JPH0729836B2 - Long ceramic plate manufacturing equipment - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial field of application] The present invention laminates a covering material made of ceramic paper on at least one of the front and back surfaces of a continuous forming strip formed by continuously extruding a raw material containing clay as a main component. The present invention relates to an apparatus for producing a long porcelain plate having a predetermined length by drying and firing it in a short time, at a low cost, in a significantly shorter time than before, and without deformation.

[Conventional technology]

For tiles and tiles, a continuous strip of undried state sent from a molding machine is cut into short pieces and further shaped by press processing, etc., which is dried and baked, or a mold is filled with material, and this is pressed by a press. It was manufactured by molding, followed by drying and firing. In addition, firing was performed by loading molded roof tiles, tiles, etc. on a trolley in 5 to 7 steps, and taking several days.

[Problems to be solved by the invention]

Since this type of equipment requires several days for the drying and firing processes, productivity is poor and the cost is increased, and the vast factory site and three times as many workers as usual (3 shifts)
Needed. Further, in the conventional apparatus, since the cloth is dried by hot air, the cloth dries from the surface and is twisted, bent or cracked, and the maximum length is about 60 cm. This is because the surface layer exposed to hot air is the first to dry from the end and is deformed, especially curved, so that the length is limited as described above.

[Means for solving problems]

In order to eliminate such defects, the present invention does not deform the die of the clay kneader due to pressure, and further extrudes a dough containing about 20% of water extruded into a predetermined shape into a predetermined cross-sectional shape by extruding, At least one of the front and back surfaces is laminated with a coating material made of ceramic paper containing alumina or silica as a main component, coated, and then dried by irradiating so-called clay component with far infrared rays in a short time (up to several hours). It is a thing. In other words, far infrared rays are radiant heat and the synergistic effect of radiation of far infrared rays from heated clay components such as silica, mica, feldspar, and magnesia. By drying and utilizing the far-infrared radiation characteristics of the ceramic paper, the drying is performed evenly and efficiently, and moreover, by making the mouth of the continuous forming strip only one end at the beginning of extrusion, the curve at the time of drying It is possible to form a length up to about 600 to 3000 mm, cut it to an arbitrary length with a traveling cutter, and feed the dried long body that is not deformed to the firing furnace. The present invention provides a long porcelain plate manufacturing apparatus configured to save energy by utilizing the melting point effect.

