JP4606148B2 - Manufacturing method of irregular roof tile - Google Patents

Description

  The present invention relates to a method for manufacturing a deformed tile among clay tiles installed on a roof. In particular, the present invention relates to an improved manufacturing method for valley corner tiles and ridge corner tiles.

  Clay tiles that have long been used as roofing materials for residential buildings are Japanese tiles, Western tiles, or flat roof tiles that are popular in recent years. Since the end is not necessarily in a fixed position, as shown in FIG. 3, valley corner roof tiles 11a, 11b, 11c, which are deformed roof tiles in accordance with the shape of the valley corner portion 11 or the ridge corner portion 12, are used. ... and ridge corner tiles 12a, 12b, 12c, ... had to be spread. The cutting work for producing such a modified roof tile is a work requiring considerable skill at a construction site where the scaffolding is poor. Furthermore, when cutting, clay tiles tend to break in unplanned directions, so the failure rate is high, and specialized craftsmen are required.

In order to solve such a problem, the applicants of the present invention disclosed in Patent Document 1 that pre-cuts such as valley corner tiles, ridge corner tiles, and the like that are manufactured by cutting a necessary roof material in advance in a factory according to the roof gradient. Propose tiles. (See Patent Document 1)
However, even when cutting in advance in a factory, a cutting device equipped with a carbide cutter is necessary, and individual manual cutting operations must be performed, resulting in low productivity and high costs. there were.
Japanese Patent No. 33881717 Patent Publication (Application Date: 1994.10.12): Paragraphs [0007] [0017], FIG. 7 and FIG.

  The present invention has been made in order to solve the above-mentioned problems, and in the conventional clay roof tile production line, by adding a simple operation, it is possible to remove irregular roof tiles such as valley corner roof tiles and ridge corner roof tiles. Provided is a method for manufacturing a modified roof tile that can be manufactured at low cost.

The above problem is that after forming the raw kneaded clay into a predetermined tile body shape, a cut is formed on the surface, dried, glazed and fired, and then divided along the cut to produce a deformed roof tile of a predetermined shape. The method according to the present invention is characterized in that, by the dividing operation, a trough corner tile having a shape in which the head side is separated by an inclined cut and a ridge corner tile having a shape in which the bottom side is separated by an inclined cut are simultaneously manufactured. This can be solved by the method of manufacturing the irregular roof tile. Further, in the present invention, after the raw material kneaded clay is press-molded into a predetermined tile body shape, it is preferable to form a cut by pushing a blade having a plate thickness of 2.5 mm or less on the surface. It is preferable that the cutting edge is formed in a concave and convex shape, and it is more preferable to push the blade to a depth of 30% to 70% with respect to the thickness of the molded body.

Since the method for manufacturing a modified roof tile according to the present invention is configured as described above, there are excellent effects as described below. Therefore, the present invention has an extremely large practical value as a method for manufacturing a modified roof tile that has solved the conventional problems.
1) First, in a conventional clay tile production line, by adding a simple operation of making a cut and dividing along it, it is possible to produce deformed tiles such as valley corner tiles and ridge corner tiles at low cost. .
2) Since the shape is the same as that of other general roof tiles up to the split operation, drying, glazing and firing can be performed on a conventional clay roof tile production line, which is advantageous in terms of production technology.

3) Since the cut can be easily provided by the cutting tool, and can be divided along the cut by applying an appropriate impact after firing, the operation is easy and can be divided into a predetermined shape in a very short time. In addition, the divided parts are relatively smooth and the appearance is excellent.
4) The cutting edge of the cutter is formed into a concavo-convex shape, that is, corrugated, and according to the indentation depth of the present invention, it is difficult to cause cracks in handling up to the firing step, and division after firing is easy. Is obtained.
5) Since a total of two tile corner tiles and one ridge corner tile can be manufactured from one molded body, a cost merit is obtained.

Next, an embodiment according to the method for manufacturing a modified roof tile of the present invention will be described with reference to FIGS.
In the method for producing a modified roof tile according to the present invention, the conventional method includes 1) a forming step for forming a raw kneaded clay into a predetermined roof body shape, 2) a drying step, 3) a glazing step, and 4) a firing step. There is basically no difference from this method, and the conventional manufacturing process can be used as it is except that a break process and a dividing process described below are added.

  The cut process, which is a feature of the present invention, is performed on the surface of the roof tile body 2 during the process of forming the roof tile body or when the molded body can be plastically processed thereafter, for example, as illustrated in FIG. It is a step of making a right-upward slanting cut line 21 of a one-dot chain line 21 or a right-downping slanting cut line 22 of a two-dot chain line, and the dividing step gives a moderate impact to the tile body 2 sintered after firing, This is a process for manufacturing irregularly shaped tiles such as valley corner tiles and ridge corner tiles having a predetermined shape by dividing the upper and lower sides along the vertical direction, and will be described in more detail below.

