Multilayer tiles and methods for manufacturing the multilayer tiles

Abstract

This product provides a multi-layer tile that can be fired in furnaces other than roller hearth kilns, and at the same time contributes to solving the waste disposal problem in tile factories. [Solution] A multi-layer tile 1 is formed by stacking a decorative layer 3 on a base layer 2 and firing them together, wherein the base layer 2 is formed from base powder granules made from tile material raw materials, and the decorative layer 3 is formed from decorative powder granules granulated by mixing glaze waste with at least tile material raw materials and firing aids for increasing shrinkage rate and melting temperature, and furthermore, the thickness y of the decorative layer 3 is set to be approximately the same as or greater than that of the base layer 2. Glaze waste refers to glaze that is generally disposed of, such as leftover glaze during tile manufacturing or glaze contained in washing water during cleaning.

Description

Technical Field

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[0001] The present invention relates to a multi-layer tile formed by integrally firing a base layer made of a tile base material and a decorative layer that decoratively covers the surface of the base layer.

Background Art

[0002] A multi-layer tile composed of a base layer formed of a tile base material and a decorative layer (glaze layer) formed to an appropriate thickness so as to cover the surface of the base layer is described in, for example, Patent Document 1. In order to prevent warping during firing due to the difference in shrinkage rate between the base layer and the decorative layer of this multi-layer tile of Patent Document 1, the layer thickness of the decorative layer is formed thinner than that of the base layer and it is fired in a roller hearth kiln.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] The multi-layer tile of Patent Document 1 has the advantage that a beautiful surface state can be maintained for a long time because the decorative layer can be made relatively thick. However, on the other hand, firing in a roller hearth kiln is essential to prevent warping caused by the difference in shrinkage rate during firing between the base layer and the decorative layer (shrinkage rate of the base layer > shrinkage rate of the decorative layer), and there is a limitation that it cannot be manufactured in a tile factory that does not have such a specific furnace.

[0005] The present invention has been made in view of the above, and an object thereof is to provide a multi-layer tile that can be fired in a furnace other than a roller hearth kiln and can also contribute to the waste treatment problem of a tile factory.

Means for Solving the Problems

[0006] To achieve the above objective, the present invention, as described in claim 1, A multi-layered tile formed by stacking a decorative layer on top of a base layer and firing it as a single unit, The base layer is formed from base powder granules made from tile material raw materials, The aforementioned decorative layer is formed from decorative powder granules obtained by mixing glaze waste with at least tile base material and firing aids for increasing shrinkage rate and melting temperature, Furthermore, the present invention provides a multi-layer tile in which the thickness of the decorative layer is set to be approximately the same as or greater than that of the base layer. Here, "glaze waste" refers to glazes that are generally considered to be discarded, such as leftover glaze from tile manufacturing or glaze contained in cleaning water.

[0007] In such multi-layer tiles, firstly, the thickness of the decorative layer is set to be approximately the same as or greater than that of the base layer, thereby balancing the layer thickness so that the decorative layer can structurally resist the shrinkage of the base layer during firing. Secondly, by mixing glaze waste with at least tile base material and firing aids to increase shrinkage rate and melting temperature, decorative powder granules that constitute the decorative layer are created. In this way, the shrinkage rate and melting temperature of the decorative layer are increased to be closer to that of the base layer, allowing it to be fired without warping not only in roller hearth kilns but also in other kilns. Furthermore, by making the decorative layer thicker than half or more of the overall thickness, it is possible to maintain a beautiful surface condition for a long period of time. In addition, when installed on walls, the joint grooves between tiles are almost entirely formed by the sides of the beautiful decorative layer, improving the aesthetic appearance and making it less likely for dirt to remain even when exposed to rainwater for a long period of time. Furthermore, by forming the decorative powder granules that constitute the decorative layer from glaze waste, the overall cost of the decorative powder granules can be reduced, including the cost of disposing of the glaze waste. Therefore, it is possible to manufacture multi-layer tiles at a low cost even with a thicker decorative layer. Furthermore, glaze waste contains various metal oxides and glass components such as feldspar and pottery stone, and the amount generated is large, making disposal difficult. By making the decorative layer thicker, it is possible to provide a large and stable use for such glaze waste.

