JPH10202645A - Device for continuously manufacturing ceramic plate - Google Patents

Abstract

PROBLEM TO BE SOLVED: To heighten dimensional precision, improve productivity and yield, and prevent occurrence of crack, torsion, waviness, and irregularity by controlling grain sizes and blending of raw materials. SOLUTION: Blending of raw materials, milling, dewatering, soil kneading, rough crushing, drying, moisture control, kneading, aging, and vacuum soil kneading are performed by a raw material control section A so as to make a raw material having a viscosity of 1P. For an extrusion molding machine 3, a machine having an extrusion pressure of about 50kg/cm<2> in extrusion capacity is used. A pump 7 is set to exhaust at about 5HP. A dryer 9 reduces water content of a continuous molding band B to about 0-5% by surface evaporation due to convection and by internal diffusion due to warm air exhaustion from a pumping tube 6, and dries it without deformation. The dried continuous molding band B is cut off by a cutter 10 so as to make a dried plate C, and fed to a kiln 12 continuously by a transporter 11. The kiln 12 is formed into a roller hearth kiln structure, to which the dried plate C is conveyed from an inlet 12a until an outlet 12b, preheated, baked, and annealed so as to send out as a baked plate D.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to raw material preparation, extrusion, drying,
The present invention relates to an apparatus for continuously manufacturing a porcelain plate manufactured through a process such as firing.

[0002]

2. Description of the Related Art Heretofore, in order to manufacture a ceramic ceramic plate using clay, there is known an apparatus which continuously manufactures by a process of extrusion molding (flat plate, hollow extruded plate, etc.), drying, cutting to a fixed size and firing. Have been.

[0003]

However, in the case of the above-mentioned hollow extruded plate, the hollow extruded plate coming out of the die is only dried from the inside until it enters the dryer. Even when externally heated by electricity, electronics, etc., the drying speed by air from inside and the drying speed from outside are different, so the product balance is deteriorated due to cracks and twists in the drying balance between inside and outside, and the dimensional accuracy is low. Bad, etc., had been caused. Moreover, since the volume of the porcelain plate manufactured by this kind of device shrinks by about 10% compared to the volume at the time of extrusion during drying and baking, deformation is particularly caused when a hollow extruded plate having a continuous hollow portion inside the plate body is manufactured. It reached the decorative surface, the decorative surface became wavy and uneven, and even if glaze was applied, this deformation could not be prevented, and the design was greatly reduced. Furthermore, when the raw material is purchased from a raw material processor, if the raw material is used as it is to produce a kneaded soil, the particle size of the raw material is automatically limited, and a desired kneaded soil cannot be obtained. Further, there has been no apparatus capable of producing a wide and thick porcelain plate accurately and stably.

[0004]

According to the present invention, in order to eliminate such a drawback, a raw material preparation-mill rubbing-dewatering-doughing-
Crushing-drying-moisture adjustment-clay formed by kneading, an extruder for continuously extruding clay raw materials, a dryer for drying the extruded continuous forming band, and a continuous preheating of the dried drying plate- An object of the present invention is to provide an apparatus for continuously manufacturing a porcelain plate, comprising a firing furnace for performing firing and slow cooling, and a cutting machine formed between a dryer and a firing furnace or after the firing furnace.

[0005]

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view of a continuous production apparatus for a porcelain plate according to the present invention. FIGS. 1 and 2 are explanatory views showing a typical example of the above apparatus. FIG. 1 shows a schematic configuration of the above-described apparatus, in which a raw material adjusting section A-an extruder 3 -a dryer 9 -a cutter 10 -a baking furnace 12.
It is the structure which consists of.

The raw material adjusting section A is composed of a raw material mixing section a, a mill rubbing section b, a dewatering section c, a kneading section d, a crushing section e, a drying section f, a moisture adjusting section g, a kneading section h, a nekashi section i, and a vacuum. It is made up of a clay kneading part j and is for manufacturing clay 1 (kneaded soil) extruded by an extrusion molding machine 3.