〔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 is an explanatory view showing a typical example of the above apparatus. In the figure, reference numeral 1 denotes clay, which is composed of one kind or several kinds of clay and is supplied to the clay kneader 2 as a raw material. The clay kneader 2 continuously feeds from the mouthpiece 3 to the next step in a sectional shape as shown in FIGS. 2 (a) to (h). Clay 1 is a natural product, and its ingredients differ depending on each production area.
These characteristics and weak points are mutually offset to obtain a predetermined mixed clay. Examples of the clay 1 include pottery stone, feldspar, kaolinite, halloysite, metahalloysite, kibushi clay,
Frog eye clay, Shigaraki clay, Kamiyama clay, Yamagata silica sand, Iideyo clay, etc. are crushed, and then water and optionally chamotte, inorganic fibers (asbestos, glass fiber), pulp 10% or less depending on the purpose ( (Weight ratio) is added by a kneading machine. The clay 1 may be ironed by a magnet if necessary. Further, the above-mentioned base 3 is not deformed by the force of the clay 1 pushed out, and a core body (not shown) is attached if necessary. Reference numeral 4 denotes a conveyer, which is a free roller, or one of a mesh belt, a cloth belt, and a steel belt (not shown). The formed continuous forming band (hereinafter, simply referred to as a continuous band) A mainly sent from the die 3 is next. It is useful as a zone for observing the extruded state, as it is conveyed in the extruded state in the process. 5 is a coating material feeder, which is a conveyor 4
The coating material α made of ceramic paper containing alumina or silica as a main component is laminated on at least one of the front surface and the back surface of the continuous band A conveyed by the pressure roller 6. The covering material α is mainly ceramic paper, but it is also possible to use a laminate of aluminum hydroxide paper, porcelain paper or the like. Further, since the coating material α is laminated on the undried continuous strip A, it is adhered by the plasticity and water content of the continuous strip A, but an adhesive may be used supplementarily. Further, since the coating material α is laminated on the continuous zone A to form the composite continuous zone A ′, it serves as an aid to the continuous zone A which is a plastic material, and also helps prevent deformation when conveyed by the conveyor 4. It is a thing. When the continuous band A is as shown in FIGS. 2 (c) to (h), it is possible to dispose a forming machine after the coating material supplying machine 5 or to arrange the pressure bonding rollers 6 in a plurality of stages. . 7 is a dryer, which dries the water in the continuous zone A containing about 18 to 20% of water to about 1% in a short time of about 5 minutes to several hours. As a heat source 8, an infrared heater is used. , A far infrared heater and the like. In particular, the infrared and far-infrared heaters emit far-infrared rays when irradiating one component in clay 1, such as quartz and feldspar,
It is useful for drying the surface layer and the central layer of the continuous zone A in a short time by the synergistic effect of far infrared rays emitted from themselves. Moreover, since far infrared rays are also radiated from the ceramic paper used as the covering material α, the thermal efficiency at the time of drying is improved and the crack (crack) of the continuous zone A is prevented. Reference numeral 9 denotes a conveyance mechanism, which is composed of a conveyance roller or a mesh belt (not shown) and has heat resistance. Numeral 10 is a traveling cutter, and the composite continuous zone A'is set to an arbitrary length, for example, 300 by a rotary blade, a laser beam, an electric discharge machine, a wire cutting, or the like.
It is cut to about 2000 mm. Of course, traveling cutter 10
Is for cutting in synchronization with the extrusion speed of the continuous zone A.
Denoted at 11 is a take-out mechanism, which sends the dry plate B, which has been cut to a fixed size, to the next process at a higher speed than the speed at which the dry plate B, which has been cut by the driving roller, the belt, etc., is sent from the kneading machine 2. Is. 12 is a firing furnace, Laura Hearth Kiln,
It consists of one type of tunnel-type firing furnace, the structure of which is entrance 12a.
A mountain-shaped temperature distribution from the outlet 12b to the preheating region 1
3, the firing region 14 and the cooling region 15 are divided in this order, and the temperature of the preheating region 13 is 150 to 700 ° C. and the firing region 14 is 300
~ 1300 ℃, the cooling region 15 is about 600 ~ 100 ℃. Of course, the temperature setting between the regions differs depending on the type and composition of the clay 1, and the temperature between the regions is not a clear division but a temporary division during continuous firing. To further explain the firing furnace 12 , the firing furnace
Reference numeral 12 is for burning a combustible gas, for example, LPG gas to burn the standard-size drying plate B, and an array of burners (not shown) for that purpose is provided corresponding to each of the above regions.
Further, a mesh belt, a metal roller, a ceramic roller, an alumina roller or the like is used as a transporting means for the constant-size drying plate B in the firing furnace 12 , and the firing area 14 is particularly 1300
Since the temperature rises up to about ℃, for example, as shown in FIG. 3, an alumina roller 18 is placed between the metal main shafts 16 and 17 so that the heat conduction is prevented from being transmitted to the drive source. The firing area 14 of the firing furnace 12 forms a furnace made of refractory bricks, etc., and passes through it linearly and continuously, and an exhaust damper (not shown) is arranged between each device and area. It is something to set up.

Next, the operation will be described. First, a clay 1 consisting of Shigaraki clay, short asbestos fibers, pulp and water is prepared. The weight% is 61.5% Shigaraki clay, 3 short asbestos fibers.
%, Pulp 1%, and water 18% were kneaded with a clay kneader (MP-100 type manufactured by Miyazaki Iron Works Co., Ltd.). Further, the clay kneader 2 is a model name MV-FM-A-1 type (manufactured by Miyazaki Iron Works) with an extrusion capacity of 100 to 150 l / hr.
Was used. A free roller is arranged in a ladder shape as the carrier 4, a ceramic paper using an inorganic binder in fibrous alumina and silica is used as the coating α, and the coating feeder 5 and the pressure roller 6 are used. The dryer 7 is installed above the carrier 4, and the dryer 7 has 10 far infrared panel heaters arranged in an interval of 10 meters to diffuse the water inside the composite continuous zone A'to the surface to accelerate the dehydration and to remove the water 1 % Can be reduced. The traveling cutter 10 synchronizes with the extrusion speed, cuts with the rotary blade without stopping the line, and the take-out mechanism 11
It is for sending to. The take-out mechanism 11 rotates at a speed at which the standard length drying plate B cut by the traveling cutter 10 can be separated from the traveling cutter 10, that is, at a speed slightly higher than the so-called extrusion speed, so that the wood openings of the regular size drying plates B do not collide. It was done like this. In addition, the preheating region 13 of the firing furnace 12 is 150
~ 800 ℃ rise in 10m, firing area 14 800 ~ 130
Raise to 0 ° C in 5 m and in cooling area 15 up to 1300-100 ° C
It is a structure that decreases with m. Therefore, the clay 1 supplied to the clay kneader 2 is continuously extruded from the die 3 in a cross section as shown in FIG. 2 (a) and at a speed of about 5 m / min.
The coating material α continuously supplied from the coating material supply device 5 is laminated and attached to the continuous band A immediately after the extrusion. This composite continuous zone A'is immediately fed to the dryer 7 via the conveyor 4 without twisting due to resistance. Of course, the conveyor 4 in this case does not pull in the composite continuous band A ', but has a free roller shape. The dryer 7 reduces the water content of the composite continuous zone A'to 1%, feeds it to the traveling cutter 10, and cuts it to a standard length of an arbitrary length, for example, 600 to 3000 mm. In the dryer 7 , when the composite continuous zone A'has a thickness of 4 mm, it was dried without deformation in about 15 minutes. Next, the standard-size dried plate B cut into the standard size is supplied to the baking furnace 12 , preheated, baked, and cooled, and then sent out as the long ceramic plate C from the outlet 12b. The firing time was 8 hours, and the maximum temperature during firing was 1150 ° C.

