JPS5939285B2 - Method for manufacturing stepped tile base and pressing mold used in this method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for producing stepped tile blanks and to a suppressor for use in this method.

As shown in FIGS. 1 and 2, stepped tiles 1 are adjacent 2 square tiles on the surface 1a side of a square tile with a thickness of t.
A front stepped portion 2 with a width w1 and a height h1 is formed on the side, and a back stepped portion 3 with a width w2 and a height h2 is formed on the other two sides on the back side 1b. (t-
As shown in FIG. 3, the stepped tile 1.1 is formed by overlapping the front step 2 and the back step j of one adjacent stepped tile 1.1. These tiles allow you to create a beautiful tile wall surface by simply butting them together without the need for joint filling work.

Conventionally, as shown in FIG. 4A, in the method of manufacturing the stepped tile base 1' for the stepped tile 1, two adjacent pressing surfaces 6a of the lower mold 6 are used as the lower mold 6 for forming the back surface of the tile. A mold having L-shaped protrusions 6b protruding from one edge thereof is used, and the pressing surface 7 of the upper mold 7 is used as the upper mold 7 for forming the tile surface.
An L-shaped protruding strip 7b with an inner surface r b / made perpendicular to two adjacent edges of a is hung down so as to face an edge 6°C of the lower mold 6 without an L-shaped protruding strip. First, after raising the frame 8, a predetermined amount of molding clay 9 is supplied onto the lower mold 6, and then the upper mold 7 is placed next to it, and the molding molding material 9 is
is pressed between the lower mold 6 and the upper mold 7 [see Fig. 4A], and then, as shown in Fig. 4B, after lowering the frame 8, the upper mold 7 is raised to form the stepped tile base 1. ' [see Figure 4C].

However, when this stepped tile base 1' is fired to form the stepped tile 1, the corner 1d forming the front step 2 of the stepped tile 1 (see FIG. 1) and/or the back step A defect occurs in which a crack occurs from the corner 1c forming part 3 to the inside of the tile.The reason why a crack occurs from the round corner 1c to the inside is as shown in FIG. The density (hardness) of part a is the density (hardness) of part b
This is because a boundary with a different density is formed between the part a and the part a, and the reason why cracks occur inward from the tile corner 1d is due to the fact that the cracks occur during pressure forming of the stepped tile base 1'. , as shown in FIG. 4B, when the frame 8 is lowered after pressurizing the upper die 7, the d portion of the stepped tile base 1'
Refer to Fig. 4 C] and the upper die 7 and the d part where the residual stress is released.
A crack occurs between the C part and the part C, which is restrained by the C part and has residual stress.

This phenomenon is thought to be due to slippage between clay particles occurring at the boundary between portions d and C.

The inventor of the present invention repeatedly conducted numerous experiments in order to eliminate the defect that causes cracks, and found that if a step is formed along the inside of the L-shaped protrusion of the lower mold, the There is no sharp density difference in the tile base part formed under pressure by the L-shaped convex stripes, and the inner part of the L-shaped convex strips on the upper mold is inclined so that it becomes closer to the inside as it approaches the suppression surface of the upper mold. In view of the phenomenon that the pressurized restraint of the tile base portion formed under pressure by the curved convex stripes can be released almost simultaneously, the present invention was completed based on this knowledge.

EMBODIMENT OF THE INVENTION Hereinafter, the manufacturing method of the stepped tile base material based on this invention is demonstrated based on the Example shown in drawing.

Reference numeral 11 in FIG. 5A is a suppression mold for forming the back surface of the tile used in the method of the present invention.

The suppression mold 11 for forming the back surface of the tile has L-shaped protrusions 11b protruding from two adjacent edges on the rectangular suppression surface 11a, and a convex protrusion 11b on the inner side of the rectangular protrusion 11b. Article 11
One step portion 11c is formed along the longitudinal direction of b.

Reference numeral 11e denotes a protrusion for forming the feet on the back surface of the tile, and a plurality of protrusions 11e, 11e, . . . are protruded in parallel on the pressing surface 11a.

Note that, as shown in FIG. 6, the stepped portion formed on the inner side of the curved convex strip 11b is a plurality of stepped portions 11c', 11c'.
It is of course possible to do...

Reference numeral 12 in FIG. 5A is a pressing mold for tile surface forming used in the method of the present invention, and the pressing mold for tile surface forming has L-shaped protrusions 12b protruding from two adjacent edges of a rectangular pressing surface 12a. In addition, the inner surface 12c of the curved protruding strip 12b
It is inclined so that it becomes closer to the inner side as it approaches the pressing surface 12a.

