Note: Descriptions are shown in the official language in which they were submitted.
2 ~ 5 3
SPECIFICATION
TILE HAVING A PATTERN AND ITS MANUFACTURING METHOD
BACKGROUND OF THE INVENTION
Field of the Inventlon
- The present lnvention relates to a nonglazed tile
provlded wlth a deslgn of many colors or a colored pattern
and its manufacturing method, particularly to a tile which
ls able to keep an initial distinct and vlvid pattern even
against long tlme abrasion and its manufacturlng method.
Such tiles may be laid on a floor of a bathroom, a lavatory
or the like, sldewalks of a park, a shopping center or the
llke, etc. Such tiles may be also used for an lnterlor or
exterlor wall material of a bullding or applled to tlling
at stepped portions of stairs or roads, corners o~
gateposts or buildings, etc.
Descriptlon of Related Art
Conventlonally, cement tlles, whlch are cheap, are
generally used for tiles having a pattern that are laid on
a sidewalk, a floor or the l~ke whlle serving as an
ornament, slnce such tlles need to be lnexpensive. Each
plece of tlle ls a plain colored tile of generally a
rectangular shape fabricated by a colored body added with a
kneaded pigment. Varlous colors of tiles are used ln
combinatlon and ~oined to each other by a ~olntlng cement.
In case one plece o~ rectangular tlle needs to have a
multicolored pattern, ln general, colored tile pieces sf
different colors are separately made, thereafter the
- colored tile pleces of different colors and shapes are
~ointed by a cement at the time of laying.
There 1~ a tlle havlng a pattern wlth only a surface
printed by a pl~ment.
However, with the method of making a pattern by a
manner of arranglng the rectangular plaln colored tiles as
the conventlonal tlles having a pattern, patterns to be
- 1 -
2~6~3
formed are llmited in simple patterns such as a diced
pattern, now that a piece of floor tile is large, l.e.
200mm or 300mm square.
With the method of ~olntlng the colored tile pleces by
a cement at the time of laying, a white llne of the
~ointing cement which is exposed after ~olning is easy to
become dirty and unclear particularly in a floor, a
pavement or the like. Moreover, if the ~olnted part ls
made into a line as narrow as possible, inadvantageously it
ls peeled off with tlme. With this method, a border of the
colored tile pieces is also limited ln a straight line or a
curved line very simllar to the straight line due to work
convenience. In addition, as the colored tile pieces are
separately made, a ~ointing work by the cement ~oining them
each other is multiplied, then taking much time and labor
in a laying work at a ~ob site.
Furthermore, though the cement tile can be
manufactured at low costs, slnce it does not experlence
burnlng, it ls lnferior to a burnt tile in luster or the
llke, and ls low ln strength, partlcularly a surface
strength thereby being abraded wlth time, e.g. when
pedestrlans pass thereon. Such a tlle needs to be thlck in
order to assure a flxed strength, so that a transportation
work efflclency ls lower~d.
The tile wlth the surface alone printed by an organlc
plgment ls lnadvantageously decolored wi~h tlme.
By the reasons mentlor,ed above, burnt tlles are
deslrously used at a sidewalk of a shop street, a park or
the like an appearance of which i8 thought lmportant.
Some methods are used for glvlng a pattern to a
nonglazing tile as a burnt tlle. One method ls to form
flutes or lrre~ularltie~. Other method is to disperse rock
powders or colored tlle powders to obtain a spotted
pattern. However, these methods are not satlsfactory ln
view of ornamentatlon. There is a tlle provided with a
baklng pattern by printing or handwriting on a surface of a
green body or a biscuit tile, too~ However, the thickness
of the pattern of thls tlle ls about O.1 to O.3mm, so that
the pattern i9 faded by abra~lon or the tiles are posslbly
slippery thereby to need some cautlon in case of wet
conditlon, wlth resultant limited applications.
In order to solve these problems, Japanese Paten~
Pu~licatlon No. 50-20962 discloses a technique of
manufacturing method of a multicolor tile in whlch a
powdery pattern is embedded into a surface of a tile ln a
thickness of 3mm. As improved methods of the above
technique, Japanese Patent Publlcatlon No 2-42323 shows a
manufacturlng method of ceramics provided with an inlald
ornamental surface, and Japanese Laid Open Patent
Publlcation Nos. 2-239905 and 2-241703 respectively
disclose techniques of manufacturlng methods of inlaid
tiles. These lnlaying methods can obtain nonglazing tiles
having a variety of patterns of a thickness of about 3mm,
since they embed prepared patterns into bodies and sinter
them.
As mentloned above, the inlald tiles excel, as
nonglazed tiles used for pavements or the llke, ln view of
varlety of patterns and thickness.
However, it ls lmportant for the inlaying method to
control density and shrinkage degree of pattern material ,
pellets and powders to be embedded as well as compression
density of concaves of bodies receiving the embedded
materials, in order to get tiles with a precise and
elaborate boundary between ~he body and the pattern.
Unless they are not controlled, gaps arise at the boundary.
Generally, the inlaying method needs two or three times of
presslng work, so that it has dlsadvanteges of taking a lot
of time and labor in making tlles and lncreasing production
costs.
In the technique of Publication No. 2-241703t a base
tile is preformed at such a pressure as malntalning its
shape. Dents are formed at the same time and inlaylng
pellets are put and fitted into the dents. Otherwise,
separately preformed base tlle pellets and inlaylng pellets
- 3
2~0~as~
are arranged in order while the base tile pellets are kept
flat, then they are pressed and formed as a whole. The
inlaid tlles thus obtained have desired strength by
burning, and has no gaps produced at the above mentioned
boundary. Moreover, different colors of clay bodies rarely
flow on presslng, so that it is posslble to make clear the
boundary between inlaid patterns and other areas.
However, the technlque of Publicatoin No. 2-241703
takes a lot of time and labor in making the base tiles
having dents. In case the tile is give such a pattern as
has a constant width of partltion line at the boundary of
the pattern, it is difficult to make the width of the
partitlon line constant, so that it is unseemly in view of
appearance.
As a manufacturing method of a body provided with a
pattern of unfixed shapes of spots, Japanese Patent
Publicatlon No. 2-8883 discloses a tile having a bordered
pattern of unflxed shapes of spots which is obtalned by
arranging and pressing to mold a lump of raw material
dusted with color pigment powder or a lump of color raw
material dusted with raw material powder in a press die.
However, the technique ls limlted in the pattern of unflxed
shapes, so that it is necessary to think out how to arrange
the color raw materlal lump or the llke in order to make a
uniform pattern.
It is known to mix and knead two colors of clays and
slice kneaded body, thereby making such a pattern as an lnk
flow. Wlth tlles obtained by this technique, slnce the
same color part go through the tile ln the thlckness
direction, the pattern ls never va~ished even lf the
surface is abraded. However, this technique is ln capable
of providing patterns other than ~he above lnk flowlng
pattern. Moreover, the tiles are fabrlcated by hand, so
that the technique is no good in workability.
Conventionally, ln tiling a corner, angle tiles which
are bent according to an angle of the corner are used. The
angle tiles are manufactured generally by pressure forming
2 1 ~ 3
of powder raw material. Specl:Eically, lts making method
utilizes a press dle which define an angle ~hape of a
pressing space between au upper mold and a lower mold of a
V-section or an inverted V-section. The powder raw
material added wlth a blnder is dlspo3ed on a whole surface
of both slopes of the lower mold and a top thereof. Then
the materlal ls pressingly formed between the upper and
lower molds, thereafter belng burned to obtain produce
tiles. Such a technique ls shown in Japanese Utllity Model
Publicatlon No. 4-30011 or the llke, for example.
Thus manufactured angle tiles have good appearance and
sufficlent corner strength, since they are formed into one
body as a whole includlng the corner and have no ~oints.
Still, a surface pattern ls limited lnto a slmple color
pattern such as one color pattern or a spotted pattern.
In recent years, there arlse needs for colorful tiles.
Therefore, many kinds of tiles with varlous patterns have
been proposed and used. For instance, in addition to the
above Publication No. 2-42323, Japanese Patent Publication
No. 2-8883 dlscloses a tile having an unfixed pattern which
is obtained by arranging and pressingly forming raw
material lump of clay body dusted with color pigment powder
ln a press die.
~ owevex, as such varlous patterns are made by use of a
plane die, the above methods are applicable to flat plate
shaped tlles, but it ls hard to apply to the above
mentioned angle tiles which are manufactured by use of a
press die with lnclined die sur~aces. Therefore, other
methods are currently adopted to make up corners uslng
tlles having the above color pattern. One method ls to
stlck two tiles at rlght angles via an adhesive. Other one
is to ~oin two tiles at rlght angles via cement and connect
them by use o~ angle members made of a metal, a synthetic
resln or the like.
However~ these methods need much labor in practising.
Moreover, lt 1~ possible that a cutting plane is exposed to
affect an appearance. There is a fear of abrasion in case
2 ~ 3 3 c~
of connecting through the cement. Thus, large improvement
i~ to ba achleved ln m~nufacturing steps ~or tiling,
durabllity, an appearance, etc. if angle tlles that has
~arlous pat~erns can be obtained. For that reason, such
tlles have been desired in the industry for a long tlme.
SUMMARY OF THE INVENTION
In vlew of the above, it ls an object of the lnventlon
to provlde a nonglazed tile having a pattern and a
manufacturlng method thereof that ls capable of clearly
maklng desired and ~arious pattern3 by slmple steps wlthout
any gaps at a boundary, that ls free from fading or
disappearing of the patterns and that prevents slip when it
gets wet.
It ls another ob~ect of the lnventlon to provlde a
tile havlng a pattern and a manufacturing method thereof
that has large abrasion resistance whlle having a fixed
wldth of partition llne at a boundary of the pattern and
that ls excellent in an appearance of the boundary o~ the
pattern.
It 1~ a still another ob~ect of the invention to
provlde a tlle having a pattern and a manufacturlng method
thereof that can easlly make such color patterns as are
lmposslble ln a common forming dle for an angle tile and
that has a sufficient ccrner strength and high quality ln
an appearance.
In accordance with one preferred mode of the
inventlon, there ls provlded a tile havlng a pattern that
is made by. disposing a plurality of molding materials of
dlfferent colors into an ln~lde space of a pre sure forming
dle while dlviding them from each other ln a planar
dlrectlon of the inside space and whlle having each color
of the moldlng materials extend from one slde to an other
slde of a thickness direction of the inslde space; presslng
and forming integrally the moldlng materials into a molded
body in the ln~ide space; and burnlng the molded body.
Preferably, the molding materlals are composed of
- 6 -
2 1 ~
different colors of colored granules fllled in a dlvlded
manner ln the inside space; and the molded body is made by
pressing and forming integrally the colored granules ln the
inside space.
More preferably, a partition means ls disposed in the
lnslde space to divide the inside space into a plurality of
formlng spaces; and each color of the colored granules are
filled in each of the forming spaces.
