JPS63218533A - Manufacture of elongated ceramic board - 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] [Field of Industrial Application] The present invention is a continuous body made by continuously extruding a raw material mainly composed of clay minerals through a hollow body of an arbitrary shape, without deformation and without producing cranks, etc. The present invention relates to a method for manufacturing a long ceramic plate in a short time of about 30 minutes to 2 hours by drying the ceramic plate quickly, then firing it, and then cutting it into regular lengths.

[Conventional technology]

Rovers, tiles, etc. are cut into short pieces at the exit of the extrusion molding machine.
The product was manufactured by sending it to a waste heat and natural drying process, drying it for about one day to a week, and then sending it to a glazing and firing process. In addition, hollow shaped bodies require a longer drying process and firing process to dry more slowly.

[Problem that the invention seeks to solve]

Ceramic plates, such as long roof tiles and tiles, are extruded into soft bodies, and unlike short pieces, it is difficult to transfer them to the drying process without deformation, so it is difficult to obtain long dried pieces without deformation or cracks. I couldn't do that. Moreover, the conventional drying process simply evaporates water from the outer surface of the extruded product, so rapid heating can cause it to crack or break.
There are problems such as large deformation, slow drying, and long drying times, resulting in increased costs, low productivity, and the need for a large storage area.

Means for Solving Problem C] In order to eliminate such drawbacks, the present invention allows the extruded product to pass through the atmosphere of a microwave and far-infrared heater while remaining continuous and moving at the extrusion speed. At the same time, especially for hollow bodies, dry air is fed inside parallel to the extrusion direction, and an exhaust port is drilled on the back side of the extruded body to exhaust water vapor from the hollow body to the outside. The extruded product is dried and fired on a straight line at the same level to eliminate the harmful effects of water vapor staying in the hollow part during heating, and to prevent deformation and cracking of the extruded product more quickly. The present invention provides a method for manufacturing a ceramic plate by drying and firing a long ceramic plate having a length of, for example, about 0.4 to 5 m quickly, efficiently, continuously, and at low cost.

〔Example〕

EMBODIMENT OF THE INVENTION Below, one Example of the manufacturing method of the long ceramic board based on this invention is described in detail using drawings. FIG. 1 is an explanatory diagram showing an outline of an apparatus used for carrying out the present invention.

In the figure, 1 is clay, which is made by mixing one or several kinds of raw materials with chamotte, etc. through a mixer (not shown), and this is passed through an extrusion molding machine 2, for example, a vacuum extrusion molding machine, to a die 3. For example, the cross-sectional shape shown in FIGS. 2(a) to 2(q) is extruded. In addition, the base 3 is provided with a core 4 for extruded hollow bodies, for example as shown in FIGS. The configuration is such that one wire is attached to each grating 4a, or one wire is attached to each grating 4a, and it is preferable that the shape of the grating 4a is such that the cross-sectional area increases from the root toward the outlet to reduce extrusion resistance. Further, a gas supply device 7 supplies a required gas such as dry air 7a to the pipe 5 via a control pulp 6.
The interior of the continuous extrusion molded body A is quickly dried by moving and pressurizing the water vapor inside the hollow body in the longitudinal direction of the extrusion molded body A using dry air or the like 7a. Note that the extruded continuous body A is a long body until dried and fired, and is then cut into an arbitrary fixed length. It should be noted that the clay 1 is a natural product and has different components depending on its production area, and a predetermined mixed clay is obtained by mutually utilizing these features and weaknesses. Examples of clay 1 include potter's stone, feldspar, kaolinite, hallosite, metahalosite, end-of-day clay, frog's eye clay, Shigaraki clay, etc., which are crushed and kneaded with water. In addition, iron may be removed from the clay 1 using a magnet if necessary. Mainly extruded product A immediately after being extruded with a punching machine
Exhaust ports a are provided at any pitch, size, and distribution density so as to penetrate into the hollow part B from the back surface of the sheet during extrusion.

