JPH0469523B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention aims to solve the following problems.

(Industrial Application Field) The present invention relates to a method for forming wall materials such as inner wall materials and outer wall materials, floor materials, etc. (these are collectively referred to as wall materials, etc. in this specification).

(Prior art) Conventionally, this type of wall material was manufactured by compressing the material with a pressure roller during the process of placing the material on a belt conveyor and moving it (for example, in Japanese Patent Application Laid-Open No. (See Publication No. 54-123126). However, the above-mentioned pressurizing means has the disadvantage that the degree of compression of the object to be compressed cannot be made uniform, resulting in a crude product.

Therefore, between the above-mentioned pressure roller and the raw material, a commonly known endless belt (for example, JP-A-53
An attempt was also made to interpose a belt (see Japanese Patent No. 109,523) and apply pressure while moving the intervening belt, but there was a problem that the uniformity of the degree of compression could not be improved.

(Problems to be Solved by the Invention) The present invention eliminates the above-mentioned conventional problems and provides a product that can be manufactured with extremely high workability, and furthermore, the finished product has less compression unevenness and has a high degree of uniform compression. The purpose of the present invention is to provide a method for forming wall materials, etc., which makes it possible to do this.

The configuration of the present invention is as follows.

(Means for Solving the Problems) The present invention takes the measures as described in the claims above, and its effects are as follows.

(Function) The belts of the upper and lower conveyors are continuously moved in the same direction. In this state, molding material is continuously supplied onto the belt of the lower conveyor. The supplied material is continuously pressure-formed between the upper and lower belts facing each other as the belts move, while the degree of shrinkage is gradually increased.

(Example) Below, drawings showing examples of the present application will be described. In FIGS. 1 to 7, 1 indicates a roll forming machine. In this, reference numeral 2 denotes a lower endless belt conveyor, and drive rollers 3 and 4 are driven to rotate in the direction of the arrow via a well-known electric motor and reducer (not shown).
and an endless belt 5 stretched over them. Reference numeral 6 designates an upper endless belt conveyor, which, like the conveyor 2 above, has driving rollers 7, 8 and an endless belt 9.
It is composed of. These conveyors 2 and 6 are arranged side by side as shown in the figure, with respective portions of the surfaces of the belts 5 and 9 facing each other vertically at a predetermined interval. Stainless steel belts are used as both the belts 5 and 9, considering that the belts have little elongation and deformation, high hardness, and are resistant to rust. 11,12
1 and 2 are pressure rollers exemplified as pressure means, respectively, and are attached to the back sides of mutually opposing portions of the belts 5 and 9 of the respective conveyors 2 and 6. These pressure means may be pressure plates that contact the back surface of each belt with little friction.
The width of the belt 5 and the width of the peripheral surface 11a of the pressure roller 11 are the same, and the width of the belt 9 and the width of the peripheral surface 12a of the pressure roller 12 are the same. . Furthermore, the width of the circumferential surface 12a of the pressure roller 12 is smaller than the width of the circumferential surface 11a of the pressure roller 11, as shown in FIG. Also, as shown in FIG. 1, the opposing distance between the belts 5 and 9 on the upper and lower belt conveyors 2 and 6 is made smaller toward the terminal end of the belts 5 and 9 in the moving direction, so that the molding material described later is As it moves, the pressure is gradually increased. Further, the arrangement pitch of the upper and lower pressure rollers 11 and 12 is made smaller toward the end in the above-mentioned moving direction, so that the pressure applied from these rollers to the molding material via the belts 5 and 9 increases sequentially. It's getting old. Reference numeral 13 denotes heating means, which is provided to heat the molding material to a constant temperature (60 to 80°C) via belts 5 and 9. Such heating promotes pressure forming of the molding material (activates the binder aluminum phosphate in the molding material).
As the heating means, a far-infrared heater, an infrared heater, or the like is used. Next, reference numeral 14 denotes left and right lateral endless belt conveyors, which, like the conveyor 2 described above, are composed of drive rollers 15, 16 and an endless belt 17, and are adapted to move in the direction of the arrow at the same speed as the belt 5. These belts serve to prevent the molding material supplied onto the lower belt 5 from falling off the belt 5, and at the same time to hold down the molding material from both sides during pressure molding. The positional relationship of the belt 17 with respect to the belts 5 and 9 is such that its lower edge is in contact with the upper surface of the belt 5 and its surface is in contact with the side surface of the belt 9, as shown in FIG.
Further, as this belt 17, the belts 5, 9
A similar material is used. 18,1
8 is an auxiliary roller provided along the back side of the belt 17, and the belt 17 is
This is provided to prevent the belt from deforming in the direction away from the belt 9. Note that this auxiliary roller 18 is also arranged with a narrower pitch as it approaches the end in the moving direction, similar to the pressure roller.
The pressure applied to the molding material gradually increases. Next, 21 is another molding material supply device, and in this example, as shown in FIG. 4, a plurality of supply elements 22, 22, . . . are arranged in the width direction of the belt 5.
Consisting of 23 is a material supply device that supplies molding material (in this specification,
material (also referred to simply as molding material) can be uniformly supplied. Reference numeral 24 denotes a scraping plate, which is configured so that the molding material supplied onto the belt 5 from the supply device 23 can be made to have a uniform thickness over its entire width. It also has the ability to move up and down. Reference numeral 25 indicates a cutter of a molded product that has been press-molded. Reference numeral 26 is a conveyor for carrying out, and an arbitrary conveyor such as a belt or a roller conveyor can be used.