(Cut formation)
The cut line of the present invention may be simultaneously with the press molding of the raw material kneaded clay, but when it is transferred to a receiving stand for testing for strain correction after molding, the thickness of the sheet is 2.5 mm or less on the surface. The cut is preferably formed by pushing the blade from above with a press. In this case, it is preferable to cut the blade by pushing it to a depth of 30% to 70% on average with respect to the thickness of the molded body.

  This blade has a metal plate such as a stainless steel plate that has been processed into the intended cut shape (in the example shown in FIG. 1, a straight line), and its height is adjusted so that when it is pushed into the formed body, the cut has the depth described above. Shall be kept. In addition, if the plate thickness exceeds 2.5 mm, the glaze will penetrate into the cuts and adhere in the post-process glazing, and this will cause trouble in the division of the post-process. . The lower limit of the plate thickness is practically at least mm because of the glaze condition and expected wear. Further, the cutting edge cross-sectional shape may be an appropriate pointed shape.

  The cutting edge of this cutter is preferably formed in a concave and convex repeated shape, for example, a curved waveform having a depth (wave height) of 10 mm or less and a pitch of 25 mm or less, a saw waveform, a rectangular concave and convex repeated waveform. In this case, there is a partial difference in the indentation depth of the blade, and as a result, there is an advantage that breakage such as cracking does not easily occur in handling from the drying to the firing process, and division after firing becomes easy.

  In addition, the depth of the formed cut is an important manufacturing condition. When the depth is less than 30%, it is difficult to divide along the cut in the subsequent division process, and the yield of non-defective products having a predetermined shape is reduced. Because. In addition, when the depth exceeds 70%, the mechanical strength decreases along the cut line, so that the roof tile body is easily damaged in the handling of the subsequent process, and the inconvenience that the defect rate increases particularly in the automatic transport device. It is not preferable. This depth value is preferably an average value in the case of a smooth cutting edge, and an average value in the deepest portion in the case of a corrugated cutting edge as described above.

(Shape of irregular roof tile)
In the example of FIG. 1, the present invention is directed to the tile body 2 of a predetermined flat roof tile, and a trough corner roof tile a having a shape in which the head side 23 is separated by an upwardly inclined slope 21 by the above-described division work (viewed from the eaves) The left side corner tile) and the ridge corner tile b (the right side corner tile as viewed from the eaves side) are also manufactured at the same time. This is a method that can simultaneously produce a valley corner tile (the right corner corner tile when viewed from the eaves) and a ridge corner tile (the left corner when viewed from the eaves).

  In addition, about such a trough corner tile and a ridge corner roof tile, if a typical multiple types of size pattern is prepared previously, there is no problem in practical use. FIG. 2 shows eight types of representative size patterns of valley corner tiles and ridge corner tiles prepared for such a purpose. Patterns 21a to 21d obtained by the upward slope cut 21 and obtained by the downward slope 22 are shown. Patterns 22a to 22d are shown. And in each, the upper corner is a valley corner tile, and the lower side is a ridge corner tile.

  In the above description, the case where the deformed tile is a valley corner tile or a ridge corner tile has been described as an example, but the present invention is not limited to this embodiment, and even after other shapes are cut after firing. For clay tiles that require dimensional adjustment, it is only necessary to form cuts with correspondingly shaped blades, and to divide them after firing to produce clay tiles of a required shape, so that they can be widely applied.

The principal part front view of the tile main body for demonstrating the manufacturing method of this invention. The principal part front view (21a)-(22d) which shows the typical size pattern of a valley corner tile and a ridge corner tile. Top view of roofing with valley and ridge corners.

Explanation of symbols

2: Tile body, 21: Upward slope cut, 22: Downward slope cut, 23: Head side, 24: Butt side a: Tani corner roof tile, b: Building corner roof tile

Claims (4)

After forming the raw material kneaded clay into a predetermined tile body shape, forming a cut on the surface, drying, glazing, firing, and then dividing the cut along the cut to produce a shaped roof with a predetermined shape , A method for manufacturing a modified roof tile, wherein a trough corner tile having a shape in which the head side is separated by an inclined cut and a ridge corner tile having a shape by separating the bottom side by an inclined cut are simultaneously manufactured by the dividing operation .   The method for producing a modified roof tile according to claim 1, wherein the raw kneaded clay is press-molded into a predetermined tile body shape, and then a cut having a thickness of 2.5 mm or less is pushed into the surface to form a cut.   The manufacturing method of the unusual roof tile of Claim 2 in which the blade edge | tip of the said cutter is formed in the uneven | corrugated repeating shape.   The method for producing a modified roof tile according to claim 2 or 3, wherein the blade is pushed to a depth of 30% to 70% with respect to a thickness of the molded body.

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