JPH046142A - Production of ceramic sheet - Google Patents

Abstract

PURPOSE:To easily obtain a ceramic sheet with a desired pattern on the decorated surface by adhering a patterned unfired ceramic sheet to the surface of ground coat glaze applied to the surface of a dried extruded product, integrating and firing them. CONSTITUTION:Clay 1 is extrusion-molded into a prescribed shape with an extrusion molding machine 3 and this molded strip A is dried with a drier 9 to form a dried plate B. Ground coat glaze 14 is applied to the surface of the dried plate B and a patterned unfired ceramic sheet 15 is adhered to the glaze 14. They are fired in a firing furnace 19 and integrated.

Description

[Detailed description of the invention] [Industrial application field] The present invention continuously extrudes a raw material mainly composed of clay,
The present invention relates to a method of manufacturing a ceramic plate by subsequently drying, cutting, and firing, in which an arbitrary pattern can be formed on the decorative surface of the ceramic plate.

[Conventional technology]

Conventionally, the method for manufacturing this type of ceramic board is to form it into a short piece in a predetermined shape using an extruder, then form an arbitrary pattern on the decorative surface by roll processing or press processing, and then drying, cutting, and firing. It was manufactured using a method.

[Problem to be solved by the invention]

However, the continuous formed band immediately after being extruded into a predetermined shape by an extruder is in a soft state containing a lot of water, so it is easy to roll and press.
The continuous forming band may be deformed or cracked due to the pressing force.
Alternatively, this phenomenon may occur suddenly during drying or firing, which greatly affects the yield. Furthermore, it was difficult to form fine patterns. Furthermore, if a shock is applied locally, it will break very easily, and there is a danger that the pieces will fall.

[Means for Solving the Problems] In order to eliminate these drawbacks, the present invention has made it possible to manufacture ceramic plates by performing drying and firing in a short time and suppressing deformation. To provide a method for manufacturing a ceramic plate, in which a ceramic sheet with an arbitrary pattern added thereto is formed integrally with a glaze, and an arbitrary uneven pattern or various patterns can be easily and precisely formed on the ceramic slug. be.

〔Example〕

EMBODIMENT OF THE INVENTION Below, one Example of the manufacturing method of the ceramic plate based on this invention is described in detail using drawings. FIG. 1 is an explanatory diagram showing a typical example of an apparatus for carrying out the above method. In the figure, 1 is clay, which is mixed with several kinds of raw materials and chamotte added as necessary via a kneading machine (not shown), and then transferred via a belt conveyor 2 to a vacuum extrusion molding machine or a vacuum extrusion molding machine. This is supplied to an extrusion molding machine 3 which is one type of clay extrusion molding machine. The extrusion molding machine 3 is shown in Fig. 3 (
As shown in a), for example, the second
The clay 1 is continuously extruded in the shapes shown in Figures (a) to (j) and formed into a shape having a hollow part a. Note that the clay 1 is a natural product and has different components depending on its production area, and these characteristics and weaknesses are mutually offset to obtain a predetermined mixed clay. Examples of clay 1 include potter's stone, feldspar, kaolinite, halloysite, metahalloysite, Honbushi clay, Frogme clay, Shigaraki clay, etc.
It is made by adding water. In addition, iron may be removed from the clay 1 using a magnet if necessary.

Furthermore, the base 4 is not deformed by the extrusion force of the clay 1, and is equipped with a core 5. To explain further, the core 5 acts as a resistance in the extrusion molding machine 3 when the shape of the continuous molding band (hereinafter simply referred to as the molding band) A is made into various shapes as shown in FIGS. 2(a) to (j). ,
This is useful for eliminating unevenness in the density distribution of the forming band A and preventing cracking and deformation during drying and firing. Also, the middle child 5
As shown in FIGS. 3(b) and 3(C), the molding band A has a plurality of lattices 5a for forming hollow portions a, and air, hot air, cold air, dry air, and steam are supplied to the hollow portions a. The grid 5a is made into a pipe shape for forced feeding or discharge,
In addition, it is connected to a pump 7 and a suction/exhaust pipe 6 for sucking and exhausting air etc. from the outside. This is extrusion molding machine 3
By forcibly supplying or discharging air, hot air, cold air, or dry air to the hollow part a of the forming band A formed by
This is effective in significantly shortening the internal drying time. Reference numeral 8 denotes a driving conveyor, which is composed of one or more types of free rollers, driving rollers, belts, mesh belts (not shown), etc., and is capable of moving at the same speed as the forming band A extruded from the extrusion molding machine 3. This is a synchronized drive. Reference numeral 9 denotes a dryer, which surrounds a part or all of the driving conveyor 8 (not shown), and uses one or more types of infrared heaters, far-infrared heaters, microwaves, waste heat from a firing furnace 19 (described later), etc. It is effective for drying the molding zone A in a short time by the heat source 9a due to the synergistic effect with the air cycle of the hollow part a, and the moisture content of the clay 1 is reduced from, for example, 18 to 20% to about 0 to 5%. The purpose is to reduce the amount of carbon dioxide and strengthen shape retention, and to make it suitable for subsequent cutting and firing.