Next, the molding material and other molding materials used in the roll forming machine 1 will be explained.

For example, the molding material has a glass component (glass cullet) of 40 to 60% by weight.
The composition consists of 10-30% by weight of aluminum oxide (Al203), 10-25% by weight of clay component, and 5-15% by weight of binder (aluminum phosphate). A mixture having such a composition is placed in a ball mill or the like and mixed for an appropriate time to form a powder mixture of 100μ or less, and then
Water is added to form a slurry, which is then granulated using a spray dryer into particles with an average particle size of 60μ to 200μ. Other molding materials include, as mentioned above, 40 to 60% by weight of the glass component (glass cullet), 10 to 30% by weight of aluminum oxide (Al203),
It consists of a binder (aluminum phosphate) and 5% by weight of a coloring agent (a metal oxide or a metal compound that can be converted into an oxide by heating, such as a carbonate). A mixture having such a composition is granulated by the same method as described above.

Next, examples of the relationship between the types and colors of the colorants used as the above-mentioned colorants are as follows.

Red iron oxide (Fe203)...red (brick red), chromium oxide...green, titanium oxide...yellowish white, cobalt oxide...blue, iron oxide (Fe304)...black In other words, one of these types or a mixture of several types can be used. However, metal oxides not exemplified here can also be used as colorants.

Regarding the material used as the molding material, we have explained above that the composition does not contain a colorant, but for example, when making wall materials with a red color, red iron oxide (Fe203) can be used as a colorant. I will do it. Therefore, other molding materials used in conjunction with this molding material are of different colors, ie, materials that are a mixture of different types of metal oxides used as coloring agents.

Next, a procedure for manufacturing wall materials and the like using the above-mentioned molding machine and materials will be explained. First, the belts 5, 9, and 17 on each conveyor are continuously moved at the same predetermined speed. The speed is appropriately set, for example, within the range of 5 to 30 m/hour. In this case, when molding a thick wall material, etc., it is preferable to slow down the feed rate so that sufficient pressure is applied to the molding material. In the above state, other molding material 31 is supplied from each supply element 22 in the supply device 21 onto the belt 5 through its supply port 22a, as shown in FIG. 6A. Next, as shown in FIG. 6B, the molding material 32 is continuously supplied from the supply device 23 through the supply port 23a so as to cover the other molding material 31. Next, as shown in FIG. 6C, a scraper plate 24 is interposed between the belts 17, 17, and its lower edge 24a flattens the upper surface of the input material. In this case, if it is desired to further reduce the thickness of the molded wall material or the like, that is, if a thin plate is to be molded, this can be done by moving the slotted plate 24 further downward. In other words, by narrowing the interval (distance) between the lower edge 24a of the pickpocket plate 24 and the top surface of the belt 5, the thickness of the loaded material can be reduced by that amount. As the belt 5 moves, the material whose surface has been smoothed as described above reaches the opposing portion between the belts 5 and 9, where it is gradually pressurized from above and below, and from the sides by the belt 17. Pressure is gradually increased. Then, it is press-formed to a predetermined thickness by pressure rollers 11' and 12' at the final stage. The above-described forming is performed continuously as the belts 5, 9, and 17 move. In addition, the molding pressure is applied by the final stage pressure roller 11',
12' is set to, for example, 600 Kg/cm ² . And the molded thing is a guillotine style cutlet 2
5 or cut into a predetermined size using a well-known cutting saw, resulting in a wall material 33 as shown in FIG. The wall materials and the like are transferred to the next firing process by a conveyor 26. In the firing process, the wall material etc. 33 is placed in a firing furnace such as a roller hearth kiln, and heated at a temperature of, for example, 650 to 800°C.
It is baked for about 5 hours.

