JP2012040761A - Method and device for molding tile - Google Patents

Abstract

The present invention provides a tile molding method and a molding apparatus capable of molding various three-dimensional design surfaces having a large level difference without providing pressure adjusting depressions on the back surface and easily changing the design.
A tile molding method for molding a convex tile molded product having a base and a convex portion, wherein a base clay is formed from a first charger by an upper surface of a lower mold and an inner surface of a frame mold. Supplying the enclosed filling space, placing the convex clay from the second charger on the upper surface of the base clay filled in the filling space in the region where the convex is formed, And a step of lowering the mold and a step of pressure-molding the base clay and the convex clay with the lower surface of the upper mold and the upper surface of the lower mold.
[Selection] Figure 1

Description

  The present invention relates to a method and apparatus for forming a convex tile.

  In a conventional tile pressure forming method, a filling space surrounded by a frame mold is filled with a clay as a raw material, and this clay is pressure-molded with a front mold and a back mold for molding the back surface of the tile.

  The tile manufacturing method of Patent Document 1 includes a frame mold, a front mold having an uneven surface, and a back mold configured by a number of divided molds, each of which is a cylinder filled with a working fluid. A molding apparatus having a structure is used. Since the back mold that forms the back side of the tile is a plurality of split molds with a cylinder structure filled with working fluid, the split mold corresponding to that part is that of other split molds for the part where the pressure pressure increases It is possible to release the pressurizing pressure by lowering earlier than the pressure, and the divided mold corresponding to the portion where the pressurizing pressure is lowered is raised for the escaped pressure. Therefore, as a result, an uneven tile pressed with a uniform pressure is formed.

  In addition, the tile manufacturing method disclosed in Patent Document 2 includes a mold hole formed in a frame mold, a lower mold having a plurality of concave surfaces on the upper surface thereof, which can be moved up and down in the mold hole, and can be moved up and down at an upper portion of the lower mold. An upper die provided on the perforated plate, a perforated plate provided on the upper surface of one side of the frame die so as to be movable back and forth with respect to the mold hole, and a first raw material provided on the upper surface of the perforated plate so as to be movable back and forth with respect to the die A molding apparatus including a charging box and a second raw material charging box capable of moving back and forth with respect to the mold hole on the upper surface of the other side of the frame mold is used. Then, the first raw material charging box is advanced and the first raw material is charged into the concave surface through the raw material charging hole. The second raw material charging box is advanced over the mold hole and the second raw material is charged onto the lower mold. Lower the upper mold and pressurize the charged raw material. Through such a process, a convex tile is formed.

Japanese Utility Model Publication No. 6-53106 JP-A-10-128720

  However, in the tile manufacturing method of Patent Document 1, the divided mold corresponding to the portion where the pressurizing pressure increases corresponding to the surface mold having the uneven surface descends faster than the other divided molds. Then, the pressurizing pressure is released, and the split mold corresponding to the portion where the pressurizing pressure is lowered is raised for the escaped pressure. That is, it is possible to pressurize the tile with a uniform pressure by providing a pressurization adjustment recess at a position opposite to the convex portion on the back surface of the tile and making the thickness of the entire uneven tile substantially constant. However, dividing the lower mold in accordance with the design surface of the upper mold has great restrictions on mold production, and when changing the uneven shape of the design surface, the structure with the surface mold that forms the design surface is included. However, complicated division types must be exchanged. Therefore, the design change is not easy.

  Similarly, the tile manufacturing method of Patent Document 2 also states that “this tile base is formed by integrally forming a convex portion made only of the first raw material B on the surface of the tile body made of only the second raw material B, and on the back surface thereof. As described in “A foot forming groove is formed”, a pressure adjusting depression is provided on the back surface of the convex tile at a position opposite to the position of the convex portion. That is, it is possible to pressurize the tile with a uniform pressure by providing a concave portion at a position opposite to the convex portion on the back surface of the tile and making the thickness of the entire convex tile substantially constant. However, when forming an uneven tile having a large level difference, it is difficult to pressurize the tile with a uniform pressure. Moreover, when changing the uneven | corrugated shape of a design surface, you have to replace | exchange the upper mold | type which makes a pair with a lower mold | type with the lower mold | type which forms a design surface. Therefore, the design change is not easy.