The dryer may be installed using infrared heaters, microwave only, or alternately, or divided into front and rear zones, and heats the atmosphere at a temperature of 200 to 500°C to prevent cracks or deformation of the fabric. It heats according to the curve. 10 is a running cutter, which cuts the dried forming band A.
The dried plate B is cut into a fixed length using a rotary blade, laser hydraulic pressure, and electric discharge machining to obtain a fixed length dry plate B. Of course, the traveling cutter 10 cuts in synchronization with the speed of the forming band A. Reference numeral 11 denotes a transfer machine that conveys the dry plate B cut into regular lengths by the traveling cutter 10 to the lower glaze applicator 12 at a faster speed than the driving conveyor 8, and transfers the forming band A and the dry plate B. This is useful for preventing collisions and for making the drying plate B into a continuous band with no gaps in the next process. The lower glaze applicator 12 includes one type of curtain flow coater, spray gun or roll coater (not shown), and coats the adhesive, waterproof layer, and decorative surface α of the unfired ceramic sheet 15, which will be described later.
It functions as a flatness improving material and a shrinkage absorbing material during firing.

Note that the lower glaze applicator 12 has a saucer 13 disposed directly below it to prevent the base glaze 14 from leaking to the outside. Further, the amount of base glaze 14 to be applied is selected depending on the purpose. 1
5 is an unfired ceramic sheet made of one or more of alumina sheet, calcium carbonate sheet, calcium silicate sheet, rock wool sheet, and other mineral fiber sheets. It is formed integrally with the glaze 14 interposed therebetween, and it is preferable that the shrinkage rate during firing substantially matches the shrinkage rate of the dry plate B. Note that the sheet 15 is not necessarily formed from only one type of component, but may be manufactured into a sheet by mixing several types of components and mineral fibers. Furthermore, the unfired ceramic sheet 15 may be made of one type, such as a decorative glaze, a material with any color or pattern drawn by printing, or a plain color. 3 is a laying auxiliary machine, which is composed of a guide roller 17, an auxiliary roller 17a, and a flattening auxiliary tool 18, as shown in FIG. It is useful for laying.

(3) is a firing furnace consisting of one type of roller hearth kiln or tunnel type firing furnace, and its configuration has a mountain-like temperature distribution from the inlet 19a to the outlet 19b, with the preheating area 20, the firing area 21, and the cooling area 22 in that order. The temperature of the preheating area 20 is 30 to 700°C, and the temperature of the baking area 21 is 30°C.
0-1300"C, cooling area 22 600-30"C
This is up to the highest level. Of course, depending on the type and composition of the clay, the temperature setting between each region will be different, and the temperature setting between each region is normal temperature - high temperature (1300°C) - room temperature, and the temperature between each region is not clearly divided but is continuous. This is a classification within firing. To explain the firing furnace in more detail, the firing furnace (2) burns combustible gas, such as LPG gas, to fire long dry boards, and the burners (not shown) for this purpose are arranged in the respective areas. This is provided in response to the

In addition, mesh belts, metal rollers, ceramic rollers, alumina rollers, etc. are used as the conveying means for the long drying plate DI7) in the firing furnace (2), but especially in the firing area 21, the temperature rises to about 1300'C. , for example, the fifth
As shown in the figure, an alumina roller 25 is placed between metal main shafts 23 and 24 to prevent heat from being transmitted to the drive source for conveyance. The firing area 21 of the firing furnace (2) is made of refractory bricks, etc., through which the air is passed continuously in a straight line, and an exhaust damper (not shown) is arranged between each device and area. It is something that should be set up. 26 is a cut portion where the unfired ceramic sheet 15 is fired and hardened to become the ceramic layer 15a;
The sensor 26a is used to read and separate the connected portion of the elongated fired plate E, which has become a continuous body due to the sensor 26a. 27
1 is a conveying machine, which is used to convey the ceramic plate F cut out by the cutting section 26 to the next process such as packaging.

