JPH03187965A - Preparation of tile - Google Patents

Abstract

PURPOSE:To prepare a tile having a curved shape surface by the modification of only one of both upper and lower molds by disposing small projections having different heights on the back surface of a plane surface tile base and utilizing a contraction phenomenon caused by calcination and a load softening action caused by self weight. CONSTITUTION:A base raw material is press-molded with a conventional upper mold for molding tiles and a modified lower mold to form a plane tile base material (a) having a plane surface. The lower mold has a plurality of grooves 4 having small grooves 5 on the bottom surfaces thereof on the molded surface. The grooves 4 all have the same depth and the small grooves 5 have different depths and widths, respectively, wherein the small groove 5 in the groove 4 at the center of the molded surface is the deepest and widest and the small grooves 5 in the grooves 4 near both the sides of the tile are shallow and narrow. A plurality of projections 2 in parallel are thereby formed on the base material (a) and a plurality of small projections 1 arranged in the longitudinal direction are also formed on the lower surface of projections 2. The base material is coated with a glaze, dried, loaded on a receiver such as a shelf plate 3 so that the back surface of the base material is directed in the lower direction, and calcined. The base material (a) is deformed until the small projections 1 contact with the receiver of the shelf plate to support the weight of the base material, whereby the whole surface of the calcined product is deformed in an approximately uniform curved surface.

Description

DETAILED DESCRIPTION OF THE INVENTION (Industrial Field of Application) The present invention relates to a method for manufacturing tiles, particularly tiles having curved surfaces.

(Prior art) Conventionally, in order to manufacture tiles with curved surfaces, upper and lower molds (AI) (A2) having curved molding surfaces are used from the beginning, as shown in FIGS. 6 and 7. A tile base (a) with a curved surface is press-molded, and then this tile base (a) is
) is fired by placing it on a sagger or shelf (3) having a curved receiving part so that its curved shape does not collapse.

(Problems to be Solved by the Invention) The above conventional manufacturing method not only requires upper and lower molds having curved molding surfaces and a sagger or shelf having a curved receiving part, but also requires - Mass production lines for dry dry mosaic tiles or small tiles cannot be used, and they must be manufactured almost manually, making them extremely expensive.

The present invention has been made in view of the above-mentioned problems of the prior art, and allows tiles with curved surfaces to be produced using existing dry mosaic tiles or small tiles by simply modifying either the upper or lower molding mold. The object of the present invention is to provide a method for manufacturing tiles that can be manufactured using a mass production line almost as is.

(Means for Achieving the Object) In order to achieve the above object, in the tile manufacturing method of the present invention, small pieces of different heights are formed to form a tile with a flat surface and a curved surface on the back surface. A tile base with protrusions is formed, the tile base is fired with the back side facing down, and the surface is formed into a curved shape by utilizing the shrinkage caused by firing and the softening effect due to its own weight. .

The small protrusions may be formed in the form of small protrusions whose height gradually decreases from the center part on the back side of the tile base to the side parts.

Further, the small protrusion may be provided at the lower end of a protrusion provided parallel to the back surface of the tile base.

(Function) In the tile manufacturing method described above, when the tile base is placed horizontally on the receiving part of a sagger or shelf board, there is a gap between the small protrusions other than the highest small protruding part and the above-mentioned receiving part. Since there is a gap corresponding to the height difference between each small protrusion and the highest small protrusion, when this is fired, it will float from the receiving part of the sagger or shelf due to shrinkage due to firing and softening of the load due to its own weight. The surface of the small protrusion part sinks and hangs down until the small protrusion part contacts the receiving part, and a curved surface is formed on the tile surface accordingly.

(Example) Hereinafter, an example of the present invention will be described according to the steps of a tile having parallel protrusions called legs on the back surface.

First, the base material (C) adjusted into granules with a particle size of 100 to 2Hμ is pressed at about 300 kg/cf using a hydraulic press machine (A).
A tile base with a flat surface that is press-formed under a pressure of fr.
a) Mold.

For the mold of the hydraulic press machine (A), the conventional upper mold for dry mosaic tile molding or small rotary tile molding is used as the upper mold (A,), but the lower mold (A2) is used for the method of the present invention. Use the modified one.

That is, the lower mold (A2) has a plurality of grooves (4) on the molding surface in order to form a plurality of parallel protrusions (2) on the back side of the tile base (a) as shown in Figs. In addition to being recessed in parallel, each groove (4) is further provided with a small groove (5) on the bottom surface thereof.

The grooves (4) all have the same depth.

On the other hand, the small grooves (5) have different depths and widths, with the small groove (5) provided in the groove (4) at the center of the molding surface being the deepest and widest, and the grooves (4) near both sides The smaller grooves (5) provided are shallower in depth and narrower in width. In this embodiment, two small grooves (5) are provided for each groove (4) in its length direction.

The tile base (a) press-formed by such a press machine (A) has a plurality of parallel protrusions (2) called legs formed on the back surface, and each protrusion (2) is formed in parallel. 2) Two small protrusions (1) arranged in the length direction are formed on the lower end surface. This small protrusion (1) is provided to form a tile with a curved surface.

Further, as another aspect of the small protrusion (1), it may be one long small protrusion, or it may be a plurality of fine small protrusions.

The height and width of the small protrusions (1) gradually decrease from those in the center of the tile base (a) to those located near both sides.

