JP2016097537A - Method for manufacturing ceramic product - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a ceramic product manufacturing method that can manufacture a ceramic product imitating natural uneven weathering.SOLUTION: A ceramic product manufacturing method includes: a molding step of molding a base material, obtained by kneading a ceramic material into a clay-like state, to form a molding 10; an aggregate dispersion step of irregularly dispersing aggregates 16, comprising the base material obtained by kneading the ceramic material into the clay-like state and having non-uniformity in size and shape, into a surface of the molding 10; an aggregate joining step of crushing the aggregates 16 on the surface of the molding 10 to join them to the molding 10; and a firing step of firing the molding 10 to which the aggregates 16 have been joined.SELECTED DRAWING: Figure 6

Description

  The present invention relates to a method for manufacturing a ceramic product, and more particularly to a method for manufacturing a ceramic product that simulates natural weathering.

  In ceramic products for construction such as tiles, there is a case where a design imitating natural weathering is required for the purpose of creating historical feeling and profound feeling. As a means for imparting a weathered texture to a ceramic product, as described in Patent Documents 1 to 3, a method of processing the product surface by forming colors or irregularities is employed.

Japanese Patent Laid-Open No. 6-304917 Japanese Patent Laid-Open No. 11-42453 JP 2001-322864 A

  In the case of forming a coloring or a concavo-convex structure on a large number of similar products, the pattern of the chromatic or concavo-convex structure is often similar in each individual product. In particular, in Patent Document 3, a concavo-convex structure is formed by pressing a tile before firing on a pressing table on which protrusions are arranged. As long as the same pressing table is used, the uneven pattern provided on the tile is It will be the same or similar. However, the natural weathering phenomenon usually occurs spatially non-uniformly, and if it is similar between individual products, the impression that it has been subjected to natural weathering is lost. In particular, in products that are used side by side, such as tiles, if the colored and uneven patterns are similar among the arranged individuals, an artificial impression is likely to be given. In other words, natural weathering cannot be expressed sufficiently.

  The problem to be solved by the present invention is to provide a method for producing a ceramic product, which can produce a ceramic product imitating non-uniform weathering due to nature.

  In order to solve the above-mentioned problems, a method for producing a ceramic product according to the present invention includes a molding step of forming a green body by kneading a ceramic material into a clay shape, and a ceramic material on the surface of the molded body. An agglomerate dispersion step of irregularly dispersing aggregates having a non-uniform size and shape, and crushing the aggregates on the surface of the molded body to form the molded body The present invention has a gist of having an aggregate bonding step for bonding to an aggregate and a firing step for firing the molded body bonded to the aggregate.

  Here, it is preferable that the aggregate joining step is performed by hitting the surface of the molded body in which the aggregate is dispersed.

  Furthermore, it is preferable that the aggregate dispersion step is performed by a scraping step in which the surface of the molded body is scraped to use the substrate constituting the scraped molded body as the aggregate.

  In this case, a powdery ceramic material may be sprayed on the surface of the molded body before the scraping step.

  And in the said shaping | molding process, it is good to form a groove | channel on the surface of the said molded object.

  Moreover, it is good to disperse | distribute a powdery ceramic material on the surface of the said molded object before or after the said particle | grain joining process.

  The ceramic product is preferably a tile.

  In the method for producing a ceramic product according to the invention, in the aggregate dispersion step, the aggregate made of the base material dispersed on the surface of the molded body is joined while being crushed in the aggregate joining step. By these steps, an uneven structure is formed on the surface of the molded body. Furthermore, a ceramic product having a concavo-convex structure as if formed by weathering due to natural wind and rain can be obtained through a firing step. Here, agglomerates having nonuniformity in size and shape are irregularly dispersed and joined to the surface of the molded body while being crushed, so that the uneven structure formed on the surface of the molded body has a nonuniform shape and distribution. It will be a thing with. Thereby, the similarity between individuals can be avoided and the ceramic product which imitated the non-uniform weathering by nature can be obtained.