The raw material preparation section a is a part for mixing coarse raw materials (about 10 mm or less) and / or fine raw materials. In addition, the raw material is a natural product, the components of which differ depending on each locality of production. These characteristics and weak points are mutually offset to obtain a predetermined mixed raw material. Examples of the raw materials include viscous materials such as Kibushi clay, Frogme clay, Shigaraki clay, pottery stone, quartzite, feldspar, kaolinite, halloysite,
It is made of a mineral material such as metahaloysite.

The mill rubbing portion b is a portion for mixing the raw materials prepared in the raw material preparation portion a while performing wet pulverization by a pin mill, a Raymond mill, a trommel mill, or the like.

The dewatering section c is a section for dewatering the raw material (sludge) mixed in the mill rubbing section b by a filter press or a drum dewatering machine. In this case, since the water to be dehydrated has a higher water content than that at the time of extrusion molding, it needs to be separately dried.

The soil kneading section d is for kneading the raw material dehydrated by the dehydrating section c and making the water uniform, thereby facilitating final water adjustment before kneading.

The crushing section e is a section where the raw material dehydrated to some extent by the dehydrating section c is hog to an appropriate size. This is because the raw material dehydrated in the dehydrating section c has a variable water content, and it is necessary to hog the lump to an appropriate size. This is for the purpose of uniformity.

The drying section f is a section for drying the raw material crushed in the crushing section e.

The moisture adjusting section g is a section for adding water to the material to be pulverized mixed by the dry pulverizing and mixing section b.

The kneading section h is a section for kneading the raw material whose water content has been adjusted by the water adjusting section g.

The stocking part i is made by stocking the raw material kneaded in the kneading part h to improve the uniformity of the particle size of the raw material, the uniformity of the overall density, the uniformity of moisture, the plasticity, etc.
This is for improving the processing accuracy in the following steps such as extrusion-drying-firing. The stocking time varies from several days to several months, although it varies depending on the place of origin and composition of the raw materials. Of course, if the raw material is made uniform in the kneading section h,
There is a case where it is not necessary to provide the.

The vacuum kneading part j is for making the raw material formed by the necessity part i extrudable by an extruder 3 to be described later.
This is for improving plasticity.

In FIG. 2, reference numeral 1 denotes a raw material adjusted by a raw material adjusting unit A made of clay. The extruder 3 is one of a vacuum extruder or a vacuum clay extruder via a belt conveyor 2. It is supplied to.

As shown in FIG. 5, the extruder 3 is connected to the extruder 3 via a base 4 and a core 5, for example, as shown in FIGS.
The clay 1 is continuously extruded in a shape as shown in (a) to (d) to form a continuous band B having a decorative surface α and a hollow portion β. In addition, the clay 1 is a raw material adjustment unit A
Is a mixed clay formed to have the desired raw material, particle size, moisture, and plasticity.

Further, the base 4 is not deformed by the pushing force of the clay 1, but is equipped with a core 5. More specifically, when the core 5 has various shapes as shown in FIGS. 3 (a) to 3 (d) and FIGS. 4 (a) to 4 (d), the core 5 has a resistance within the extruder 3. This is useful for removing unevenness in the density distribution of the continuous molded band B and preventing cracking and deformation during drying and firing.

An adjusting bar 3a moves up and down by rotating the head of the adjusting bolt 3b as shown in FIG. 6 (a), and can freely expand and contract the cross-sectional area of the path through which the clay 1 flows. It is. The short adjustment bar 3a
By arranging a plurality of in parallel, the cross-sectional area of the path through which the clay 1 flows can be adjusted separately at any position in the width direction, so that a uniform pressure of the clay 1 can be supplied to the base 4 at a constant pressure. It is possible to manufacture a continuously formed belt B that is extruded straight and parallel and has no adverse effect on the product and has improved productivity.

As shown in FIG. 6 (b), the core 5 has a plurality of grids 5a for forming a hollow part β in the continuous molding band B, and air, hot air, cold air, and dry air in the hollow part β. ,
Grating 5a for forcibly sending or discharging steam
In the form of a pipe, and is connected to a pump 7 for sucking and discharging air and the like from the outside and a suction and exhaust pipe 6. This is to force the air cycle of the hollow part β by forcibly sending or discharging air, hot air, cold air, or dry air to or from the hollow part β of the continuous forming band B formed by the extruder 3. This is effective for greatly shortening the drying time inside the continuous forming band B.