  In recent years, a method of attaching the back surface of a tile with an organic adhesive instead of mortar is frequently used. Therefore, when using mortar, it is necessary to form a recess that allows the mortar to enter the back of the tile, but when using an adhesive, the back of the tile should be in surface contact with the application surface. Even if the back foot is eliminated or the back foot is provided, the height needs to be substantially constant in any part.

  However, the manufacturing method of the tile disclosed in Patent Document 1 is described in the specification as “Unevenness on the back side of a tile having an uneven shape with a large level difference, but the shape on the back side of the tile is particularly a surface. It is not necessary to be one, so there is no particular problem as a product. '' As described, it is possible to mold uneven tiles with large steps, but in order to pressurize the tiles with uniform pressure , The back of the tile must be greatly recessed. That is, when forming a concavo-convex tile having a large level difference, the back foot of the portion where the pressure adjusting depression is provided on the back surface of the tile becomes high.

  Similarly, in the tile manufacturing method of Patent Document 2, it is possible to form a convex tile having a large level difference, but in order to pressurize the tile with uniform pressure, a pressure adjusting depression on the back surface of the tile is used. Must be increased according to the convex part of the design surface.

  The problem to be solved by the present invention is to form a tile that can be easily changed in design, even if it is a convex tile with a large level difference, without forming a pressure adjustment recess in the region on the back side of the convex part. It is to provide a method and a molding apparatus.

According to the molding method of the present invention,
A method of forming a convex tile, comprising a base and a convex, wherein the surface of the convex forms at least part of the design surface,
An upper mold, a lower mold, a frame mold to which the upper mold and the lower mold are fitted, and
A first charger that supplies the first dredged soil,
A second charger supplying a second dredged soil,
Using a pressure molding apparatus comprising:
Supplying the first clay from the first charger to a filling space formed by the inner surface of the frame mold and the upper surface of the lower mold;
In a partial region of the upper surface of the first clay filled in the filling space,
Piling up the second clay from the second charger so that the pressure compression ratio of the base and the convex is equal;
Pressing the first clay and the second clay with the upper mold, the lower mold, and the frame mold; and
It is characterized by having.

  A preferred embodiment of the molding method of the present invention is a so-called front molding method in which the design surface is molded on the upper surface. That is, according to this aspect, the upper mold has an uneven surface for forming a design surface, and the upper mold is filled in the filling space in the region where the convex portion is formed. , Characterized by supplying a second clay.

  Another preferred embodiment of the molding method of the present invention is a so-called back surface molding method in which the design surface is molded on the bottom surface. That is, according to this aspect, the lower mold has an uneven surface for forming a design surface, and a convex portion of the design surface is formed on the upper surface of the first clay filled in the filling space. A second clay is supplied to a region facing the region.

The molding apparatus of the present invention is a tile molding apparatus used for the molding method,
An upper mold, a lower mold, and a frame mold in which the upper mold and the lower mold are respectively fitted;
A first charger for supplying a first clay to a filling space formed by the inner surface of the frame mold and the upper surface of the lower mold;
And a second charger for supplying a second clay to a partial region of the upper surface of the first clay filled in the filling space.

According to the present invention, when forming a convex tile having a large level difference, the tile can be uniformly pressure-molded without providing a pressure adjusting recess on the back surface of the tile. Therefore, since it is not necessary to provide a concave portion in the region on the back side of the convex portion on the back side of the tile, it is possible to eliminate the back foot on the back side of the tile or make the height of the back foot substantially constant in any part. . And since the shaping | molding apparatus of this invention does not need to use a split type for the upper mold | type and lower mold | die for forming a design surface, it can change easily an upper mold | type, a lower mold | type, and a 2nd charger. Therefore, it is possible to manufacture various convex tiles with a wide variety.

  ADVANTAGE OF THE INVENTION According to this invention, even if it is a convex tile with a big level | step difference, the shaping | molding method and shaping | molding apparatus of a tile which can be shape | molded without providing a pressure-adjustment hollow on the back surface, and can change a design easily are provided. it can.