The suppression mold 11 for forming the back side of the tile is used as a lower mold, the suppression mold 12 for forming the tile surface is used as an upper mold, and the frame 13 is used as the upper mold.
After raising the mold by a predetermined amount, as shown in FIG. 4B, a predetermined amount of molding clay 14 is supplied onto the suppression mold 11 for forming the back surface of the tile.

If necessary, an appropriate amount of the molding rod 14 on the edge 11d without the L-shaped convex strip 11b of the pressing die 11 for forming the back surface of the tile is removed by an appropriate means.

Next, as shown in FIG. 5C, the upper mold, which is the suppression mold 12 for forming the tile surface, is connected to the L-shaped convex strip 12b of the tile surface molding pressing mold 12, and the lower mold, which is the pressing mold for forming the back surface of the tile. 1
The molded clay 14 is formed under pressure by lowering the molded clay 14 so that the edge 11d without the L-shaped convex stripes 11b of the molded clay 11 faces each other.

Continuously, as shown in the fifth diagram, immediately or simultaneously after lowering the frame 13, the tile surface forming suppression mold 12, which is the upper mold, is lowered.
is raised to obtain the detached stepped tile base 21.

Since the stepped portion 11c (11c') is formed on the inner side of the L-shaped convex strip 11b of the tile back molding press mold 11, the e and f portions of the molded stepped tile base 21 (see the fifth diagram) are formed. The density difference between the part and the part f and part g becomes small.

Furthermore, since the inner surface 12c of the L-shaped convex strip 12b of the tile surface molding pressing mold 12 is sloped, the i section of the stepped tile base 21 can be removed by simply raising the tile surface molding pressing mold 12 by a small amount. can be released from the mold in a short time, and the i
The mold release time difference between the part and the j part is extremely short, and slippage between the clay particles due to the mold release time difference does not occur at the boundary between the i part and the j part.

FIG. 7 shows an embodiment of the present invention in which a suppression mold 16 for surface molding is used as a lower mold, and a suppression mold 11' for back surface molding is used as an upper mold.

Similar to the suppression mold 11 for forming the back side of a tile, the suppression mold 11' for forming the back side of the tile has L-shaped protrusions 11'b protruding from two adjacent edges on the square suppression surface 11'a. At the same time, a stepped portion 11'c is formed on the inner side of the curved convex strip 11b along the longitudinal direction of the curved convex strip 11'b.

The tile surface forming suppression mold 16 has L-shaped protrusions 16b protruding from two adjacent edges of a rectangular suppression surface 16a.

First, after moving the upper surface of the tile surface forming suppression mold 16, which is the lower mold, to a predetermined position within the fixed frame 13', the molding mold 14' is supplied onto the tile surface forming suppression mold 16. The surface of the molding piece ±14' is the upper surface 13'a of the frame 13'.
so that they form approximately the same plane.

Next, the upper mold, the suppression mold 11' for forming the back surface of the tile, is placed on the molding clay 14' so that the edge 16d without the L-shaped surface 16b of the pressing mold 16 for forming the back surface of the tile faces the forming mold 14'. Press it to form it under pressure.

Subsequently, the press-formed clay is moved to the outside of the frame 13' while being pressed by both upper and lower pressing molds 11' and 16, and then the pressing of both upper and lower pressing molds 11' and 16 is released to form a step. A tile base 22 with attached tiles is obtained.

L-shaped convex strip 11'b of the suppression mold 11' for forming the back side of the tile
Since the stepped portion 11'C is formed on the inner side of the stepped tile base 22, the difference in density between the edge portion and the first portion and between the first portion and the m portion can be reduced.

Note that the method for manufacturing a stepped tile base according to the present invention is applicable to a relatively small and thin stepped tile base (for example, 100 mm
Even if the inner surface 16c of the L-shaped protruding strip 16a of the tile surface forming press mold 16 is substantially vertical, the resulting step is Since the thickness of the stepped tile base 22 and the thickness of the sole (not shown) of the stepped tile base 22 are thin, no cracks occur at the boundary between the q part and the p part of the stepped tile base 22.

FIGS. 8 and 9 show the stepped tile base 21 (the fifth
A stepped tile 21' obtained by firing a tile (see figure) is shown, and the stepped tile 21' has an outer surface 21'a of the tile that forms the surface step portion 23.

The center part of 21'a is moved inward by an appropriate dimension S (for example.

5-57nrIL) is recessed, and the back step part 24
The center portions of the tile side surfaces 21'b and 21'b forming the portions are also recessed inward by an appropriate amount S, so that the adjacent stepped tiles 21' can be recessed inward during tile construction.