[0008] Furthermore, as described in claim 2, the multi-layer tile according to claim 1 is provided, wherein the tile base material of the decorative layer consists of unfired tile waste material. Here, "tile waste material" refers at least to waste material resulting from defects during molding or powdered waste material collected during cleaning. By using unfired tile waste as the raw material for the decorative layer of the tile, it is possible to further reduce the price of multi-layer tiles. Moreover, since glaze waste and tile waste are troublesome for tile factories, utilizing both simultaneously can significantly reduce the overall waste disposal costs for the tile factory.

[0009] Furthermore, as described in claim 3, A method for manufacturing multi-layer tiles, in which a decorative layer is placed on top of a base layer and fired together as a single unit, The base layer is formed from base powder granules made from tile material raw materials, The aforementioned decorative layer is granulated by mixing glaze waste with at least tile base material and firing aids for increasing shrinkage rate and melting temperature. The base powder and the decorative powder are sequentially filled into a mold such that the thickness of the decorative layer is approximately equal to or greater than the thickness of the base layer, and then pressed and molded together. Furthermore, the present invention provides a method for manufacturing multi-layer tiles, in which the molded product is removed from the mold and fired with the base layer side facing downwards. The multi-layered tiles of the present invention can be manufactured by the above manufacturing method, but in particular, the manufacturing method of claim 3 allows for efficient manufacturing because the base layer and the decorative layer are pressure-molded together in a single mold.

[0010] Furthermore, as described in claim 4, A method for manufacturing a multi-layer tile obtained by stacking a decorative layer on a base layer and firing them integrally, The base layer is formed of base powder particles composed of tile base material, The decorative layer is obtained by granulating by mixing at least a tile base material and a firing aid for increasing the shrinkage rate and melting temperature with glaze waste, Filling the base powder particles into a mold and press-molding, and taking out the formed base layer from the mold, On the other hand, filling the mold with an amount of the decorative powder particles that can be approximately equal to or more than the layer thickness of the base layer after press-molding and press-molding, and taking out the formed decorative layer from the mold, Then, there is provided a method for manufacturing a multi-layer tile in which the decorative layer is placed on the base layer and fired integrally. Although the multi-layer tile of the present invention can also be manufactured by such a manufacturing method, particularly in the manufacturing method of claim 4, since the base layer and the decorative layer are press-molded separately, it becomes possible to manufacture a thick multi-layer tile even with an existing mold.

Effect of the Invention

[0011] As described above, the multi-layer tile of the present invention can be fired without causing warping regardless of the roller hearth kiln, and can also greatly contribute to the waste treatment problem of the tile factory.

Brief Explanation of Drawings

[0012] [Figure 1] It is a perspective view of a multi-layer tile. [Figure 2] It is a cross-sectional view of a multi-layer tile including a partially enlarged view. [[ID=三十二]] [Figure 3] It is a cross-sectional view of a press device. [Figure 4] It is a cross-sectional view of a press device. [Figure 5] It is a cross-sectional view of a press device. [Figure 6] It is a cross-sectional view of a press device.

Mode for Carrying Out the Invention

[0013] Embodiments of the present invention will be described below with reference to the drawings. As shown in the perspective view of FIG. 1 and the cross-sectional view of FIG. 2, the multilayer tile 1 of the present invention is obtained by stacking a thick decorative layer 3 having a layer thickness y equal to or greater than the layer thickness x on a base layer 2 having a layer thickness x and integrally firing them.

[0014] The base layer 2 is formed of base powder particles 4 made of tile base materials such as feldspar, silica, and clay, and may be made of the same materials as existing tiles, or may be made of unfired tile waste base materials (at least waste base materials due to defects during molding or powdered waste base materials collected during cleaning) generated during the process before firing the tiles.

[0015] The decorative layer 3 is formed of decorative powder particles 5 obtained by mixing at least a tile base material and a firing aid for increasing the shrinkage rate and melting temperature with glaze waste and granulating them to a predetermined particle size.

[0016] The glaze waste constituting the decorative powder particles 5 is generated in the process and facilities for glazing tiles in tile factories, etc. Specifically, it is glaze remaining during tile production or glaze contained in washing water during cleaning, etc., which is generally a waste object, and is a well-known mixture of various metal oxides and glass components such as feldspar and pottery stone. Incidentally, although glaze waste has been reused by adding it during the new production of glaze and tile bases, the amount is only about 2 - 3% of the whole, and most of it is disposed of as industrial waste.

