JPH0466974B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial Application Field] The present invention relates to a method for manufacturing a tile with a sole foot, and particularly to a method for manufacturing a tile in which the structure of the foot surface of the sole foot is improved.

[Prior Art] To manufacture tiles, raw materials are shaped, calcined if necessary, glazed, and fired. When firing in a roller hearth kiln, conventionally, the tile 1 is placed so that the foot surface 3 of its sole 2 is flat, as shown in FIG. 3 and FIG. 4, which is an enlarged view of the main part of FIG. 3. It is molded.

Roller hearth kilns, for example, have an internal width of 100 to 150
A large number of high-alumina porcelain rollers are placed in the kiln, which is approximately 40 to 50 meters long and has a length of 40 to 50 meters.The porcelain rollers are rotated and tiles are placed above them. The tiles are transported from the tile to the exit and fired on the way. Roller hearth kilns are mainly used in Japan when flat firing (tiles are fired horizontally) or for small lot production.

When firing tiles directly with this roller hearth kiln, i.e. without using a setter,
The tile substrate often adheres to the roller. This welding is caused by small chips in the tiles as they move through the roller hearth kiln (the edges of the soles are particularly prone to chipping). This is due to the fact that debris from the floor or substrate scraps scraped off by the rollers adhere to the rollers in the high-temperature section of the roller hearth kiln.
As mentioned above, since the sole surface of the foot is flat, the contact area with the roller becomes large, and welding to the roller is likely to occur. This kind of welding is
This is noticeable in porcelain tiles that are fired at high temperatures.

[Problems to be Solved by the Invention] Conventionally, in order to prevent the tile base from adhering to the roller, an anti-fusing material such as alumina powder (hereinafter sometimes abbreviated as alumina) was applied to the back surface of the tile. What is done is done. however,
In this case, since alumina must be applied to the entire surface of the sole, a relatively large amount of alumina will remain attached to the tile after firing. When a tile with a large amount of alumina adhered to the back surface is constructed in this way, the adhesion between the tile and the mortar becomes poor and construction defects are likely to occur. Therefore, it was necessary to remove the alumina powder remaining on the back surface of the tiles prior to tile construction.

[Means for Solving the Problems] The first aspect of the present invention is a tile manufacturing method that includes a step of molding clay into a tile base and firing it in a roller hearth kiln. In doing so, a protrusion is formed on the sole surface of the sole, and the molded article is passed through a roller hearth kiln in the direction in which the protrusion extends without a setter.

A second aspect of the present invention provides a tile manufacturing method that includes a step of molding clay into a tile base and firing this in a roller hearth kiln. It is characterized by forming stripes and attaching an anti-fusing material only to the apex portions of the protrusions.

[Function] In the tile manufacturing method of the present invention, since the protrusion is provided on the sole of the molded body, the contact area between the foot surface of the tile sole and the roller of the roller hearth kiln is reduced, so that welding is prevented. It's hard to do. Also,
When firing tiles with sole feet in a roller hearth kiln, the edges of the sole tend to chip, and the fragments caused by these chips become a cause of welding. However, in the manufacturing method of the present invention, this It is also possible to avoid contact of the edges with the roller hearth. Therefore, chipping of the sole edge can be prevented, which also prevents welding of the tile base and the roller.

In addition, when applying an anti-fusing material such as alumina to the back of the tile to reduce the adhesion of the tile base to the roller, there is no need to apply it to the entire foot surface.
Since it is necessary to apply it only to the top end of the foot surface, deterioration in tile adhesion due to the influence of alumina, etc. remaining on the tile is prevented.

[Example] The present invention will be described in more detail below with reference to the drawings.

FIG. 1 is a cross-sectional view of a tile manufactured by a method according to an embodiment of the present invention. The tile 4 according to this embodiment has a sole 5 on its back surface, and the foot surface 6 of the sole 5 has a chevron-shaped cross-section as shown in FIG.

When such a tile 4 is fired in a roller hearth kiln, only the top end 6a of the foot surface 6 comes into contact with the roller, making it difficult for the tile 4 to adhere to the roller. In addition, since the edge 6b of the sole 5 does not come into contact with the roller, the edge 6b is less likely to be bent, and this also makes it less likely that the tile 4 will be welded to the roller.