Numeral 8 denotes a driving conveyor, which comprises at least one of a free roller, a chain, a driving roller, a belt, a mesh belt, etc., and controls the speed of the continuous forming band B extruded from the extruder 3. Driven at the same speed, or a little faster. In addition, when tension is applied to pull out the belt at a slightly higher speed, the extruded band B can be smoothly extruded without bending.

Reference numeral 9 denotes a dryer, which surrounds a part of the driving transfer device 8 or the entirety thereof (not shown), and includes an infrared heater, a far infrared heater, an oil heater, a hot air heater, a microwave,
Using a heating machine, at least one of waste heat of a firing furnace 12 described later, and the like, the continuous forming zone B is formed by the heat source 9a into the hollow portion β.
Is effective for drying in a short time by a synergistic effect with the air cycle of
The purpose is to reduce the 0% value to about 0 to 5% to enhance the shape retention and to make the shape capable of being cut and fired thereafter. The dryer 9 is provided with an infrared heater, a microwave only, or alternately, or divided into a former stage and a latter stage, with a heating temperature of about 200 to 500 ° C. and a microwave of about 5 to 100 W · h / kg. The heating is performed in accordance with a certain heating curve such that the dough does not crack or deform.

In the dryer 9, heating is performed up to the moisture area (about 8%) at the limit of cracks, cracks, and explosions. When heating is continued up to the deformation limit, continuous production of a large-sized ceramic plate E with high precision is performed. Can be made possible. In this case,
Since the shrinkage of about 3 to 10%, which is deformed when manufacturing the porcelain plate E, is almost finished during drying, the deformation during firing in the next step can be made very small, and cracks, cracks,
Effective for preventing explosion. Since the water region up to about 8% is a deformation region in which the shrinkage is large, drying is performed up to this water region. Of course, the limit of the moisture range differs depending on the components of the clay 1, and the dryer 9 is heated according to the material of the clay 1.

Numeral 10 denotes a cutting machine, which is a dried continuous band B.
The continuous forming band B extruded by the extruder 3 with a rotary blade (diamond saw, tip saw, cutting whetstone, etc.), laser, water pressure (water jet), etc.
Is moved and cut in synchronization with the speed of the drying plate C. The length is 600 mm or more.

Numeral 11 denotes a transfer machine which conveys the drying plate C cut to a fixed size by the cutting machine 10 to the firing furnace 12 at a speed higher than that of the driving conveyor 8.
And to prevent collision.

Reference numeral 12 denotes a baking furnace, which is a kind of a roller hearth kiln or a tunnel type baking furnace, and has a configuration ranging from an inlet 12a to an outlet 12b, at normal temperature and high temperature (about 1300 ° C.).
As a normal temperature, the temperature distribution becomes mountain-like, and the preheating region 1
3, the sintering region 14 and the cooling region 15 are arranged in this order. The temperature of the preheating region 13 is 30 to 700 ° C, the sintering region 14 is 300 to 1300 ° C, and the cooling region 15 is 600 to 3 ° C.
The temperature was set to about 0 ° C.

Of course, depending on the type and composition of the clay 1, the temperature setting between the respective regions is different, and the temperature between the respective regions is not clearly divided, but is a tentative division in the continuous firing. is there. The firing furnace 12 will be described in more detail. The firing furnace 12 burns a combustible gas, for example, an LPG gas, and fires the drying plate C. The arrangement of burners (not shown) corresponds to each of the above regions. It is provided.

As a means for transporting the drying plate C in the firing furnace 12, a mesh belt, a metal roller, a ceramic roller, an alumina roller, a mullite roller, or the like is used.
In particular, since the temperature in the range of the sintering region 14 rises to about 1300 ° C., for example, as shown in FIGS. Is conveyed without being transmitted to the Of course, the metal spindles 16 and 17 have a firing area 14 of 1300 ° C.
Since the temperature rises to the order of magnitude, it is formed outside the firing region 14. The sintering area 14 of the sintering furnace 12 is made of a refractory brick or the like, and is made to pass straight through the furnace. Exhaust dampers (not shown), etc. are provided between each device and the area. Is provided.