The widths of the small protrusions (1) may all be the same, but since the load due to the weight of the tile base (a) is most likely to be applied to the center part, the widths of the small protrusions (1) may be the same, so the widths of the small protrusions (1) may be the same, but as the load due to the weight of the tile base (a) is most likely to be applied to the center part, It is preferable to gradually widen the area.

Next, the tile base (a) with a flat surface formed as described above is glazed and dried by a conventional method, and then a well-known sagger or shelf with a flat receiving part (the two are substantially the same) is glazed and dried. Therefore, in the following explanation, both will be collectively referred to as shelf boards (3
), placed with the back side down, packed in a kiln, and fired.

Firing is performed at approximately 1200°C in a tunnel kiln.

At this time, the small protrusions (1) on the back of the tile base (a) have different heights, so they contact the receiving part of the shelf board (3),
There are some that do not make contact and form a gap between them and the receiving part.
Due to the shrinkage of the tile base (a) during firing and the softening of the load due to its own weight, the part of the tile base (a) where the small protrusion (1) is floating from the receiving part sinks, and the small protrusion (1) becomes attached to the shelf board ( As a result of the deformation until it comes into contact with the receiving part (3) and supports the load, the entire surface is deformed almost uniformly into a curved shape.

Thus, upon completion of firing, a product tile (b) whose entire surface exhibits a substantially uniform curved shape is obtained.

In the embodiment described above, the small protrusions (1) are provided on all the protrusions (3), and the height of the small protrusions (1) is gradually reduced from the central part to the side parts, so that the entire tile surface is covered. Although the small protrusions (1) are curved almost uniformly, it is not necessary to provide the small protrusions (1) on all the protrusions (2), for example, it is not necessary to provide them on the protrusions (2) at both end portions.

However, if the small protrusions (1) are not provided on the protrusions (2) at both ends, the softening of the load at both ends of the tile base (a) will be supported by the wide protrusions (2). Now, this protrusion (
Corresponding to 2), the surfaces at both ends of the tile may become flat and it may be difficult to form a neat curved shape. Therefore, when trying to curve the entire surface almost uniformly, it is necessary to curve all the protrusions as in the previous embodiment. Preferably, the strip (2) is provided with a small protrusion (1).

In addition, when installing tiles using mortar on building walls, etc., the protrusions (2) improve the adhesion between the tiles and the mortar applied to the building structure, making it difficult for the tiles to peel off. However, it is not necessary to provide it.

Therefore, in a tile that does not have a protrusion (2) on the back surface, the small protrusion (1) is directly provided at an appropriate location on the back surface of the tile.

Furthermore, the present invention is not limited to the production of curved tiles with simple surfaces as in the above-mentioned embodiments; It is possible to manufacture tiles with any curved shape.

(Effects of the Invention) Since the present invention is constructed as described above, it produces the following effects.

(1) By simply modifying only one of the upper and lower molds of the press machine, the existing mass production line for dry mosaic tiles or small tiles can be used almost as is to manufacture the tiles, and the shape can be adjusted to suit the curved shape of the tile. Since there is no need to prepare a pot or a shelf board, the manufacturing cost is lower and the manufacturing period is shorter than that of conventional methods.

(2) By adjusting the height, shape, arrangement, etc. of the small protrusions, it is possible to obtain glue with an arbitrary curved surface such as a curved surface, and the small protrusions are the surface of the tile base during firing. Since the area supporting the softening load is small, the surface of the tile corresponding to the supporting portion becomes flat and the curved surface shape is not damaged, and a beautiful curved surface shape can be formed.

(3) The protrusions of different heights used to form tiles with curved single-layer surfaces are small protrusions, so when installing the tiles,
There is no wobbling of the tiles and it is easy to install.

[Brief explanation of drawings]

Figures 1 to 4 are cross-sectional views showing the steps of the tile manufacturing method of the present invention. Figures 1 and 2 show the process of press-forming the tile base, and Figure 3 shows the process of press-forming the tile base during firing. FIG. 4 shows the state in which it is placed on a pot or shelf, and the state in which it has been deformed into a curved shape due to shrinkage due to firing and softening under load. Figure 5 is a bottom view of the tile base, Figures 6 and 7 are cross-sectional views showing the conventional method, Figure 6 shows the press forming process of the tile base, and Figure 7 shows how the tile base is shaped into a sagger during firing. In particular, they are shown placed on a shelf. a: Tile base b = Tile 1: Small projection for forming a tile with a curved surface 2: Projection provided on the back surface of the tile.

Claims (3)

[Claims] (1) A method for manufacturing a tile in which a tile base (a) with a flat surface is formed, and then this tile base (a) is fired to form a tile (b) with a curved surface, the tile base comprising: (a) Providing small protrusions (1) of different heights on the back side to form a tile (b) with a curved surface, and firing this tile base (a) with the back side facing down; A tile manufacturing method characterized by forming a surface into a curved shape by utilizing shrinkage due to firing and load softening effect due to its own weight. (2) Small protrusion (1) provided on the back side of the tile base (a)
The tile according to claim 1, characterized in that the tile is formed into small protrusions (1) whose height gradually decreases from the center to both sides of the back surface of the tile base (a) and then fired. Method. (3) Protrusions (2) are provided in parallel on the back side of the tile base (a), and a small tile (b) having a curved surface with different heights is formed at the lower end of the protrusions (2). The tile manufacturing method according to claim 1, characterized in that the protrusion (1) is provided and the tile is fired.