JPH03270902A - Cast molding method for ceramic plate with spot pattern - Google Patents

Abstract

PURPOSE:To form simply a spot pattern by means of a spot material of the minimum required quantity and providing a clear recessed and projected pattern on its pattern surface by casting a base slurry retamining portion from below in the state that the spot material is sprayed thinly on the surface of the base slurry introduced preliminarily in a mold. CONSTITUTION:60-90% of the whole quantity of base slurry 16 constituting a main component of a ceramic plate is introduced from a casting inlet 13 into a bottom force 11 and heaped up in the bottom force. Then, a screen 18 in which a spot material 17 is contained is positioned right above said base slurry 16, and vibration is applied to scatter the spot material 17 on the surface of base slurry 16. Then, the screen 18 is moved from above the bottom force 11 and a top force 10 is lowered to carry out mold clamping. In said state, a remaining portion is cast from the casting inlet 13 into the mold and the water content of the base slurry 16 is absorbed into the inner surfaces of the top force 10 and the bottom force 11, and the base slurry 16 and the spot material 17 are molded integrally in the mold.

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Field of Application] This invention relates to the cast formability of a ceramic plate with a spotted pattern.

[Conventional technology]

Recently, large patterned ceramic plates have been attached to interior and exterior walls, ceilings, etc. to enhance the aesthetic appearance of buildings.

As such a patterned ceramic board, a ceramic board with a spotted pattern is often used, the surface of which is a mixture of spots of various colors to form a colored pattern.

The above ceramic plate with a spotted pattern is usually manufactured by the following method called a "dry press method."

That is, first, several kinds of colored ceramic pulverized materials (hereinafter referred to as "spotted materials") are prepared, and these are uniformly mixed into a powder composition that is the heath material of the ceramic plate. Then, as shown in Fig. 7, this mixed material is
The material is heaped up and filled into the lower mold 1 for breath molding, and then press molded by the upper mold 2. Note that 3 is a spotted material and 4 is a base material. Due to the pressure and heating during this pressing, the heath material and spot material bind to each other to form a molded product. Therefore, after removing the mold, it is fired to obtain the desired spotted patterned ceramic board.

[Problem to be solved by the invention]

However, in the dry press method, since the dotted material must be uniformly dispersed throughout the base material, a large amount of expensive dotted material is required, resulting in an increase in material cost. In addition, since a solid material is used, even if an attempt is made to create a concavo-convex pattern on the inner surface of the upper mold 2 to create not only a spotted pattern but also a concavo-convex pattern, the flowability of the material is poor, and the inside of the concavo-convex pattern of the upper mold 2 is There is a problem in that the material does not penetrate sufficiently into the surface, making it impossible to clearly transfer the uneven pattern.

This invention was made in view of the above circumstances, and it is possible to easily obtain a spotted pattern by using the minimum amount of spotted material.
Moreover, the object of the present invention is to provide a method for forming a ceramic plate with a speckled pattern, which can give a clear uneven pattern to the speckled surface.

[Means to solve the problem]

In order to achieve the above object distantly, the method of casting a ceramic plate with a spotted pattern according to the present invention includes the steps of preparing a pair of upper and lower casting molds each having a casting port opening in the center of the shaping recess of the lower mold; A preliminary introduction step in which most of the base slurry is introduced into the lower mold from the pouring port of the lower mold, and speckled material is sprinkled onto the surface of the introduced base slurry from above the lower mold into which the base slurry has been introduced. It comprises a spotted material scattering step, and a casting molding step of integrally molding the spotted material and the base slurry in the mold by casting the remainder of the base slurry from the casting opening of the lower mold after closing the lower mold and the upper mold. The structure is as follows.

[Effect]

That is, this invention provides a ceramic board with a spotted pattern,
Instead of using the conventional dry press method, it has three special processes: ■ Preliminary introduction of base slurry into the lower mold, ■ Sprinkling of spot material on the surface of the base slurry inside the lower mold, and ■ Casting of the remaining portion of the base slurry. It is molded using a casting method. According to this casting method, the base slurry residue is cast from below with the spotted material placed thinly on the surface of the base slurry that has been preliminarily introduced into the mold, so that the base slurry residue is lifted upward by the base slurry residue. , evenly pressed against the inner surface of the upper mold. Therefore, when this is removed from the mold, a molded article with spotted material dispersed on the surface is obtained, and upon firing, a ceramic plate with a spotted pattern is obtained. The amount of speckled material used in this cast molding method only needs to be exposed on the surface side as a pattern, and material costs can be kept low. In addition, the distribution pattern of the dotted material scattered on the surface of the pre-introduced base slurry is lifted upward in the same position when the remaining part of the base slurry is cast, and is pressed against the inner surface of the upper mold to form the dotted material. It is advantageous to be able to predict the finished speckled pattern at the time of spraying. Therefore, when distributing the spotted material, it is possible to design the shade and arrangement of the spotted pattern. Furthermore, by casting the base slurry residue, the upper surface of the material (spotted material dispersion surface) is sufficiently pressed against the inner surface of the upper mold. It is clearly transferred to . Therefore, it is possible to obtain a ceramic plate with a complex surface pattern combining a spotted pattern and an uneven pattern, which could not be achieved using conventional dry pressing methods.

Next, the present invention will be explained in detail based on examples.

〔Example〕

FIG. 1 shows an example of a set of upper and lower casting molds used in the present invention. In the figure, reference numeral 10 denotes an upper mold, which can be moved up and down by driving a hydraulic cylinder (not shown). A lower mold 11 is fixed on a base 12, and a casting port 13 is opened at the center of a recess in the mold. 14
is a flow path for casting material communicating with the casting port 13, to which a material supply pipe 15 extending from a material supply source (not shown) is connected.