The above description is merely one example of the apparatus for manufacturing a long porcelain plate according to the present invention, and the dryer 7 may be used together with a conventional hot air or microwave heater and a far infrared heater. . Further, a plurality of firing lines may be formed after the traveling cutter 10, or the firing furnace 12 may be installed in a different direction via a direction changer instead of being in series with the traveling cutter 10. In addition, the mouthpiece 3 of the kneading machine 2 is put out by two members and divided at its outlet, divided into two after drying, or a line in which a plurality of kneading machines 2 are installed in parallel is provided, and The width may correspond to this. Further, it is also possible to perform glaze on the coating material α of the standard length drying plate B, or to print on the coating material α of the long porcelain plate C after firing. In this case, glaze and printing are performed on the covering material α, which is easy. Further, the traveling cutter 10 can be disposed after the outlet 12b of the firing furnace 12 and firing can be continuously performed. In addition, when the continuous strip is formed into a hollow shape, air, dry air, hot air or the like can be blown into the hollow portion from the core in the die 3 to further accelerate the drying.

〔The invention's effect〕

As described above, according to the apparatus for manufacturing a long porcelain plate according to the present invention, the drying time of the continuously extruded molding strip is dried from the inside by using far infrared rays, and the far infrared rays are also emitted from the coating material. As a result, the thermal efficiency is greatly improved, and it is possible to significantly reduce the time unit by the minute or hour as compared with the conventional day unit. The continuously extruded molding strip has one opening until it is dried, and since it is dried from the center layer of the extrusion molding strip, the extrusion molding strip does not bend, crack, or twist, The yield is high. The covering material functions as a reinforcement and can prevent deformation during transportation. The cost is low because it can be dried in a short time.
High-precision cutting is possible because the machine cuts when it is dried and dimensionally stable. Due to the above relationship, the long strip can be easily manufactured. There is no deformation or cracks during drying, and since a roller hearth kiln is used, it can be fired continuously.
Since the melting point of inorganic materials such as magnesium asbestos carbonate and glass powder is lowered by 50 to 100 ° C, the energy and time required for firing can be greatly reduced. There are features such as.

[Brief description of drawings]

FIG. 1 is an explanatory view showing a typical example of a continuous production apparatus for a long porcelain plate according to the present invention, FIGS. 2 (a) to (h) are explanatory views showing an example of a continuous forming band, and FIG. It is a perspective view which shows a part of baking furnace. 1 ... Clay, 2 ... Clay machine, 5 ... Coating material supply machine, 10 ...
… Running cutter, 12 …… Baking furnace, A …… Continuous forming band, A ′
…… Composite continuous belt, C …… Long porcelain plate.

─────────────────────────────────────────────────── ─── 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. A clay kneader for continuously extruding a raw material containing clay as a main material, and a coating material made of ceramic paper laminated on at least one of the front and back surfaces of a continuous molding strip fed from the clay kneader. A coating material feeder for coating, a dryer for drying the composite continuous strip in which the coating material is laminated in a continuous strip in a short time, and a cutting machine for cutting the continuous strip fed from the dryer to a fixed length, An apparatus for producing a long porcelain plate, comprising a firing furnace for firing the cut fixed-size dry plate.