Next, the operation will be explained. Therefore, as materials for clay 1, silica sand waste, several types of melting point depressants, and fiber minerals are prepared.

The weight percentage is 65% silica sand sludge, 25% melting point depressant (Kamato feldspar, sericite minerals, etc.), and Wollastonite O.
%, and to 100% by weight of this main raw material, 20% by weight of water and 0.3% by weight of sodium pyrophosphate as a deflocculant were mixed, and this was mixed in a clay kneading machine (Model MP-100 manufactured by Miyazaki Iron Works Co., Ltd.). It was kneaded with

In addition, the extrusion molding machine 3 has an extrusion capacity of 50 kg/c+II
The extrusion pressure was as follows. The pump 7 is set to exhaust at 58P, and the dryer mainly uses a microwave heating device and a far infrared heating device, and uses a calorific value equivalent to 35 kcal-h to evaporate the moisture in the forming zone A by convection, absorb and exhaust it. The moisture is reduced to about 0 to 5% in about 20 to 40 minutes by internal diffusion by exhausting hot air at about 30° C. from the tube 6, and the product is dried without deformation. Next, the dried forming strip A is cut into 3 m lengths by a traveling cutter 10.
The drying plate B is continuously fed by the transfer device 11 directly below the lower glaze applicator 12, and the base glaze 14 is applied to the decorative surface α. Next, on this decorative surface α, an unfired ceramic sheet 15 whose shrinkage rate is set to be almost the same as that of the drying plate B is placed on the decorative surface α of the glazed drying plate C, and is adhered by pressing.
to be sent to. This firing furnace (2) is formed in a roller hearth kiln structure, and the long dried boards are sequentially fed and conveyed to the rollers from the inlet 19a to the outlet 19b.
Preheating → firing → slow cooling and sending out a long fired plate E. Next, the connecting portion is cut off by the cutter 26 to form the ceramic plate F, which is transported by the transporter 27 to the next process such as a packaging process (not shown).

[Other Examples]

What has been described above is only one embodiment of the method for manufacturing a ceramic plate according to the present invention, and a glazing machine 28 for applying a glaze may also be installed as shown by the dashed line in FIG.

〔Effect of the invention〕

As described above, according to the method for manufacturing a ceramic plate according to the present invention, (1) the unfired ceramic sheet is integrally bonded to the decorative surface via the base glaze, so it can be formed without being influenced by the color of the raw material of the main body. ■Any pattern, color, design, or emboss can be formed on the unfired ceramic sheet before firing, resulting in a ceramic plate with a unique design. ■Waterproofness and frost resistance of decorative surfaces can be significantly improved. ■ Ceramic plates with dramatically improved design can be manufactured with good productivity and yield. It has the following characteristics and effects.

[Brief explanation of drawings]

FIG. 1 is an explanatory diagram showing a typical example of the method for manufacturing a ceramic plate according to the present invention, FIGS. 2(a) to (j) are explanatory diagrams showing an example of a continuously formed band, and FIGS. 3(a) to (C) is an explanatory diagram showing the cap, Fig. 4 is an explanatory diagram showing one embodiment of the laying auxiliary machine, and Fig. 5
The figure is an explanatory diagram showing an example of a firing furnace. 1... Clay, 3... Extrusion molding machine, 4... Mouthpiece, 5
... Core, 7... Pump, 9... Dryer, 10.
... Traveling cutter, 12... Lower glaze applicator, Tsukishi... Laying auxiliary machine, ■... Firing furnace. No.? Diagram (phantom chart diagram +4+ = C: 50 22ro... Kuchikuchi to Kuchi I#r Rororo 0 Rororororo 00ku Rororororororororororororo. Figure (To) Figure Cow Figure Figure

Claims (1)

[Claims] (1) A base glaze is applied to the surface of a dry extruded product made of clay and has a predetermined shape. Next, an unfired ceramic sheet with a pattern drawn on it is placed and adhered on top of the base glaze, and then fired. A method for producing a ceramic plate characterized by integrating the two.