Since the molding material 32 and the other molding material 31 are of the same quality, the wall material etc. 33 fired as described above is made into porcelain in an integrated state. In other words, the fired wall material is densified to the same degree as the molding material even in areas where other molding materials are present. Therefore, the wall materials, etc. maintain the original excellent properties of the material, such as hygroscopicity and mechanical strength, throughout the entire area.

The wall materials etc. 33 fired as described above are cut with a chipsaw or the like as necessary on the peripheral side to give an appropriate finish, and then transferred to the final polishing process, so that the surface on which the pattern is exposed is polished. The product is polished to a glossy surface.

In the above manufacturing process, each supply element 22 may supply another molding material of the same color or a different color. Also, by continuously supplying other molding materials from each supply element, a striped pattern is created in the finished wall material, etc., and by intermittently supplying other molding materials from each supply element, , dotted patterns appear on wall materials, etc. Furthermore, by repeatedly moving each supply element 22 in the width direction of the belt 5 while supplying the other molding material described above, a wavy pattern can be created on the wall material or the like. The intermittent supply of other molding materials as described above or the control of the movement of the supply element 22 in the width direction may be performed manually by an operator or automatically by a control device such as a computer.

Furthermore, when forming wall materials etc. as mentioned above,
The front and rear positions of the other molding material supply device 21 and the material supply device 23 may be interchanged. In this case, the wall material or the like can be molded with the pattern exposed on the side facing the belt 9. In that case, in the molding material supplied from the supply device 23, a groove is formed at a position corresponding to the position where the other molding material is supplied, and by supplying the other molding material to the groove. , the thickness of the entire material between the upper and lower belts 9 and 5 can be made approximately uniform. Furthermore, when molding a wall material or the like as described above, the thickness of the pattern may be arbitrary. If necessary, the thickness may extend from the upper surface to the lower surface of the wall material 33.

Next, FIGS. 8 to 11 showing different embodiments of the present application will be described. This example shows an example in which a striped pattern is formed by a pattern forming plate after another forming material is uniformly supplied over the entire width of the belt. In the figure, another molding material supply device 2
1e is configured to be able to supply other molding material uniformly over the entire width of the upper surface of the belt 5e. Reference numeral 35 denotes a pattern forming plate, which has a large number of comb-like teeth 35a on its lower edge. This pattern forming plate is provided on the rear side of another molding material supply device 21e, as shown in FIG. Incidentally, the above-mentioned large number of teeth 35a may each have a different arbitrary shape, or may have various mutual spacings. Furthermore, pattern forming board 3
5 may be moved back and forth in the width direction of the belt 5e.

In the case of such a structure, as shown in FIG.
After being almost uniformly supplied onto the surface of the molding material 31e, the other molding material 31e is formed into a plurality of strips by the teeth 35a of the pattern forming plate 35, as shown in FIG. Thereafter, as shown in C and D, the supply of the molding material and the smoothing of the surface are carried out in the same manner as in the previous embodiment, and further pressure molding is carried out to form the wall material 33e as shown in Fig. 11. can get.