Preferably, the partition means is a par~itlon wall
made of a clay body lnto a predetermlned moisture content,
and the partition wall is pressed and formed integrally
with the colored granules to make the molded body.
Preferably, the molding materials are blockS
respectlvely prepared before being disposed in the inside
space, and the block is made by kneading a raw material
ml~ed powder, a pigment and water to prepare a plurality of
colored clay bodles of different colors o~ a predetermined
moisture content, molding each color of the colored clay
bodies lnto a colored base material of a flxed thickness,
and Joinlng a plurality of colored base materials of
different colors in its ~hlckness directlon lnto one body.
Preferably, the molded body ls made by gatherlng,
plling and ~olnlng a plurality of base materials of
dlfferent colors, cuttlng the ~oined base materials in the
gathering and plling dlrection into a constant wldth
thereby maklng the block, and disposing and pre~slng the
blocks ln the lnslde space whlle a cutting surface of the
block belng faced vertlcally.
Preferably, the base materlal has a bar shape; the
block ls made by gathering, twiRtlng and Jolnlng the ba~e
materials of different colors; and the molded body ls made
by dlsposing the block in the inslde space ln the planar
dlrection and pressingly forming the block therein.
Preferably, the molding material comprises a preformed
body of a plate shape prepared before belng dlsposed in the
pressure forming die; the pressure formlng die compri~es an
upper mold and a lower mold definlng a forming space of
2 1 ~ 3
substantlally an angle section therebetween; and the molded
body i5 made lnto an angle plate by disposing a pair of
preformed bodles on opposite slopes of the lower mold,
disposing a joinlng materlal between opposlng end surfaces
of the preformed bodles along a corner of the lower mold,
and pressing the preformed tile bodies and the ~oinlng
material between the upper mold and the lower mold into one
body.
In accordance with one preferred mode of the
invention, there ls provided a manufacturing method of a
tile having a pattern, comprising: a molding material
disposing step for disposing a plurality of molding
materials of different colors into an inside space of a
pressure forming dle while divlding them from each other in
a planar direction of the inside space and whlle having
each color of the molding materials extends from one side
~ to an other side of a thickness direction of the lnside
space; a pressure forming step for pressing and forming
integrally the molding materials into a molded body in the
inside space; and a burning step for burning the molded
body.
Preferably, the molding materials are composed of
different colors of colored granules; the molding material
disposl~g step is a colored granule filllng step for
filling the plural colored granules in a divlded manner in
~he inside space; and the molded body is made by pressing
and form~ng integrally the colored granules in the inside
space in the pressure formlng step.
More preferably, the method further comprises, before
the colored granule filling step, a partition means
disposlng step for disposing a partition means in the
inside space to divide the inside space lnto a plurality of
forming spaces, each color of the colored granules being
filled in each of the forming spaces.
Preferably, the partition means is a partl~lon wall
molded of a clay body into a predetermined moisture
content in a partition wall forming step before the colored
- 8 -
2 ~ 5 3
granule filling step, and the partition wall is pressed and
formed integrally with the colored granules in the pressure
forming step to make the molded body.
Preferably, the molding materials are blocks
respectively prepared before the moldlng material disposing
step; and the block is made by a raw material kneading step
for kneading a raw material mixed powder, a plgment and
water to prepare a plurallty of colored clay bodies of
different colors of a predetermined molsture content, a
base material moldlng step for molding each color of the
colored clay bodies into a colored base material of a fixed
thickness, and a ~oining step for ~oining a plurality of
colored base materials of different colors in its thickness
direction into one body.
Preferably, the ~oinlng step comprises a gathering and
piling step for gathering and piling a plurallty of hase
materlals of dlfferent colors, and a cuttlng step for
cutting the gathered and plled base materlals in the
gatherlng and plling dlrection lnto a constant width
thereby making the block, and the molded body is made by
disposing and pressing the blocks in the inside space whlle
a cuttlng surface of the block being faced vertlcally.
Preferably, the base material has a bar shape; the
~oining step is a twlsting step for gathering, twisting and
joining the base materlals of different colors lnto the
block; and the molded body is made by disposing the block
ln the lnslde space ln the planar direction and pressingly
formlng the block therein before the pressure formlng step.
Preferably, the molding material comprlses a preformed
body of a plate shape prepared ln a preformed body ~ormlng
step before the molding materlal dlspo~ing s~ep; the
pressure formlng die comprises an upper mold and a lower
mold defining a forming space of substantially an angle
section therebetween; in the dlsposing step, a palr of
preformed bodies are disposed on opposite slopes of the
lower mold, and a ~olning material is disposed between
opposlng end surfaces of the preformed bodie~ along a
21~$~
corner of the lower mold; and ln the pressure formlng step,
the preformed tlle bodles and the Jolnlng materlal are
pressed between the upper mold and the lower mold lnto one
body, thereby making the molde~d hody of an angle plate
shape.
Further ob~ects and advantzlges of the lnventlon wlll
be apparent from the following d~escription, reference being
had to the accompanying drawlngs, whereln preferred
embodiments of the invention are clearly shown.
BRIEF DESCRIPTION OF T~ DRAWINGS
FIG. 1 is a plan view showing one example of a flrst
embodiment of a tile having a pattern of the inventlon.
FIG. 2 ls a flowchart showlng manufacturing steps of
the ~ir t embodlment of a tile having a pattern of the
invention.
FIG. 3 ls a perspectlve view of a partltion plate used
ln manufacturlng the first embodiment of a tlle having a
pattern of the invention.
FIG. 4 is a ~ectional view of a pressure formlng die
showlng a state ~ust after filling a color granule in a
color granule filllng step ln FIG. 2.
FIG. 5 is a schematlc view of a device for maklng a
color granule used in the color granule filling step of
FIG. 2.
FIG. 6 ls a sectional vlew of the pressure forming die
showing a state ~ust after fllllng a lining granule in a
lining granule fllling step ln FIG. 2.
FIG. 7(a) is a plan vlew showlng a modlflcatlon of the
flrst embodlment of a tlle havlng a pattern of the
invention.
FIG. 7(b) is a plan view showing another modlfication
of the first embodlment of a tile having a pattern of the
lnventlon.
FIG. 7(c) is a plan view showing ~till another
modiflcation of the flrst embodlment of a tile havlng a
pattern of the inventlon.
- 10-
2 ~
FIG. 7(d) i~ a plan view showing still ano~her
modiflcation of the first embodiment of a tile havlng a
pattern of the invention.
FIG. 7(e) ls a plan view showing stlll another
modlflcation of the flr~t embocliment of a tile havlng 2
pattern of the lnvention.
FIG. 7(f) is a plan vlew showing still another
modlfication of the firYt emboaliment of a tlle having a
pattern of the lnvention.
FIG.8 is a plan view showing an example of a second
embodiment of a tile having a pattern of the lnvention.
FIG. 9 is a flowchart showing manufacturing steps of
the second embodiment of a tile having a pattern of the
lnventlon.
FIG. 10 i~ a schematic drawing of a contlnuous moldlng
machine used in a partition wall forming step of FIG. 9.
FIG. 11 is a perspective VlPw showlng an extruded
product molded by the contlnuous moldlng machine of FIG.
10 .
FIG. 12 i~ a perspective view of a part~tion wall
obtained by cutting the extruded product of FIG. 10.
FIG. 13 is a perspective view showing a partltion wall
stlcking sheet materlal obtained in a partltlon wall
sticklng stap of FIG. 9.
FIG. 14 is a sectlonal view of a pressure forming die
used in a colored granule filIing step and a llnlng granule
filling step of FIG. 9.
FIG. 15 is a plan vlew showlng a filled state of
colored granules of FIG. 14.
FIG. 16 iY a sectlonal view showing a nonglazing tile
burn~ in a burning step of FIG. 9.
FIG. 17(a) ls a plan view showing an example of a
t hlrd embodiment of a tile havlng a pattern of the
inventlon.
FIG. 17(b~ is a plan vlew showing a modlfication o~ a
third embodlment of a tile havlng a pattern of the
inventlon.
2 ~L D ~ 3
FIG. 17~c) is a plan vlew showing a modification of a
third embodlment of a tile having a pattern of the
invention.
F~G. 17 (d) is a plan view showlng a modiflcation o~ a
third embodiment of a tile havlng a pattern of the
invention.
FIG. 17te) is a plan view showlng a modificatlon of a
third embodiment of a tile havlng a pattern of the
lnventlon.
FIG. 17(f) ls a plan view showing a modification of a
thlrd embodlment of a tlle having a pattern of the
lnvention.
FIG. 18 is a schematlc drawin~ showlng dlagramatically
a moldlng of a molded thin plate ln manufacturing the third
embodiment of a tlle having a pattern of the lnventlon.
FIG. 19 1Q a perspective view showing the molded thln
plate of FIG. 18.
FIG. 20(a) is a schematic view showlng a pressing die
of a molded thln plate to be a partltlon wall of the tlle
havlng the pattern of FIG. 17(a).
FIG. 20 (b) ls a ~chematlc view showing a presslng dle
of a molded thin plate to be a partltion wall of the tile
having the pattern of FIG. 17(c).
FIG. 20(c) 15 a schematic vlew showlng a presslng dle
of a molded tbin plate to be a partltion wall of the tile
havlng the pattern of FIG. 17(d).
FIG. 20(d) ls a schematlc view showing a presslng dle
of a molded thin plate to be an inside partitlon wall of
the tile havlng the pattern of FIG. 17(e).
FIG. 20(el is a schematic vlew showing a pressing die
of a molded thln plate to be an outslde partltion wall of
the ~lle havlng the pattern of FIG. 17~e).
FIG. 20(f) ls a schemat.tc vlew showing a presslng die
of a molded thin plate t o be a partition wall of the tile
havlng the pattern of FIG. 17(f).
FIG. 21 is a plan vlew showing a fllled state of
colored granules ln manufacturlng the tile havlng the
- 12 -
21 ~6~S~
pattern of FIG. 17(e) among the thlrd embodiment of tiles
of the lnvention.
FIG. 22 is a ~ectional vlew howlng a ~lle havlng a
pattern after burnlng ln manufacturing the tlle having the
pattern of FIG. 17(e) among the thlrd embodiment of tlles
of the lnvention.
FI~. 23 ls a plan view showing a fourth embodiment of
a tile havlng a pattern of the lnventlon.
FIG. 24 ls a flowchart showlng manufacturing step~ of
the fourth embodlment of a tile having a pattern of the
lnvention.
FIG. 25 is a schematlc drawing showlng a forming state
in a base material formlng step of FIG. 24.
FIG. 26 is a perspective vlew showing a molded base
materlal ln the base materlal forming step of FIG. 24.
FIG. 27 ls a perspectlve view showing a layered body
ln a layerlng step of FIG. 24.
FIG. 28 ls a perspectlve vlew showlng a pressing state
ln a press forming step of FIG. 24.
~ IG. Z9 ls a plan vlew showlng a flfth embodlment of a
tile having a pattern of the lnvention.
FIG. 30 ls a flowchart showlng manufacturing steps of
the flfth embodlment of a t~le having a pattern of the
lnvention.
