JP2577968B2 - Manufacturing method of patterned wall materials - Google Patents

Description

The present invention relates to a wall material or a floor material such as an inner wall material and an outer wall material (these materials are collectively referred to as a wall material in the present specification). The present invention relates to a method for producing a patterned wall material provided with a pattern.

(Prior Art) Conventionally, this type of patterned wall material is formed by applying a single color or a plurality of colors of glaze to the surface of the formed tile by a method such as transfer or screen printing, and then firing. However, such a conventional patterned wall material has a problem that the operation is extremely complicated and time-consuming. Further, since the pattern of the wall material and the like formed by the method is extremely thin, there is a problem that the pattern is gradually discolored or faded due to long-term outdoor use, and the surface is polished due to lack of thickness. There was also a problem that the work could not be performed, sufficient gloss could not be obtained, and the commercial value was low.

(Problems to be Solved by the Invention) The present invention, except for the above-mentioned conventional problems, can be manufactured with extremely high workability, and furthermore, a product formed by a good integration state of a main molding material and a pattern material is obtained. An object of the present invention is to provide a method for producing a patterned wall material having excellent moisture absorption and mechanical strength, high pattern durability, and high commercial value.

(Means for Solving the Problems) The present invention provides a method for continuously supplying a main powdery molding material having a property of being porcelain by firing between two endless belt conveyors, A powdery pattern material having the same properties as above and having a large thickness on the belt is supplied, and the supplied material is continuously heated between the two belts as the belt moves. Provided is a method of forming a patterned wall material in which both the main molding material and the pattern material are made into porcelain in an integrated state by press-molding and integrating, and firing the material of the integrated patterned wall material. Is what you do.

(Operation) The upper and lower conveyor belts are continuously moved. In that state, between the conveyor belts,
A powdered main molding material is supplied and a pattern material of the same quality is supplied. These materials are continuously heated and pressed between the upper and lower belts facing each other as the belt moves, and are integrated into a dense shape. When this integrated product is fired, it becomes porcelain in one piece,
It becomes a patterned wall material with excellent strength.

(Embodiment) A drawing showing an embodiment of the present invention will be described below. 1 to 7, reference numeral 1 denotes a roll forming machine. In this, 2 is a lower endless belt conveyor,
The driving rollers 3 and 4 are driven to rotate in the direction of the arrow through a well-known electric motor and a reduction gear (not shown), and an endless belt 5 is stretched over them. Reference numeral 6 denotes an upper endless belt conveyor, which comprises driving rollers 7 and 8 and an endless belt 9 similarly to the above-mentioned conveyor 2. These conveyors 2, 6 are juxtaposed as shown in the figure, with parts of the surfaces of the belts 5, 9 facing each other up and down with a predetermined interval. Stainless steel belts are used as the belts 5 and 9 in consideration of the fact that the belts are small in elongation and deformation, high in hardness, and hard to rust. 11,1
Reference numeral 2 denotes a pressing roller exemplified as a pressing means, which is provided on the back side of each of opposing portions of the belts 5 and 9 in the respective conveyors 2 and 6. These pressurizing means may be pressurizing plates that contact the back of each belt with little friction. The width of the belt 5 is the same as the width of the peripheral surface 11a of the pressure roller 11, and the width of the belt 9 is the same as the width of the peripheral surface 12a of the pressure roller 12. . Further, the width of the peripheral surface 12a of the pressure roller 12 is smaller than the width of the peripheral surface 11a of the pressure roller 11, as shown in FIG. The facing distance between the belts 5 and 9 in the upper and lower belt conveyors 2 and 6 is as shown in FIG.
It is designed to be smaller toward the end in the moving direction of 5, 9 so that a molding material described later is gradually pressed with the movement of the belt. The arrangement pitch of the upper and lower pressure rollers 11 and 12 is reduced toward the end of the moving direction so that the pressure applied to the molding material from these rollers via the belts 5 and 9 is sequentially increased. It has become.
A heating means 13 is provided for heating the molding material to a fixed temperature (60 to 80 ° C.) via the belts 5 and 9.
Such heating promotes pressure molding of the molding material (the aluminum phosphate as a binder in the molding material is activated). Note that a far-infrared heater, an infrared heater, or the like is used as the heating means. Next, reference numeral 14 denotes left and right endless belt conveyors, which are composed of drive rollers 15, 16 and an endless belt 17 like the above-mentioned conveyor 2, and are moved at the same speed as the belt 5 in the direction of the arrow. These belts serve to prevent the molding material supplied on the lower belt 5 from spilling off the belt 5 and to press the molding material from both sides during the pressure molding. This belt 17 with respect to the belts 5 and 9
3 is such that the lower edge thereof contacts the upper surface of the belt 5 and the surface thereof contacts the side surface of the belt 9 as shown in FIG. The belt 17 is made of the same material as the belts 5 and 9. 18,
.. Are auxiliary rollers provided along the back side of the belt 17 and are provided to prevent the belt 17 from being deformed in a direction away from the belt 9 at the time of pressure molding of the molding material. . Note that, similarly to the pressure roller, the auxiliary rollers 18 are arranged so that their pitches are narrower as they approach the end in the moving direction, so that the pressing force on the molding material gradually increases. Reference numeral 21 denotes a pattern material supply device, which in this example comprises a plurality of supply elements 22, 22,... Arranged in the width direction of the belt 5 as shown in FIG. Reference numeral 23 denotes a main material supply device configured to uniformly supply a main molding material (also referred to as a main material or simply a molding material in the present specification) over the entire width of the belt 5. twenty four
Is a slimy plate, which is configured so that the molding material supplied onto the belt 5 from the supply device 23 can be made uniform in thickness over its entire width. It is provided with up and down movement freely. Numeral 25 denotes a cutter of a molded product which has been subjected to pressure molding. Reference numeral 26 denotes an unloading conveyor, which may be any belt or roller conveyor.

