JPH10230510A - Continuously producing apparatus of earthenware plate - Google Patents

Abstract

PROBLEM TO BE SOLVED: To realize few kind and mass production of small-sized earthen plate by a method wherein a continuously molded band extruded from an extrusion molder is dried and cut and then continuously preheated, baked and slowly cooled in a tunnel kiln baking furnace. SOLUTION: When clay 1 preheated at a stock preheating part A is fed through a belt conveyor 2 to an extrusion molder 3, the extrusion molder 3 continuously extrudes the clay 1 in a predetermined shape through a mouthpiece 4 and a core so as to mold a continuously molded band B with a shape having decorative surfaces and hollow parts. Next, a drier 9 dries the continuously molded band B with its heating source 9a. Next, the dried continuously molded band B is cut with a cutter 10 so as to obtain standard length dried plates C. By transporting a truck 13, on which a plurality of dried plates are pilled up, on the rails in a tunnel kiln baking furnace 12 from an inlet 12a to an outlet 12b at a certain speed, the continuous preheating, baking and slow cooling of the dried plates are executed. Further, the baked plates D left the baking furnace 12 are conveyed with a conveyor 14 to the next process so as to obtain earthen plate E.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an apparatus for continuously manufacturing a porcelain plate manufactured through processes such as raw material preparation, extrusion, (cutting), drying, (cutting), and firing.

[0002]

2. Description of the Related Art Conventionally, in order to produce a large ceramic porcelain plate using clay, continuous processes such as extrusion molding (flat plate, hollow extruded plate, etc.), drying, fixed-size cutting, and firing (roller hearth kiln) are performed. An apparatus for manufacturing a ceramic plate is known.

[0003]

However, the apparatus using the conventional roller hearth kiln sintering furnace is suitable for producing large varieties and small quantities of large porcelain plates. Not suitable for mass production, there has been a demand for an apparatus capable of producing small-sized ceramic plates in a small variety and in large quantities.

[0004]

SUMMARY OF THE INVENTION In order to eliminate such drawbacks, the present invention provides an extruder for continuously extruding a clay raw material, a dryer for drying an extruded continuous molding strip, and a dried drying plate. To provide a continuous ceramic plate manufacturing apparatus comprising a tunnel kiln firing furnace for continuously preheating, firing, and slow cooling of steel, and a cutting machine formed between a dryer and a tunnel kiln firing furnace or between an extruder and a dryer. Things.

[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 schematic diagrams showing a typical example of the above-described apparatus, in which a raw material adjusting section A-an extruder 3-a dryer 9-a cutter 1 is used.
This is a configuration including a 0-tunnel kiln firing furnace 12.

[0006] The raw material preparation section A is a raw material preparation section-mill rubbing section-
The process includes a dewatering section, a clay kneading section, a crushing section, a drying section, a moisture adjusting section, a kneading section, a necking section, and a vacuum kneading section. It is for.

[0007] In FIG. 2, reference numeral 1 denotes a raw material adjusted by a raw material adjustment unit A made of clay. The extruder 3 is a vacuum extruder or one of vacuum clay extruders via a belt conveyor 2. It is supplied to.

As shown in FIG. 7, 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 (f) 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. Also, FIGS. 3A to 3E and FIGS.
5 (a) to 5 (h) and FIG. 6 (a) for the continuous forming band B shown in FIG.
(J) ((b) to (j) show plan views), tiles, roofing materials (tiles), interior materials, exterior materials, and the like.

Further, the base 4 is not deformed by the pushing force of the clay 1, but is equipped with a core 5. More specifically, the core 5 is for forming the hollow portion β in the continuous formed band B,
3A to 3E, resistance is generated in the extruder 3 and the continuous forming band B is formed.
This is useful for removing unevenness in the density distribution of and preventing cracking and deformation during drying and firing.

Reference numeral 3a denotes an adjustment bar which moves up and down by rotating the head of an adjustment bolt 3b, as shown in FIG. 8 (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 separately adjusted at any position in the width direction, so that the uniform clay 1 can be supplied to the base 4 at a constant pressure, It is possible to manufacture a continuous molded strip B which is extruded straight and parallel and has improved productivity without adversely affecting the product.