FIG. 31 ls a perspectlve vlew showlng a rolllng state
ln a rolllng step of FIG. 30.
FIG. 32 ls a p~rspective vlew showing a block cut in a
cuttlng step of FIG. 30.
FIG. 33 is a front view showing a cutting plane of the
block of FIG. 32.
FIG. 34 is a plan vlew showlng a ~lxth embodiment of a
tile having a pattern of the lnventlon.
FIG. 35 is a perspective view showlng round bars
durlng manufacturing of the slxth embodiment of a tile
havlng a pattern of the invention.
FIG. 36 ls a perspectlve vlew showing a state of
gathered round bars durlng manufacturlng of the slxth
- 13 -
2 ~ f3 ~3
embodiment of a tile having a pattern of the invention.
FIG. 37 ls a plan view showing a seventh embodiment of
a tile having a pattern of the invention.
FIG. 38 is a a perspective view showins a state of
gathered small bars during manufacturing of the seventh
embodiment of 8 tile having a pattern of ~he inven~ion.
FIG. 39 iR a plan view showing a eighth embodlment of
a tile havlng a pattern of the lnvention.
FIG. 40 is a perspective vlew showing a triangle bar
during manufacturing of the eighth embodlment of a tile
having a pattern of the invention.
FIG. 41 is a plan view showing a ninth Pmbodiment of a
tile having a pattern of the invention.
FIG. 42 ls a flowchart showing manufacturing steps of
tiles havlng patterns in nlnth to eleventh embodlments of
the invention.
FIG. 43 is a schematic drawlng showlng a continuous
molding machine used in a bar molding step of FIG. 42.
FIG. 44 is a perspective view showing bars in the bar
molding step of FIG. 42.
FIG. 45 is a schematic drawing showing a twister used
ln a twistlng stPp of FIG. 42.
FIG. 46 ls a plan vlew showing twlsted bars twisted in
the twlsting step of FIG. 42.
FIG. 47 ls a plan view showing twisted bars arranged
ln a die ln a pressure forming step of FIG. 42.
FIG. 48 is a schematic drawing showlng a pressure
forming state in the pressure forming step ln FIG. 42.
FIG. 49 ls a plan view showing a tenth embodlment of a
tlle having a pattern of the invention.
FIG. SO is a plan vlew showlng twlsted bars in a
manufacture of a tenth embodiment of a tile havlng a
pattern of the lnventlon.
FIG. 51 is a plan view showing a double-twlsted bar ln
a manufacture of a tenth embodlment o~ a tile having a
pattern o~ the lnventlon.
FIG. 52 is a plan vlew showing a coiled state o~ a
- 14 -
2 1 ~
double-twlsted bar ln a manufacture of a tenth embodiment
of a tile having a pattern of the invention.
FIG. 53 1~ a plan view showing a eleventh embodiment
of a tile havlng a pattern of the ~nventlon.
FIG. 54(a~ is a perspective vlew showlng an appearance
of an example of an angle tile havlng a colored pattern
obtained by twelfth to slxteenth embodlments.
FIG. 54(b) ls a perspectlve view showlng an appearance
of a modlficatlon of an angle tile havlng a colored pattern
obtalned by the twelfth to slxteenth embodlment-~.
FIG. 54(c) is a persp~ctive view showing an appearance
of a modlfication of an angle tlle having a colored pattern
obtained by the twelfth to sixteenth embodiments.
FIG. 54(d) 1~ a perspectlve vlew showlng an appearance
of a modlficatlon of an angle tile having a colored pattern
obtained by the twelfth to sixteenth embodlments.
FIG. 55 ls a flowchart showing manufacturing steps of
the twelfth embodiment of an angle tile of the inventlon.
FIGo 56 is a perspective view diagramatlcally showing
a plaln tlle pressing machine used in the twelfth
embodiment of the lnventlon.
FIG. 57 ls a perqpectlve vlew showing a preformed main
plate body made by the plaln tile presslng machine of FIG.
56.
FIG. 58 ls a schematic drawing showlng a bar presslng
machine used in the twelfth embodiment of the invention.
FIG. 59 is a perspective view showing a ~oining bar
made by the bar pre~sing machine of FIG. 58.
FIG. 60 ls an explanatory drawing of a used state of a
pre~sing die of an angle tile presslng machlne used in the
twelfth embodiment of the lnvention.
FIG. 61 is a flowchart showing manufacturing steps of
the thirteenth embodlment of an angle tlle of the
lnventlon.
FIG. 62 ls a perspectlve view showing a preformed main
plate body formed in a preformed tile body iormlng step of
the thirteenth embodiment of the invention.
- 15 -
FIG. 63~a) ls an explanatory drawlng of a used state
of a frame of a pressing dle of an angle tile pressing
machine used ln the thirteenth embodiment of the invention.
FIG. 63(b) ls an explanatory drawing of a used state
of trimming metal fittings of a pressing die of an angle
tile pressing machine used in tlle thirteenth embodiment of
the invention.
FIG. 64 is a schema~ic drawing showing an extruder
used ln a preformed tlle body forming step and a ~oining
bar forming step o~ the fourteenth embodiment of the
invention.
FIG. 65 ls a perspective vlew showing a preformed main
plate body formed in the preformed tile body formlng step
of the fourteenth embodiment of the invention.
FIG. 66 i~ a perspective vlew showlng a ~oinlng bar
molded by the extruder of FIG. 64.
FIG. 67 is an explanatory dxawing of a used state of a
pressing die of an angle tile presslng machlne used in the
fourteenth embodiment of the invention.
FIG. 68 ls an explanatory drawlng of a used state of a
pressing die of an angle tlle presslng machine used in the
fifteenth embodiment of the inventlon.
FIG. 69 ls an explanatory drawing of a used state of a
pressing die of an angle tlle presslng machine used ln the
sixteenth embodiment of the invention.
FIG. 70(a) is an explanatory drawlng showlng a
modified mode of an arranging manner of materials ln an
arranging step of a preformed tlle boy and a ~oining bar in
each of the twelfth ~o slxteenth embodlments of the
invention.
FIG. 70(b) ls an explanatory drawlng showlng a
modlfled mode of an arranglng manner of materials ln an
arranging step of a preformed tile body and a ~olnlng bar
ln each of the twelfth to sixteenth embodiments of the
lnvention.
FIG. 70(c) is an explanatory drawing showing a
modified mode of an arranglng manner of materials in an
- 16 -
2 ~ 5 3
arranglng step of a preformed tile boy and joining granules
ln each of the twelfth to sixteenth embodiments of the
lnvention.
FIG. 70(d) i8 an explanatory drawing showing a
modified mode of an arranglng manner of materials in an
arranglng step of a preformed t:Lle boy and joining granules
in each of the twelfth to sixteenth embodiments of the
inventlon.
FIG. 70(e) is an explanatory drawing showing a
modified mode of an arranging manner of materials in an
arranging step of a preformed tile boy and joining granules
in each of the twelfth to sixteenth embodiments of the
inventlon.
FIG. 70(f) is an explanatory drawing showlng a
modified mode of an arranging manner of materials ln an
arranging step of a preformed tile boy and joining granules
in each of the twelfth to sixteenth embodiments of the
invention.
FIG. 71 is a perspectlve view of a seventeenth
embodiment of an angle tile of the lnvention.
FIG. 72 is a sectlonal view of a pressure forming
machlne showing a process of filling colored granules in a
pressure forming die in a preformed tile body forming step.
FIG. 73 is a perspective view of a partitlon plate
used in filling the colored granules in the pressure
forming die in the preformed tlle body forming step.
FIG. 74(a) is a perspective view of a long preformed
tile body formed in the preformed tlle body forming step.
FIG. 74(b) ls a perspective view of a short preformed
tile body formed in the preformed tile body forming step.
FIG. 75 is a partlal perspective view of a ~oinlny bar
formed in a joining bar forming step.
FIG. 76 is a sectional view of an angle tile pressing
die showing a state in a preformed tlle body and ~olnlng
bar disposing step.
FIG. 77 1s a perspective view of an eighteenth
embodiment of an angle tile of the invention.
- 17 -
2 1 ~
~ IG. 78 is a sectional vlew of a pressure foxmlng
machine showing a process of filllng colored granules ln a
pressure forming dle in a preformed tlle body formlng step.
FIG. 79 is a perspective view of a partltion plate
used ln fllling the colored granules in the pressure
forming dle in the preformed til~e body forming step.
FIG. 80 ls a perspective view of a preformed tlle body
formed in the preformed tlle body forming step.
FIG. 81 is a sectional view of an angle tile pressing
die showing a state in a preformed tlle body and joining
bar dlsposing step.
FIG. 82ta) is a p~rspective view showing a
modification of sllp preventing lugs.
FIG. 82(b) is a perspectlve view showing another
modification of sllp preventlng lugs.
FIG. 82(c) ls a perspective view showing still another
modification of sllp preventlng lugs.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now to the drawings, wherein like reference
characters designate like or corresponding parts throughout
the several vlews, several preferred modes of the lnventlon
wlll be described hereafter.
[ FI RS T EM~ODIMENT]
A first embodlment of the inventlon will be descrlbed
hereunder referrlng to FIGs. 1 to 6.
Referrlng to FIG. 1, a tlle having a pattern 81 ls a
nonglazlng tlle of a dimenslon of 100mm square. The
pattern ls composed of a light black part 82 provided at an
slde part and a light red part 83 provided at an inslde
clrcular part. The llght black part 82 and the llght red
part 83 are made of the same raw material but mixed with
dlfferent pigments. They are burnt lnto one body. A
llning layer 1~ formed on a rear part (not shown) of the
tile 81.
The tlle 81 was manufactured as ~ollows. FI~. 2 show~
- 18 -
2 1 ~ 3
manufacturing steps.
Flrs~, ln a partition plate di~po~lng step S501, a
partition plate 84 as a partitlon means ~hown ln FIG. 3 is
fabrlcated of a thin steel plate of a thlckness of
approxlmately lmm ln such a manner to correspond to the
pattern of the tlle 81. This partition plate 84 ls
composed of a center partition 85 and an outer wall 86
formed ln one body. The center partitlon 85 is a ring
plate shape wlth a height of 10 to 12mm and constitutes a
border of multicolors. The outer wall 86 is a rectangular
frame shape wlth the same helght of 10 to 12mm and is
contacted wlth an inside wall of a pres~ure forming die
descrlbed later. A handle 87 is attached to an upper end
of the partltlon plate 84. The outer wall 86 i9 provided
for a purpose of holding the c~nter plate 85 at a flxed
positlon, but lt may be omitted and only the inslde center
plate 85 may be disposed in the die according to a formed
pattern. The thlckness of the partition plate 84 is
preferably made thln in order to make the border as
distinct as possible. Still, lf it is too thln, it would
be easlly deformed in works of l~s disposing and taklng-ollt
or filling of granules mentioned later. Thus, it is
necessary to determine the thickness in consideratlon
thereof. It ls possible to chamfer a lower end of the
partition plate 84 into a tapered shape.
