JPS6232137B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for manufacturing glass mosaics.

As is well known, the mainstream method for producing glass mosaics has been manual production methods. That is, for example, there is a method of producing small quantities one by one using a crucible kiln, or a method of removing seeds from a tank kiln and molding them with a mechanical press.

With this method, there are problems in that production efficiency is low and costs are high when making ordinary glass mosaics, except when very special shapes, patterns, etc. are required.

This invention was made with the aim of solving these conventional problems.The molten base material is drawn out from a tank kiln and rolled by a pair of mold rollers to form a continuous molded glass mosaic. The present invention provides a method for manufacturing a glass mosaic, which involves obtaining a single glass mosaic by fracturing the glass mosaic at both the vertical and horizontal thin parts formed in advance.

Embodiments of the present invention will be described below with reference to the drawings.

FIG. 1 is a schematic diagram showing an example of a glass mosaic manufacturing apparatus and process for explaining the present invention. Figure 2 is a front view of the rollout machine seen from the direction of arrow A in Figure 1, and Figure 3 is a front view of the rollout machine seen from the direction of arrow B in Figure 1.
FIG. 4 is a front view of the deburring roller seen from the direction of arrow C in FIG. 1, and FIG. A plan view of the deburred glass mosaic continuous molded body, FIG. 6 is a plan view of the first breaking roller seen from the direction of arrow D in FIG. 1, and FIG. 7 is a glass mosaic broken by the first breaking roller. A horizontally broken piece of the continuous body, which is a plan view seen from the direction of arrow D in Fig. 1, Fig. 8 is a front view of the second breaking roller seen from the direction of arrow C in Fig. 1, and Fig. 9. 2 is a plan view of a single glass mosaic formed by breaking horizontally broken pieces with a second breaking roller, as seen from the direction of arrow D in FIG. 1. FIG. Figure 10 is an enlarged plan view of the part in Figure 2, Figure 11 is an enlarged plan view of the XI part in Figure 2, and
Figure 2 is an enlarged cross-sectional view of the roll-out machine shown in Figure 1 from XII-XII, Figure 13 is an enlarged detailed view of the single glass mosaic shown in Figure 9, and Figures 14 to 16 are other implementations of the sole of the glass mosaic alone. This is what is shown. Note that the same parts are given the same reference numerals throughout the figures.

First, the configuration will be explained. This invention consists of the following five steps. In other words, (1) General-purpose raw materials for glass mosaics are adjusted to a particle size that is easy to melt, and then mixed in a commonly used ratio (if necessary, product glass waste (cullet) may be added in an appropriate ratio). , high temperature tank kiln T
(Fig. 1) and melting the glass to obtain a sufficiently homogeneous molten base G without impurities or air bubbles; By letting it flow out, it is pulled out horizontally into a belt shape and guided to a rollout machine M (see Fig. 2) consisting of a first type roller 2 and a second type roller 3, where it is rolled and formed into a pattern. A lattice-like thin wall portion consisting of vertical and horizontal thin wall portions 4 and 5 formed (see Figures 3, 5, and 12)
(3) placing the continuous glass mosaic molded body S ₁ on a roll conveyor _C and guiding it to a slow cooling furnace R; (4) burrs 6 ( _third
Figure) is a deburring roller made of an elastic material.
A continuous glass mosaic molded body S ₂ is obtained by dropping it along the vertical thin wall portion 4 at H ₀ (4th and 5th
(See figure) Burr removal process (5) Glass mosaic continuous molded body with burr 6 removed
S ₂ is successively broken along the horizontally thin wall portion 5 by a first breaking roller H ₁ made of an elastic material to form a horizontally broken piece 7 (see FIG. 7), and then this horizontally broken piece 7 is broken into a second broken piece made of an elastic material. The glass mosaic is broken along the vertical thin wall portion 4 with a breaking roller H ₂ to obtain a single glass mosaic U.

Here, the melting temperature of the raw material in the tank kiln T is generally 1300 to 1550°C. The viscosity of the molten base G is preferably about 10 ³ to ^{10 4} poise, which is suitable for molding in a continuous molding process. Note that t ₁ in the tank kiln T is an on-off valve for the substrate outlet 1 .