  Here, when the aggregate bonding step is performed by hitting the surface of the molded body in which the aggregate is dispersed, the step of crushing the aggregate and the step of bonding to the surface of the molded body are performed simultaneously and efficiently. Can be executed.

  Further, when the aggregate dispersion process is performed by a scraping process in which the surface of the molded body is scraped and the base material constituting the scraped molded body is an aggregate, the aggregate dispersion process may be simply executed. Can do. Moreover, it is easy to obtain an aggregate having nonuniformity in size, shape, and spatial distribution. Furthermore, since a groove-shaped concave structure is formed on the surface of the molded body after being scraped out, it is easy to form a large unevenness on the surface of the molded body.

  In this case, when the powdered ceramic material is sprayed on the surface of the molded body before the scraping step, the sprayed powder becomes a nucleus, and the formation of aggregates is promoted. Thereby, the efficiency of a scraping process can be improved.

  And if a groove | channel is formed in the surface of a base material in a shaping | molding process, it will become easy to scrape out the base material from the surface of a molded object in the following scraping process. This also increases the efficiency of the scraping process.

  In addition, when the ceramic product to be manufactured is a tile, non-uniform weathering due to nature can be expressed well even if a large number of tiles are arranged side by side by forming the uneven structure unevenly. Moreover, since the tile has a planar shape, it is easy to execute the aggregate dispersion step and the aggregate joining step.

It is a perspective view which shows the molded object used in the manufacturing method of the ceramic product concerning one Embodiment of this invention. It is a schematic diagram which shows the 1st powder spraying process which sprays a powder material on a molded object. (A) is a perspective view which shows a dental appliance, (b) is a schematic diagram which shows the scraping process performed using a dental appliance. It is a perspective view which shows the state which passed through the scraping process. It is a schematic diagram which shows the 2nd powder spraying process which sprays a powder material after a scraping process. (A) is a perspective view which shows a plate-shaped instrument, (b) is a schematic diagram which shows the aggregate joining process performed using a plate-shaped instrument. It is a perspective view which shows the state which passed through the aggregate joining process. It is a perspective view which shows the state which passed through the chamfering process. It is a photograph which shows an example of the tile obtained.

  Hereinafter, the manufacturing method of the ceramic product concerning embodiment of this invention is demonstrated, referring drawings. Below, the case where a ceramic tile is manufactured is demonstrated as an example of a ceramic product.

(Manufacturing process)
The manufacturing method includes (1) a molding step, (2) a first powder spraying step, (3) a scraping step, (4) a second powder spraying step, (5) an aggregate joining step, (6) a chamfering step, ( 7) Each manufacturing process of a baking process is included. Below, each process is demonstrated.

(1) Molding Step First, in the molding step, a molded body 10 that becomes a tile base is manufactured. Specifically, first, water is appropriately added to a ceramic material derived from a mineral or the like and kneaded into a clay shape to produce a base (also referred to as dough or clay). Then, the substrate is extruded into a long rectangular shape using an extrusion molding machine, and the substrate is cut into a desired length using a cutting means such as a metal wire. Thereby, the substantially rectangular parallelepiped shaped molded body 10 as shown in FIG. 1 is formed. Here, the molded body 10 has a shape in which two tile shapes (11a, 11b) are joined on the back surface, and is used for division for division after firing at the boundary between the two pieces (11a, 11b). A groove 12 is formed. A plurality of processing grooves 14 are formed on the surfaces 13 of the two tiles along the extrusion direction. The dividing groove 12 and the processing groove 14 can be formed by providing a structure corresponding to the shape of the extrusion port portion of the extrusion molding machine.