After the partltlon plate 84 was fabricated, it was
dlsposed on a bottom surface of a pressure forming die 91
shown in FIG. 4.
On the other hand, in a colored granule filling step
S502, colored granules were prepared for forming a colored
part. For the preparation of the colored granules, a tile
~ody con~lsting of 50% feldspar, 20% china clay and 30~
clay was added with 2% black pigment for kneading, 0.5~ CMC
and water. This tile body was then mlxed and ground in a
trommel 101 ~hown in ln FIG. 5 thereby to obtain a Ylip
102. Thereafter, it was pumped up to a spray drler 104 by
a pump 103, and dried and granulated by the spray drier 104
- 19-
.
2 1 ~ 3
to obtain the colored granules. This llght black colored
granules was s~ored ln a storage/feed tank 105. Simllarly,
the above tlle body was added with 3% of a red pigment for
kneadlng thereby to obtain light red colored granules by a
simllar operation. The light red colored granules were
stored ln another storage/feed tank 106. ~hese two klnds
of granules had their molsture content regulated in about
7% by controlling drying conditlon. A raw materlal
supplylng means used ln the colored granules fllling ~tep
S502 may dlrectly supply the raw materlal from a measuring
means or supply them evenly over a flxed wlde area by a
robot or the llke.
After such preparatlon, the llght black granules and
the llght red granules were filled into the pressure
forming dle 91 whlch had the partition plate 84 dlsposed
therein. In thls filling work, the light black granules
were filled to a height of 7 to 8mm, by use of a feeder not
shown, ln an outer formlng space 95 that was surrounded by
the center partition 85 and the outer wall 86 of the
partition plate 84, among a formlng space 10 to 12mm deep
defined by a lower mold 93 and a side mold 94, while an
upper mold 92 was kept raised in the pressure forming die
91 of FIG. 4. At thls time, care was taken of so that the
llght black granules aia not lntrude into an inner forming
space 96. When they intruded, they were sucked and
elimlnated.
Next, the llght red granules were filled into the
lnner formlng space 96 to a height of 7 to 8mm in the same
manner as the light black granules. Here, the light red
granules may reversely be fllled prior to fllling of the
light black granules, or they may be filled at the same
time.
After the colored granules were fillsd, in a partitlon
plate removlng step S503, the partltion plate 84 were
removed by taking the handle 87 which was attached to the
upper end of the outer wall 86. Thereby, the light black
granules and the light red granules overflowed the border
- 20 -
2 1 ~
to each other and were mixed ln a very ~mall amount. If
the colored granules overflow to each other and are mixed,
a ~olning strength is improved between the dlfferent
colored granules, though the border is made slightly
indlstlnct.
In a llnlng granule fllling step S50A, on the other
hand, linlng granules as uncolored body grains were
prepared ln the same manner as the colored granules, by use
of the ~ame tile body as that of the light black and red
granules, wlthout any pigment added. They were stored in a
storage/feed tank 107. Then as shown in FIG. 6, the lininy
granules were filled lnto a llning granule forming space 97
whlch was defined over the fllled llght black and red
granules, to the same height as an upper surface of ths
slde mold 94.
Next, in a pressure ~orming step S505, each klnd of
the colored granules and the llning granules in the
pressure forming dle 91 were pressed and molded at a
pressure of lOOkg/cm2. At this time, though not shown
lllustratively, lf a pressing surface of a bottom part of
the l-pper mold 92 1~ given concaves and convexes of a flxed
wldth, it ls posslble to form concavo-convex ribs or
protrusions for heightenlng an aahering strength at the
same time on the rear surface o~ the tile 81.
Thereafter, ln a burning step S506, a block which was
molded ln the pressure forming step S505 was turned over,
and burnt under a condition of a burniny temperature of
1250~ and a burning tlme of 30 hours. The 6 to 7mm thick
nonglazing tlle 81 was obtalned, by burning, as shown ln
FIG. 1 which had a pattern of the llght black part 82 and
the llght red part 83 at the front side while llned by
uncolored porcelain at the rear slde.
As mentloned above, thls embodiment of the tile 1~
obtalned by: d:Lsposing the partitlon plate 84 in the
pressure forming die 91; then fllling the llght black
granules and the llght red granules respectively in the
outer formlng space 95 and the lnner forming space 96 both
- 21 -
2 1 ~ 3
deflned by the partition plate 84; removing the partitlon
plate 84 and then filling the linlng granules over the
fllled colored granules; pressing and molding them lnto one
body; and burning them.
Accordlng to this embodiment, since the partl~ion
plate 84 is disposed beforehand in the pressure forming dle
91 so as to fill the colored granules in the forming spaces
95, 96 and the llning granules are filled and pressed after
removal of the partition plate B4, it is possible to easily
form a multicolored pattern and improve a joining property
between the light black granules and the light red
granules, thereby preventing the border part from being
peeled off and cracked, though the border line is made
slightly indistinct lf a very small amount of the colored
granules overflow the border at the time of pressing.
Moreover, the pattern is never faded or vanished, thus
exhibitlng the same pattern as the initial one, even if the
tile surface is abraded with long tlme of use.
Furthermors, the lining granules are ~oined to bo~h
the colored granules so as to also enlarge the joining
strength between them. The lining granules are fllled ln
each forming space so as to flat a filled surface of the
colored granules that is apt to become irregular, thereby
making it easy to standardize the tile thlckness.
In addition, since both the colored granules and the
lining granules are filled, pressed and thereafter burnt,
it is posslble to improve an overall strength and a surface
hardness, thereby preventing abrasion of the tile surface.
Moreover, both the colored granules dried are good in
fluldlty ln filling, and easy to handle or suitable for
mass production.
While the above embodlment uses the uncolored lining
granules in addition to the two colored granules, one of
the colored granules may be used for the liner. That is,
after one of the two colored granules are fllled ln one of
the formlng spaces 95, 96, the other colored granules are
filled wholly up to the lining granule forming space 97.
- 22 -
2 ~ 3~
This make material control easy. Moreover, the linlng
granules may be obtalned by granulating sewage disposal
waste soll, waste tile material or the like. In this case,
it is po~slble to manufacture the tile at low cost~, whlch
wlll serve for waste dlsposal and contribute to recycle of
resources.
The above embodiment of the manufacturlng method of
the tlle having the pattern is composed of: the partition
plate disposlng ~tep S501 for disposing the partitlon plate
84 ln the pressure formlng die 91; the colored granule
filling step S502 for filling the llght black granules and
the light red granules respectively in the outer forming
space 95 and the inner forming space 96 both defined by the
partltion plate 84 after disposing the partitlon plate 84;
the partition plate removlng step S503 for removlng the
partitlon plate 84 out of the pressure forming die 91 after
fllllng the colored granules; the lining granule fllllng
step S504 for filling the llning granules over both the
filled colored granule~s the pressure forming step S505 for
pressing and forming the colored granules and the llnlng
granules ln the pressure forminy die 91 into one body after
fllllng both the colored granules and the llnlng granules
in the pressure forming dle 91; and the burning step S506
for burning the block molded in the pressure forming die
91 .
According to the above method, slnce the colored
granules are fllled ln the formlng spaces 95, 96 after
dlsposlng the partltlon plate 84 ln the pressure formlng
dle 91 and t~en the llnlng granules are fllled therein, the
pattern of the tile can be made with an easy operatlon, and
dlfferent colors of granules can be fllled slmultaneously.
Here, the colored granules used in manufacturlng the
present embodlment of the tile are preferably obtained by:
uslng the same materials as ordinary tlles like feldspar,
china clay, kaolin, clay, etc.; adding coloring pigments,
organic caklng agent, water thereto; mixing and grinding
them lnto sllp by a trommel or the like; and pelletizing
- 23 -
2 1 ~ 3
them into a flxed molsture content by a spray dxler or the
llke. The particle diameter 13 preferably 20-50 meshes.
Moreover, the colored granules may be used in a powdered
state without pelletlzing process. Stlll, the pelletlzed
granules of a fixed moisture content are good in
workablllty and suitable for mass production. This i9
because advantageously they have no lrregular color and are
unsticky and spread entirely over the pressure formlng dle
91 .
The colorlng pigment may be such pigments for kneadlng
as chromium oxlde, lron oxlde and Mn-Al pink, in addltion
to such natural pigments as chromite and loess.
Preferably, an adding amount thereof is generally two to
three percent.
Moreover, lt is best for the llnlng granules to use
the same granulated gralns as the colored granules in view
of a Jolnlng strength and a shrlnkage percentage, since one
ob~ect of the lnventlon 1 to relnforce the joined part of
the colored granules of the tile surface correspondlng to
the partltlon plate 84 and prevent lts crazlng. However,
since the llnlng granules do not appear on the tile in a
normal US8, other materlal may be utllized as long as the
~oinlng strength and the shrlnkage percentage can be
regulated. For example, it ls possible to use a material
that i5 obtained by mixing re~uses, such as crashed flne
powders oP tile waste and drled waste soil powder of sewage
dl~po al, as a maln materlal wlth slllca or the like, and
ad~ustlng a melting polnt and a shrinkage percentage. This
makes recycle of resources posslble.
It ls preferable to use a cellulose ether such as MC
tmPthYl cellulose), CMC (carboxymethyl cellulose sodium~,
ethyl cellulose and benzyl cellulose, or a synthetic resln.
The flrlng or burning after pressure molding may be
performed correspondlngly to a manu~acturlng conditlon of
general nonglazing tlles. Here, lt ls posslble to give
luster to the fired tll~ by properly poll~hing its surface.
Whlle, ln the above embodlment, the lining granules
- 24 -
2 ~ 5 ~
are fllled together wlth the colored granules, lt ls
po3~1ble ~o ellmlnate the ~llllng o~ the lining granules.
In case of elimlnating the filllng of the llning granules,
materlal control ls made easy, ~nd manufacturing ~teps are
simplified.
Whlle, in the above embodiment, the llning granule~
are filled over the colored granules after fllllng of the
rolored ones, the order of fllllng work may be changed.
Namely, the colored granules may be filled over the llnlng
granules after fllllng the linlng granules. In this case,
the partitlon plate 84 ls to be dlsposed on the lining
granules which were filled beforehand ln the pressure
formlng dle 91. Accordingly, lt is unnecessary to closel~
contact the lower end of the partition plate 84 wlth the
surface of the pressure formlng die 91 in a unlform manner,
so that the partitlon plate 84 may be fabrlcated without
speclal care for accuracy at the lower end.
Whlle the above embodlment of the tile 81 has the
pattern that a circle ls formed ln a square frame, deslred
patterns may be given to varlous shapes o~ tlles, such as a
rectangular tile 81a shown ln FIG. 7(a), a rectangular tlle
81b shown ln FIG. 7~bl, a rectangular tlle 81c shown ln
FIG. 7(c), a rectangular tlle 81d shown ln FIG. 7(d), a
hexagonal tile shown ln FIG. 7(e), and a circular tlle 81f
shown in FIG. 7(f). For example, ln the tile 81c of FIG.