Furthermore, even when alumina is applied to the back surface of the tile 4 when fired, alumina only needs to be applied to the top end 6a of the sole 6, so the amount of residual alumina is reduced and the tile adhesion is improved by the residual alumina. Almost no decrease occurs. Also,
The amount of alumina used is also reduced, making it possible to reduce costs.

In the tiles shown in Figures 1 and 2, the thickness of the tile body is 8 mm, the depth of the dovetail groove 7 is 2 mm, the width of the sole is 8 mm, and the protruding height of the foot surface is 0.5 mm.
In this case, welding of the tile 4 to the roller could be completely prevented by applying less than 1/4 the amount of alumina compared to the conventional method. In addition, almost no welding occurred even when alumina was not applied.

In addition, various studies have been conducted on tiles of this size, and it has been found that for the sole 6 having the shape shown in FIG. 2, it is preferable that the protruding height of the sole is approximately 0.5 to 2 mm. was recognized.

FIG. 5 is an enlarged sectional view showing the shape of the sole of a tile employed in a different embodiment method of the present invention. In this sole foot 8, there are two protrusions 8 having a chevron-shaped cross section.
a and 8b are provided.

Further, the sole 9 of FIG. 6 is provided with protrusions 9a and 9b having an arcuate cross-section. In the sole 10 of FIG. 7, the top surface of the protrusion 10a is a flat surface 10b.
It is said that Further, in the sole 11 of FIG. 8, a protrusion 11a having an arcuate cross-section is formed. Although not shown, in the case where two or more protrusions are provided as shown in Figure 5 or 6, one of the protrusions, for example 8a and 9a, is omitted and the protrusions are partially provided. It can also be used as the sole of the foot.

In addition, in the sole foot illustrated above, the sole foot itself is provided so as to have a thick tip from the tile body, but as shown in FIGS. Good too. Also the 11th
As shown in the figure, the entire sole may be shaped like an arc.

The procedure itself of the tile manufacturing method of the present invention is the same as the conventional method. That is, the raw material is prepared into clay, which is then molded, and tiles are manufactured through processes such as firing, glazing, and glazing. Of course, it is also possible to use unglazed firing without glazing.

As the roller hearth kiln, various types of roller hearth kilns can be employed, such as one using electricity as a heat source, one using gas as a heat source, or one having multiple stages of rollers.

[Effects of the Invention] As is clear from the above description, according to the tile manufacturing method of the present invention, welding to the roller of a roller hearth kiln is prevented, manufacturing is easy, and the yield is high. In addition, welding can be prevented by not using alumina to prevent welding at all, or by using only a very small amount of alumina, and a decrease in the adhesion of tiles due to residual alumina can be prevented.

[Brief explanation of drawings]

FIG. 1 is a sectional view showing the overall structure of a tile manufactured by a method according to an embodiment of the present invention, and FIG.
3 and 4 are cross-sectional views showing tiles manufactured by the conventional method, and each of the figures in FIGS. FIG. 3 is an enlarged cross-sectional view showing the sole shape of the tile. 4...Tile, 5-14...Sole foot.

Claims (1)

[Scope of Claims] 1. In a tile manufacturing method that includes a step of molding clay into a tile base and firing this in a roller hearth kiln, when forming the tile base, a protrusion is formed on the foot surface of the sole. A method for manufacturing a tile with soles, characterized by forming stripes and passing the molded product through a roller hearth kiln in the extending direction of the protrusions without a setter. 2. The manufacturing method according to claim 1, wherein the protrusions have a chevron-shaped cross-section. 3. In a tile manufacturing method that includes a step of molding clay into a tile base and firing it in a roller hearth kiln, when forming the tile base, a protrusion is formed on the foot surface of the sole, and A method for manufacturing a tile, characterized in that an anti-fusing material is attached only to the top end of the protrusion. 4. The manufacturing method according to claim 3, wherein the protrusions have a chevron-shaped cross-section.