(2) First powder spraying step Next, as shown in FIG. 2, in the first powder spraying step, on the surfaces 13 and 13 on both sides of the molded body 10 on which the processing groove 14 is formed, a ceramic material is used. The first powder 20 is sprayed. The first powder 20 may be made of a ceramic material common to the substrate constituting the molded body 10 or may be made of a different ceramic material, but unlike the substrate constituting the molded body 10, the water content is low. It is made of a powdery ceramic material with high fluidity such as sand, and has a smaller particle size than the aggregate 16 described later. In addition, each process after this process is performed with respect to each surface 13 and 13 of the both sides of the molded object 10 used as the surface of two tiles, Moreover, the some molded object 10 is put in order and several molded object 10 is arranged. However, for easy understanding, the processing on one surface 13 of one molded body 10 is illustrated and described.

(3) Scraping step Next, in the (3) scraping step, the surface 13 of the molded body 10 on which the first powder 20 is dispersed is scraped using the tooth-like appliance 30. As shown in FIG. 3A, the tooth-like instrument 30 has a shape in which teeth 32 made of a large number of nails protrude from one surface of a plate 31 made of wood or the like. Here, the teeth 32 have an irregular arrangement that deviates from the regular arrangement in which the rows are aligned vertically and horizontally.

  The plate 31 of such a tooth-like instrument 30 is gripped from the surface on which the teeth 32 do not protrude, and the teeth 32 are applied to the surface 13 of the molded body 10 as shown in FIG. Then, while rotating as indicated by the arrow D 1, translational movement is performed as indicated by the arrow D 2, and the entire surface 13 of the molded body 10 is scratched by the tips of the teeth 32. When the surface 13 of the molded body 10 is scratched by the teeth 32, the scraped portion of the substrate is scraped to form a groove-like concave structure 15, and the scraped substrate is sprinkled with the first powder. Aggregates 20 as nuclei to form aggregates 16.

  In this way, the entire surface 13 of the molded body 10 is scraped with the tooth-like device 30, and all the aggregates 16 that have fallen to the outside of the molded body 10 are collected within a recoverable range and dispersed over the entire surface 13 of the molded body 10. Let Then, as shown in FIG. 4, the concave structure 15 is irregularly formed on the entire surface 13 of the molded body 10, and the aggregates 16 of base materials having various sizes and shapes are irregularly dispersed on the surface 13. Is obtained. The processing groove 14 formed on the surface 13 of the original molded body 10 is not substantially retained in its original shape by forming a large number of concave structures 15 by the (3) scraping process.

(4) Second powder spraying step Next, in (4) the second powder spraying step, as shown in FIG. 5, the second powder 40 made of a ceramic material is applied to the surface 13 of the molded body 10 in which the aggregates 16 are dispersed. Spray. Then, the second powder 40 is applied to the surface of the aggregate 16 by dispersing the aggregate 16 again on the surface 13 of the molded body 10 on which the second powder 40 is dispersed. The second powder 40 used here may be the same as or different from the first powder 20 dispersed in the (2) first powder dispersion step, It is made of a powdery ceramic material having a low water content and high fluidity such as sand, and has a particle size smaller than that of the aggregate 16. From the viewpoint of simplifying the manufacturing process, the second powder 40 may be the same as the first powder 20.

(5) Aggregate Bonding Step Next, in the (5) aggregate bonding step, the aggregate 16 is crushed and bonded to the surface 13 of the molded body 10. Here, the plate-shaped instrument 50 as shown to Fig.6 (a) is used. The plate-like instrument 50 is provided with a gripping portion 52 at one end of a flat plate portion 51 made of wood or the like.

  As shown in FIG. 6B, the surface 13 of the molded body 10 in which the aggregate 16 is dispersed on the plane of the flat plate portion 51 is gripped from above the aggregate 16. Strike (arrow D3). As a result, the aggregate 16 is crushed and flattened, and is pressed against the surface 13 of the molded body 10 and joined to form a joint convex portion 16 ′. When the entire surface 13 of the molded body 10 is struck with the plate-like instrument 50, a joint convex portion 16 'is formed on the entire surface 13 as shown in FIG. 7, and a convex having an irregular size, shape and arrangement like a cloud. The structure covers the surface 13 of the molded body 10.

