KR100376726B1 - Method for manufacturing tile - Google Patents

Abstract

Tile manufacturing method according to the present invention, comprising the steps of weighing and blending each raw material in an amount suitable for tile production; Mixing the blended raw materials; Grinding the mixed raw material into particles of a predetermined size; Aging the ground mixed raw material; Mixing the mixed raw materials into a coma / kneader while controlling moisture; A primary product molding step of continuously extruding a mixed raw material having a predetermined viscosity into a vacuum strip molding machine into a tile strap form; Cutting the product in the form of tile straps discharged from the vacuum drill machine into a predetermined size; Forming a product having a fine pattern by inserting the cut at least one product into a press mold having a cavity having a fine pattern; Drying the molded product; Firing to increase the strength of the dried product; Product screening / inspection step: and packaging step. According to this, since the first injection-molded product by the vacuum drill machine is put into a mold having a fine pattern and pressurized secondly, it is possible to produce a delicate and fine three-dimensional pattern such as a natural stone pattern which cannot be manufactured by the conventional method. Eggplants can be produced at low cost.

Description

Tile manufacturing method {Method for manufacturing tile}

The present invention relates to a method for producing a tile used for finishing the floor or wall of a building, and more particularly, to a tile manufacturing method capable of forming a very fine and fine three-dimensional pattern such as natural stone pattern.

As a method for producing a tile, a dry tile production method using a press die and a wet tile production method using a vacuum drill machine are generally known.

The dry tile manufacturing method is a method of producing a tile by putting a powdery raw material mixture containing less than about 10% of water into a press mold having a predetermined cavity and pressure firing, which is mainly used for the production of flat tiles. This will be described in detail with reference to the tile manufacturing process diagram shown in FIG. 1.

As shown in Figure 1, a general dry tile manufacturing method, raw material mixing step (S10), raw material mixing step (S11), raw material grinding step (S12), raw material drying step (S13), product forming step using a press mold ( S16), the product drying step (S17), the product firing step (S18), the product selection / inspection step (S19) and the product packaging step (S20). In addition, after the product drying step (S17), before the product firing step (S18) may be added a milking step (S21) for applying a glaze on the surface of the product.

Kaolin, feldspar, pottery stone, clay and feldspar are used as raw materials in the dry tile manufacturing method. Each raw material is weighed in an amount suitable for tile production, and the weighed raw material, water, and corners are combined at a predetermined ratio (S10). The blended raw materials are mixed by a mixer (S11), and then crushed and discharged by a ball mill (Bollmill) (S12). The pulverized raw material mixture is stored in a slip tank (S13), and again transferred to a spray dryer, dried (S14), and then stored in a powder silo (S15). After that, the raw material mixture is transferred to a press powder silo and press-molded (S16). Powder moisture in press molding is on the order of 7-8%.

The press mold has a cavity corresponding to the shape of the tile to be manufactured, and the cavity is filled with a raw material mixture. The press mold is composed of upper and lower molds, and is usually opened and molded by hydraulic pressure. As the upper and lower molds are joined together, the internal raw material mixture is pressed and fired into a product having a cavity shape.

The molded product taken out from the press die is put into a drying chamber and dried (S17), and then put into a firing furnace and fired (S18). Firing proceeds at a temperature in the range of approximately 1100 to 1200 ° C. to increase the strength of the molded article. This firing condition may vary from product to product. Here, prior to firing the dried molded product may further proceed with the oiling step (S21) for applying the glaze on the surface of the product. A dairy product has a smoother and cleaner surface than non-dairy products. Thereafter, the sorting and inspection work for the finished product discharged from the kiln is carried out (S19) to determine the quality of the product, and packaging (S20).

In the dry tile manufacturing method as described above, the movement of the raw material to each step is made by a conveyor belt, and in the product firing step (S18), the product is mounted on a trolley and moved.

Meanwhile, the wet tile manufacturing method is a method of forming a tile while continuously extruding a raw material mixture having a predetermined viscosity containing about 20% of moisture into a tile strap by using a device called a vacuum drill machine. In addition to flat plains, tiles with rough regular patterns can be molded. This will be described in detail with reference to the process diagram shown in FIG. 2.

As shown in Figure 2, the wet tile manufacturing method, raw material mixing step (S30), raw material mixing step (S31), raw material grinding step (S32), raw material ripening step (S33), secondary raw material grinding step (S34), Coma / kneading step (S35), product molding step (S36), vacuum cutting machine (S36), product cutting step (S37), product drying step (S38), product firing step (S39), product sorting / inspection step (S40) and Product packaging step (S41) is made. In addition, after the product drying step (S38), before the product firing step (S39) may be added a milking step (S42) for applying a glaze on the surface of the product.