As shown in FIG. 8 (b), the core 5 has a plurality of lattices 5a for forming a hollow portion β in the continuous molding band B, and air, hot air, cold air, and dry air are provided in the hollow portion 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 means that the air cycle of the hollow portion β is forcibly performed by forcibly supplying or sucking air, hot air, cold air, and dry air to the hollow portion β of the continuous forming band B formed by the extruder 3. This is effective for greatly reducing the drying time inside the continuous forming zone B.

Numeral 8 denotes a driving conveyor, which comprises one or more 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. Further, when tension is applied such that the belt is pulled out at a slightly high speed, the continuous molding band B can be smoothly extruded without bending.

Numeral 9 denotes a dryer, which surrounds a part of the driving carrier 8 or the whole of the carrier 8 not shown, and includes an infrared heater, a far infrared heater, an oil heater, a hot air heater, a microwave,
Using a heater, at least one of waste heat of a tunnel kiln firing furnace 12 described below, and the like, the heat source 9a is effective for drying the continuous forming zone B in a short time by a synergistic effect with the air cycle of the hollow part β. The purpose of this is to reduce the water content of the clay 1 from, for example, 18 to 20% to about 0 to 5%, to enhance the shape retention, and to make it a property that can be subsequently cut and fired. is there. The dryer 9 is provided with an infrared heater, a microwave only, or alternately, or divided into a former stage and a latter stage, and a heating temperature of 200 to 50.
Microwave heating at about 0 ° C. is performed at about 5 to 100 W · h / kg in accordance with a certain heating curve that does not cause cracking or deformation of the dough.

Further, the dryer 9 heats up to the moisture area (about 8%) at the limit of cracks, cracks, and explosions, and if the heating is continued to the deformation limit, it is possible to continuously manufacture the ceramic plate E with high precision. It can also be. In this case, the ceramic plate E
Since the shrinkage of about 3 to 10%, which is deformed in manufacturing the product, is almost completed during drying, the deformation during firing in the next step can be extremely reduced, and it is effective in preventing cracks, cracks, and explosions during firing. is there. 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 continuous continuous band B which has been dried.
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. Of course, the cutting machine 10 may be formed after the extruder 3. The cutting length is about 50 mm to 500 mm.

Reference numeral 11 denotes a loading section, which is a section for loading the drying plate C cut to a fixed size by the cutting machine 10 on a carriage 13 of a tunnel kiln firing furnace 12 described later.

Reference numeral 12 denotes a tunnel kiln firing furnace, which is a kind of tunnel type kiln firing furnace, and has a structure ranging from an inlet 12a to an outlet 12b at a normal temperature and a high temperature (about 1000 ° C.).
As a normal temperature, it becomes a mountain-like temperature distribution, preheating area,
The sintering region and the cooling region are categorized in this order, the temperature of the preheating region is 30 to 500 ° C., and the sintering region is 200 to 100
The temperature was set to 0 ° C. and the cooling area was set to about 500 to 30 ° C. The firing time is about 24 hours to 72 hours.

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 rather is a tentative division in continuous firing. is there. Further, the tunnel kiln firing furnace 12 will be described in detail. The tunnel kiln firing furnace 12 burns a combustible gas, for example, an LPG gas, to fire the drying plate C. The arrangement of the burners (not shown) is as described above. It is provided corresponding to each area.

The sintering area of the tunnel kiln sintering furnace 12 is made of a refractory brick or the like and is made to pass straight through the furnace. Exhaust dampers (shown in FIG. ), Etc. are provided.

The tunnel kiln firing furnace 12 is formed such that a plurality of carts 13 rotate once. The carts 13 on which a plurality of drying plates C are stacked are used as rails 12c in the tunnel kiln firing furnace 12. After moving at a constant speed in the tunnel kiln firing furnace 12 from the inlet 12a to the outlet 12b, and lowering the firing plate D at the outlet 12b, only the empty carriage 13 rotates once to return to the inlet 12a. It was done. FIG. 9 shows an example of the carriage 13.
(A), (b), formed as shown in FIG. 10 (a), (b), using a supporting member 13a as shown in FIG. Are formed so as to be stacked in a plurality of stages. The number of carts 13 to be used differs depending on the purpose.