(6) Chamfering step Next, in the (6) chamfering step, the molded body 10 having the convex structure obtained above is rolled on a plane such as a work table. Thereby, the edge of a molded object and the corner | angular corner | angular part are shaved, and the outer edge 17 of the molded object 10 will be in the rounded state like FIG.

(7) Firing step Finally, the obtained molded body 10 is appropriately dried, and then (7) the firing step is performed without using glaze at a temperature according to the composition of the substrate. Then, the tiles in a state where the two sheets are combined on the back surface are divided one by one in the dividing groove 12. An example of the tile thus obtained is shown in the photograph in FIG.

(The state of the ceramic product obtained and the contribution of each process)
As described above, in this production method, in the (3) scraping step, aggregates 16 having a nonuniform size and shape and irregular arrangement are formed. And (5) In the aggregate joining step, the aggregate 16 is crushed and joined to the surface 13 of the molded body 10. When the aggregate 16 is crushed by the plate-like instrument 50, the irregularity of its shape and size further increases. Thus, without using an auxiliary member that defines the pattern of the concavo-convex structure such as a transfer mold, the concavo-convex structure is formed by forming the aggregate 16 by scraping the substrate and crushing the aggregate 16. The concavo-convex structure is formed while being controlled by various accidental factors such as the magnitude and direction of the force applied during scraping or crushing. Thereby, an irregular uneven structure as shown in FIG. 9 can be formed on the tile surface 13.

  When ceramic products such as bricks and tiles undergo natural weathering, the surface 13 is spatially unevenly shaved and irregular irregular structures are formed, so that irregularities formed in this manufacturing method are formed. The rough structure has an appearance similar to natural weathering. Further, as described above, since the auxiliary member that defines the pattern is not used to form the concavo-convex structure, the pattern of the concavo-convex structure is unlikely to be the same between individual tiles. Therefore, even when a plurality of tiles are arranged side by side on the wall surface of the building, it is difficult to give a sense that the unevenness is artificially formed, and an impression close to natural weathering can be given. The base material constituting the molded body 10 and the aggregate 16 is made of red ceramic material such as brick, and the outer wall of the building is constructed using tiles having such irregular uneven structure. For example, even if it is a new building, it is possible to produce a rich atmosphere and luxury that have gone through history as if an old building made of brick was weathered.

  In this manufacturing method, (3) in the scraping step, the base material on the surface 13 of the molded body 10 is scraped out with the teeth 32 of the tooth-like device 30, so that the agglomeration force of the clay-like base material is used to spontaneously congeal. A collection 16 is formed. At this time, aggregates 16 having various sizes and shapes are obtained depending on variations in various parameters such as the magnitude and direction of the force applied from the teeth 32 to the surface 13 of the molded body 10 and the already formed aggregate 16. . From the viewpoint of increasing the variation in size and shape of the aggregate 16, it is preferable that the arrangement of the teeth 32 of the dental appliance 30 deviate from the regular arrangement in the vertical and horizontal directions as described above. Further, in the (3) scraping step, when the movement pattern in the rotational direction (arrow D1) and translational direction (arrow D2) of the dental instrument 30 is regular due to operator's wrinkles or the like, the frequency It is preferable that the teeth 32 are arranged so as not to line up in the high movement direction. As described above, when the tooth-like appliance 30 is manufactured by driving nails into the plate material 31, the arrangement of the teeth 32 can be easily adjusted by adjusting the arrangement and direction of the nails.

  In addition, (3) the size of the aggregate 16 formed in the scraping step is determined depending on the type of substrate constituting the molded body 10, the density of the teeth 32 of the dental device 30, and the surface 32 of the molded body 10 from the teeth 32. It varies depending on the magnitude of the applied force. The size of the aggregate 16 may be appropriately selected according to the concavo-convex structure to be formed. However, from the viewpoint of simulating natural weathering in the brick, the size of the aggregate 16 is about 1 mm to 1 cm in diameter. Preferably there is.