Raw material blending step (S30), raw material mixing step (S31), raw material grinding step (S32), secondary raw material grinding step (S34), product drying step (S38), product firing step (S39), product selection in the manufacturing process The inspection step (S40), the product packaging step (S41) and the oiling step (S42) is made similar to the process of the dry tile manufacturing method described above. Therefore, redundant description is omitted here, and only the features of the wet tile manufacturing method will be described.

The raw material ripening step (S33) is to make the moisture of the mixed raw material constant, it is made by stacking the ground raw material mixture to a predetermined place by a forklift for about one day. If the moisture of the mixed raw materials is not constant, it is difficult to control the warpage of the injection molded product. Therefore, it is necessary to keep the moisture of the mixed raw materials constant.

The mixing / kneading step (S35) is a step of mixing while supplying moisture to the pulverized raw material mixture in order to make the raw material mixture into a moldable state having a predetermined viscosity, and is usually performed by an apparatus called a mixing / kneading machine. .

The raw material mixture mixed / mixed by the coma / kneader is fed to a vacuum drill machine by a conveyor belt or the like. This vacuum drill machine continuously extrudes the raw material mixture in the form of a tile strap through a nozzle while removing the air present in the kneaded raw material mixture (S36). Tile straps of various shapes may be molded according to the shape of the nozzle, and when a pair of rollers having a predetermined pattern is installed at the rear end of the nozzle, a pattern may also be formed on the surface of the extruded tile strap. Can be.

The product cutting step (S37) is a process of automatically cutting the tile strap discharged through the nozzle of the vacuum drill machine to the required standard.

The product cut in this step is manufactured into tiles of the finished product by sequentially going through drying, milking, firing, screening / inspection and packaging steps.

However, in the conventional tile manufacturing method as described above, that is, dry tile manufacturing method using a press mold or wet tile manufacturing method using a vacuum drill machine, the production of tiles having a flat pattern or rough pattern of unpolished However, there is a problem that a tile having a fine and delicate pattern, such as a natural stone pattern, which has recently been spotlighted, cannot be manufactured.

In other words, in the conventional dry tile manufacturing method, it is possible to produce a tile having a delicate pattern by press firing powdered mixed raw materials using a press mold having a fine pattern, but in this case, very large pressure is required. There is a difficulty in constructing the system in terms of cost and space, and even if the mold is pressurized by a large hydraulic pressure, a problem arises in that the defective rate is increased because the mixed raw material remains in the pattern part where the fine unevenness of the mold is severe. In addition, there may be a method of forming by increasing the moisture content of the mixed raw material in order to prevent such incomplete molding and to use less hydraulic pressure, but in this case, the mixed raw material is agglomerated by a large amount of moisture does not make accurate weighing Another problem arises that causes molding failure.

On the other hand, the wet tile manufacturing method, as mentioned above, by installing a pair of rollers having a predetermined pattern on the rear end of the nozzle of the vacuum drill machine can produce a tile having a regular, rough pattern, natural stone There is a limit in manufacturing tiles having fine and delicate patterns such as patterns. That is, not only is it difficult to manufacture a roller having a delicate pattern, but there is a problem of high cost, and furthermore, due to the problem that raw material mixture residue remains on the surface of the roller, the complete pattern cannot be formed by lamination. It is impossible to produce tiles having fine and delicate patterns, such as the like.

The present invention has been made in view of the above, and using a conventional dry tile manufacturing method and a wet tile manufacturing method can produce a tile having a fine and delicate three-dimensional pattern such as natural stone pattern at low cost The purpose is to provide a manufacturing method.

1 is a dry tile manufacturing process using a conventional press mold,

2 is a wet tile manufacturing process diagram using a conventional vacuum drill machine, and

3 is a tile manufacturing process according to an embodiment of the present invention.

Tile production method according to the present invention for achieving the above object comprises the steps of blending each raw material in an amount suitable for tile production; Mixing the blended raw materials; Constantly grinding the particles of the mixed raw material; Storing the aged mixed raw material for a predetermined time to mature; Coma / kneading step for controlling and mixing the moisture of the mature mixed raw material; A primary product molding step of feeding the mixed / kneaded mixed raw material into a vacuum drill machine and continuously extruding it in the form of a tile strap; Cutting the product in the form of tile straps discharged from the vacuum drill machine into a predetermined size; Forming a product having a fine pattern by inserting the cut at least one product into a press mold having a cavity having a fine pattern; Drying the molded article; Firing step to increase the strength of the dried product; Product screening / inspection step: and packaging step.