It should be noted that the same reference numerals as those in the previous figure are appended with an alphanumeric letter "e" for parts that are functionally the same or equivalent to those in the previous figure, and redundant explanations are omitted.
(Furthermore, in the following figures, the same idea is applied sequentially to alphabets f and g, and redundant explanations are omitted.) Next, Figs. 12 to 14 show further different embodiments of the present application. This is an example of a product in which the surface of a wall material or the like is provided with transparent glass so that a product with a three-dimensional pattern can be molded. In the figure, reference numeral 37 denotes a glass material supplying device, which is capable of supplying glass powder (glass cullet) 39 made of the same material as the glassy component contained in the molding material onto the belt 5f over its entire width. 38 is a suri-kiri board.

In the above configuration, belts 5f, 9f
Along with the movement of the wall materials, etc., the molding of wall materials, etc. is performed in the order shown in FIGS. 13A to 13F. That is, first, as shown in A, the glass material supply device 37 is placed on the belt 5f.
Glass material 39 is supplied from. Next, as shown in (B), the glass material 39 is smoothed to a uniform thickness using a scraping plate 38. Next, as shown in c, another molding material 31f is supplied thereon,
Next, as shown in d, a linear pattern of another molding material 31f is formed by the pattern forming plate 35f. In this case, the lowered position of the pattern forming plate 35 is such that the other molding material 31f forms a linear pattern and the glass material 39
It is best to lower it to a position that will not cause it to collapse significantly. Next, as in the previous case, the molding material 32f is supplied as shown in E, and the surface is smoothed with a scouring plate 24f as shown in F. Thereafter, pressure forming is performed in the same manner as described above, and a wall material 33f as shown in FIG. 14 is obtained. When such a wall material or the like is fired, the glass material 39 on the surface thereof is melted and becomes glass-like.

Next, FIGS. 15 and 16 show further different embodiments of the present application. In the figure, reference numeral 41 denotes an adhesive applicator which applies an adhesive or adhesive to the surface of the belt 5g at a position corresponding to the pattern to be formed. A nozzle designed to spray 5 g is used. 42 indicates an air nozzle.

In the case of such a configuration, the belt weight is 5g.
In the moving process, the adhesive applicator 41
Adhesive or adhesive is applied to the surface of the belt 5g at locations corresponding to the pattern to be formed. Next, add 3 pieces of other molding material onto 5 g of the belt.
1g is uniformly supplied across the entire width. Next, the other molding material 31g on the belt 5g is blown away by the air blown out from the nozzle 42. As a result, on the surface of the belt 5g, other molding material 3 was applied only in the areas where the adhesive or adhesive had been applied.
1g remains. Thereafter, supply of molding material and pressure molding are performed in the same manner as described above, and 33 g of wall material etc. as shown in FIG. 16 is obtained.

According to the method described above, the other molding material 31g on the belt 5g does not shift in position during any of the feeding process of the molding material 32g, the leveling process of its surface, and the process of pressure forming, and the contour is maintained. It becomes possible to make wall materials, etc. that have a sharp pattern. In addition, the above-mentioned adhesive or pressure-sensitive adhesive should not cause any part of the molding material or other molding material to adhere to and remain on the belt 5g during pressure molding, or to not remain as carbon after the molded body is fired. It is better to use something like this. As such, it is preferable to use a common synthetic resin adhesive or pressure-sensitive adhesive.

Furthermore, the thickness of the pattern on wall materials etc. formed as described above is sufficiently thicker than that of conventional glazes, and the pattern will not disappear even if the surface on which the pattern is exposed is polished as described above. There's nothing wrong with that. In this specification, such a thickness will be referred to as a large thickness.

(Effects of the Invention) As described above, in the present invention, when molding the wall material 33, the upper and lower belts 5 and 9 are continuously moved, and the molding material 32 is placed on the lower belt 5 in the state of By continuously supplying the material, the material can be press-formed continuously as the belts 5 and 9 move, and the wall material etc. can be formed with extremely high workability.

Moreover, in the case of the above-mentioned pressure forming, in the present invention, the two belts 5 and 9 are both made of stainless steel, and the elongation and extension ratio are extremely small. etc.), the above-mentioned stainless steel plate can act as a press plate with a large thickness, and has the advantage of pressurizing the molded product with less compression unevenness.