  In the above embodiment, after the (3) scraping step, the aggregates 16 that have dropped from the surface 13 of the molded body 10 are all returned to the surface 13 of the molded body 10 within a recoverable range. In this case, the substrate constituting the molded body 10 is used for forming the concavo-convex structure without excess or deficiency, and the concavo-convex structure can be effectively formed while suppressing the material cost. However, the distribution density of the aggregates 16 can be appropriately adjusted according to the density of the uneven structure to be formed. For example, a part of the generated aggregate 16 may be distributed on the surface 13 without returning to the surface 13 of the molded body 10. Alternatively, in addition to the aggregate 16 generated in the scraping step (3) from the molded body 10 to be tiled, the aggregate 16 generated using another separately prepared substrate is dispersed on the surface 13 of the molded body 10 to be tiled. May be. In addition, from the viewpoint of forming a concavo-convex structure having various appearances on the tile surface, in addition to the agglomerates 16 generated by the (3) scraping process from the base of the molded body 10, agglomerates composed of different types of ceramic materials, etc. Another material may be mixed and spread on the surface 13 of the molded body 10.

  Further, in the present embodiment, the base 16 is scraped from the surface 13 of the molded body 10 (3) The agglomeration 16 is generated and dispersed by the scraping step, which is highly non-uniform as described above. This contributes to the easy formation of the aggregate 16, but in addition, a groove-like concave structure 15 is provided on the surface 13 of the molded body 10 after being scraped, thereby forming a large unevenness difference. Contribute. Moreover, the effect that the irregularity of the concavo-convex structure formed through the following (5) aggregate joining step is increased due to the diversity of the positional relationship between the concave structure 15 and the generated aggregate 16. . Further, (3) when the aggregates are generated and dispersed by the scraping step, the plurality of molded bodies 10 are arranged side by side as described above, and the surfaces 13 of the molded bodies 10 are collectively placed with the tooth-like appliance 30. Therefore, the aggregates 16 can be generated and dispersed at a time for a large number of molded bodies 10 even by manual work.

  However, the formation and dispersion of the aggregates 16 are not necessarily performed by the (3) scraping process as described above, and the appropriately formed aggregates 16 are formed on the surface 13 of the molded body 10 by any aggregate dispersion process. What is necessary is just to disperse. For example, after forming the aggregate 16 using a base material different from the molded body 10 to be tiled, on the surface 13 of the smooth molded body 10 or the surface 13 of the molded body 10 appropriately formed with a concave structure, What is necessary is just to disperse. In this case, the substrate constituting the aggregate 16 may be the same as or different from the substrate of the molded body 10 to be a tile. As described above, when the aggregate 16 is generated and dispersed by the (3) scraping process, the process can be simplified. On the other hand, when the separately formed aggregate 16 is dispersed, A high degree of freedom can be obtained in the formation of the structure.

  (5) The agglomerate joining step is not necessarily performed using a flat plate member such as the plate-like instrument 51, but the surface 13 of the molded body 10 in which the aggregates 16 are dispersed using the flat plate member. , The top of the aggregate 16 that was granular can be flattened, and a concavo-convex structure in which the top of the convex is flat can be obtained. This is very similar to the uneven structure that was created by the natural smooth weathering of the surface of tiles and bricks that were originally smooth. Further, by adopting a method of hitting using the plate-like instrument 51, if a plurality of molded bodies 10 are arranged side by side, the aggregates 16 are collectively collected with respect to a large number of molded bodies 10 even by manual work. Planarization and bonding can be performed.

  Furthermore, in the said embodiment, in the (4) 2nd powder spraying process, the 2nd powder 40 which is a powder material with a particle size smaller than the aggregate 16 is sprayed on the surface 13 of the molded object 10, and also 2nd powder. 40 is applied to the surface of the aggregate 16. Thereby, reflection of light, such as the sun, can be suppressed on the surface of the tile after firing. Thereby, an artificial impression can be excluded and the weathering by nature can be expressed more highly. If the second powder 40 is of the same type as the ceramic material constituting the molded body 10 or the aggregate 16, or a similar color, the natural impression can be further enhanced. On the other hand, the second powder 40 may be positively colored on the surface 13 of the molded body 10 by using a material having a color different from that of the ceramic material constituting the molded body 10 or the aggregate 16. In addition, you may perform the dispersion | distribution of the 2nd powder 40 after the (5) aggregate joining process.