Next, a molding material and a pattern material used in the roll molding machine 1 will be described. As an example of the molding material, the component (% by weight) is a vitreous component (glass cut).
40-60 wt%, aluminum oxide (Al ₂ O ₃₎ 10 to 30 wt%, clay component 10 to 25% by weight, binder (aluminum phosphate) consists 5 to 15% by weight of the composition. The mixture having such a composition is placed in a ball mill or the like and mixed for an appropriate period of time to obtain a powdery mixture having a particle size of 100 μ or less.Then, water is added to form a slurry.
It is granulated into μ particles. Patterning composition, it said Like vitreous component (glass cullet) 40-60 wt%, the colorant (metal oxide to aluminum oxide (Al ₂ O ₃₎ 10 to 30 wt%, binder (aluminum phosphate) as an example And 5% by weight of a metal compound which can be converted to an oxide by heating (for example, carbonate). The mixture having such a composition is granulated by the same method as described above.

Next, the following are examples of the relationship between the types and colors of the above-mentioned coloring agents.

Bengala (Fe ₂ O ₃ ): red (brick), chrome oxide: green, titanium oxide: yellow-white, cobalt oxide: blue, iron oxide (Fe ₃ O ₄ ): black That is, one or several of these are mixed and used. However, even a metal oxide not exemplified here can be used as a coloring agent.

In the above, the composition of the material used as the molding material without mixing the colorant has been described. However, for example, when a red-based wall material or the like is to be manufactured, the reddish bengara (Fe ₂ O ₃ ) Will be used.
Therefore, as a pattern material to be used in combination therewith, a material of a different color, that is, a material obtained by mixing different kinds of metal oxides used for the colorant is used.

Next, a procedure for manufacturing a wall material and the like using the above-described molding machine and material will be described. First, belts 5, 9,
17 is continuously moved at a predetermined same speed. The speed is appropriately set within a range of, for example, 5 to 30 m / hour.
In this case, when forming a thick wall material or the like, it is preferable to reduce the feed speed so that sufficient pressure is applied to the molding material. In the above state, the pattern material 31 is supplied from each supply element 22 in the supply device 21 to the belt 5 through the supply port 22a as shown in FIG. Next, as shown in FIG.
A main molding material 32 is supplied over the pattern material 31 continuously through 23a. Next, as shown in FIG.
And the upper surface of the input material is flattened with the lower edge 24a. In this case, when it is desired to further reduce the thickness of the wall material or the like to be formed, that is, when forming a thin plate,
This can be dealt with by moving the slipper plate 24 further downward. That is, the lower edge 24a of the slimy plate 24 and the belt 5
When the distance (distance) from the upper surface of the material is reduced, the thickness of the material supplied can be reduced by that amount. The material whose surface has been smoothed as described above reaches the opposing portion of the belt 5 and the belt 9 as the belt 5 moves, and is gradually pressurized from above and below, and gradually by the belt 17 from the side. Pressurized. Then, pressure molding is performed to a predetermined thickness by the final-stage pressure rollers 11 'and 12'. The above-described forming is performed continuously as the belts 5, 9, 17 move. The molding pressure is, for example, 600 at the final pressure rollers 11 'and 12'.
kg / cm ² is set. The molded product is cut into a predetermined size by a guillotine-type cutter 25 or a known cutting saw to obtain a wall member 33 as shown in FIG. The wall material and the like are transferred to the next firing step by the conveyor 26 for conveyance. In the firing step, the wall material 33 is placed in a firing furnace such as a roller hearth kiln,
It is fired at a temperature of 0 to 800 ° C. for about 3 to 5 hours.