As shown in FIGS. 10 to 12, the first type roller 2
is a mold roller that molds the back side of the single glass mosaic U, that is, approximately half of the bottom side;
The mold roller 3 is a mold roller that molds approximately half of the surface side. The first type roller 2 and the second type roller 3 are designed to mesh as shown in FIG. 12. That is, the glass mosaic continuous molded body S ₁ has both vertical and horizontal thin-walled parts 4,
5, a gap g corresponding to the thickness of the thin-walled portions 4, 5 is provided between the ridges 2a, 3a of each mold roller 2, 3 so that they mesh with each other. Therefore, when the melting element G is formed by both the first and second type rollers 2 and 3 which are driven and rotated in the direction of the arrow a, the glass mosaic unit U is integrated into the thin parts 4 and 5. A continuous band-shaped molded body joined together, that is, a glass mosaic continuous molded body S ₁
becomes. The thin wall portions 4 and 5 have sufficient strength to maintain the shape of the band-shaped compact during the slow cooling process, but have a thickness that allows them to be easily broken by applying a slight force during the breaking process. It's facing down.

The first type roller 2 has a single glass mosaic U
A protrusion 9 is provided to form a sole 8 (FIG. 13). The protrusions 9 are not limited to the pattern shown in FIG. 10, and may be provided, for example, to form the chevron-shaped soles in FIG. 14 or the lattice-shaped soles in FIG. 15. .

The slow cooling furnace R is a tunnel furnace, and its length varies depending on the size and shape of the glass mosaic. Normal 10~
The range is 30m. The temperature gradient in the longitudinal direction inside the furnace is determined by parameters such as the heat capacity of the glass mosaic, the supplied heat, or the speed of the roll conveyor C. The slow cooling temperature range is usually about 400 to 450°C. It is desirable that the glass mosaic continuous molded body _S1 be at a temperature at the outlet of the lehr R that can be handled by hand.

As shown in FIG. 4, the deburring roller _H0 consists of a feed roller 10 and a presser roller 11.
It is being driven in the direction of arrow b. Then, the burr 6 of the glass mosaic continuous molded body _S1 immediately after molding is pressed by the collar 11a of the presser roller 11 and is broken at the vertical thin wall portion 4, and is removed as shown in FIG.

The first breaking roller H ₁ consists of a pedestal 12 with a groove 12 a and a pressing roller 13 . The glass mosaic continuous formed body S ₂ fed from the deburring roller H ₀ is pressed from above into the groove 12 a of the pedestal 12 by the pressing roller 13 and is broken at the lateral thin wall portion 5 .

As shown in FIGS. 1 and 8, the second breaking roller H ₂ consists of a pair of upper and lower feed rollers 14 and 15 that are driven in the direction of arrow C, and each roller 1
4 and 15 are provided with independent protrusions 16. The protrusions 16 are provided at intervals of every other vertical thin wall portion 4 of the continuous glass mosaic molded body _S2 , and
Each of the upper and lower feed rollers 14 and 15 has its protrusion 16
are interlocked with each other so as to match the spacing of the vertical thin wall portions 4. Therefore, when the horizontal broken pieces 7 are now fed into the second breaking roller _H2 , they are broken at the vertical thin wall portions 4 and divided into individual glass mosaic units U. FIG. 9 shows this state.

Figure 16 shows the sole of the single glass mosaic U.
This is an example in which glass beads 17 (preferably average particle size of about 1 to 2 mm) are used instead of molding. The glass beads 17 may be introduced before the molten base material G is fed into the rollout machine M.

That is, as shown in FIG. 18, (the same parts as in FIG. 1 are given the same reference numerals). The molten base material G is fed into the mold surface, distributed evenly, and pulled out from the tank kiln T.
It is advisable to attach it to the mold at the same time as the molding.

Figure 17 shows that the sole of the single glass mosaic U was made with silica sand 18 (average grain size 1) without molding.
Approximately mm is preferable. ).
In the case of silica sand 18, roll silica sand paper 19 made by attaching sand 18 to a long strip of paper is used.
As shown in the figure (the same parts as in FIG. 1 are given the same reference numerals), the molten base material G may be fed into the roll-out machine M at the same time.

That is, roll silica sand paper 19 is
The molten base material G is introduced so as to be wrapped around the first type roller 2 with the attached surface facing outward.
It is advisable to simultaneously mold it using the roll-out machine M while attaching it to the mold. Then, the attached paper portion of the rolled silica sand paper 19 is burned away by the heat of the molten base material G, leaving only the silica sand 18 as the sole.