The perspective view of the convex-shaped tile which is embodiment of this invention The perspective view of the shaping | molding apparatus which is embodiment of this invention Sectional drawing of the shaping | molding apparatus which is embodiment of this invention, and explanatory drawing of a shaping | molding process Sectional drawing of the shaping | molding apparatus which is embodiment of this invention, and explanatory drawing of a shaping | molding process

  Hereinafter, based on FIGS. 1-4, embodiment in the 1st aspect of this invention is described. FIG. 1 is a perspective view of a convex tile having a large level difference. FIG. 2 is a perspective view of a forming apparatus for forming a convex tile. 3 and 4 are cross-sectional views and process descriptions of the molding apparatus.

The tile molded product 6 of FIG. 1 includes a base portion 6a whose back surface is flat and a convex portion 6b formed on the front side of the base portion 6a. In the tile molded product, the base 6a and the convex portion 6b may not have a clear boundary. In the present invention, the size of the tile molded product 6 is preferably 16 cm ² to 900 cm ² . In FIG. 1, a tile having a flat back surface is illustrated, but the tile molded product formed according to the present invention may have a back foot on the back surface. When the back foot is formed, the surface other than the back foot on the back surface of the tile, that is, the tile bottom surface is flat. The term “flat” means that the height difference is substantially constant and there is no pressurization adjustment recess.

  According to the molding method of the present invention, the convex shape of the tile molded product is at least one of a convex portion having a non-uniform height depending on the portion and a convex portion having a ridge that is not parallel to the side of the tile molded product. A convex shape can be formed. The height of the convex portion 6b is preferably 3 mm or more and 5 cm or less, and more preferably 6 mm or more and 25 mm or less. In the present invention, even with a convex shape having such a large step, since the convex portion and the base portion are uniformly pressurized, it is possible to produce a tile without cracking and warping after firing. Become.

  FIG. 2 is an overall view of the molding apparatus 10 according to an aspect of the present invention. The mold 1 includes an upper mold 1a having a concave lower surface, a lower mold 1b having an upper surface, and a frame mold 1c into which the upper mold 1a and the lower mold 1b are respectively fitted. The concave shape of the lower surface of the upper mold 1a is formed corresponding to the convex shape of the surface of the tile molded product 6, and forms the design surface of the tile molded product. This concave shape is an indefinite or regular groove or indentation, and includes an “upper die 1a only” or “upper die 1a and frame die 1c” groove or indentation. According to a preferred embodiment of the present invention, the upper mold 1a and the lower mold 1b are not divided, but are integrated. Therefore, it is possible to easily change the shape of the design surface of the tile molded product by exchanging the design mold (in this example, the upper mold 1a) for forming the design surface and the second charger described later. .

  By fitting the lower mold 1b with the frame mold 1c, a filling space 12 is formed by the upper surface of the lower mold 1b and the inner surface of the frame mold 1c. The filling space 12 means a gap surrounded by the upper surface of the lower mold 1b and the inner surface of the frame mold 1c (even after being filled with the base clay 3 and the convex clay 5 described later). (Referred to as filling space 12). Next, the first clay is supplied to the filling space 12 from the first charger. The clay is a granule prepared for dry press molding, and is appropriately mixed with clay, feldspar, porcelain stone and the like. In this example, the first clay is a base clay 3 for forming a base, and the second clay is a convex clay 5 for forming a convex. Further, in this example, the first and second chargers are a raw material basket for supplying clay, that is, a first raw material basket 2 and a second raw material basket 4. The first raw material basket 2 fills the filling space 12 with the base clay 3 in the first raw material basket 2 while moving forward or backward horizontally on the upper surface of the frame mold 1c. Then, after the second raw material clay 4 for supplying the convex clay 5 moves to the upper surface of the base clay 3 filled in the filling space 12, the convex clay in the second raw material clay 4 is obtained. 5 is supplied to the upper surface of the base clay 3. Then, the lower mold 1b is lowered from the frame mold 1c, and at least a part of the convex clay 5 stacked on the base clay 3 on the upper surface of the lower mold 1b is surrounded by the inner surface of the frame mold 1c. Fit in the designated space. Then, the upper mold 1a is fitted to the frame mold 1c, and the base clay 3 and the convex clay 5 are pressed at once with the lower surface of the upper mold 1a, the upper surface of the lower mold 1b, and the frame mold 1c. A tile molded product 6 is manufactured.