7(c), a pattern ls defined by a white part and a spotted
part that is made of a body wlth blue granules dispersed.
The tile 81d of FIG. 7td) has a pattern defined by three
colors.
The partitlon plate may make its pattern forming lower
end or all the part thinner or thlcker than the above
embodlme~t. Thlnner one prevents breakage of the pattern
ln removlng the partltlon plate. Thlcker one makes an
outllne o~ the pattern lndlstlnct thereby exhlbitlng a
unlque appearance. Moreover, it is pos~lble to use part of
a pressure formlng die as a substltute for an outer wall of
a partltion plate, which forms an outer part of a tlle, 50
- 25 -
21~ a3
as to ellminate the outer wall and simpllfy its
constructlon.
[ SECOND EMBODIMENT ~
A second embodlment will be described hereunder
referring to FIGs. 8 to 16.
Referring to FIG. 8, a tile havlng a pattern 111 ls a
nonglazing tlle of a dimenslon of 200mm square. The
pattern is formed by an outer light black part 113 and an
inner llght red part 114 wlth a white rlng part 112 of a
constant width of 6mm borderlng them. All of these white
ring part 112, llght black part 113 and light red part 114
are made of the ~ame raw materlal and burnt lnto one body.
However, they have respectively different plgments mixPd
thereln and show different colors. A llning layer ls
formed on a rear side thereof (not shown).
Manufacturlng steps of the tile 111 is described
hereafter referring to FIG. 9.
Flrst, in a partitlon wall forming step S511, a tile
body conslsting of 50~ feldspar, 20% china clay and 30%
clay was added with 10% zirconium sillcate, namely
superfine powders of zlrcon as a white pigment, 1~ CMC and
25~ water. Then, they were pu~ lnto and mixed in a mixer
122 of a contlnuous moldlng machine 121 which was composed
of the mixer 122, a kneader 123 and an extruder 124, and
sufficiently kneaded by the kneader 1~3 thereby preparlng a
clay body for a partition wall 132. Thereafter, a
cyllndrical molded body 131 shown in FIG. 11 was obtalned
through a mouthpiece 125 by use of the extruder 124. Next,
this cyllndrical molded body 131 was cut into a 15mm
length, and drled a predetermined tlme at a temperature not
more than 200~ by a drier. Thus, most of moisture of the
cyllndrlcal molded body 131 was evaporated thexeby to
obtaln the rlng partltion wall 1~2 shown ln FIG. 12 whlch
has 7~ moisture content and an outer dlameter of 200mm and
a thlckness of 6mm.
Next, ln a partltion wall sticking step S512, an
- 26 -
organic adheslve known ln the art was coated on one cut
surface of the partition wall 132 as a partition means
obtalned in the step S511. Such a partition wall 132 was
put on and stuck to a prede~e:rmlned position o~ a sheet
material 133 of Japanese paper whlch is the same dlmension
as an lnslde dimension of a bottom surface of a presqure
forming die 91, which was similar to that of the first
embodiment. Then, the sheet material 133 with the
partltlon wall 132 stuck thereto, as shown in FIG. 13, was
lald on the bottom surface of the pressure forming die.
Here, an lnner dimenslon of the pressure ~orming die 91 was
210mm square.
On the other hand, in a colored gxanule filling step
S513, colored granules for forming a colored part were
prepared, separately from the partition wall 132. The
preparation of the colored granules was carried out in the
same manner as the first embodiment, by use of the device
shown in FIG. 5.
After ~uch preparation, light black granules and light
red granules were filled in the pressure formlng die 91
that accommodated the sheet materlal 133 with the partltlon
wall 132 ~tuck thereto. In thiR filling work, the upper
mold 92 of the pressure formlng die 91 was kept raised as
shown in FIG. 14. Then, the llght black granules were
filled, by use of a feeder (not shown), lnto the outer
formlng space 95 which was surrounded by the pressure
forming dle 91, the ring partition wall 132 and the
underlylng sheet material 133, among the forming space~
deflned by the lower mold 93 and the slde mold 94, up to
such a height as an upper end of the partit~on wall 132 was
not hidden. At thls tlme, a care was paid for so that ~he
llght black granules did not o~erflow into the inner
formlng space 96 formed by the partitlon wall 132 and the
sheet materlal 133. Any ones whlch were erroneously
overflowed thereinto were sucked and ellminated.
Next, the light red granules were filled into the
inner formlng space 96 up to such a helght as the upper end
- 27 -
2 1 ~
of the partltion wall 132 was not hldden, a~ in the light
black granules. A state after filling is shown ln FIG. 15.
Regardlng the fllllng works o~ the llght black and red
granules, contrary to the above, the red ones may be filled
first as in the first embodlment, or both of them may be
fllled at the same tlme.
After the light black and red granules were fllled ln
the formlng spaces 95, 96 of the pressure forming dle 91,
ln a llning granule fllling step S514, linlng granules as
uncolored body gralns were prepared ln the same manner as
the flrst embodlment, and stored ln the storage/feed tank
107 for the llnlng granules shown ln FIG. 5. Then, these
linlng granules were filled lnto the llning granule forming
space 97 from over the already filled light black and red
granules up to a height twice that of the partitlon wall
132, namely a helght of 25 to 30mm.
Next, ln a pressure forming ~tep S515, each color of
granules and the llning ~ranules ln the pressure forming
die 91 were pressed and formea at a pre~sure of lOOkg/cm2.
Thereafter, in a burnlng step S516, a block formed in
the pressure forming step S515 was turned over, and burnt
under a condition of a burnlng temperature o~ 1250~ and a
burning tlme of 30 hours. A nongla~lng tile 111 of a
section shown in FIG. 16 was obtained by burnlng. As to an
appearance, the tile 111 has its front side design surface
formed with a pattern which ls composed of an lnner light
black part 113, an outer light red part 114 and a white
ring part 112 bordering them, and its rear side lined by
the uncolored porcelain, as shown in FIG. 8.
Here, the heet matertal 133 of Japanese paper ls
burnt out by hlgh temperature heat in the above burnlng. A
plastlc sheet or the llke may be used as the sheet material
133. However, a common European paper needs some attention
slnce residue is left after burning.
As mentioned above, the second embodimznt of the tile
ls obtained by: forming the partition wall 132 of a fixed
moisture content from a clay body and dlsposlng it in the
- 28 -
2~3~
pressure molding dle 91; ~hen filllng the light black
granule~ and the light red granules in the outer forming
space 95 and the lnner formlng space 96 both deflned by the
par~ltion wall 132; thereafter i'illlng the llnlng granules
over the filled colored granules to press and mold into one
body; and burnlng them.
Accordlng to thls embodiment, slnce the partltlon wall
132 is disposed beforehand in the pressure formlng dle 91
so as to deflne the forming spaces 95, 96 for the colored
granules, the partitlon wall 132 ~unctions as a shieldlng
wall in the pres~lng step. Thus, it ls prevented that the
colored granules overflow the border, thereby maklng the
pattern di tlnct. Moreover, slnce th~ llnlng granules are
filled over the colored granules and pressed lntegrally
therewith, the border part between the partltion wall 132
and the colored granules i5 glven a sufficlent ~oining
strength. As a result, the border part of the pattern can
be restralned from cracking or the like. Moreover, since
the colored granules and the lining granules are fllled,
pressed and molded, and flred thereafter, an overall
strength and a surface hardne~s are lmproved. ~hereby, the
tile i~ prevented from abrasion at the surface as well as
dixt or stain at thP border part.
In additlon, slnce multlcolored patterns can be
provlded on one plece of tlle, many klnds of patternlngs
can be reallzed, though conventional technique ls only
capable of formlng such a slmple pattern as a diced pattern
ln splte of a trend of these days in whlch a size of one
tile piece has been becomlng larger such as 200mm square or
300mm square.
~ ere, the llning granule~ may be the same color as
that of one of the colored granules as in the first
embodiment. The lining granules may be obtalned by
granulatlng sewage disposal waste soil, waste tlle materlal
or the llke.
The above second embodlment of the manufacturlng
method of the tlle havlng the pattern ls composed of: the
- 29 -
2 1 ~ 3
partltlon wall formlng step S511 for forming the partition
wall 132 of a predetermined moisture con~ent from a clay
body; the partition wall sticking step S512 for sticking
the formed partltion wall 132 to the sheet material 133 of
the same dlmension as that of the bottom surface ln the
pressure formlng dle 91 whlle belng standed; the colored
granule filling step S513 for disposing the sheet material
133, to whlch the partition wall 132 has been stuck, ln the
pressure forming die 91 and fllling the light black
granules and the light red granules respectlvely ln the
outer formlng space 95 and the lnner forming space 96 both
defined by the partition wall 132; the llnlng granule
filllng step S514 for filling ths lining granules over the
partitlon wall 132 and the upper surface of both the fllled
colored granules; the pressure forming step S515 for
pressing and forming the partltlon wall 132, the colored
granules and the lining granules ln the pressure forming
dle 91 lnto one body; and the burning step S516 for burning
the pressea and formed block and burning out the sheet
materlal 133 by the heat.
According to the above method, since the colored
granules and the llnlng granules are filled ln the formlng
spaces 95, 96, 97 after disposlng the partition wall 132 in
the pressure forming die 91, a desired distinct pattern can
be glven to the tile wlth an easy operation, and different
colors of granules can be filled simultaneously. Slnce
each color of the granules that has been dried into a fixed
moisture content has a good fluidity at the time of
filllng, so that they are ea~y to handle and sultable for
mass production.
Furthermore, slnce the sheet materlal 133 that i9 as
large as the ~ottom surface of the pressure forming dle 91
ls disposed in the pressure forming die 91, while havlng
the molded partltion wall 132 stuck ln a standed state
thereto, the colored granules are blocked by the sheet
materlal 132 from going over the border part in the dle 91
at the time of presslng. Thus, the border part of the
- 30 -
2~ 3~
pattern can be more distinct. Inasmuch as the sheet
material 133 for sticking the partition wall 132 is made of
Japanese paper as a combusting material, it is burnt out at
the time of burning after pressing, so that lt ne~er
affects an appearance of tile surface nor material property
of the tlle after burning.
[THIRD EMBODIMENTl
Next, a third embodiment of the inventlon will be
described referring to FIGs. 17(a) to 22.
The third embodiment shows tlles of relatively small
dlmenslon such as 100mm square or 150mm square while having
patterns illustrated in FIG. 17(a) to FIG. 17(f).
FIG. 17(a) to FIG. 17(f) show six kinds of tiles 141a,
141b, 141c, 141d, 141e, 141f respectively having different
patterns. The tiles 141a-141f are nonglazing tiles of
approximately 100mm square or an outer dimension smaller
than that of the tlle 111 in the second embodlment. The
tiles 141a, 141b, 141c, 141d, 141f have patterns that dark
brown parts 143a, 143b, 143c, 143d, 143f and green parts
144a, 144b, 144c, 144d, 144f are disposed at opposlte sides
o~ whlte border part 142a, 142b, 142c, 142d, 142f. The
tlle 141e has a pattern that a dark brown part 143e, a
green part 1~4e or a yellow part 145e are disposed at
opposite sides of a white border part 142e. The whlte
border part 142a-142f is approxlmately 3mm wide which ls
narrower than the white rlng part 112 approximately 7mm
wide in the second embodlment, slnce the tlle 141a-141f has
a smaller outer dlmension.