The present invention uses the casting mold described above to mold a ceramic plate with a spotted pattern, for example, in the following manner.

That is, as shown in FIG. 2, first, 60 to 90% (by volume) of the total amount of base slurry 16, which is the main component of the ceramic plate, is introduced into the lower mold 11 from the pouring port 13. Pour it into the mold. Next, as shown in FIG. 3, a sieve 18 containing spotted material 17 is positioned directly above the introduced base slurry 16, and
The dotted material 17 is dispersed on the surface of the base slurry 16 by applying vibration to the base slurry 16. Then, the distribution state of the spotted material 18 is confirmed with the naked eye, and when the desired spotted pattern is obtained, the sieve 18 is moved from above the lower mold 11, the upper mold 10 is lowered, and the mold is removed. Tighten. In this state, as shown in FIG. 4, the remaining part of the base slurry 16 is poured into the mold from the pouring port 13, and the moisture of the base slurry 16 is absorbed into the inner surfaces of the upper mold 10 and the lower mold 11, and the base slurry 16 is poured into the mold. The slurry 16 and spot material 17 are formed into one body. When this is removed from the mold, a ceramic molded surface with speckled material 17 appropriately distributed on the surface as shown in FIG. 5 is obtained. Therefore,
By firing this molded surface, a ceramic plate with a spotted pattern can be obtained.

Therefore, according to this formability, since the remaining part of the base slurry is cast from below with the speckled material 17 placed thinly on the surface of the base slurry 16 previously introduced into the mold, the speckled material 17 is poured into the base. The remainder of the slurry 16 lifts it upward and presses it uniformly against the inner surface of the upper die 10. Therefore, the amount of spotted material 17 that is exposed on the surface side as a pattern is sufficient, and the material cost can be kept low.

In addition, the distribution pattern of the dotted material 17 scattered on the surface of the pre-introduced base slurry 16 is lifted upward and shaped by the casting of the remainder of the base slurry 16, so that the dotted material 17 is spread. At this point, you can predict how the speckled pattern will look, which is convenient for designing the color and placement of the speckled pattern.

In the above embodiment, a simple flat ceramic plate is shaped, but if, for example, an uneven pattern is formed on the inner surface of the upper die 10, as shown in FIG. 6, the base slurry 16
By casting the remaining portion, the scattered surface of the spotted material 17 is sufficiently pressed against the inner surface of the upper mold 10, so that the uneven pattern on the inner surface of the upper mold 10 is clearly transferred to the material side during casting. Therefore, it is possible to obtain a ceramic plate with a complex surface pattern combining a spotted pattern and an uneven pattern, which could not be achieved using the conventional dry pressing method.

Further, the base slurry 16 and spot material 17 used in this invention may be any conventionally known materials, but
It is preferable to use materials whose shrinkage rates during firing are similar to each other. For example, the firing shrinkage rate of the base slurry 16 is 10%.
In the case of 10% or less, the speckled material 17 also has the same composition as the base slurry 16, and its firing shrinkage rate is 10%.
It is preferable to set it to around %. That is,
This is because if the firing shrinkage rates of the two are significantly different, fine voids and cracks may be generated at the boundary between the base portion and the speckled material portion after firing.

[Effects of the Invention] As described above, the moldability of the ceramic plate with a spotted pattern of the present invention is improved by lowering the remaining portion of the base slurry with the spotted material thinly placed on the surface of the base slurry that has been preliminarily introduced into the mold. Since it is cast from the side, the dotted material is lifted upward by the base slurry residue into which it is cast, and is evenly pressed against the inner surface of the upper mold. Therefore, if this is removed from the mold, a molded surface with speckled material dispersed on the surface will be obtained.
A ceramic plate with a spotted pattern is obtained by firing. The amount of speckled material used for this cast moldability is only needed to be exposed on the surface side as a pattern, and the material cost can be kept low. In addition, the distribution pattern of the dotted material scattered on the surface of the pre-introduced base slurry is lifted upward in its original position by casting the remaining base slurry, and is pressed against the inner surface of the upper mold to form the dotted material. You can predict how the speckled pattern will look when you spray it. Therefore, when distributing the spotted material, it is convenient to be able to design the color and arrangement of the spotted pattern. Furthermore, by casting the base slurry residue, the upper surface of the material (spotted material dispersion surface) is sufficiently pressed against the inner surface of the upper mold. It is clearly transferred to . Therefore, it is possible to obtain a ceramic plate with a complex surface pattern combining a spotted pattern and an uneven pattern, which could not be achieved using conventional dry pressing methods.

[Brief explanation of drawings]

FIG. 1 is a sectional view showing an example of a casting mold used in the present invention, FIGS. 2, 3, 4 and 5 are explanatory views showing an example of formability using the casting mold described above, The figure is an explanatory diagram showing another molding example of the present invention, and FIG. 7 is an explanatory diagram of the moldability of a conventional spotted patterned ceramic plate.

Claims (1)

[Claims] (1) A process of preparing a pair of upper and lower casting molds with casting ports opening in the center of the forming recess of the lower mold, and a preliminary step of introducing most of the base slurry into the lower mold from the casting port of the lower mold. From above the injection process and the lower mold into which the base slurry was introduced,
A speckled material scattering step of scattering speckled material onto the surface of the introduced base slurry, and after closing the lower mold and upper mold, the remaining base slurry is poured from the casting opening of the lower mold to cover the speckled material in the mold. and a casting process of forming a base slurry.