[0017] The tile base material mixed with the glaze waste may be the same as the tile base material of the base powder particles 4, but it is preferably an unfired tile waste base material generated during the process before firing the tiles. By doing so, the problems of disposing of troublesome glaze waste and tile waste base materials for tile factories can be solved simultaneously.

[0018] The firing aids mixed with the glaze waste to increase shrinkage rate and melting temperature are high-refractory materials such as calcined kaolin, zircon, and alumina. Any material that can increase the shrinkage rate and melting temperature during firing when added to the decorative powder granules 5 which contain a large amount of glaze components with low shrinkage rate and low melting temperature is acceptable. Since the composition of the glaze waste is not uniform depending on the type of tile being manufactured and the color of the glaze, the proportions of the tile base material and the materials and proportions of the firing aids should be adjusted as appropriate according to the glaze waste.

[0019] Next, a method for manufacturing the multi-layer tile 1 of the present invention using the base powder granules 4 and decorative powder granules 5 described above will be explained with reference to Figures 3 to 6. Figures 3 to 6 are cross-sectional views of the press device 6. The illustrated press apparatus 6 is a typical one used for dry pressure molding, and is generally composed of a mold 7 and a powder supply device 8 that supplies base powder 4 and decorative powder 5 to the mold 7.

[0020] The mold 7 comprises a lower mold 10 having a mold hole 9 that penetrates in the vertical direction, a slidable member 11 that can slide up and down within the mold hole 9 of the lower mold 10, and an upper mold 12 that is positioned above the lower mold 10 and can slide up and down in alignment with the mold hole 9.

[0021] The lower mold 10 is fixed, and a box-shaped mold recess 13 is formed between the inner circumferential surface of the mold hole 9 of the lower mold 10 and the top surface of the piece member 11.

[0022] The powder supply device 8 comprises a flat right standby area 14 provided on the right side of the upper surface of the lower mold 10, a base powder box 15 that can reciprocate and slide between the right standby area 14 and the upper surface of the mold hole 9, a flat left standby area 16 provided on the left side of the upper surface of the lower mold 10, and a cosmetic powder box 17 that can reciprocate and slide between the left standby area 16 and the upper surface of the mold hole 9. The base powder box 15 and the cosmetic powder box 17 are both rectangular frames that are open at the top and bottom, and the base powder granules 4 and cosmetic powder granules 5 are filled inside these frames, respectively. When the base powder box 15 or cosmetic powder box 17 is slid back and forth between the right standby area 14 or the left standby area 16 and the upper surface of the mold hole 9 on the upper surface of the lower mold 10, the base powder granules 4 or cosmetic powder granules 5 are supplied to the mold recess 13 in a level state.

[0023] Since the press device 6 has the above configuration, first, with the upper die 12 waiting above the mold hole 9 of the lower die 10 as shown in Figure 3, the die member 11 is lowered by a predetermined amount in the direction of arrow y1 to expose the mold recess 13. Then, the base powder box 15 is slid in the direction of arrow y2 in Figure 3 and stopped on the mold recess 13. As a result, as shown in Figure 4, the base powder granules 4 in the base powder box 15 are filled into the mold recess 13, and when the base powder box 15 is slid in the direction of arrow y3 in the same figure and returned to the right waiting area 14, the base powder granules 4 remain in the mold recess 13 in a level state. The amount of base powder granules 4 in the mold recess 13 is set according to the thickness of the base layer 2 after pressure molding.

[0024] Next, with the base powder box 15 returned to the right waiting area 14 as shown by the dashed line in Figure 4, the mold member 11 is lowered one more step in the direction of arrow y4 in the same figure to make the mold recess 13 reappear on the upper surface of the lower mold 10, and the cosmetic powder box 17 is slid in the direction of arrow y5 in Figure 4 and stopped on the mold recess 13. As a result, as shown in Figure 5, the cosmetic powder granules 5 in the cosmetic powder box 17 are filled onto the base powder granules 4 beyond the mold recess 13, and when the cosmetic powder box 17 is slid back to the left waiting area 16 in the direction of arrow y6 in the same figure, the cosmetic powder granules 5 remain in the mold recess 13 in a level state. The amount of cosmetic powder granules 5 in the mold recess 13 is set according to the thickness of the cosmetic layer 3 after pressure molding.