According to this, since the first injection-molded product by a vacuum drill machine is put into a mold having a fine pattern and pressurized secondly, a delicate and fine three-dimensional pattern such as a natural stone pattern which cannot be manufactured by the conventional method can be obtained. Eggplant can produce tiles.

In addition, the tile manufacturing method according to the present invention further includes a drying step of exposing the product to the atmosphere for a predetermined time in order to remove the moisture of the primary molded product discharged from the vacuum drill machine. According to this, since the moisture content of the product that is injection-molded by the press die is low, the product can be easily taken out, and the defect rate can be reduced.

In addition, the tile manufacturing method according to the present invention is characterized in that when cutting the product discharged from the vacuum drill machine, the size of the product is cut slightly smaller than the cavity size of the press die. Thereby, the product can be easily seated in the cavity of the mold during injection molding of the product using the press mold.

In addition, the tile manufacturing method according to the present invention further comprises applying a release agent to the cavity of the press mold before the product is seated in the cavity of the press mold in order to ensure that the product molded by the press mold is taken out from the mold without damage. Include. Thereby, the damage of a product at the time of product extraction etc. can be prevented more effectively.

In addition, the tile manufacturing method according to the present invention further comprises applying a glaze on the surface of the dried product after the secondary product molding using a press die. According to this, the three-dimensional feeling of the molded product can be improved further.

Hereinafter, preferred embodiments of the present invention will be described with reference to the accompanying drawings.

3 is a process chart of the tile manufacturing method according to the present invention.

As shown in Figure 3, the tile manufacturing method according to the present invention, raw material mixing step (S50), raw material mixing step (S51), raw material grinding step (S52), raw material ripening step (S53), secondary raw material grinding step (S54), coma / kneading step (S55), primary product molding step (S56) using a vacuum drill machine (S56), product cutting step (S57), natural drying step (S58), secondary product molding step using a press mold ( S59), the product drying step (S60), the product firing step (S61), the product selection / inspection step (S62) and the product packaging step (S63). In addition, after the product drying step (S60) may be added to the oiling step (S64) for applying a glaze on the surface of the product before firing. Hereinafter, each step will be described in detail.

In the raw material mixing step (S50), for example, the raw materials such as kaolin, feldspar, pottery stone, clay and feldspar are weighed in an amount suitable for tile production, and then the raw materials, water, and corner are mixed at a predetermined ratio. In the raw material mixing step (S51), the raw material blended by the above step is mixed using a mixer or the like. In the raw material crushing step (S52), the raw materials mixed by the above steps are pulverized to a predetermined particle size by using a roller crusher.

The aging step (S53) is made by stacking the pulverized raw material mixture as described above by a forklift to a predetermined place for about one day, whereby, the moisture of the mixed raw material can be kept constant, more A stable blending and mixing effect can be obtained.

Thereafter, the aged mixed raw materials are put into a roller crusher using a forklift or the like to be pulverized (S54).

The pulverized mixed raw material which is pulverized and discharged from the roller crusher is introduced into a coma / kneader through a conveyor belt. The coma / kneader mixes and discharges the mixed raw material to form a moldable state having a predetermined viscosity while controlling the moisture of the pulverized mixed raw material (S56). Here, the moisture is adjusted to about 22%.

As described above, the mixed raw material discharged from the coma / kneader is introduced into the vacuum drill molding machine by the conveyor belt. Vacuum molding machine is continuously extruded in the form of a tile strap while mixing the mixed raw material again while removing the air contained in the mixed raw material (S56).

Cutting step (S57) is a process of automatically cutting the tile straps continuously extruded through the nozzle of the vacuum drill molding machine as required as described above, whereby the tile straps are cut in units of tiles and loaded on the drying cart. Since the cut tile-like product contains about 22% of moisture, this moisture must be removed under molding conditions by a press die. To this end, the tile-shaped product loaded on the drying cart is dried for one or two days in the air (S58). In the cutting of the tile straps in the cutting step, it is preferable to cut the cut product to a size smaller than the cavity size of the mold so that the cut product is easily seated in the mold cavity in the later mold process.