Reference numeral 19 denotes a transfer device, which is an outlet 12b of the firing furnace 12.
The calcined plate D having a temperature lowered to about 30 ° C. is transported to the next step such as a packing step of the next step, and is made into a ceramic plate E.

Next, the operation will be described. Therefore, the raw material preparation unit A performs raw material preparation, mill rubbing, dehydration, kneading, crushing, drying, moisture adjustment, kneading, nekashi, and vacuum kneading to produce a raw material for the clay 1.

The extruder 3 has an extrusion capacity of 50 k.
g / cm ^{2 with} an extrusion pressure of FIG.
A continuous molded strip B having a cross section as shown in FIG. The pump 7 was set to exhaust at 5HP, and a microwave heater and a far-infrared heater were used as the dryer 9,
Water is reduced to 0 to 5% in about 20 to 40 minutes by surface evaporation and absorption by convection of the water in the continuous forming zone B by convection, and internal diffusion by hot air exhaustion at about 30 ° C. from the exhaust pipe 6 for deformation. Without drying.

Next, the dried continuous forming band B is
3m + alpha (considering shrinkage of length after firing)
Then, it is cut into a drying plate C and is continuously fed to the firing furnace 12 by the transfer device 11. The firing furnace 12 is formed in a roller hearth kiln structure. The drying plate C is sequentially fed from the inlet 12a to the outlet 12b and transported to the rollers, and is preheated, fired, gradually cooled, and sent out as the fired plate D. I do.

Thereafter, although not shown, the porcelain plate E is transported to the next process such as a packing process by a transport device 19 in the next process.

What has been described above is merely one embodiment of the continuous ceramic plate manufacturing apparatus according to the present invention, and is described with reference to FIGS.
14 (a) to 14 (c).

In FIGS. 8A and 8B, FIGS.
(B) shows an apparatus in which the pump 7 is removed or an apparatus in which the hollow part β is not formed. In particular, (a) shows an apparatus in which the cutting machine 10 is formed after the firing furnace 12. .

9 (a) to 9 (c) to 13 (a) show a processing section 20, a polishing section 21, a glazing section 24 after the firing furnace 12.
A product processing part J composed of a baking machine 25 is formed.

The processing unit 20 processes an arbitrary pattern on the decorative surface α.
The end plate is formed, and the like, and a processed plate F having an improved design of the decorative surface α is obtained. As the method, a fired plate D
A machine tool having a strength capable of processing is used. For example, an NC-controlled machine tool having a rotary blade at a tip, a diamond saw, a water jet,
It is made of a laser or the like. In the processing section 20, the fired plate D can be processed during the transportation, or can be stopped and processed. Further, the processing unit 20 is installed so as to be interchangeable.

In the processing section 20, when the firing plate D is stopped and processed, the firing plate D sent from the transporter 19 and the firing plate D being processed do not collide with each other. The speed and stock time of the conveyor 19 are adjusted in consideration of the speed of the so-called continuous forming band B and the processing time in the processing section 20.

The polishing section 21 is provided by a polishing machine 22 which can be moved three-dimensionally in front, back, left, right, up and down, with a diamond polishing foil 23 attached to the end of the decorative surface α of the fired plate D fired and baked by the firing furnace 12. The polishing surface G is polished to flatten the decorative surface α. The polishing section 21 is installed so as to be interchangeable.

In the polishing section 21, the baking plate D can be stopped and polished, or polished during transportation.
When the processing is performed by stopping the firing plate D, the firing plate D sent from the transporter 19 and the firing plate D being polished do not collide with each other. The speed and stock time of the transporter 19 are adjusted in consideration of the polishing time in 21.

The glaze section 24 is for applying glaze to the decorative surface α of the fired plate D fired and baked by the firing furnace 12, and is made of one or more of a spray gun, a flow coater, a desk sprayer and the like. It is applied with a constant thickness by a glaze machine 24a to form a glaze plate H. Glazes include, for example, lead glaze, lead-free glaze, tin glaze, porcelain glaze, majolica glaze, furnace glaze, Bristol glaze, rockingham glaze, Zegel porcelain glaze, raw glaze, clay glaze, frit glaze, volatile glaze, gloss glaze, It consists of mat glaze, aventurine glaze, crystal glaze, raster glaze, transparent glaze, opaque glaze, etc., which is glazed on the cosmetic surface α, protective (coating) material for the cosmetic surface α, cosmetic material, waterproof material, durable material, etc. It functions as.