In the wall material 33 or the like 33 fired as described above, the main molding material 32 and the pattern material 31 are made of the same material, so that the two are integrated into a porcelain. That is, the fired wall material and the like are densified in the same manner as the molding material even in the portion where the pattern material is present. Therefore, the wall material or the like maintains the original excellent properties such as the hygroscopicity and mechanical strength of the material over the entire area.

As described above, the wall material 33 fired as described above is subjected to a polishing process in the final process after the peripheral side surface is cut appropriately by a tip saw or the like as necessary, and the surface on which the pattern is exposed is polished. Finished with a glossy surface to produce a product.

When a pattern is formed in the above manufacturing process, the same color pattern material or a different color pattern material may be supplied from each supply element 22. In addition, by continuously supplying the pattern material from each supply element, a striped pattern can be formed on the completed wall material or the like. By supplying the pattern material from each supply element intermittently, the wall material can be formed. A dot pattern can be formed on a material or the like. Further, by supplying the pattern material while repeatedly moving the supply elements 22 in the width direction of the belt 5, a wavy pattern can be formed on a wall material or the like. The intermittent supply of the pattern material or the control of the widthwise movement of the supply element 22 as described above may be performed manually by an operator or automatically by a control device such as a computer.

Further, when the wall material or the like is formed as described above, the front and rear positions of the pattern material supply device 21 and the main material supply device 23 may be interchanged. In this case, a wall material or the like can be formed in a state where the pattern is exposed on the side facing the belt 9. In this case, in the molding material supplied from the supply device 23, the groove is formed at a position corresponding to the position where the pattern material is supplied, and the pattern material is supplied to the groove so that the upper and lower belts can be formed. The overall thickness of the material between 9,5 can be made substantially uniform. Further, when a wall material or the like is formed as described above, the thickness of the pattern may be arbitrary. If necessary, the thickness may be from the upper surface to the lower surface of the wall material 33 or the like.

Next, FIGS. 8 to 11 showing different embodiments of the present application will be described. This example shows an example in which a pattern material is uniformly supplied over the entire width of a belt, and then a striped pattern is formed by a pattern forming plate. In the figure, a pattern material supply device 21e is configured to be able to supply a pattern material uniformly over the entire width to the upper surface of the belt 5e. 35 is a pattern forming plate,
A plurality of comb-shaped teeth 35a are provided at the lower edge. This pattern forming plate is supplied to a pattern material supply device as shown in FIG.
It is provided on the rear side of 21e. In addition, each of the above-mentioned multiple teeth 35a may be differently formed into an arbitrary shape, or the interval between them may be variously changed. Further, the pattern forming plate 35 may be reciprocated in the width direction of the belt 5e.

In such a configuration, after the pattern material 31e is supplied substantially uniformly on the belt 5e as shown in FIG. 10 (a), the pattern forming plate is formed as shown in (b). 35 teeth 35
The pattern material 31e is formed into a plurality of strips by a. Thereafter, as shown in (c) and (d), the supply of the molding material and the leveling of its surface are carried out in the same manner as in the previous embodiment, and then the pressure molding is carried out, and the wall as shown in FIG. Materials 33e are obtained.

In addition, functionally considered to be the same or equivalent to those in the previous figure, the same reference numerals as those in the previous figure denote the same parts as in the previous figure.
And duplicated description is omitted. (Also in the following figures, alphabetical letters “f” and “g” are added in order based on the same concept, and overlapping explanations are omitted.) Next, FIGS. 12 to 14 show still another embodiment of the present invention. This is an example in which transparent glass is provided on the surface of a wall material or the like as a product so that a product with a three-dimensional appearance can be formed. In the figure, reference numeral 37 denotes a glass material supply device capable of supplying glass powder (glass cullet) 39 of the same material as the vitreous component contained in the molding material over the entire width of the belt 5f. . 38 is a slick board.

In the above configuration, the molding of the wall material and the like is performed in the order shown in FIGS. 13 (a) to 13 (f) with the movement of the belts 5f and 9f. That is, first, as shown in (a), the belt
A glass material supply device 37 supplies a glass material 39 onto 5f. Next, as shown in (b), the glass material 39 is made uniform in thickness by a slimy plate 38. Next, as shown in (c), the pattern material 31f is supplied thereon, and then, as shown in (d), a linear pattern of the pattern material 31f is formed by the pattern forming plate 35f. In this case, the lowering position of the pattern forming plate 35 may be lowered to a position where the pattern material 31f becomes a linear pattern and the glass material 39 does not largely collapse. Next, as in the above case, the molding material 32f is supplied as shown in (e), and the surface is leveled by the slicky plate 24f as shown in (f). Thereafter, pressure molding is performed in the same manner as described above, and a wall material 33f or the like 33f as shown in FIG. 14 is obtained. By firing such a wall material or the like, the glass material 39 on the surface thereof is melted into a glass state.