Hereunder, manufacturing steps of the third embodiment
of a tile will be descrlbed referring to the tlle 141e of
FIG. 17(e) as an example.
Regarding the third embodiment of the tlle 141a-141f,
the white border part 142a-142f that has a small wldth of
about 3mm i5 preferably formed by use of a pressing dle, ln
order to make its handling in the following steps easier.
The third embodiment is the same as the second
- 31 -
3 JI ~
embodlment in other operations such a~ preparation of
colored granules and lining granules, thelr filllng into a
pressure formlng dle, pressing and forming, and burntng.
First, a tlle body consl~ting of 50% feldspar, 20%
chlna clay and 30~ clay was ~dded wlth 5% tltanium oxlde,
1~ CMC and 25~ water. Then, they were mlxed and kneaded
into a clay body 151, and the clay body 151 was molded by a
double stage mlll 152 shown ln FIG. 18 thereby to obtaln a
molded thln plate 153 250mm wide, 3mm thick and lOOOmm long
as shown in FIG. 19.
Thereafter, a little amount of titanium white was
sprlnkled over a surface of the molded thin plate 153 that
had been laid on a base. Then, such molded thln plate 153
was cut, along longltudinally extending cuttlng llnes shown
by two-dotted chaln lines in FIG. 19, into 7mm wlde strlps.
These strips were gently wound.
A whlte molded strlp cut into 7mm wldth had lts one
end posltloned at one end of a lower mold 163d, 163e whlle
an upper mold 162d, 162e was kept ralsed. A pressing dle
161d, 161e was used for fabricatlng the tlle 141e of lOOmm
square as shown ln FIG. 20(d) and FIG. 20(e). Then, the
upper mold 162d, 162e was lowered to pre~s the strlp.
~hereafter, the whlte molded ~trip had lts other end cut
off, lf such end was out of the pressing die 161d, 161e.
The tile 141e of FIG. 17(e) ls manufactured by use of two
smaller white strlps and two larger white strips, whlch are
presslngly molded by the pressing die 161d of FIG. 20(d)
and the presslng dle 161e of FIG. 20(e), re~pectlvely.
The tlle 141a of FIG. 17(a) can be fabricated by use
of a whlte molded strip formed by a presslng dle 161a of
FIG. 20(a). The tile 141c of FIG. 17(c) can be fabricated
by use of two white molded strlps formed by a presslng die
161b of FIG. 20(b). ~he tile 141d of FIG. 17(d) can be
fabrlcated by use of two whlte molded strlps formed by a
presslng dle 161c of FIG. 20~c). The tlle 141f of FIG.
17(f) can be fabrlcated by use of four white molded strlps
formed by a presslng die 161f of FIG. 20(f).
- 32 -
2~ 3
The whlte strips molded by the presslng die 161d of
FIG. 20 ~d) and ~he pres31ng die 161e of FIG. 20 (e) were
dried at a ~emperature of not more than 200~ into 7
molsture content. Two small strlps and two large strips
were used and mutually ~olned by coatlng an organlc
adheslve on a ~olnt surface, thlsreby formlng one partitlon
wall 171 shown in FIG. 21.
Next, an organlc adheslve was coated on a bottom
surface o~ the partition wall 171, and the partltlon wall
171 was stuck to such a sheet material as a Japanese paper
or a plastlc sheet, and disposed ln a pressure formlng dle.
On the other hand, in addltlon to the above operatlon,
three tlle bodles each conslstlng of 50~ feldspar, 20~
chlna clay and 30~ clay were added respectlvely and
separately with kneadlng plgments of dark brown, green and
yellow. CMC and water were ~urther added to each tile
body. Then, each o~ them was mlxed, crashed and made into
a sllp by the same operatlons as each color of granules ln
the second embodiment, and dried and pelletized by the
spray drier 104. Thereby, brown colored granulesj green
colored granules and yellow colored granules were prepared.
Thereafter, the three colors of the granules prepared
beforehand as above were fllled one by one lnto formlng
spaces deflned by the pressure formlng die, the partltlon
wall 171 and the sheet materlal, from the inside to the
outslde. Then, uncolored llnlng granules were fllled over
these three colored granule~. FIG. 21 shows their fllllng
~tate ln the pressure forming dle. In FIG. 21, the
innermost ls yellow granules, the center ls green granules,
and the outermost is dark brown granules.
After thls, they were pressed and formed into a block
by the same operatlon as the sseond embodiment. Such a
pressed block was flred to obtaln the tile 141e
approximately 10mm thlck shown ln FIG. 17(e) and FIG. 22.
That is, the third embodlment i9 dlfferent from the
second embodlment ln the formlng proces~ of the partitlon
wall.
- 33 -
2 ~ 3
Here, in the second and thlrd embodlments, a partition
wall may be obtained by: usinq the same raw material as
that of common tiles such as feldspar, chlna clay, kaolin,
clay or the llke; adding thereto a pigment, an organic
caking agent and water to prepare a kneaded clay body;
forming the clay body by means of extrusion, roller moldlng
or the like; cutting it into a constant wldth; and drylng
it into a predetermined molsture content. The moisture
content is preferably a value substantially the same~ as
that of the colored granules, and more preferably 6 to 8%
from experlence. It is possible to use similar materials
to those of the first embodiment, as colored granules,
lining granules, pigments, and organic caking agents. The
burnlng work may be done according to a manufacturl~g
condit~on of general nonglazlng tiles, as in the first
embodiment.
While, ln the second and thlrd embodlment, the
partition wall is disposed in the pressure forming die
after being stuck to the sheet materlal like a Japanese
paper or a plastlc sheet, and then the colored granules are
filled into the pressure forming die, other modlflcatlons
are posslble For instance, the partition wall may be
disposed directly ln the pressure forming die without use
of the sheet material. However, it may be caused in this
case that the colored granules flow into between the
partition wall and the bottom surface of the die thereby to
make the pattern of the border part slightly indistinct, at
the time of filllng the colored granules in the die.
Therefore, it is preferable to use the sheet material in
case there is a problem in a finished article due to a
grain diameter and fluidity of filled colored granules, a
degree of flatness of the bottom surface of the partition
wall or the like.
While the above embodlments of the partition walls are
made lnto a constant width of 3mm or 7mm, othex shapes may
be adopted. For example, it may have a wldth change such
as an expanded part provided at some position. In this
- 3~ -
2 ~ 5 ~
case, it iS po~sible to give a di~erent ~eellng to the
pattern compared with that of each o~ the above
embodlments.
Moreover, ln the above embodiments, each of the
partition walls may make its surface roughness of a side
wall coarse or into a concavo-convex surface or formed with
an undercut. In this case, it ls possible to make the
~olnlng strength larger b~tween the partltion wall and the
colored granules, thereby restralning more effectlvely
cracks or crazes from belng caus~d at the Jolned surface.
In addltlon, the above second and thlrd embodlments of
the partitlon walls may be the same color a~ one of the
colorPd granules thereby to obtaln a pattern wlth a border
line havlng no wldth.
IFOURTH EMBODIMENTI
A fourth embodiment of the lnventlon wlll be descrlbed
hereunder, referring to FIGs. 23 to 28. A tlle havlng a
stripe pattern is illustrated as an example.
Referrlng to FIG. 23, a tile 181 has a strlpe pattPrn.
The pattern may be formed by whltlsh parts 181a and
blacklsh parts 181b, for example. The whltish part 181a
and the blackish part 181b respectlvely go through the tlle
181 in a thickness dlrection with a constant sectional
area, o that, if the tlle 181 ls sliced at any plane
parallel to a ~ront surface, the same pattern as the front
surface appears at all tlmes.
Next, manufacturlng steps of thls tlle wlll be
descrlbed referring to FIG. 24.
In manufacturlng the tlle 1~1, flrst, ln a raw
material kneading step S521, two klnds of raw material
mixed powders were prepared: raw material mlxed powders
obtalned by blendlng 50~ feldspar, 20~ chlna clay, 10%
kaolin and 20~ clay; and colored raw materlal mixed powder
obtalned by addlng 2% chromlte pigment powders to a body of
the same composltion as the above raw materlal mlxed
powder. Each of the raw material mixed powders was added
- 35 -
2 1 ~
wlth 20~ water and kneaded sufflclently by a kneader.
Thereby, two kinds of clay bodies 182 were prepared. Here,
the flrst raw material mlxed powders as a body havlng the
above composition are made into a whitlsh color after
burnlng, while the colored raw materlal mixed powderR
further added wlth the chromlte pigment powders are made
lnto a blackish color.
Next, ln a base materlal moldlng step S522, each of
the clay bodles 182 kneaded ln the step S521 was molded
lnto a plate 184 200mm wlde, 500mm long and 8mm thick, a~
shown in FIG. 26, by use of a double stage mill 183 shown
ln FIG. 25.
Then, in an adhesive coating step S523, an adheslve
was coated on a ~olnt surface o~ the plate 184 by a known
method llke spraying, brushlng, etc. Thereafter, ln a
layering step S524, whltlsh plates 184a and blackish plate
184b were plled up one after another, such as black, whlte,
black, white and black, lnto five layers and sllghtly
pushed on each other as a whole to form a layered body 185.
The layered body 185 is about 40mm hlgh.
After the above preload, ln a cuttlng step S525, the
layered body 185 composed of flve layers of the plates 184
had its surface provlded wlth cut lines by a plano wlre at
40mm lntervals and was cut off vertlcally. Each 40mm wlde
layered body was further cut ln its length dlrectlon at
15mm lntervals, thereby obtalning blocks 186. The
dimension of this block 186 1s abouf 40mmX40mmX15mm. The
two-dot chain llnes ln FIG. 27 show the cut llnes on the
surface of the layered body 185 and a cutting line for a
unlt of block 186.
Next, in a pressure forming step S526, as shown ln
FIG. 28, four cut blocks 186 were placed with lts opposite
surfaceR ln the thlcknesR dlrectlon disposed at the upslde
and the downslde ln a pressure forming dish 187, whlch was
85mm square and constltuted a pressure forming die, so that
strlpes made by the five layered square pattern were
crossed each other. Then, the pressure ~ormlng dlsh 187
- 36 -
2 1 ~ 3
was loaded in~o a pre3slng machine and the blocks 186 were
pressed at a pressure o~ 50kg/cm2 thereby to obtaln a
pressed block.
Thereafter, ln a drying and burnlng step S527, the
pressed block compoqed o~ the four bloc~s 186 wlth their
strlpes crossed was dried at a temperature of 200~, and
then burned 30 hours at a temperature of 1200~. Thus, the
nonglazlng ~lle 181 of 75mm squa:rP was obtained whlch had a
pattern composed of five layers of black and whlte strlpes.