Note that the exhaust port a discharges moisture and water vapor in the hollow part B of the extruded body A to the outside, and strengthens the dehumidifying function of the dry air or the like 7a supplied to the hollow part B. In particular, the water vapor in the hollow part B is a long body, and as the water vapor moves away from the cap 3, the pressure of dry air etc. 7a is added to it, resulting in high humidity.
Cracks, uneven heating, and continuous extrusion molded product A
It is useful for eliminating the causes of extremely undesirable phenomena. Further specific examples include the configurations shown in FIGS. 4(a) and (bl) and FIGS. 5(a) and (b). That is, FIGS. 4(a) and (b) A perforation plate 10 provided with a comb blade 9 is driven via a drive source 11 so as to reciprocate up and down on the end surface of the mouthpiece 3, and a guide hole 10a is bored in the perforation plate 10. 5(al) and (b) are composed of a rotating body 12 and nails 13 implanted on its surface, and the rotational speed corresponds to the extrusion speed of the extrusion molded body A. ■ is a conveyor that combines one or more types of free rollers 15, drive belts 16, etc., and is arranged in a straight line along the extrusion direction at the same level as the outlet of the mouthpiece 3, and is extrusion molded. This is for conveying the body A as it is to the next process at the extrusion speed. U is a microwave heating device where the microwave α penetrates into the inside of the extruded body A and it takes time for heat conduction. This is to convert the microwave α into thermal energy without any heat, generate heat in a few seconds to a few minutes, and evaporate the moisture in the clay 1.
The extruded product A contains about 22 to 15% water by weight, and has the ability to evaporate, for example, 5 to 10% of this water.

In particular, this type of extruded product A shrinks in volume until the moisture content reaches about 6 to 10%, but when the moisture content falls below that, the volume does not shrink. Therefore, the microwave heating device H will be specifically explained using FIGS. 1 and 6. It includes a waveguide 18 that guides the microwave α oscillated from a microwave oscillator (not shown) to a desired location, and A conveyance system consisting of a reflecting plate 19 that reflects the reflected microwave α, a rotary blade 20 that stirs the reflected microwave α, and a free roller that moves the extruded product A at an extrusion speed and is dielectric but does not spark. part 21 and extrusion molded body A
The inlet and outlet 17a, 17b, the air supply port 23 that sucks a large amount of air etc. β from the heated space 22 and supplies it to the heated space 22, and the air supply port 23 surrounded to prevent microwave α from leaking to the outside. It is composed of an enclosure 24. Note that the inlet and outlet 17a, 17b are formed to have a structure and length that also function as a filter to prevent the microwave α from leaking to the outside.

Further, the heating space 22 for heating the extrusion molded product A is, for example, about 1 to 5 m, although it varies depending on the purpose. Furthermore, in the conveying section 21, microwave α, air, etc.
The structure is such that the extrusion molded product A can be transported without absorbing this.

An example of this is shown in FIGS. 7(a) and 7(bl), which consists of a fixed 8-rod 25, a pipe-shaped free roller 26 made of Teflon, and an 8-bar support 2q as shown in FIG. To explain further, Fig. 7 (a)
1, the width of the free roller 26 is divided into three parts, for example, to reduce the resistance when the extrusion molded product A passes through. In the figure, the free roller 26a is composed of a single free roller 26a. Further, the 8-bar support 27 is provided with a passage hole 27a so that the microwave α can be irradiated from the back side of the extrusion molded body A as well. Further, 21a is a shielding plate, which is provided so that the extruded body A is uniformly irradiated with the microwave α. Note that the transport section 21 corresponds to the same level as the transport machine and is arranged in series. The hammer is a far-infrared heater device that is effective for drying extruded product A from the center to the surface layer in a short time, and reduces the moisture content of clay 1 from, for example, 8 to 10% to 1 to 0%. This is to strengthen shape retention. The structure consists of a free-roller conveying section 29, a plurality of far-infrared heaters 30, and an enclosure 31, which heats the extrusion molded product A, especially the surface layer, to reduce water content and make it a dry product.

PIO, air, etc. β is stirred by a fan or the like (not shown) to more efficiently evaporate water vapor from the surface of the extruded product A. Both are roller hearth kiln type firing furnaces with Yamabushi temperature distribution from the inlet 32a to the outlet 32b, and are divided into a preheating area 33, a firing area 34, and a cooling area 35 in that order, and the temperature of the preheating area 33 is as follows. 150-70
0°C, firing zone 34 is 800-1300°C, cooling zone 3
5 is about 600-100℃. Of course,
Depending on the type and composition of the clay, the temperature setting between each region is different, and the temperature between each region is not clearly divided, but is a temporary division in continuous firing. Furthermore, to explain about the firing grill, the firing grill uses combustible gas,
For example, LPG gas is burned to sinter the extrusion molded band A, and burners (not shown) for this purpose are arranged corresponding to each of the regions. In addition, as a means for conveying the extruded product A in the firing furnace dish, a mesh belt,
Metal rollers, ceramic rollers, alumina rollers, etc. are used, but since the temperature rises to about 1300°C especially in the firing area 34, for example, as shown in FIG. An alumina roller 38 is placed thereon to prevent thermal conduction from being transferred to the drive source. 39 is a running power lid that cuts the fired extruded product A into a predetermined size, and 4o is a take-out machine that feeds the long ceramic plate A' cut into a predetermined length to a packaging section (not shown). It is for the purpose of

