JPH0242323B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION OBJECTS OF THE INVENTION (Industrial Field of Application) The present invention relates to a method for manufacturing a ceramic product, such as a tile, in which a decorative surface is expressed in an inlaid manner.

(Prior Art) FIG. 3 is a side sectional view schematically showing a tile with an inlaid decorative surface (hereinafter referred to as a decorative tile). In this decorative tile, the upper surface of the tile main body 1 is a decorative surface 1a, and decorative chips 2 are buried in a part of the decorative surface 1a.
The decorative chips 2 are formed using a material different from that of the tile body 1, and the decorative chips 2 are formed on the entire decorative surface 1a of the tile body 1.
The outline of the frame is clearly distinguishable, giving it an aesthetic appeal. Note that the unevenness provided on the lower surface of the decorative tile is the sole. Further, among such decorative tiles, there is also one in which a plurality of decorative chips 2 are arranged on the decorative surface 1a of the tile body 1.

Incidentally, conventionally, this decorative tile has generally been manufactured by a dry method, and there are roughly two methods for manufacturing the same.

First, one method (hereinafter referred to as the first manufacturing method) is to mold and fire the tile body 1 and the decorative chips 2 separately, and then bond them together with an adhesive in a post-process.

The other method (hereinafter referred to as the second manufacturing method) uses a special dry press machine (hereinafter referred to as the special press machine) as shown in FIGS. 4A to 4C. In other words, in this special press machine, the lower mold 3 is divided into multiple parts (the drawing shows the one divided into two parts).
Each of the divided molds 3a and 3b can independently move up and down. This second manufacturing method will be explained in accordance with its progress. First, as shown in FIG.
A recess 4 is formed between the frame mold 5 and the frame mold 5. and,
Dry clay for the decorative chip 2 (see Figure 3) is loaded into the recess 4, and the split mold 3a of the lower mold 3 is pressed while lightly pressing the top surface of the dry clay with an upper mold (not shown). The material is raised to a predetermined height to obtain a green substrate 2 with decorative chips 2 as shown in FIG. After that,
As shown in Figure C, the fully divided mold 3 in the lower mold 3
Align a and 3b to the same level, lower mold 3 and frame mold 5
A recess 6 (the decorative chip 2) formed by
Dry clay for the tile body 1 (see Figure 3) is loaded into the green body (excluding 2 minutes), and the entire body is pressed to obtain a green body for the decorative tile, which is used in the subsequent process. It is fired.

(Problems to be Solved by the Invention) The first manufacturing method includes a tile body 1 and a decorative chip 2.
Different firing distortions (shrinkage, warping, etc.) occur on both sides, and there are many problems with consistency between the two. In addition, the process of bonding the tile body 1 and the decorative chip 2 together was troublesome, and the adhesive sometimes leaked out from the gap between the two. Furthermore, there is no guarantee of the adhesive strength between the tile body 1 and the decorative chips 2, and the decorative chips 2 sometimes come off when the decorative tiles are used for many years.

In addition, in the second manufacturing method, when trying to manufacture various decorative tiles with different sizes or with different shapes of decorative chips 2,
Lower molds of special press machines are required for each type of press (various lower molds with different combinations of split molds), and the manufacturing cost of the lower molds becomes enormous. Therefore, in practical terms, the size of decorative tiles and the shape of decorative chips 2 have tended to be limited to a small number of types. Moreover, the operating mode of the special press machine is complicated, and there is a problem in that its productivity is poor.

The present invention has been made in view of the above circumstances, and provides a ceramic product with an inlaid decorative surface that solves all the problems seen in the conventional first manufacturing method, second manufacturing method, etc. An object of the present invention is to provide a novel manufacturing method (hereinafter referred to as the method of the present invention).

"Structure of the Invention" (Means for Solving the Problems) The gist of the method of the present invention is to prepare a decorative chip material for inlaying green material press-formed at low pressure by a dry method, and The decorative chips are placed on the side of the mold on which the decorative surface of the ceramic product is to be molded so that a desired pattern is formed, and the clay for the main body of the ceramic product is loaded into the mold. A composite material of the decorative chips and the main body material is formed by simultaneously pressing the loaded decorative chip material and the loaded clay for the main body until a predetermined high pressure is reached, and the composite material is fired. It is.