The pressed block of 85mm square contracted into 75mm
square.
While, ln thi~ embodiment, the dlmension of the block
186 ls 40mm square, 1t may be set into a desired dimenslon
such as 20mm square or 80mm ~uare. In this caRe, lt ls
necessary to approprlately choose the number of layers or a
thickness of the plate 184 or the like according to a
dimenslon of a finished tlle. For example, ~he thlckness
of the block 186 obtained by cutting vertically the layered
body 185 needs to be approximately twlce as large as that
of the flnlshed tlle. A tlle of 75mm square needs to be
about 15mm thick. A tlle of 150mm square needR to be about
20mm thick. A tlle of 300mm square need to be about 30mm
thlck. The thlckness of the plate 184 obtalned by the clay
body can be set ln a desired value accordlng to a
speciflcation of a used rolllng mlll.
As mentloned above, the above embo~l -nt of the tlle
ls obtalned by: moldlng the whl~lsb plates 184a and the
~lacklsh plates 184b as dlfferent colors of molded base
ma~erlals out of the colored clay body 182 of a
predetermlned molsture content; layerlng the plates 184a,
184b whlle coating an adhesive on their ~olnt ~ur~aces;
cuttlng the layered body at ~lxed lntervals in their
layerlng directlon to ~orm the blocks 186; disposlng and
presslng the blocks 186 wlth the cuttlng surface ~aced
upslde or downslde in the pres~ure formlng dlsh 187; and
drylng and burnlng the pressed block.
Accordlng to the above embodiment, a dlstlnct border
- 37 -
21~53
llne is formed in the pattern by the ~oint surface of the
whltish plate~q 184a and the blackish parts 184b which go
through the tile in the thickness direction. Thus, there
ls no problem ~hat the tile has its surface layer abraded
and its pattern faded or vanished.
Since any glaze ls not used on the surface of the
tile, the tile surface is rough and hard to sllp if it gets
wet ln a bathroom , a pavement or the llke, thereby
assuring safety.
Here, though the pattern at the ~ectlon of the block
186 is pressingly spread a llttle ln pre~slng work,
~ n~.~ruch aq all the blocks are made of the same body
materlal and fabricated out of the clay bodies 182 of the
same density, or inasmuch as an adheslve ls coatea on the
~olnt surface, there are caused no cracks or the like nor
any clearance
The manufacturlng method of the present embodiment
comprises: the raw material kneading step S521 for
kneading, on the one hand, the raw materlal mixea powders
and water, and on the other hand, the raw material mixed
powder~ and plgment and water, thereby to prepare the
uncolored clay body 182 and the colored clay body 182; the
base materlal moldlng step S522 for molding the uncolored
clay body 182 and the colored clay body 182 respectlvely
lnto the whltlsh plates 184a and the blackl h plates 184b
as the baqe material; the adheslve coating step S523 for
coating an adheslYe on the ~oint surface of the whltlsh
plates 184a and t he blackish plates 184b; the layering step
S524 as a gath~rlng and pillng step for layerlng the
whlti~h plates 184a and the blacklsh plate 184b on whlch
the adhesive ha~ been coated; the cuttlng step S525 for
cutting the layered body 185 at fixed lnterval~ in the
layerlng dlrection to form the blocks 186; the preRsure
formlng step S526 for dlsposing and presslng the blocks 186
in the pressure forming dlsh 187 while lts cutting surface
ls faced upslde; and the drylng and burning step S527 for
drylng and burnlng the pressed blocks 186.
- 38 -
2 ~ 5 3
Accordingly, lt ls pos~lble to manufacture the tlle
with ease by the simple steps from the raw material
kneading s~ep S521 to the drylng and burning step S527.
[FIFTH EMBODIMENT]
Next, a fifth embodiment ~f the lnvention will be
described referrlng to FIGs. 29 to 33. A tile having a
~plral pattern 19 shown as an example.
Referring to FIG. 29, a tlle 191 has a splral pattern.
For lnstance, the pattern i8 composed of a dark brownlsh
part l91a and a yellow part l91b. The dark brownlsh part
191a and the yellow part l91b go through the tile 191 ln
lts thlckness dlrectlon, respectively, as ln the fourth
embodiment. Thus, lf the tile is sliced at any plane
parallel to its front surface, the ~ame c;piral pat~ern as
that of the front surface appears at all times.
Next, manufacturing steps of the tile 191 wlll be
descrlbsd referrlng to FIG. 30. The flfth embodiment is
prlnclpally differ~nt ~rom the ~ourth embodiment in that lt
has a colling step S535 after a layerlng step S53~.
In manufacturlng the tile 191, first, ln a raw
materlal kneadlng step S531, two kinds of colored raw
materlal mixed powder were prepared by addlng, on one
hand, 2~ lron oxlde, and on the other hand, 2~ loess,
respectively to the same raw material mlxed powder~ as
those of the fourth embodlment whlch consist of 50%
feldspar, 20~ china clay, 10~ kaolin and 20% clay. Each
kind of colored raw materlal mlxed powders were added wlth
water and kneaded, thereby obtainlng two klnds of clay
bodles whlch were respectively controlled to a molsture
content of 25~. The raw material mlxed powders added wlth
the lron oxide become dark brownlsh color and the raw
material m1xed powders added with the loess become
yellowlsh color.
Next, in a base materlal molding step S532, each clay
body was molded by the double s~age rolllng mlll 183
thereby obtalning a d~rk brownish plate 192a and a
- 39 -
2 ~ 3
yellowlsh plate 192b each of whlch ls a rectangular shape
200mm wide, 500mm long and 3mm thlck.
Then! in an adheslve coating step S533, an adhesive
wa~ coated on ~olnt ~urfaces of eaah of the two plates 192a
and 192b. Thereafter, ln a layerlng ~tep S53~, the dark
brownlsh plate 192a was placed below and the yellowish
plate 192b was plled up thereonO They were gently pushed
to each other as a whole 90 as no~ to generate any
clearance between the layers, thereby to obtaln a layered
body 192 shown ln FIG. 31. Then, in the colling ~tep S535,
the layered body 192 of two layers was ~oiled lnto a roll
by a wlnding machlne, whlle maklng one lateral end an axis
for wlndlng, thereby obtalnlng a cylindrlcal bar of 40mm
dlameter and 500mm length.
Next, ln a cuttlng ~tep S536, thls cylindrical bar wa~
cut into round slices one after another at 20mm intervals,
thereby formlng cyllndrical blocks 193 shown in FIG. 32.
Thus obtalned block 193 has a splral pattern on lt~ ~ection
as hown in FIG. 33.
After this, as in the fourth embodlment, ln a pressure
formlng step S537, a total of sixteen cyllndrlcal cut
blocks 193 were placed, four blocks 193 ln each of four
rows in a pressure formlng dlsh, whlle each hlock 193
havlng lts opposlte surfaces ln the thlckness dlrectlon
dlsposed at the upside and the downslde therein. This
pressure formlng dish as a pressure forming dle ls a
~ -nslon of 175mm square. Then, they were pressingly
molded at a pressure of 75~g/cm2. Thereafter, ln a drying
and burnlng step S53B, a pressed hlock composed of the
slxteen blocks 193 was dried at a temperature of lS0~ to
200~, and then burned 30 hours at a temperature of 1200~.
Thus, the nonglazlng tlle 191 of 170mm square was o~talned
whlch had a two colored ~piral pattern as shown ln FIG. 29.
The pressed block of 170mm square contracted lnto 150mm
square ln a flnlshed state.
As mentioned above, the fifth embodiment of the tlle
ls made by: molding two kinds of colored clay bodles of a
- 40 -
2 ~ 3
predetermlned molsture content into the dark brownish plate
192a and the yellowlsh plate 192b; layering the plates 192a
and 192b whlle coating an adhesive on the ~olnt surfaces
thereof; coiling them lnto a bar and cuttlng the bar ln the
layering dlrection at flxed lntervals, thereby obtalnlng
the blocks 193; disposlng and pressingly molding the blocks
193 wlth their cutting surface ;Eaced above in the pressure
formlng dish; and drylng and burnlng the pressed block.
The manufacturing method of thls embodiment of the
tlle comprises: the raw materlal kneading step S531 for
kneadlng the raw material mixed powders, plgments and water
lnto ~he colored clay bodies of a predetermined molsture
content; the base materlal moldlng step S532 for moldlng
the colored clay boales into the dark brownlsh plate 192a
and the yellowish plate 192b as plate base materials; the
adhesive coating step S533 for coating the adhesive on the
joint surfaces of these plates 192a, 192b; the layering
step S534 as the collecting and piling step for layering
the plates 192a, 192b with the adhesive coated thereon,
thereby forming the layered body 192; the coiling step S535
as a deformlng step for coiling the layered body 192; the
cutting step S536 for cutting the coiled body at flxed
intervals to ~orm the blocks 193; the pressure forming step
S537 for disposlng and presslngly molding the blocks 193
with their cuttlng surface faced above ln the pressure
formlng dish; and the drying and burning step S53~ for
drying and burnlng the pressed block.
Accordingly, the fifth embodlment ls expected to have
slmilar advantages to those of the fourth embodlment. In
partlcular, ln the fifth embod~ment, since the plates 192a,
192b are plled up ln two layers ln the step S534 and coiled
in the coillng step S535, a varlety of patterns like spiral
patterns can be obtain~d.
[SIXTH EMBODIMENT]
Next, in sixth to eighth embodiments, a tile having a
pattern obtained by comblnlng bars llke cylindrical bars or
- 41 -
2 1 ~
square bars w111 be described.
First, ln the sixth embodiment, a tile having a
pattern using two colors of cylindrical bars will be
descrlbed referring to FIGs. 34 t~ 36.
In FIG. 34, a tile 201 has a diced pattern. rrhe
pattern is formed by whitlsh parts 201a and blackish earts
201b, for example.
In manufacturlng the tile having such pattern, to
start with, two kinds of clay bodies of a moisture content
of 20~ which were colored respectively into white and black
were prepared ln the same manner as the fourth embodiment.
Next, they were molded from an extruder using a round
nozzle, thereby obtaining' many whitish bars 202a anq
blackish bars 202b each of which is 9mm diameter and 500mm
long, as shown ln FIG. 35. After an ad~esive was coated on
~oint surfaces of these bars 202a, 202b, as shown in FIG.
36, the two kinds of bars 202a, 202b were gathered and
piled substantlally in a square bar shape of four rows and
four decks ln a holder 205 while making their end surfaces
flush. The holder 205 ls composed of a channel shaped
stainless frame 203~ which has front and rear openings of
40mmX50mm, both slde walls of 50mmX600mm and a bottom
surface of 40mmX600mm, and a slldlng plate 204 38mm wide,
550mm long and 5mm thlck, which ls assembled on the bottom
surface of the frame 203 so as to be movable back and
forth. ~his step constitutes a gathering and piling step.