Further, the interval between the two belts 5 and 9 is set to become smaller and narrower in the direction of movement of the molding material, and the pressure rollers (11, 12, etc.) are arranged to face each other vertically, and the pitch of the pressure rollers is Since the material 32 is successively smaller and more precisely arranged in the direction of movement of the molding material, the degree of curvature of the stainless steel belt can be reduced and its durability can be increased. The pressure is applied sequentially in the moving direction, and the degree of contraction has the effect of increasing successively in the moving process. Increasing the degree of shrinkage during this movement increases the grain density of the material while applying vibration, which has an excellent effect in reducing unevenness in the material and increasing the degree of uniform compaction.

Furthermore, since the belts 5 and 9 are made of stainless steel, their surfaces are smooth and have a rust-proofing effect, so the surface of the molded product can be finished smoothly, and the product can be easily released from the belt. This method is effective in obtaining molded products with beautiful surfaces, and also has good wear resistance, which prevents metal powder from being mixed into the molding material.

Furthermore, since the driving rollers 7, 8, 3, and 4 have large diameters, even if the belt is made of stainless steel, the degree of detachment is small.On the other hand, the pressure roller 1 with a small diameter
1 and 12 as well as other devices as shown in FIG.

Furthermore, in the present invention, the lower belt conveyor is made longer toward the rear than the upper belt conveyor, and the molded product that has been press-molded is transferred to the drive roller located at the end of the lower belt conveyor. Since the molded product is separated at the top using a cutter, the molded product can be sent to the next stage with less bending.

[Brief explanation of drawings]

The drawings show an embodiment of the present application, in which Fig. 1 is a schematic vertical cross-sectional view of a roll forming machine, Fig. 2 is a plan view of the roll forming machine with the upper conveyor removed, and Fig. 3 is a - 4 is a side view showing the relationship between the lower conveyor and other molding material supply devices, FIG. 5 is a perspective view of a pickpocket board, and FIG. FIG. 7 is a perspective view of wall materials, etc., FIG. 8 is a vertical cross-sectional partial view showing a different embodiment, FIG. 9 is a perspective view of a pattern forming plate, and FIG. 10 is forming of wall materials, etc. by the apparatus shown in FIG. 8. 11 is a perspective view of the wall material, etc., FIG. 12 is a longitudinal cross-sectional partial view showing a further different embodiment, FIG. 13 is a process diagram of the process of forming the wall material, etc. using the apparatus shown in FIG. 12, and FIG. 14 is a perspective view of the same wall material, etc.
FIG. 15 is a partial longitudinal sectional view showing a further different embodiment, and FIG. 16 is a perspective view of a wall material etc. formed by the apparatus shown in FIG. 15. 2, 6... Endless belt conveyor, 5, 9... Belt, 11, 12... Pressure roller, 21... Other molding material supply device, 23... Material supply device, 31... Other molding material, 32... Molding material.

Claims (1)

[Claims] 1. Two endless belt conveyors, each made of a stainless steel belt, are arranged vertically facing each other with a space between the belt surfaces of each conveyor, and the interval is vertically increasing in the direction of movement of the molding material. The distance between the belts is set to be narrow, and the diameter of each drive roller on each conveyor is made large so that a pressure roller storage space can be formed inside the supporting endless belt. , a plurality of pressure rollers having a diameter significantly smaller than that of the drive roller are attached to the back side of each of the mutually opposing portions of the two belts, and the arrangement pitch of the plurality of pressure rollers is the same as that of the upper and lower rollers. The positions are set so that they match in the vertical direction and gradually become smaller in the direction of movement of the molding material, and on the other hand, the molding material and the surface of the molded product are placed on the belt of the lower conveyor. The opposing belts of both conveyors are continuously moved in the same direction while continuously supplying the pattern material to be delivered, and while the belts are moving, the supplied molding material is transferred to the mutually opposing upper and lower belts. Pressure forming is carried out while the degree of reduction is successively increased between the belts, and the press-formed molding material is advanced while being pressed by endless belts placed on both sides, and further The belt conveyor is longer toward the rear than the upper belt conveyor, and the molded product that has been press-molded is separated by a cutter on a drive roller located at an end of the lower belt conveyor. How to form wall materials, etc.