JPS62193803A - Manufacture of decorative design tile - Google Patents

Abstract

(57) [Summary] This bulletin contains application data before electronic filing, so abstract data is not recorded.

Description

DETAILED DESCRIPTION OF THE INVENTION (Industrial Application Field) The present invention relates to a method for producing decorative design tiles that take advantage of the feel of earth. Specifically, when molding the potted soil into a plate shape and/or after molding, at least a part of the separately prepared potted soil composition is exposed to the surface, which is different from the conventional method, and is used for the interior and exterior of structures. The present invention relates to a method for producing suitable decorative design tiles.

(Prior Art) Large tiles with a length of 30 cm or more are sometimes collectively referred to as design tiles, and are highly decorative. Traditionally, large tiles were manufactured using the pressing method,
Methods such as the pouring method are also known, but U.S. Patent No. 44
The method disclosed in No. 95118 is a particularly excellent method. This method is a method of manufacturing large tiles by extruding potted clay into a cylindrical shape, forming the potted clay into a plate shape while maintaining its orientation, and then drying and firing it. It is considered a law. According to this method, 1pen is 6
It is known that tiles with a diameter of 0 cm or more can be easily manufactured using a saw. However, although such large tile bases can now be made, the surface decoration is done in the same way as traditional tiles, such as by applying pongee or by transferring patterns.

(Problems to be Solved by the Invention) By the way, with these decoration methods, the occurrence of defects such as pinholes on the surface is unavoidable, and furthermore, assuming that the incidence of such defects is constant per unit surface area, the tile As the size of the tile becomes larger and the surface area of the tiles increases, the yield rate of the product decreases due to the occurrence of pinholes and the like.

That is, the present invention is a method for producing large tiles in which potting clay is extruded into a cylindrical shape, the potting clay is formed into a plate shape while maintaining its orientation, and then dried and fired. and/or a method for producing decorative design tiles, which is characterized in that after molding, a separately prepared cup clay composition is molded or coated so that at least a part of it is exposed on the surface, and then dried and fired; in principle, glazed It is a tile that has not been painted.

Therefore, the tiles obtained by the method of the present invention are decorative tiles that make use of the feel of the clay itself. Although this method is not suitable for mass production of exactly the same products, it is possible to mass produce products that have the same basic design but each piece has a slightly different design. Furthermore, since the designs are not colored by glaze or transferred in principle, defects such as pinholes are reduced, yields are improved, and aesthetics are improved.

(Example) The present invention will be described below with reference to Example 11 and Example 2. The composition of the cup clay can be prepared using raw materials such as kaolin, feldspar, and silica, which are commonly used in tiles. Furthermore, in order to improve the orientation of the potting soil, it is desirable to blend raw materials with anisotropic particle shapes such as plate-like or fibrous shapes. It is particularly desirable to blend raw materials such as sericite, wollastonite, kaolin, talc, and magnesium hydroxide in an amount of 30% or more.

In this example, these formulations had an additional water content of 25-40%
%, and kneaded it uniformly using a vacuum drain machine to make a cup for extrusion.

There are no particular restrictions on the composition of the potting clay composition (hereinafter referred to as separate composition) prepared separately during and/or after shaping the potting clay into a plate shape, but it is preferable that the potting clay has significantly different firing shrinkage from that of the potting clay. do not have. By making slight changes to the composition of the cup soil,
By adding pigments with different tones, such as metal oxides, to create a change, tiles with a wide variety of aesthetics can be obtained.

The shape of the separate composition that is the basis of the design of the present invention is not particularly limited and can be freely changed. However, when producing large quantities of products with a somewhat uniform design, a different composition may be made into a string shape as shown in Example 2, or a different composition may be formed into a plate shape in advance using the same method as cup clay. A method is used in which the intended shape is cut out from the material.

As shown in Example 1, when molding potted clay into a plate shape, a different composition was placed on top and molded into a plate shape together with the potted clay. Alternatively, a pre-formed different composition was molded into a plate shape using mortar or the like. In addition to the method of adhering to the clay, methods such as spraying a slurry of another composition may also be used. In this example, the moisture content of the separate slurry composition is adjusted to 45-70%. In any case, in order to take advantage of the features of the present invention, it is necessary in terms of design that at least a portion of the separate composition be exposed on the surface of the plate-shaped cup clay before being dried.

Once the design has been completed, the potted clay is shaped into a plate and is then dried, fired, and its dimensions adjusted. U.S. Patent No. 4,495,118
The steps after drying disclosed in this issue are one of the excellent methods, and are also used as the steps after the present invention.

Note that the amounts (parts) of each material in the examples are parts by weight.

Water was added to 100 parts of kaolin, 100 parts of silica, 20 parts of feldspar, and 80 parts of wollastonite, and the mixture was kneaded in a vacuum drain machine, and the resulting cup soil was extruded into a cylindrical shape. Furthermore, another composition was prepared in advance by adding 5 parts of common salt to this cup clay and kneading it in a vacuum drain machine, extruding the obtained pot clay into a cylindrical shape and forming it into a plate shape with a thickness of 2 mm.

Rectangular and circular shapes were punched out from the plate made of this different composition. This punched out different composition was extruded into a cylindrical shape, and the cup clay was placed on top of the cut-out, using a roll to form a 60cm x 60cm
After molding into a plate with a thickness of 8 mm, or molding the cup soil described above into a plate shape, masking it in the desired pattern, and spraying a slurry of cup soil with a different composition, drying in a far-infrared drying oven. After drying ■! When fired in a roller hearth kiln at 40° C., large decorative design tiles having rectangular and oval patterns with a slightly red color and desired patterns were obtained.

Example 2 Kaolin 50 parts, silica 100 parts, feldspar 20 parts,
100 parts of wollastonite, 10 parts of plate-shaped magnesium hydroxide
Water was added to 0 parts and kneaded using a vacuum drain machine, and the resulting cup soil was extruded into a cylindrical shape. A separate composition was prepared in advance by hand-forming the separate composition of Example 1 into a string shape with a thickness of about 20 mm. This different composition string was extruded into a cylindrical shape, placed on top of the cut-out cup, and rolled into a 60cm x
It was formed into a plate of 100 cm and 8 mm thick, dried in a far-infrared drying oven, and then fired in a roller hearth kiln at 1180°C to obtain a large decorative design tile with a slightly red colored wave pattern.

Although the decorative design tiles obtained by the method of the present invention can be used without the use of additives, there is no harm in using supplements, such as partially using supplements, and the width of the design may be increased. It is also possible to expand.

(Effects of the Invention) As explained above, the large decorative design tiles obtained by the method of the present invention in which at least a portion of the clay composition is exposed on the surface have a good yield. It is a mass-produced product that has an excellent earthy feel, and can create a very calming atmosphere when used for the interior and exterior of buildings and structures. This will greatly contribute to the improvement of the quality of the products.

Claims (1)

[Claims] A method for producing large tiles in which potting soil is extruded into a cylindrical shape, the potting clay is formed into a plate shape while maintaining its orientation, and then drying and firing is performed, in which the potting clay is formed into a plate shape. 1. A method for producing a decorative design tile, which comprises molding or coating a potted clay composition separately prepared during and/or after molding so that at least a portion thereof is exposed, and then drying and firing.