More specifically, FIGS. 9A and 9B
((A) side view) shows a case where a plurality of drying plates C are stacked. FIGS. 10A and 10B
((A) side view) shows a case where one sheet is placed between the support members 13a.

When a drying plate C as shown in FIGS. 3A to 3E is used, the hollow portion β of the drying plate C serves for firing from the inside, resulting in dimensional errors and deformation due to firing unevenness. , Cracks, twists and the like can be prevented.

As shown in FIGS. 10 (a) and 10 (b), in the case of firing one by one, it is possible to fire even if glaze is applied to the decorative surface α of the drying plate C. .

Reference numeral 14 denotes a transporter, which is a kiln for tunnel kiln 1
The fired plate D, whose temperature has dropped to about 30 ° C., which has come out of the outlet 12b of No. 2 is conveyed to the next step such as the next packing step, and is used as a ceramic plate E.

What has been described above is merely an embodiment of the continuous ceramic plate manufacturing apparatus according to the present invention, and is shown in FIGS. 12 (a) to 12 (d).
To FIG. 15.

12 (a) to 12 (d), FIG. 12 (a) shows an apparatus in which a glazing portion 15 is formed after a cutting machine 10, and FIG.
The figure shows a device in which a glazing unit 15 and a baking machine 16 are formed after a tunnel kiln firing furnace 12, (c) a device in which a processing unit 17 and a glazing unit 15 are formed after a cutting machine 10, and (d) a core. 5. This is an apparatus in which the pump 7 is removed, and shows an apparatus for manufacturing a porcelain plate E in which the hollow portion β is not formed.

FIGS. 13 (a) to 13 (d) show an apparatus in which a cutting machine 10 is formed after the extruder 3.
This is an apparatus that prevents the drying plate C from being deformed or cracked or twisted due to shrinkage due to drying.

FIGS. 14 (a) to 14 (d) show a processing portion 17 formed after the cutting machine 10. The processing portion 17 is cut and pressed while the cut continuous forming band B is soft. In this way, the processing is facilitated.
For this purpose, a continuous band B made of a flat plate as shown in FIG. 4 (a) is used for forming the continuous band B shown in FIGS. 5 (a) to 5 (h) and 6 (a) to 6 (j).
And ceramic plates E of various shapes can be manufactured. FIG. 15 shows an apparatus in which a cutting machine 10 is formed after the extruder 3 and a glaze unit 15 and a baking machine 16 are formed after the tunnel kiln baking furnace 12.

The glaze section 15 is for applying glaze to the decorative surface α, and is applied with a certain thickness by one or a plurality of glaze machines such as a spray gun, a flow coater, and a desk sprayer to form a glaze plate. Things. Glazes include, for example, lead glaze, lead-free glaze, tin glaze, porcelain glaze, majolica glaze, furnace glaze, Bristol glaze, rockingham glaze, Seegel porcelain glaze,
Raw glaze, clay glaze, frit glaze, volatile glaze, gloss glaze, mat glaze,
It consists of aventurine glaze, crystal glaze, raster glaze, transparent glaze, opaque glaze, etc., which is glazed on the decorative surface α and functions as a protective (coating) material for the decorative surface α, a cosmetic material, a water-resistant material, a durable material, etc. Things.

The baking machine 16 is for hardening the glaze applied to the decorative surface α by the glazing unit 15 into a glass state, and is a gas, electricity, petroleum, or the like, or an infrared heater, a far infrared heater, a microwave heater, an oil heater, or the like. Heater, hot air heater,
Using one or more of the dryer 9, the tunnel kiln firing furnace 12, and the waste heat of the tunnel kiln firing furnace 12, for example, at a temperature lower than the maximum heating temperature of the firing area, for example, at a temperature of about 750 to 950 ° C. It is fired and cured to form a glazed fired plate. The glazing unit 15 and the baking machine 16 are installed so as to be interchangeable. Of course, the glaze unit 15 and the baking machine 16 move together.