Next, a method for manufacturing a long ceramic plate according to the present invention will be explained. First, as clay 1, raw materials consisting of, for example, Creed clay, chamotte, water reducing agent, and water are prepared. The weight percentages are 61.5% of creed clay, 20% of chamotte, 0.5% of water reducing agent (trade name: Cellflow II - manufactured by Kogyo Seiyaku Co., Ltd.),
18% water was kneaded using a clay kneader (model MP-100, manufactured by Miyazaki Tekko Co., Ltd.). In addition, the extrusion molding machine 2 is a model name MV-FM-A-1 (with an extrusion capacity of 100 to 1501/hr).
Miyazaki Tekko Co., Ltd.) was used. The gas supply device 7 was set to blow air at 2 HP.

In addition, the frequency of the microwave heating device U is 2450MHz.
, the output is 5 kW, the length of the space to be heated 22 is 3 m, and a large amount of air etc. β is supplied to the space to be heated 22 from the air supply port 23 of the enclosure 24, and the air is generated during heating from the exits 17a and 17b. The structure is such that water vapor is released to the outside, the water vapor pressure in the heated space 22 is reduced, and dew condensation water is prevented from forming on the heated object and the inner wall of the enclosure 24. It was made into a free roller made of manufactured pipes.

It is assumed that the microwave heating evaporates 18% (weight %) of water in extruded body A to 7% (weight %). Furthermore, for a far-infrared heater device, 10 far-infrared panel heaters with a wavelength of 4μ to 400μ are arranged as far-infrared heaters 30 in a distance of 10 meters, and the moisture inside the extrusion molding zone A is diffused to the surface for rapid dehydration. and reduce moisture to 0-6%
It can be reduced to Further, in the far-infrared heater device Sendai, air etc. β was stirred by a fan, so that water vapor on the surface of the extruded product A was more easily diffused. Therefore, the extrusion molded body A of the ceramic plate having the cross section shown in FIG.
Assume that extrusion is performed continuously using a hollow plate with a thickness of 20 m at I+in. The extruded continuous extrusion molded article A is conveyed linearly from the die 3 through the conveyor at the extrusion speed described above without causing any deformation or cranking. In addition, at this time,
The nozzle 3 moves up and down from the punching machine to punch exhaust ports a into each hollow part B from the back side of the extruded body A at a constant pitch. Its size depends on the hollow part B, for example, 3 crane angles or 5 square angles.
Fiφ is drilled at various pitches of 50 to 200 cranes (here, 4wφ). The soft extruded body A with the exhaust port a drilled in this way is heated by a microwave heating device H.
The 22-18% water content of the extruded product A is reduced to approximately 5-18%.
The total moisture content was reduced to ~5% in 15 minutes and then fed in a continuum to the far infrared heater device, reducing the remaining moisture to approximately 1%.
It is evaporated at about 100 liters to form a dry product. At this time, water vapor is supplied to the microwave heating device 17 at the same time as air etc.
It is emitted to the outside as if sprayed from the exits 17a and 17b, and the exit for the far infrared heater device. This is to wipe away the water vapor that has appeared on the surface of the extrusion molded product A, and at the same time, the water vapor in the hollow part B is discharged to the outside from the exhaust port a by dry air etc. 7a, thereby further strengthening the evaporation of the water vapor. . Note that the synergistic effect of the air flow and the movement of the extruded body A in the advancing direction further promotes evaporation. In addition, as a comparative example, when air is not supplied to the microwave heating device WH, water vapor becomes saturated within the enclosure 24, and about 1% compared to when dry air etc. 7a is supplied.
/3 evaporation and disadvantages due to condensation. Next, the continuous belt-shaped extruded body A with the moisture content reduced to about 0 to 7% is fed to the firing furnace, preheated, fired, and cooled, and then fed from the outlet 32b to the traveling counter 39, where it is fired. The continuous extrusion molded band A is cut into a predetermined size, for example, 300 to 6000 mm.
A long ceramic plate A' having a length of about tm is obtained. The cut long ceramic plate A' is conveyed by a take-out machine 40 at a speed faster than the extrusion speed and sent to the packaging process.