(Function) When forming the body material of the ceramic product body (described as tile body 1 in the conventional example) using a dry press machine (hereinafter simply referred to as a press machine),
A decorative chip material (corresponding to the green material body 2 of the decorative chip 2 described in the second conventional manufacturing method) press-molded in advance at low pressure by a dry method and clay forming the body material material (body material material) soil) into the space (inside the mold) formed between the upper and lower pressurizing surfaces of the press machine, and press both at the same time until a predetermined high pressure is reached. ing.
The decorative chip material is applied to the surface between the top surface of the loaded body clay and the pressure surface of the upper die of the press machine, or the surface between the bottom surface of the loaded clay and the pressure surface of the bottom die of the press machine. It is prescribed that there should be an intervention. In other words, the positional relationship of the decorative chip material with respect to the main body clay to be loaded can be roughly divided into two types depending on the combination of the upper mold and the lower mold in the press machine.
One is when the surface of the ceramic product on which the decorative surface is to be molded is formed on the lower mold, in which case the decorative chip material is placed face down on the pressurized surface of the lower mold, and then Load clay for the main body. The second case, contrary to the first case, is when the surface on which the decorative surface of the ceramic product is to be formed is formed in the upper mold, and at that time, the clay for the main body is loaded into the mold of the press machine. After that, the decorative chip material is placed facing up on the upper surface of the loaded main body pouch.

In the composite material obtained by pressing under such conditions, the bonding interface between the decorative chip material and the main material material is filled without any gaps on its decorative surface. To explain this point in detail, the decorative chip material is made of raw material formed by a dry method and used as it is. In other words, the decorative chip material is in an unfired state and its outline is clearly recognized (the ridgeline portion is acute). Therefore, if this decorative chip material is pressed at the same time as the clay for the main body of a ceramic product, the compressive force will cause the clay for the main body to be packed into the surrounding shape of the decorative chip material without any gaps. Become. Therefore, even when the composite material is fired, the bonding interface between the decorative chips and the main material does not become rounded, and the pattern on the decorative surface, which is the most important aspect of the ceramic product's appearance, is not damaged. It won't happen. Furthermore, in the method of the present invention, unlike the special press machine used in the conventional second manufacturing method, a very general press machine in which the upper die and/or the lower die move up and down as a whole can be used. Therefore, there is no need to modify equipment, and productivity is significantly improved. Furthermore, the arrangement position of the decorative chip material can be changed as appropriate with respect to the pressurizing surface of the lower die of the press machine or the upper surface of the loaded main body clay, and the shape of the decorative chip material can be changed as appropriate. Since this can be done freely, the variety of patterns that can be formed on the decorative surface of ceramic products can be infinitely increased.

(Example) The present invention will be described below based on drawings showing examples thereof. Note that this embodiment will also be described using an example in which decorative tiles are manufactured.

The most characteristic feature of the method of the present invention is that when forming the main body material of the ceramic product main body (hereinafter referred to as tile main body 1 [see Fig. 3]), the main body material forming the main body material is The purpose of this method is to load clay and a decorative chip material made of green material (unfired material) formed by a low pressure dry method into a mold of a press machine and press them at the same time to a high pressure.

First, decorative chip material will be explained. The decorative chip material is a green material formed by molding clay by a dry method, and its external shape is arbitrary. however,
Although the thickness varies depending on the thickness of the main body material after molding, it is generally preferable to keep it at 5 mm or less. The reason for this is that if
If the decorative chip material is made thicker than 5 mm, the body material formed in the subsequent pressing process will have a difference in clay filling density depending on the presence or absence of the decorative chip material at each pressurizing point, which will cause cracks, cracks, or warping during firing. This is because there is a risk of inviting On the other hand, if the decorative chip material is too thin, it will also be difficult to work with. According to the inventor's experiments, the optimal thickness of the decorative chip material was 2 to 3 mm. In addition, when forming the above-mentioned decorative chip material by dry method, 100 to 150
It shall be pressed at a low pressure of about Kg/cm ² . This is because the decorative chip material is pressed again at the same time as the main body clay in the subsequent process, but the clay filling density of the decorative chip material after pressing is higher than the clay filling density of the main body material. This is because nothing should happen.