The sintering machine 25 hardens the glaze applied to the decorative surface α of the sintering plate D by the glazing unit 24 into a glass state.
Far-infrared heater, microwave heater, oil heater, hot air heater, dryer 9 described above, firing furnace 12, firing furnace 12
Using one or more kinds of waste heat, for example,
Lower than the maximum heating temperature, for example, 950 to 110
It is fired and cured at a temperature of about 0 ° C. to form a glazed fired plate I. The glazing unit 24 and the baking machine 25 are installed so as to be interchangeable. Of course, the glaze unit 24 and the baking machine 25 move together. Further, the temperature setting is not particularly limited, and may be higher than, the same as, or lower than the maximum heating temperature of the firing region 14.

Reference numeral 26 denotes a transport / stock yard for sending the porcelain plate E to the next step such as a packing step (not shown).

More specifically, in FIGS. 9A to 9C, FIG. 9A shows an apparatus in which a ceramic plate E is provided after the firing furnace 12, FIG.
(C) shows an apparatus in which a porcelain plate E is provided after the polishing section 21.

10 (a) to 10 (c), FIG. 10 (a) shows an apparatus in which a glazing unit 24 and a sintering machine 25 followed by a porcelain plate E,
(B) The figure is a device which made the ceramic plate E after the processing part 20-polishing part 21, (c) The figure is the processing part 20-glazing part 24-firing machine 25.
After that, it is a device made of a ceramic plate E.

11 (a) to 11 (c), FIG. 11 (a) shows an apparatus in which a polishing section 21-glazing section 24-baking machine 25 has been replaced with a ceramic plate E, and FIG. 11 (b) shows a processing section 20-polishing section 21. -Glazing unit 24-This is a device in which a ceramic plate E is provided after the baking machine 25. Of course, FIGS. 9 (a) to 9 (c) to 11 (a)
This is a modification example of FIG. 11B, which is basically the configuration of FIG. 11B. 11 (c), a transfer / stock yard 26 is formed after the baking furnace 12, the processing unit 20, and the polishing unit 21, and a baked plate D, a processed plate F, a polished plate G, and glazed firing are formed at the transfer / stock yard 26. To be able to take out the board I,
This is an apparatus that can manufacture four types of porcelain plates E including a fired plate D, a processed plate F, a polished plate G, and a glazed fired plate I in a series of flow operations. Of course, in the case of FIG.
(A)-(c) -Processing part 20 as shown in FIG.
It can be manufactured by combining the following components.

Referring to FIGS. 12A to 12C, FIGS.
(C) shows an apparatus in which the pump 7 is removed or an apparatus in which the hollow part β is not formed. In particular, (c) shows the apparatus after the baking furnace 12, the processing section 20, and the polishing section 21. A stock yard 26 is formed so that the fired plate D, the processed plate F, the polished plate G, and the glazed fired plate I can be taken out at the portion of the transfer and stock yard 26. , A processed plate F, a polished plate G, and a glazed fired plate I. Of course, in the case of FIG.
As shown in (c) to FIG. 11 (b), it can be manufactured by combining the respective components after the processing part 20.

FIG. 13A shows the configuration of an apparatus in which the processing section 20 and the polishing section 21 are installed in reverse. Note that FIG.
In FIG. 11, the portion indicated by the dotted line is a non-operating portion or a portion that is operating but not processed, and the operating portion is determined by what kind of ceramic plate E is manufactured. .

FIG. 13 (b) shows an apparatus in which a long fiber material addition section k is formed after the moisture adjustment section g of the material adjustment section A. This is because the continuous forming zone A shrinks by about 5% during drying because the clay 1 contains about 20% moisture, but the long fiber cracks and cracks on the drying plate C due to the shrinkage. It is effective as a material for preventing cracks and cracks from occurring. Of course, if you dry so that cracks and deformation do not occur,
It is unnecessary.