Next, FIGS. 15 and 16 show still another embodiment of the present application, and show still another example of the pattern forming method. In the figure, reference numeral 41 denotes an adhesive application device which applies an adhesive or a pressure-sensitive adhesive to a surface of a belt 5g at a position corresponding to a pattern to be molded. Is sprayed onto the belt 5g. 42 indicates an air nozzle.

In such a configuration, the adhesive or the pressure-sensitive adhesive is applied to the surface of the belt 5g at a location corresponding to the pattern to be molded by the adhesive application device 41 during the movement of the belt 5g. You. Next, a pattern material 31g is uniformly supplied over the entire width of the belt 5g. Next, the air blown out from the nozzle 42 blows off the pattern material 31g on the belt 5g. As a result, on the surface of the belt 5g, the pattern material 31g remains only where the adhesive or the pressure-sensitive adhesive has been applied. Thereafter, supply of the molding material and pressure molding are performed in the same manner as described above, and the wall material and the like 33 as shown in FIG.
g is obtained.

According to the method described above, the pattern material 31g on the belt 5g does not displace in any of the supply process of the molding material 32g, the process of smoothing the surface thereof, and the process of pressure molding, and the contour is clearly defined. It is possible to produce a wall material or the like having a patterned pattern. The adhesive or pressure-sensitive adhesive is such that a part of the molding material or the pattern material does not remain on the belt 5g during pressure molding or remains as carbon after firing the molded body. It is better to use As such a material, it is preferable to use an ordinary synthetic resin adhesive or pressure-sensitive adhesive.

Moreover, the thickness of the pattern in the wall material or the like formed as described above is sufficiently thicker than that of the conventional glaze, and the pattern disappears even if the pattern surface is polished as described above. There is nothing. In the present specification, such a thickness is referred to as a large thickness.

(Effect of the Invention) As described above, in the method of manufacturing a patterned wall material according to the present invention, when forming the patterned wall material 33, the upper and lower belts 5, 9 are continuously moved, and in that state, the belt 5 By continuously supplying the main molding material 32 on the top and supplying the same pattern material 31, the materials are powdery and flowable. Unity improves. Moreover, the above pattern material 31
Can be formed to a sufficiently large thickness. This has the effect that the durability of the pattern can be increased in the finished product of the patterned wall material.

Further, the wall material 33 molded as described above is a molding material
Since 32 and the pattern material 31 are the same material, the wall material 33
By baking, the molding material 32 and the pattern material 31 are made into a porcelain in an integrated state, and are densified. is there.

[Brief description of the drawings]

The drawings show an embodiment of the present invention. FIG. 1 is a schematic longitudinal sectional view of a roll forming machine, FIG. 2 is a plan view of the roll forming machine showing a state where an upper conveyor is removed, and FIG. FIG. 4 is a side view showing the relationship between the lower conveyor and the pattern material supply device, FIG. 5 is a perspective view of a slick plate, FIG. 6 is a molding process diagram of a wall material, etc. FIG. 7 is a perspective view of a wall material, etc.
FIG. 8 is a partial longitudinal sectional view showing a different embodiment, FIG. 9 is a perspective view of a pattern forming plate, FIG. 10 is a molding process diagram of a wall material or the like by the apparatus of FIG. 8, and FIG. FIG. 12 is a partial longitudinal sectional view showing still another embodiment, FIG. 13 is a molding process diagram of a wall material and the like by the apparatus of FIG. 12, FIG. 14 is a perspective view of the wall material and the like, FIG. 15 is a partial longitudinal sectional view showing still another embodiment,
FIG. 16 is a perspective view of a wall material and the like formed by the apparatus of FIG. 2,6 …… Endless belt conveyor, 5,9 …… Belt, 11,12…
... pressure roller, 21 ... pattern material supply device, 23 ... main material supply device, 31 ... pattern material, 32 ... main molding material.

Continuation of the front page (72) Inventor Hiroyuki Sasaki 35 Fukamama, Nagagusa-cho, Obu-shi, Aichi Japan High Voltage Electric Co., Ltd. Technical Research Institute (56) References JP-A-63-62706 (JP, A) JP-A-59-35904 (JP, A) JP-A-57-148604 (JP, A)

Claims (1)

(57) [Claims] 1. A powdery main molding material having a property of being porcelain by firing is continuously supplied between two endless belt conveyors, and has the same properties as the main molding material, and is further provided on a belt. A large amount of powdery pattern material is supplied, and the supplied material is pressure-formed and integrated while continuously heating between the two belts with the movement of the belt, A method for producing a patterned wall material, comprising firing the integrated material of the patterned wall material and porcelain both the main molding material and the pattern material in an integrated state.