Next, a description will be given of forming a composite material by simultaneously pressing the decorative chip material formed as described above and the clay for the main body. As shown in FIG. 1, the plurality of decorative chips 10, 10, . Arrange. Naturally, the arrangement pattern of the decorative chips 10 is arbitrary depending on the desired decorative pattern. Then, the tile body 1 (see FIG. 3) is inserted into the space (inside the mold) 11 formed between the lower mold 7 and the frame mold 8.
Load clay 12 for use. The body clay 12 is
The material is different from the decorative chip material 10 in terms of hue, brightness, saturation, gloss, etc. However, it is preferable that the coefficient of linear expansion (the amount of shrinkage due to firing) is the same as or similar to that of the decorative chip material 10. Then, the upper mold 9 of the press is lowered to press the decorative chips 10 placed in the mold 11 and the loaded clay 12 for the main body until a high pressure of 200 to 500 kg/cm ² is reached. A composite material in which a decorative chip material and a main material material are combined and integrated is obtained. In the case of the obtained composite material, decorative chip material 10
Since the molding pressure is higher than that of the molding pressure, there is no difference in clay filling density between the decorative chip material and the main body material. In the figure, the unevenness formed on the pressurizing surface 9a of the upper mold 9 (the surface that forms the non-decorative back surface of the ceramic product) is for forming the sole of the tile body 1 (see FIG. 3). It is something. Thereafter, the composite material is fired to obtain a decorative tile.

(Study of another embodiment) FIG. 2 is a side sectional view showing another embodiment of the method of the present invention. The press machine used in this embodiment has a pressurizing surface 13a (the surface on which the decorative surface of the ceramic product is formed) for forming the decorative surface 1a of the tile body 1 on its upper die 13.
is formed. Therefore, unlike the embodiment described above, first, the space 11 formed between the lower mold 7 and the frame mold 8 (inside the mold) is filled with the main body clay 12, and then the loaded main body clay Decorative chip materials 15, 15, . . . are arranged facing upward on the soil 12. The decorative chip material 15 was prepared so that its cross-sectional shape was trapezoidal. Therefore, in the decorative tile obtained by firing the pressed composite material, the decorative chips are embedded in the tile body in a dovetail shape, and the decorative chips never fall off. In addition, in the method of the present invention shown in the figure, a mat 14 made of soft rubber is laid on the pressure surface 7a of the lower mold 7 (the surface on which the non-decorative back surface of the ceramic product is molded).
If there is no decorative chip material 15, there will be a tendency for partial deviations in pressure force to occur depending on the presence or absence of the decorative chip material 15. This is to even out the packing density. In this way, the detailed configuration of the method of the present invention can be changed as appropriate depending on the mode of implementation.

"Effects of the Invention" As is clear from the above explanation, according to the method for manufacturing a ceramic product with an inlaid decorative surface according to the present invention,
All the problems seen in the conventional first manufacturing method, second manufacturing method, etc. could be solved. That is,
A summary of the effects achieved by the present invention is as follows.

You can freely change the shape of the ceramic product, the shape of the decorative chips, the arrangement of the decorative chips, etc.
Moreover, these changes are extremely easy.

At the initial stage of pressing when molding a composite material, the pressure is low and the clay for the main body filled in the mold is in a state where it can move freely according to the surrounding conditions, so the decorative chip material is The arrangement does not fluctuate, and as the press pressure increases, a composite material in which the decorative chip material and the main material material are firmly bonded can be obtained stably as the press pressure increases.

Since the press machine used to carry out the present invention only needs to be equipped with a general mold that moves up and down, no modification of equipment or special tools is required, and the entire molding operation is extremely easy.

The productivity of this type of ceramic product is greatly improved since it requires a process of gluing the main body material and the decorative chips together, a long drying process, etc.

The main body material and the decorative chips are made of clay which has the same coefficient of linear expansion and has a uniform clay filling density during molding, so there is no risk of cracking, splitting or warping occurring during firing.

[Brief explanation of drawings]

FIG. 1 is a side sectional view showing the method of the present invention, FIG. 2 is a side sectional view showing another method of the present invention, and FIG. 3 is a side sectional view schematically showing a decorative tile with an inlaid decorative surface. , and FIGS. 4A to 4C are side sectional views schematically showing a second manufacturing method using a conventional dry method. DESCRIPTION OF SYMBOLS 1... Tile body, 1a... Decorative surface, 2... Decorative chip, 7... Lower mold, 7a... Pressure surface, 8...
Frame mold, 9, 13... Upper mold, 9a, 13a... Pressure surface, 10, 15... Decorative chip material, 11... Inside mold of press machine, 12... Clay for main body.

Claims (1)

[Claims] 1. Prepare a decorative chip material for inlaying of green material press-molded at low pressure by a dry method, and apply the desired pattern to the surface of the mold of a dry press machine on the side where the decorative surface of the ceramic product is to be molded. At the same time, the clay for the body of the ceramic product is loaded into the mold, and the placed decorative chips and the loaded clay for the body are simultaneously pressed until a predetermined high pressure is reached. 1. A method for producing a ceramic product with an inlaid decorative surface, which comprises forming a composite material of a decorative chip material and a main body material, and firing the composite material.