What has been described above is only one embodiment of the method for manufacturing a long ceramic plate according to the present invention, and as shown by the two-dot chain line in FIG. It is also possible to manufacture a long ceramic plate with a glazed body by extending the length of the glaze body up to 100 degrees, or by interposing a glazing machine between the above-mentioned re-apparatuses as shown by the dashed line. In addition, waste heat is supplied from the firing furnace to the far infrared heater device as shown by the dashed line.
Drying can also be made more efficient. In addition, as shown in FIG. 11 (al), a guide 41 may be provided on each conveyor or roller, or a separate mechanism (not shown) may be used to
It is also possible to guide the sides with rollers or the like. Furthermore, as shown in FIG. 11(b), it is also possible to make an extrusion molded product whose decorative surface is embossed.

Furthermore, the microwave heating device U and the far-infrared heater device can be arranged in the opposite manner to that shown in FIG.

〔Effect of the invention〕

As described above, according to the method for manufacturing a long ceramic plate according to the present invention, the process from extrusion containing 20 to 15% moisture to firing to a moisture content of θ% can be performed in a straight line at the same level, and at the same extrusion speed, without deformation. Since it is manufactured without any problems, long ceramic plates can be easily formed. Further, the long ceramic plate has the characteristic that it can be manufactured linearly and in a shorter time from extrusion to product in about 30 to 2 hours, which is about 1,710 to 1,150 hours, compared to conventional products. Furthermore, since it can be manufactured in the above-mentioned time, the area of the manufacturing line is small, and there is no need for a drying place, and there is no transportation at all during that time, so it has features that cost and productivity are significantly improved.

[Brief explanation of the drawing]

FIG. 1 is an explanatory diagram schematically showing an apparatus for carrying out the method for manufacturing a long ceramic plate according to the present invention, and FIGS.
Q) is an explanatory diagram showing an example of the cross section of an extrusion molded product, and Fig. 3 (
al~(d) is a perspective view showing an example of the core, FIG. 4(a)
,(b)1. FIGS. 5(a) and (b) are explanatory diagrams showing an example of a punching machine, FIG. 6 is an explanatory diagram showing a cross section of a microwave heating device, FIGS. 7(a) and (b), and FIG. Figure 9 (a
), (b) is an explanatory diagram showing an example of supporting a free roller, a roller, etc., FIG. 10 is a perspective view showing the back side of a long ceramic plate,
FIG. 11 (al, (bl) are explanatory diagrams showing other examples. 1... Clay, 2... Extrusion molding machine, 4... Core, ■
...Drilling machine, ■...Microwave heating device, broken...
far-infrared heater device, η... firing furnace, 39... traveling cutter, A... extrusion molded body. Figure 2 C to illusion S (1, + 'to (Og to rtl), A (藷 = butterbur illustration 2nd figure te), -A C5ノ, ;' to hata)
/Yu /A (A, /A Fig. 2 ()) [8<hJf A ctsuno, A (G)
) /to (n)
/4 Figure 1 (0) r spatula Cf) , A Go to Figure 3 C) (&) Figure 3 (°゛ ≦+ (Figure 10 (b) Figure S (I/and Figure 6 1) Mouth Figure 7 (to) r21 <'b> Figure 8 Figure '1 (phantom f plug 3+ ha Figure 70 Figure 1/Figure (shin

Claims (1)

[Claims] (1) In manufacturing a ceramic plate by continuously extruding a raw material made of clay mineral from the outlet of an extrusion molding machine into a hollow body of an arbitrary shape that corresponds to the die, and drying, firing, etc. the hollow extruded body. , the extrusion molded body extruded from the extrusion molding machine is extruded, dried, and fired as a continuous body;
After firing, the extruded body is cut into a predetermined length, and a large number of exhaust ports are drilled on the back side of the hollow part of the extruded body immediately after extrusion.
Dry air or the like is supplied to the core built into the die to exhaust the water vapor in the hollow part of the extruded product to the outside and dry it, completing the process from extrusion to firing in about 30 minutes to 2 hours. A method for manufacturing a long ceramic plate characterized by the following.