In addition, other than glass beads 17 and silica sand 18,
Any heat-resistant inorganic material that does not melt due to the heat of the molten base material G can be made into particles of a desired size and used as the sole. In addition, glass beads 17,
The silica sand 18 can be used either when using the first type roller 2 provided with the protrusions 9 for the soles as shown in FIG. 10, or when using a type roller (not shown) without the protrusions 9. It can be introduced as appropriate and used as the sole.

As explained above, the present invention involves pulling out a molten base from a tank kiln, rolling it with a pair of mold rollers to form a continuous molded glass mosaic, and then rolling this into a continuous molded body of glass mosaic through both vertical and horizontal thin walls formed in advance during the molding process. Since the glass mosaic is broken at a portion to obtain a single glass mosaic, it is possible to continuously manufacture a large amount of glass mosaic, thereby improving production efficiency and reducing costs.

[Brief explanation of the drawing]

Fig. 1 is a schematic diagram showing an example of a glass mosaic manufacturing apparatus and process for explaining an embodiment of the present invention, and Fig. 2 is a front view of the rollout machine in Fig. 1 as seen from the direction of arrow A. , FIG. 3 is a plan view of the continuous glass mosaic molded body in FIG. 1 as seen from the direction of arrow B, FIG. 4 is a front view of the deburring roller in FIG. 1 as seen from the direction of arrow C, and FIG. 7 is a plan view of the deburred glass mosaic continuous formed body as seen from the direction of arrow D in FIG. 1, FIG. 6 is a plan view of the first breaking roller in FIG. 1 as seen from the direction of arrow D, and FIG. The figure is a plan view of the horizontal broken pieces of the glass mosaic continuous body obtained by being broken by the first breaking roller in FIG. 1, as seen from the direction of arrow D;
8 is a front view of the second breaking roller in FIG. 1 as seen from the direction of arrow C, FIG. 9 is a plan view of the single glass mosaic in FIG. 1 as seen from the direction of arrow D, and FIG. Enlarged plan view of Figure 2, No. 11
The figure is an enlarged plan view of XI in Fig. 2, and Fig. 12 is an enlarged sectional view of the rollout machine taken along line XII-XII in Fig. 1.
Figure 13 shows a single glass mosaic; Figure A is a plan view of the front side, Figure B is a plan view of the back side, Figure C is a cross-sectional view of Figure A, Figures 14, 15, FIGS. 16 and 17 are plan views showing other embodiments of the sole of a single glass mosaic, and FIGS. 18 and 19 show other embodiments of the sole forming step in the continuous molding process of the present invention. It is a process outline diagram. T...tank kiln, G...molten base material, 2...first type roller, 3...second type roller, M...rollout machine, 4...vertical thin section, 5...horizontal thin section, _S1 , _S2 ...glass mosaic Continuous molded body, C... conveyor, R... lehr, 6... burr, 7... horizontal broken pieces, U... glass mosaic unit, 17... glass beads, 18... silica sand.

Claims (1)

[Scope of Claims] 1. After adjusting the required raw materials to an appropriate particle size, the mixture is mixed in the required quantity ratio, or if necessary, product glass scraps are added in an appropriate quantity ratio, and the mixture is placed in a high-temperature tank kiln. A first type roller and a second type roller are used to draw out the molten base horizontally in the form of a belt from a tank kiln. Continuous molding process to obtain a band-shaped glass mosaic continuous molded body by guiding the glass mosaic into a roll-out machine and molding it into a pattern pattern while rolling it, and molding it so that it can be broken in a lattice-like thin-walled part consisting of both vertical and horizontal thin-walled parts, and glass mosaic. A slow cooling step in which the continuous molded body is placed on a conveyor and led to a slow cooling furnace to gradually cool it to a slow cooling temperature range in which stress and strain inside the molded body can be removed, and a strip-shaped glass mosaic continuous molded body that has reached at least the slow cooling temperature range. The burr removal process involves removing burrs from both ends of the glass mosaic along the vertically thin-walled parts, and the glass mosaic continuous molded body from which the burrs have been removed is successively broken along the horizontally thin-walled parts to create horizontally broken pieces, which are then cut into vertically thin-walled pieces. A method for manufacturing a glass mosaic, which comprises a breaking process in which a single glass mosaic is obtained by breaking along the sections. 2. In the continuous forming process, when forming the molten base material,
2. The method for producing a glass mosaic according to claim 1, further comprising a step of forming a sole of a single glass mosaic by introducing a heat-resistant inorganic material such as glass beads or silica sand.