The long fibers are made of inorganic fibers, mineral fibers, organic fibers, etc., such as glass fibers, rock fibers, metal fibers, slug fibers, wollastonite, asbestos, rock wool, ceramic fibers, pulp, and the like.
Chemical fiber, etc.

FIGS. 14A to 14C show an apparatus in which a processing section 20 is formed after the extruder 3 or the dryer 9.

The parts without numbers are shown in FIGS.
(B) and so on. Of course, it is possible to form the device according to the present invention by combining the respective components.

[0054]

As described above, according to the continuous production apparatus for a porcelain plate according to the present invention, a porcelain plate with high dimensional accuracy can be produced by controlling the particle size of the raw materials and the blending of the raw materials. Ceramic plates with good productivity and good yield can be manufactured. The quality is improved and stabilized. It can prevent cracking, twisting, corrugation and unevenness of the decorative surface of the ceramic plate.
It is easy to adjust the moisture during the production of kneaded soil. There are features and effects such as.

[Brief description of the drawings]

FIG. 1 is a schematic explanatory view showing a typical example of a continuous ceramic plate manufacturing apparatus according to the present invention.

FIG. 2 is an explanatory diagram showing a typical configuration of a continuous ceramic plate manufacturing apparatus according to the present invention.

FIG. 3 is an explanatory view showing an example of a continuously formed band.

FIG. 4 is an explanatory view showing an example of a continuously formed band.

FIG. 5 is an explanatory view showing an extruder.

FIG. 6 is an explanatory view showing a tip portion and a core of the extruder.

FIG. 7 is an explanatory view showing an example of a firing furnace.

FIG. 8 is an explanatory view showing another embodiment of the continuous ceramic plate manufacturing apparatus according to the present invention.

FIG. 9 is an explanatory view showing another embodiment of the continuous ceramic plate manufacturing apparatus according to the present invention.

FIG. 10 is an explanatory view showing another embodiment of the continuous ceramic plate manufacturing apparatus according to the present invention.

FIG. 11 is an explanatory view showing another embodiment of the continuous ceramic plate manufacturing apparatus according to the present invention.

FIG. 12 is an explanatory view showing another embodiment of the continuous ceramic plate manufacturing apparatus according to the present invention.

FIG. 13 is an explanatory view showing another embodiment of the continuous ceramic plate manufacturing apparatus according to the present invention.

FIG. 14 is an explanatory view showing another embodiment of the continuous ceramic plate manufacturing apparatus according to the present invention.

[Explanation of symbols]

 α Coated surface β Hollow part a Raw material preparation part b Mill rubbing part c Dehydration part d Moulding part e Crushing part f Drying part g Moisture adjustment part h Kneading part i Nekashi part j Vacuum soil kneading part k Long fiber material addition part A Raw material adjusting section B Continuous forming strip C Drying board D Burning board E Ceramic board F Working board G Polishing board H Glazing board I Glazing firing board J Product processing section 1 Clay 2 Belt conveyor 3 Extruder 3a Adjusting bar 3b Adjusting bolt 4 Cap 5 Core 5a Lattice 6 Suction and exhaust pipe 7 Pump 8 Driving transfer machine 9 Dryer 9a Heat source 10 Cutting machine 11 Transfer machine 12 Firing furnace 12a Inlet 12b Outlet 13 Preheating area 14 Firing area 15 Cooling area 16 Metal spindle 17 Metal spindle 18 Alumina roller 19 Conveyor 20 Processing part 21 Polishing part 22 Polishing machine 23 Diamond polishing foil 24 Glazing part 24a Glazing machine 25 Firing 26 transport and stock yard

Claims (1)

[Claims] 1. An extruder for continuously extruding clay formed by mixing raw materials, milling, dewatering, dewatering, kneading, crushing, drying, adjusting water content, and kneading, and extruding continuous molding. It is characterized by comprising a dryer for drying the belt, a baking furnace for continuously preheating, baking, and gradually cooling the dried drying plate, and a cutting machine formed between the drier and the baking furnace or after the baking furnace. Continuous ceramic plate manufacturing equipment.