  Furthermore, in the present embodiment, by performing the (6) chamfering step, it is possible to better represent the shaving of the tile due to natural weathering. Moreover, (7) In a baking process, by performing unglazed without using glaze, the texture like an old brick can be expressed well.

  In this embodiment, (1) forming the processing groove 14 on the surface 13 of the molded body 10 in the molding step, and (3) performing the (2) first powder spraying step before the scraping step. Dispersing the first powder 20 does not directly affect the appearance of the resulting tile, but contributes to the efficiency of the tile manufacturing process. That is, by forming the processing groove 14 on the surface 13 of the molded body 10, the teeth 32 of the tooth-like device 30 are easily caught in the (3) scraping step, so that it functions as a foothold for scraping. Scraping can be promoted. In addition, (2) by dispersing the first powder 20 in the first powder spraying step and (3) performing the scraping step, the first powder 20 functions as the core of the aggregate 16, It can promote growth.

  In addition to the steps described above, various designs can be expressed in the tile by using various steps in combination. For example, the region where the concavo-convex structure is formed through each of the above steps and the smooth region where the concavo-convex structure is not formed coexist on the surface of one tile, or using a tool such as a trowel, as described above An atmosphere different from simple weathering can be expressed by providing streaks or steps on the surface of a tile having a rough structure. Also, in the above, the tiles were unglazed, but the natural atmosphere and the artificial colors can be obtained by actively giving various colors by coloring the base before molding and coloring after molding, and by giving glaze with glaze. Various designs using uneven shapes, such as a design in which various atmospheres are fused, can be expressed.

  As mentioned above, although embodiment of this invention was described in detail, this invention is not limited to the said embodiment, A various change is possible in the range which does not deviate from the summary of this invention. For example, the ceramic product to be manufactured has a flat plate-like structure like the above tile, which is preferable from the viewpoint of (3) scraping process and (5) agglomerate joining process, There is no need for the tile, and (1) it can be formed into various shapes in the forming step. Moreover, in said embodiment, although (3) scraping process and (5) aggregate joining process were performed manually, you may use a machine.

DESCRIPTION OF SYMBOLS 10 Molded body 13 (Molded body) surface 14 Processing groove 15 Concave structure 16 Aggregate 16 'Joint convex part 20 First powder 30 Tooth-like tool 40 Second powder 50 Plate-like tool

Claims (7)

A molding process for forming a molded body by molding a base material made of clay-like ceramic material;
An aggregate dispersion step of irregularly dispersing aggregates having a non-uniform size and shape on the surface of the molded body, which is made of a clay kneaded ceramic material;
Crushing the agglomerates on the surface of the molded body, and joining the agglomerates to the molded body;
And a firing step of firing the formed body joined with the aggregate.   The method for producing a ceramic product according to claim 1, wherein the agglomerate joining step is performed by hitting a surface of the formed body in which the agglomerates are dispersed.   The said aggregate dispersion | distribution process is performed by the scraping process which scrapes the surface of the said molded object, and uses the base | substrate which comprises the scraped-out molded object as the said aggregate. Manufacturing method of ceramic products.   The method for producing a ceramic product according to claim 3, wherein a powdery ceramic material is sprayed on the surface of the molded body before the scraping step.   The method for producing a ceramic product according to claim 3 or 4, wherein a groove is formed on a surface of the molded body in the molding step.   The method for producing a ceramic product according to any one of claims 1 to 5, wherein a powdered ceramic material is dispersed on the surface of the molded body before or after the particle bonding step.   The method for manufacturing a ceramic product according to any one of claims 1 to 6, wherein the ceramic product is a tile.