JPH03211009A - Manufacture of plate-shaped light-weight ceramic building material or the like - Google Patents

Abstract

PURPOSE:To lighten a material while maintaining its beautiful appearance and strength by providing a number of projections for forming recesses all over one surface, cutting peripheral sections, accommodating a plastic material having the thickness a little larger than the inner mold dimension and the vertical and lateral lengths a little smaller than the inner mold dimension into a ceramic plate-shaped press mold with a small channel on the surface, press molding and burning the same. CONSTITUTION:A number of projections 4 for forming recesses are provided at least on one surface of a mold 3 mainly on a bottom force, and peripheral sections are cut, and a plastic material 2 like a ceramic clay having its thickness a little larger than the inner dimension and the length smaller than the vertical and lateral lengths is accommodated in a ceramic plate-shaped material press mold 3 with a small channel 7 on anyone of cut surfaces 6, press molded and burned. The peripheral sections mean the positions in the vicinity of peripheries with almost equal intervals of peripheries or the peripheries of the projections 4 positioned in the peripheries. When a number of projections 4 for forming recesses are provided, the row of projections is inclined from the direction of a plate-shaped material of a product by 10-30 degrees, or the height and distribution density of the positions 4 are varied in accordance with the positions of weight applied to the product or the like to upgrade the quality.

Description

[Detailed Description of the Invention] [Industrial Application Field] This invention is used in the field of manufacturing plate-shaped ceramic building materials such as tiles and roof tiles, and makes it possible to reduce their weight. Regarding the method.

[Conventional technology and its problems]

Conventionally, in order to reduce the weight of plate-shaped building materials such as tiles and roof tiles, a method has been proposed in which a large number of recesses (1) as shown in FIG. 3 are formed on the back surface of the material. However, the material used in this case is mainly a plastic ceramic raw material such as clay, and as shown in No. 4M, the dimensions of the rough area (2) are determined from the inner dimensions (product dimensions) of the press mold (3). The thickness was made slightly larger and the length and width were made smaller, and then, as shown in Figure 5, this was pressed and rolled. Therefore, at that time, the rough ground (2) made of plastic raw material is moved outward in the peripheral area, and at that time it slides past the protrusion (4) for forming the recess (1). The flow of the raw material (2) is thereby impeded, and a void (5) is created outside the appropriate recess, and as shown in Figure 3, the recess at the periphery is all transformed into a deformed recess 00. Moreover, the edges tend to become wavy and the deformed recesses 051 tend to break off at the edges, so there is a problem that it cannot be commercialized in practice.

[Technical means for solving the problem] The present invention was made to solve the problem, and as shown in Fig. 1.2, at least one side of the mold (3) (mainly the lower mold) There are many recesses (1) forming protrusions (
4), cut the peripheral part, and provided a small groove (7) on one of the cut surfaces (6). ) A plastic raw material (raw material) (2) such as ceramic clay, which is slightly larger in thickness and slightly smaller in length and width, is press-formed and then fired. “Periphery” in this case
can mean a position near the periphery (edge) at approximately equal intervals, or around the protrusion (4) located at the periphery, and the cutting means, for example, the shape (3). This means cutting straight 1 to 2 cm inside from the edge parallel to it, or cutting around the protrusion (4) located at the periphery to match its outline. Further, the small groove (7) provided on the cut surface may be provided on either of the two cut surfaces produced by cutting, and it is desirable that the depth thereof becomes as shallow as possible toward the inner surface of the mold (3).

In addition, when providing a large number of protrusions (4) for forming recesses (1), a row of them (a row connecting the ones that are the shortest distance from each other)
is inclined by 10 to 30 degrees, preferably about 20 degrees, from the direction of the plate-like product (i.e., the direction of the vertical edge of the mold (3)), or at a position that prevents the load from being applied to the product. In addition, the quality of the -layer is improved by varying the height and distribution density of the protrusions (4).

[Example 1] To describe an example of application in the case of ordinary tile tiles, almost the entire surface of the press mold (lower mold) (3) (excluding the draining step, buttock part, etc.) is covered with a 6 mm diameter and high Helmet-shaped recess-forming protrusions (4) with a diameter of 3 mm are provided so that every three centers form an equilateral triangle while maintaining a pinch of 10 mm from each other, and the vertical rows are shaped like molds (3). It should be tilted 20 degrees from the direction of both lateral edges.