[0025] Next, with the cosmetic powder box 17 returned to the left waiting area 16 as shown by the dashed line in Figure 5, the upper mold 12 is lowered in the direction of arrow y7 in the same figure, and the base powder granules 4 and cosmetic powder granules 5 in the mold recess 13 are press-molded together as shown in Figure 6. Next, the upper mold 12 is raised in the direction of arrow y8 in Figure 6 and returned to its original position, and at the same time, the mold member 11 is raised in the direction of arrow y9 in the same figure to remove the molded multi-layer tile 1 from the mold recess 13. The multi-layered tile 1, removed from the mold 7, is placed in a refractory setter (saggar) (not shown) with the base layer 2 facing downwards, and the setter and tile together are placed in a furnace and fired under predetermined firing conditions.

[0026] Alternatively, the base layer 2 and the decorative layer 3 can be separately pressure-molded using the press device 6 described above, and the separately molded decorative layer 3 can be placed on top of the thus molded base layer 2. The setter and the entire assembly can then be placed in a furnace and fired in the same manner as described above. [Examples]

[0027] A mixture of 55% by weight of glaze waste, 28% by weight of tile body material (unfired tile waste body), 6% by weight of calcined kaolin (calcination aid), 6% by weight of zircon (calcination aid), and 5% by weight of alumina (calcination aid) was prepared and granulated using a sieve with an opening of 4 mm to produce decorative powder granules 5. To this decorative powder granules 5, 3% by weight each of mold release oil (main component: mixture of kerosene and oil) and diluted commercially available PVA were added as molding aids. Then, using a general tile base material consisting of feldspar, silica, clay, etc. as the base powder material 4, the base powder material 4 and decorative powder material 5 were sequentially filled into the mold 7 as described above, and the base layer 2 and decorative layer 3 were press-molded together with approximately the same thickness. The total thickness of the multi-layer tile 1 is approximately 10 mm. Next, the base layer 2 was placed on a setter and fired in a tunnel kiln at approximately 1250°C for 24 hours. The multi-layer tile 1 fired in this manner was confirmed to be of good quality, with the base layer 2 and decorative layer 3 forming a single unit without warping. Furthermore, through repeated prototyping, it was confirmed that the cosmetic layer 3 could be made to a thickness that accounts for 3 / 4 of the total thickness. [Explanation of Symbols]

[0028] 1 ... Multi-layered tiles 2 ... Base layer 3… Makeup layer 4 ... Base powder / granules 5. Cosmetic powders and granules 7…Mold x ... thickness of the base layer y ... thickness of the cosmetic layer

Claims

1. A multi-layered tile in which a decorative layer is placed on top of a base layer and fired together as a single unit, The base layer is formed from base powder granules made from tile material raw materials, The aforementioned decorative layer is formed from decorative powder granules obtained by mixing glaze waste with at least tile base material and firing aids for increasing shrinkage rate and melting temperature, Furthermore, the multi-layer tile is characterized in that the thickness of the decorative layer is set to be approximately the same as or greater than that of the base layer.

2. The multi-layer tile according to claim 1, characterized in that the tile base material of the decorative layer consists of unfired tile waste material.

3. A method for manufacturing multi-layer tiles, in which a decorative layer is placed on top of a base layer and fired together as a single unit, The base layer is formed from base powder granules made from tile material raw materials, The aforementioned decorative layer is granulated by mixing glaze waste with at least tile base material and firing aids for increasing shrinkage rate and melting temperature. The base powder and the decorative powder are sequentially filled into a mold such that the thickness of the decorative layer is approximately equal to or greater than the thickness of the base layer, and then pressed and molded together. Furthermore, a method for manufacturing multi-layer tiles, characterized in that the molded product is removed from the mold and fired with the base layer side facing downwards.

4. A method for manufacturing multi-layer tiles, in which a decorative layer is placed on top of a base layer and fired together as a single unit, The base layer is formed from base powder granules made from tile material raw materials, The aforementioned decorative layer is granulated by mixing glaze waste with at least tile base material and firing aids for increasing shrinkage rate and melting temperature. The base powder material is filled into a mold and pressure-molded, and the base layer thus formed is removed from the mold. On the other hand, after pressure molding, the decorative powder granules are filled into the mold in an amount that is approximately equal to or greater than the thickness of the base layer and pressure molded, and the decorative layer thus formed is removed from the mold. A method for manufacturing multi-layer tiles, characterized in that the decorative layer is then placed on the base layer and fired integrally.

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