The processing section 17 processes the cut continuous formed band B into a shape as shown in FIGS. 5 (a) to 5 (h) and 6 (a) to 6 (j), or forms an arbitrary pattern on the decorative surface α. Of the decorative surface α, etc., to improve the design of the decorative surface α. As a method therefor, there is a machine tool having a workable strength, for example, an NC having a rotary blade formed at a tip.
It consists of a controlled machine tool, a diamond saw, a water jet, a laser, etc., or a press machine or a cutting machine. The processing unit 17 can perform processing in the middle of conveyance, or can stop and perform processing. Further, the processing section 17 is installed so as to be interchangeable.

Of course, a stock yard for storing semi-finished products formed in each step may be formed in consideration of a time difference between the next step and each step.

[0033]

As described above, according to the apparatus for continuously producing ceramic plates according to the present invention, (1) a ceramic plate having high dimensional accuracy can be produced. (2) A ceramic plate with good productivity and good yield can be manufactured. (3) The quality is improved and stabilized.
(4) It is possible to prevent cracks and twists of the ceramic plate, corrugations and irregularities on the decorative surface. (5) In the case of manufacturing a porcelain plate having a hollow portion, heat penetrates into the interior even in the case of multi-stacking during firing, so that turbulence hardly occurs. (6) Due to the multi-stage stacking, a porcelain plate with a roasted taste that cannot be obtained with a roller hearth kiln type firing furnace can be obtained due to kiln changes at the end and middle. (7) A glaze-coated ceramic plate can be manufactured by using a support member (saya, setter, etc.) of the cart. (8) Inexpensive ceramic plates can be mass-produced. (9) It is possible to manufacture simply by improving the conventional apparatus for manufacturing ceramic products. (10) Small varieties and mass production of small ceramic plates are possible. There are features and effects such as.

[Brief description of the drawings]

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

FIG. 2 is a schematic configuration diagram showing a representative example of a continuous ceramic plate manufacturing apparatus according to the present invention.

FIG. 3 is an explanatory view showing an example of a ceramic plate.

FIG. 4 is an explanatory view showing an example of a ceramic plate.

FIG. 5 is an explanatory view showing an example of a ceramic plate.

FIG. 6 is an explanatory view showing an example of a ceramic plate.

FIG. 7 is an explanatory view showing an example of an extrusion molding machine.

FIG. 8 is an explanatory view showing a tip portion and a core of the extruder.

FIG. 9 is an explanatory view showing an example of a bogie used for a tunnel kiln firing furnace.

FIG. 10 is an explanatory view showing an example of a truck used in a tunnel kiln firing furnace.

FIG. 11 is an explanatory view showing an example of a support member constituting a truck used in a tunnel kiln firing furnace.

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.

FIG. 15 is an explanatory view showing another embodiment of the continuous ceramic plate manufacturing apparatus according to the present invention.

[Explanation of symbols]

 α Decorative surface β Hollow part A Raw material adjusting part B Continuous forming zone C Drying plate D Fired plate E Ceramic plate 1 Clay 2 Belt conveyor 3 Extruder 3a Adjusting bar 3b Adjusting bolt 4 Cap 5 Core 5a Grid 6 Suction and exhaust pipe 7 Pump 8 Driving transfer machine 9 Dryer 9a Heat source 10 Cutting machine 11 Loading unit 12 Tunnel kiln firing furnace 12a Inlet 12b Exit 12c Rail 13 Dolly 13a Support member 14 Transfer unit 15 Glazing unit 16 Baking machine 17 Processing unit

Claims (1)

[Claims] 1. An extruder for continuously extruding a clay raw material, a dryer for drying the extruded continuous forming band, and a tunnel kiln firing for continuously preheating, firing and gradually cooling the dried drying plate. An apparatus for continuously producing porcelain plates, comprising a furnace and a cutting machine formed between a dryer and a tunnel kiln firing furnace or between an extruder and a dryer.