  After press molding, the upper die 1a is raised and returned, and the upper surface of the lower die 1b is raised and returned until it is flush with the frame die 1c, or the frame die 1c is lowered and lowered until it is flush with the lower die 1b. The tile molded product 6 is demolded by a method such as The demolded tile molded product 6 is pushed out of the molding apparatus 10 by the next first raw material basket 2 or the second raw material basket 4 or transferred to a conveying device by a tile suction device having a suction cup. Thus, the process proceeds to the glazing process or the firing process. The tile molded product is baked or subjected to baking after glazing to complete the tile.

  Next, a process for forming a convex tile will be described in detail with reference to FIGS. 3 and 4A to 4H.

  FIG. 3A shows a state in which the base clay 3 is supplied to the filling space 12 formed by the upper surface of the lower mold 1b and the inner surface of the frame mold 1c. The first raw material basket 2 filled with the base clay 3 advances horizontally with the upper surface of the frame mold 1 c facing upward from the filling space 12, and supplies the base clay 3 into the filling space 12. The filling space 12 is filled with the base clay 3.

  FIG. 3B shows a projecting portion after the first raw material basket 2 has finished supplying the base clay 3 into the filling space 12 and the upper surface of the frame mold 1c has been retreated horizontally from above the filling space 12. The second raw material basket 4 filled with the working clay 5 represents a state where the upper surface of the frame mold 1c is advanced horizontally toward the upper side of the filling space 12. The second raw material clay 4 includes a shutter 4a for holding the convex clay 5 and can drop the convex clay 5 at a predetermined timing.

  FIG. 3C shows a state in which the second raw material clay 4 is lowered toward the upper surface of the base clay 3. Even at this time, the convex clay 5 is not dropped from the second raw material clay 4 onto the upper surface of the base clay 3.

  (D) of FIG. 3 opens the shutter 4a of the second raw material basket 4, and protrudes from the second raw material basket 4 to at least part of the region where the convex portion is formed on the upper surface of the base clay 3. This represents a state in which the part clay 5 is supplied. In order to make the pressure density of the base clay 3 and the convex clay 5 uniform at the time of pressure molding, the convex clay 5 is made higher than the convex part of the tile molded product, that is, An amount that is higher than the concave shape of the lower surface of the upper mold 1 a is supplied to the upper surface of the base clay 3. By doing in this way, it becomes possible to equalize the pressure compression ratio of the base part 6a and the convex part 6b of the tile molded product at the time of pressure molding.

  FIG. 4E shows a state where the lower mold 1b is lowered. The lower mold 1b is lowered, and the base clay 3 and the convex clay 5 on the upper surface of the lower mold 1b are made lower than the upper surface of the frame mold 1c. Therefore, the filling space 12 surrounded by the upper surface of the lower mold 1b and the inner surface of the frame mold 1c expands downward. By the steps of (D) and (E), the convex clay 5 is put on a part of the upper surface of the base clay 3. FIG. 3 (F) shows a state where the second raw material basket 4 that has finished supplying the convex clay 5 on the upper surface of the base clay 3 houses the shutter 4 a and rises above the filling space 12. To express.

