molding machine for continuously extruding a raw material containing clay as a main material in a predetermined shape, and an extrusion molding body at the exit of the molding machine horizontally corresponding to the extrusion speed of the extrusion molding body in the next step. A delivery machine was provided which, during the transportation, forms a spray-shaped, stucco-shaped pattern by applying a raw material of the same material as the main material by implanting on the decorative surface of the extruded product during the transportation. A conveyor, an open continuous dryer that reduces the water content of the extruded product delivered from the carrier to about 0 to 2% in about 10 to 60 minutes, and an extruded product in the continuously dried state to a standard size. 1. An apparatus for producing a long porcelain plate, comprising: a traveling cutter for cutting into pieces, and a roller hearth kiln type baking furnace for baking the cut fixed-size dry plates.