Excess mortar for attaching the tiles on the back side of the stepped tiles 21', 21' is allowed to escape to the front side of the tiles through the gap formed by the depression when the stepped tiles 21' are butted together. .

The inventor conducted an experiment under the following conditions and obtained the following results.

<Experimental conditions> 1. The raw material in the form of clay slurry for molding was spray-dried, and then the coarse particles were crushed using a device integrator or roll crusher, etc. 2. Pressing mold conditions (1) Material: Steel ( 2) Dimensions: See Figure 5A E 2ooms Mouth = 5.8 mm Ha = 7.0 m
m==1.0mm E=4. To Q@Atsushi = 4. Length = 2.011L1L T = 4.5 Wire, 0mm 3 Pressure conditions (1) Thickness of molded clay: See Fig. 5B Nu = 22.8
mm (2) Thickness dimension of stepped tile base after pressure forming 2nd 5th
Refer to Figure C Le = 11.4W shoulder (3) Pressure crab 300 Kg/crA <Experimental results> As a result of firing the stepped tile base obtained by the method of the present invention based on the above experimental conditions, the surface step part and the back step part were fired. There were no cracks occurring from the corners of the tiles that made up the section.

As described in detail above, the method for manufacturing a stepped tile base according to the present invention causes cracks to occur in the corner portions of the stepped tiles that constitute the front and back steps of the fired stepped tiles. It has the excellent effect of providing a stepped tile base that does not cause any damage.

In addition, the suppressed type according to the present invention is capable of manufacturing a stepped tile base that does not generate cracks in the tile corners that constitute the front step or back step of the stepped tile obtained by firing. It is possible to provide a suppression type that allows

[Brief explanation of drawings]

Fig. 1 is a plan view showing a conventional stepped tile, Fig. 2 is a sectional view taken along the line ■-■ in Fig. 1, and Fig. 3 is a sectional view showing the tile construction state using the conventional stepped tile. FIG. 4 is a simplified cross-sectional view for explaining a conventional method for manufacturing a stepped tile base, FIG. 5 is a simplified cross-sectional view for explaining an embodiment of the method for manufacturing a stepped tile base according to the present invention, and FIG. The figure is a cross-sectional view showing the convex strips of a pressing mold for forming the back side of a tile, FIG. 7 is a cross-sectional view illustrating an embodiment of the method for manufacturing a stepped tile base according to the present invention, and FIG. 8 is a cross-sectional view showing the back side of a stepped tile. Figure 9 is the 8th
It is a sectional view taken along the line IX-IX in the figure. 11N1')... Suppression type for molding the back side of the tile, 11b(
llb')・L-shaped surface groove, 11c (11c wa...
・Stepped portion, 12...Press mold for tile surface molding, 12b・
... L-shaped surface strip, 14 ... Molding clay, 16 ... Suppression type for tile surface forming, 2N22) ... Stepped tile base.

Claims (1)

[Scope of Claims] 1. In a method for manufacturing a stepped tile base, molding is performed on a lower die consisting of a suppression mold for tile surface forming in which L-shaped protrusions are protruded from two adjacent edges on a rectangular suppression surface. After a predetermined amount of clay is supplied, a step is formed on the inner side of the L-shaped protrusions protruding from two adjacent edges on the square suppressing surface, and a step is formed along the L-shaped protrusions. Obtaining a stepped tile base by pressing an upper mold made of a mold onto the molding surface with the L-shaped protruding stripes of the upper mold and the edges without the L-shaped protruding stripes of the lower mold facing each other. A method for producing a stepped tile base characterized by: 2. In a method for manufacturing a stepped tile base, a tile surface suppressor in which a stepped portion is formed on the inner side of an L-shaped protrusion protruding from two adjacent edges on a rectangular suppressing surface along a convex protrusion. After supplying a predetermined amount of molding clay onto the lower mold of the mold,
An upper mold made of a tile surface suppression mold in which the inner surfaces of L-shaped protrusions protruding from two adjacent edges of the square suppression surface are inclined so that the closer they get to the suppression surface, the more inward the surface is. A stepped tile base, characterized in that a stepped tile base is obtained by pressing the L-shaped protrusions of the upper mold and the edge without the L-shaped protrusions of the lower mold against each other and pressing them onto the molded surface. manufacturing method. 3. A pressing mold for the back surface of a tile, characterized in that a stepped portion is formed on the inner side of the L-shaped ridges protruding from two adjacent edges on the square pressing surface, along the ridges. 4. A suppression mold for a tile surface, characterized in that the inner surfaces of the L-shaped protrusions protruding from two adjacent edges on the square pressing surface are inclined so that the closer they get to the suppression surface, the closer to the inside it becomes. .