Also, 8 mm from the edges of the pillar side, collar side, and butt side of mold (3)
, cut this at a distance of 20 fences from the head side, and cut the cut surface (6
) are formed with several small grooves (7). Their width is 5
Approximately 1 mm deep at the bottom (outer) end of mold (3)
Make a reverse taper so that the top (inner) end is almost zero.

After doing this, as before, as shown in FIG. 2, it is fixed together with the outer frame (8) using mounting bolts (9).

In addition, one out of several recess-forming protrusions (4) is a nest 00)
In this case as well, a small groove (for applying force) and an exhaust hole (11) are formed behind it if necessary.

Using such a lower mold (3) and a conventional upper mold, a general-purpose wasteland (
When 2) was press-formed and fired, although the weight was reduced by approximately 15% and the material was saved, the product did not show any deformation recesses θ9, cracks, or deformation of the surrounding areas, and the aesthetic appearance was poor. A product was obtained that did not cause a decrease in strength.

[Example 2] As in Example 1, a recess forming protrusion (4) was formed on the general purpose lower mold (3).
), cut around the protrusion (4) located on its periphery, and make a small groove (7
) will be established. When molding and firing were carried out in the same manner, the same good results as in the previous example were obtained.

[Example 3] The recess-forming protrusions (4) were made larger in distribution density and height in both lateral parts of the frame tile mold (3) than in the central part, and the following was carried out in Example 1.
Or, when the process was carried out in the same manner as in 2, the rough ground (2) dried first in the corners, especially the inner corner of the notch, so no cranking occurred there, and the flat part in the center, where the bending load was applied, was not strong enough. I was able to keep it.

Although each of the embodiments described above relates to roof tiles, the present invention is not limited thereto, and can of course be applied to tiles, other building materials, civil engineering materials, and the like.

[Action and effect]

According to the present invention, when aiming to reduce the weight of plate-shaped ceramic products such as tiles and roof tiles, even if a large number of protrusions for forming recesses are provided on the press mold, unlike in the past, the surrounding On the outside of the protrusion, the air in the void created by rolling the rough ground is not contained and is discharged from the small groove on the cut surface, where the air pressure resistance disappears, so the pressurized plastic material (the rough ground) is filled there again. Since there is no difference in residual pressure between the materials, the recesses of the product are reproduced exactly as in the mold, and the surrounding area is straight and unbroken, making it possible to reduce weight while maintaining great aesthetics and strength.

In particular, by tilting the array slightly from the direction of the product,
Alternatively, the effect of the layer can be enhanced by changing its distribution state and height depending on the location of the load.

[Brief explanation of drawings]

FIG. 1 is a sketch showing an example of a press mold used in the present invention;
Figure 2 is a sectional view of the main part when it is set, Figure 3 is a plan view showing the product manufactured by the conventional method, and Figure 4 is a schematic cross-section of the conventional press die for manufacturing the product before pressing. FIG. 5 is a schematic sectional view showing the state after pressing.

Claims (5)

[Claims] (1) A plate press mold for ceramics is provided with a large number of protrusions for forming recesses on the entire surface on at least one side, the peripheral part is cut, and small grooves are provided on the cut surface. A manufacturing method for lightweight ceramic building materials in the form of plates, which is characterized by press-forming and firing plastic raw materials (raw materials) that are slightly thicker and slightly smaller in length and width. (2) The method for manufacturing a plate-shaped lightweight ceramic building material, etc., according to claim 1, wherein the "peripheral part" is "a peripheral part spaced approximately at a constant distance from the periphery (edge)". (3) The method for manufacturing a plate-shaped lightweight ceramic building material, etc. according to claim 1, wherein the "periphery" is "around the protrusion located at the periphery". (4) The plate-shaped lightweight ceramic according to claim 1, wherein "protrusions are provided" means "protrusions are provided such that the rows thereof are inclined by 10 to 30 degrees with respect to the direction of the plate-shaped body" Manufacturing methods for building materials, etc. (5) The plate shape according to claim 1, in which "protrusions are provided" means "protrusions are provided so that the distribution density or height varies depending on the position of the load applied to the product" Manufacturing method for lightweight ceramic building materials, etc.