Then, at least one or more products cut into a tile shape are put into a press mold having a fine pattern such as a natural stone pattern to be molded on the tile, and the upper and lower molds are combined to form a desired fine pattern on the surface of the tile. (S59). At this time, the product to be molded is already a dense structure while undergoing a vacuum drill molding process, and since the moisture content is properly controlled through the natural drying process, the raw material residue in the mold when forming the fine pattern Does not remain, and a complete molded product can be obtained. In addition, since the moisture content of the mixed raw material is higher than the conventional dry, it does not require a large hydraulic pressure for the mold operation. In other words, the mold system used in the existing dry tile manufacturing method can be used as it is without major changes.

In producing the mold used in the tile manufacturing method of the present invention as described above, first, a portion to be molded, such as natural stone, is floated with gypsum, and then the plaster is floated with gypsum. Then, in the latter gypsum, one pattern part of the natural stone appears as yin and yang, and the mold is used for the present invention, which is commissioned by a casting factory.

The product taken out from the mold is put into a drying chamber in a state loaded on a drying cart and dried (S60). Then, the dried product is immediately put into the kiln and fired under a predetermined condition (S61). Thereafter, the process of screening and inspecting the fired product is carried out (S62), and the product is determined to be packaged and shipped (S63).

The oiling step (S64) is a step of applying a glaze on the surface of the product, as shown in the drawing, is performed before a predetermined time after the drying step (S60), according to which the pattern on the surface of the product has a three-dimensional appearance can give a more luxurious image have.

And, although not shown in the drawing, in taking out the product after molding the product using a press mold, in order to ensure that the product is taken out from the mold, the step of applying a release agent to the cavity of the mold before seating the product in the mold It may be further provided. According to this, the defective rate of a product can be remarkably lowered.

In addition, in the following description, the pattern to be molded has been described as a natural stone pattern, but the natural stone pattern can be molded into a very delicate and fine pattern corresponding thereto.

According to the present invention as described above, the mixed raw material is formed in the form of a tile trap of the already dense structure while passing through the vacuum drill machine, and has a fine pattern while the moisture content is dried to a suitable level for press molding. Since it is put into a press mold and molded into a finished product, it is possible to produce a tile having a fine and delicate pattern, such as natural stone pattern, which was impossible to manufacture by the conventional method.

In addition, the tile manufacturing method according to the present invention does not add any other system, and since the system used in the existing dry and wet tile manufacturing process can be used as it is, no additional cost is required. That is, tiles having fine and delicate patterns such as natural stone patterns can be manufactured at low cost.

On the other hand, while the above has been shown and described with respect to preferred embodiments of the present invention, the present invention is not limited to the above-described embodiment, the field to which the invention belongs without departing from the spirit of the invention claimed in the claims below. Of course, anyone skilled in the art can make various modifications, as well as such modifications are within the scope of the claims.

Claims (5)

(correction) a) a raw material mixing step of weighing each raw material in an amount suitable for tile production and blending the raw material with water and corners in a predetermined ratio; b) a raw material mixing step of mixing the blended raw materials; c) a raw material grinding step of grinding the mixed raw material into particles of a predetermined size; d) raw material aging step of aging by storing the pulverized mixed material for a predetermined time; e) coma / kneading step of mixing the mixed raw material into the coma / kneader to adjust the moisture while mixing; f) The primary raw material for densifying the structure of the tile so that the pattern can be clearly formed by removing the air by inserting the mixed raw material having a predetermined viscosity of the mixed water / kneader into the vacuum drill molding machine in the form of a tile strap Product forming step; g) a product cutting step of cutting the product of the tile strap form discharged from the vacuum drill machine into a predetermined size; h) a natural drying step of evaporating moisture by exposing the cut product to the atmosphere for a predetermined time in order to control the water content of the cut product; i) a pattern forming step of molding the product having a fine pattern by inputting at least one of the naturally-dried product into a press mold having a cavity having a fine pattern; j) a product drying step of drying the molded product; k) product firing step to increase the strength of the dried product; l) Product screening / inspection stage: and m) product packaging step; comprising a tile manufacturing method. (correction) The method of claim 1, When the product is cut by the step g), the size of the product is characterized in that to cut slightly smaller than the cavity size of the press die. (delete) (correction) The method of claim 1, And (n) applying a releasing agent to the cavity of the press mold before step i) so that the product molded by the press mold is withdrawn from the mold without damage. (correction) The method of claim 1, The method of claim 1, further comprising applying a glaze on the surface of the dried product after step j).