  In FIG. 4G, after the second raw material basket 4 is returned to the original position in order to lower the upper mold 1a, the upper mold 1a is lowered and fitted to the frame mold 1c, and the upper mold 1a and the lower mold 1a are lowered. The state which pressurizes with the type | mold 1b and the frame type | mold 1c is represented. (H) in FIG. 4 represents a state in which the upper surface of the lower mold 1b is raised and restored until it is flush with the upper surface of the frame mold 1c after pressure molding. When the base clay 3 and the convex clay 5 are pressure-molded, the convex clay 5 is formed on the upper surface of the base clay 3 so as to correspond to the concave shape formed on the surface of the upper mold 1a. Because it is arranged, the back side of the tile is greatly recessed to correspond to the uneven shape with a large step, or the back foot forming groove on the back side of the tile is increased to correspond to the uneven shape with a large step, as in the past. There is no need to do it. Therefore, even when there is a large difference in the thickness of the tiles, the tiles can be uniformly pressure-molded with a single press-molding operation without providing a pressure adjustment recess on the back surface, and the tile bottom surface is flat. Can be molded into Furthermore, it is possible to easily change the shape of the design surface of the tile molded product by exchanging the design mold (in this example, the upper mold 1a) and the second raw material basket 4 for forming the design surface. Become.

  Another preferred embodiment of the molding method of the present invention is different from the first embodiment in that pressure molding is performed with the design surface of the tile molded product facing down and the back surface facing up. And according to this aspect, the 1st raw material straw supplies the convex part and the base clay for filling. The upper surface of the convex portion filled in the filling space and the base clay, the region where the convex portion is formed below (that is, the region facing the region where the convex portion is formed) A clay for pressure adjustment is piled up. By doing in this way, it becomes possible to make the press density of a thick part and a thin part uniform at the time of pressure forming.

  In the above example, the raw material basket 4 provided with a shutter is used for the second charger, but the shutter may not be provided. In such an embodiment, the convex-forming clay or the pressure-adjusting clay is directly supplied in a state where the raw material clay 4 without a shutter is lowered toward the upper surface of the base clay 3.

  According to the molding method of the present invention, it is possible to mold a convex tile without a back foot in one molding. Alternatively, according to the molding method of the present invention, it is possible to mold a tile having a convex design surface with a large step without providing a pressure adjustment recess, so that the shape of the back foot in a state where the tile is viewed from the back Can be freely designed without being restricted by the shape of the convex portion, and the height of the back foot of the tile can be made almost constant. According to the molding apparatus of the present invention, it is possible to easily change the design of a tile product simply by exchanging the design mold for forming the design surface and the second charger.

DESCRIPTION OF SYMBOLS 1 Mold 1a Upper mold 1b Lower mold 1c Frame mold 2 First raw material basket 3 Base material clay 4 Second raw material material 4a Shutter 5 Protrusion material 6 Tile molded product 6a Base 6b Protrusion 10 Molding device 12 Filling space

Claims (5)

A method of forming a convex tile, comprising a base and a convex, wherein the surface of the convex forms at least part of the design surface,
An upper mold, a lower mold, a frame mold to which the upper mold and the lower mold are fitted, and
A first charger that supplies the first dredged soil,
A second charger supplying a second dredged soil,
Using a pressure molding apparatus comprising:
Supplying the first clay from the first charger to a filling space formed by the inner surface of the frame mold and the upper surface of the lower mold;
In a partial region of the upper surface of the first clay filled in the filling space,
Piling up the second clay from the second charger so that the pressure compression ratio of the base and the convex is equal;
Pressing the first clay and the second clay with the upper mold, the lower mold, and the frame mold; and
A method for forming a tile, comprising: The upper mold has an uneven surface for forming a design surface,
The second clay is supplied to a region of the upper surface of the first clay filled in the filling space where the convex portion is formed.
The method of claim 1. The lower mold has an uneven surface for forming a design surface,
The second clay is supplied to a region of the upper surface of the first clay filled in the filling space that is opposed to a region where the convex portion of the design surface is formed. The method according to 1. A convex tile formed by the method according to any one of claims 1 to 3, comprising a base portion and a convex portion, and the surface of the convex portion forms at least a part of a design surface. A tile having a flat bottom surface. A tile forming apparatus used in the method according to any one of claims 1 to 3,
Upper mold,
With the lower mold,
A frame mold into which the upper mold and the lower mold are respectively fitted;
A first charger for supplying a first clay to a filling space formed by the inner surface of the frame mold and the upper surface of the lower mold;
A tile forming apparatus comprising: a second charger for supplying a second clay to a partial region of the upper surface of the first clay filled in the filling space.

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