Then, the gathered bars 202a, 202b were fed forward
together with the sllding plate 204. Then, a bundle of
cylindrlcal bars 202a, 202b was sliced into a block bodies
5mm thick. Four block bodles were placed with their
cutting sur~ace faced above in a pres~ure forming die and
pre~singly formed thereby. In this pressing, the block had
its pattern, which was originally composed of multiple
clrcles, changed into a diced one that clearances between
the bars 202a, 202b were filled, as shown in FIG. 34, since
the bars 202a, 202b were adJusted in a moderate moisture
content and easlly deformed so as to be expanded in every
- 42 -
2 ~
directlon and shaped into squares.
In ~his embodiment, the diameter of each bar 202a,
202b is 9mm, ~lnce four cylindrlcal bars 202a, 202b are
arranged for each row or each lin0. However, the diameter
of each bar may be changed according to the number which
will be disposed in the holder 205 and, especially, the
width thereof. For example, in case five cylindrical bars
202a, 202b are arranged in order in 40mm wide holder 205,
the diameter o~ each bar ls 7.5mm.
1~V~N1~ EMBODIMEN~3
;~ In the seventh embodiment, a tile having a mottled
pattern is described referring to FIGs. 37 and 38. ~he
pattern is obtained by deformlng three colors of
cyllndrlcal bars.
In FIG. 37, a tile 211 has a mottled pattern. For
instance, the pattern is composed of brownlsh parts 211a,
whitish part 211b, inner blackish parts 211c and outer
blackish parts 211d.
In manufacturing the tile of the above pattern, first,
brown, white and black clay bodies of a moisture rontent of
20~ were prepared ln the same manner as the fourth
embodiment.
Next, these clay bodies were respectively extruded
from a round nozzle of a conventional extruder to prepare
many brownish bars 212a, whitish bars 212b and blackish
bars 212c each of which was 3mm diameter and 500mm long.
Then, an adhesive was coated on ~olnt surfaces of these
bars, and three brownish bars 212a and three whi~ish bars
212b were disposea one by one in a circle so as ~o surround
a black1sh bar 212c as a center. Thereafter, they were
enclosed by a blackish rlng tube 212d, which was made by
rolllng a blacklsh plate 30mm wide, 500mm long and 2mm
thick, thereby preparing a unlt gathered body 212 of 13mm
diameter shown in FIG. 38. This step cons~itutes a
gatherlng and plling step.
Next, the unit gathered bodies 212 of a round ~ar
- 43 -
21~$3
shape were further gathered and piled ln three rows and
three llnes by use of a holder 205 slmllar to that of the
slxth embodlment shown ln FIG. 36, thereby forming a
gathered and piled body. Then, it was sliced into 15mm
thick blocks in the same manner as the sixth embodiment.
~hey were dlsposed in order in a pressure formlng dish,
pressingly formed, dried and burned. Thus obtained ~ile
has a pattern that small square mottles are circularly
llned on a hlack background.
[EIGHTH EMBODIMENT]
In the eighth embodiment, a tile having a lozenge
pattern uslng two colors of triangle bars will be
descrlbed, re~erring to FIGs. 39 and 40.
In FIG. 39, a tile 221 has a 1O2enge pattern. Each
lozenge is composed of a brownish part 221a and a whitish
part 221b, for example.
In manufacturing the tile, to begin with, a brown clay
body and a white clay body were prepared, each of which had
a moisture content of 20~.
Next, they were molded into two colors of isosceles
triangle bars 222 having a side of 40mm and an altitude of
20mm, as shown ln FIG. 40, using a known extruder. Then,
an adhesiYe was coated on ~oint surfaces of the~e triangle
bars 222, and thereafter they were closely ~oined with
thelr apexes contacted so that the same colors were
symmetrically disposed into a square shape as a whole.
Then, the gathered body was cut into 15mm thick blocks. A
plurallty of cut blocks were placed in order in a pressure
formlng dish of 85mm square while thelr cut surface faced
above, presslngly formed and dried and fired. Thereby, a
tile of 75mm square which had two colors of lozenges
arranged ln order was obtalned.
Thus obtalned tiles can be of course used as tiles for
building materials in such a place as a bathroom and a
lavatory, or tlles for construction material in such a
place as a pavement and a park. In addition, they are
- ~4 -
2~$~3
applicable or widely used for an ashtray for family use, a
saucer, a tea caddy, a basin, or accessories like a
pendant. Specially, due to the characteristics that the
pattern is never faded nor vanished lf the surface ls
abraded, they have outstanding advantages when used as
tlles for building use such as a bathroom or a lavatory or
tiles for constructlon use such as a pavement or a park.
Moreover, each color in the pattern goes through in the
thickness directlon, and a spectrum pattern is formed at
slde surface or the llke, so that they can exhlbit very
massive lmpression when used for furniture or fixtures.
Here, ln the fourth to elghth embodiments, the clay
body may be obtalned by adding a coloring pigment and water
to the same raw material as the normal tiles such as
feldspar, china clay, kaolin, clay, etc., and kneading
them. In this case, the moisture content of the clay body
is set in such a value as, when the blocks are disposed in
the die to be pressed, the block are never destroyed by
their expanslon and can flow to such a degree as to be
fllled up to corners. By experlments, 20+5% is the best.
As the coloring pigment, pigments for kneading may be
used like methyl cellulose, lron oxlde and Mn-Al pink, in
addition to na~ural pigments like chromlte and loes~. ~he
added amount is preferably one to two percent in normal
uses.
As the adhesive for ~oining the molded bodies to each
other, cellulose ether such as methyl cellulose, CMC
(carboxymethyl cellulose sodium), ethyl cellulose or benzyl
cellulose, or a synthetic resin may be used. In addltion
to such cellulose ether or synthetic resin, any one whlch
can prevent the molded bodies from peeling off mutually by
burning may be used. Moreover, in addition to organic
adhesives like a synthetic resin, an inorganlc adhesive may
be used as a matter of course. The inorganlc adhesive is
advantageous ln view of property, but expensive. In view
of cost~, the organlc adhesive is advantageous.
The drylng and burnlng after pressing may be carrled
- 45 -
2 ~ 3
out in accordance wlth a manufacturlng condltlon of common
tlles.
In the fourth to eighth embodiments, whlle the
adheslve is coated on the ~oint surfaces of the molded
bodles of different colors after the colored clay bodies
are molded lnto plates or bars, modi~icatlon is possible.
For example, the adhesive may be added beforehand to the
colored clay bodles. In this case, particularly, it is
possible to prevent crazes or cracks from being generated
in the same color body in burnlng. Moreover, lt ls
possible to omlt the step for coatlng the adhesive
separately on the ~oint surfaces of the differently colored
clay bodies, thereby simplifying more the manufacturing.
In the fourth to eighth embodiments, while plate or
bar shaped molded bodies are gathered and cut into a
constant width, thereby making the blocks, other
modifications are possible. For example, after the bar
molded bodies are gathered, they may be twisted in a
circumferentlal direction by holding their circumference.
In this case, different patterns may appear on each desired
cuttlng plane parallel to the surface of the tile, thereby
enabling a varlety of patterns.
In the fourth to eighth embodlments, varlous colors
may be used in additlon to the above mentioned colors. The
size of the tlle can be desirou~ly set. The number of
tiles dlsposed in the die can be appropriately determined
such as one, two, four, or sixteen.
In the fourth to eighth embodiments, while the bars
llke t he round bars or square bars are molded by the
extruder, the machine or means for molding is not limited
thereto.
[NINTH EMBODIMENT]
A ninth embodiment of the lnventlon will be de~crlbed
referrlng to FIGs. 41 to 48. A tlle has a mottled spiral
pattern.
In FIG. 41, a tlle 231 has a mottled spiral pattern
- 46 -
composed of two mottled bars. The pattern is composed,
e.g. of whitlsh parts 231a, blackish parts 231b and dark
brownlsh parts 231c. The mottled spiral bar is disposed
parallel whlle twisted, so that, when sliced on a desired
plane parallel to a surface of the tile, a dlfferent
pattern f~om that of the surface appears.
Next, manufacturlng steps of thls tlle i8 descrlbed
referring to FIG. 42.
In manufacturing the tile 231, to start with, in a raw
materlal kneadlng step S541, three klnds of raw material
mixed powders were prepared: a flrst kind of raw materlal
mixed powders consisting of 50% feldspar, 20% china clay,
10% kaolin and 20% clay; a second kind of colored raw
m~terial mlxed powders composed of the first raw material
mlxed powders added wlth 2% chromlte pigment powaers; and a
thlrd kind of colored raw material mlxed powders composed
of the flrst raw materlal mixed powders added wlth 1% red
iron oxide. 3~ CMC as an adhesive and 25% water were added
to each kind of raw materlal mixed powders. Then, as shown
in FIG. 43, each klnd of powders were put into a mixer 233
of a contlnuous moldlng machine 232. They were
sufficiently kneaded by a pug mill 234 to prepare three
klnds of clay bodles. The first kind of powders become a
whitish color, the second klnd become a blackish ~olor and
the thlrd kind become a dark brownish color.
Next, ln a bar forming step S542, each kind of clay
bodies obtained by the step S541 was extruded from a
mouthplece 236 having a circular opening by use of an
extruder 235 of the continuous molding machlne 232, thereby
obtaining a soft whitish round bar 237a, a soft blacklsh
round bar 237b and a soft dark brownlsh round bar 237c each
of which was 8mm diameter and lOOOmm long, as shown in FIG.
44.
In a twisting step S543, ~s shown ln FIG. 45, the
whltish bar 237a and the blacklsh bar 237b were put lnto
each of two supply holes of a twister 238, and twisted
under such a preset conditlon as they were twisted to a
- 47 -
2 ~
medium degree at a low speed in accordance with an
operatlon of ~wlstlng a rope. lrhus, there was produ~ed a
rope llke twlsted bar 239a of approximately 15mm diameter
of mottled pattexn of black and whlte as shown in FIG. 46.
Similarly, the whitish bar 237a and the dark brownish bar
237c were put lnto the supply ports of the twister 238 and
twisted, thereby obtaining a rope llke twlsted bar 239b of
approximately 15mm dlameter of a mottled pattern of white
and dark brown.
Next, in a pressure forming step S544, as shown in
FIG. 47, two dlfferent colored ropes or the twisted bar
239a and the twisted bar 239b were disposed in a pressure
forming die 240 of llOmm square, while being coiled in
close contact about two rounds in the clockwise direction,
and had their rest cut off. As shown in FIG. 48, the
pressure forming die 240 is composed of a fixed lower mold
241 having a square hole and a movable lower mold 242 which
vertically moves ln the fixed lower mold 241. A pressed
body can be taken out easily by raising the movable lower
mold 242 after presslng. After the twisted bar 239a and
the twlsted bar 239b were accommodated in the pressure
~orming die 240 while colled, the rests of the twisted bar
239a, 239b which had been cut were packed ln a space
defined at corners of the die 240. The pressing was
carried out at a pressure of 75kg/cm2.
~ y this pressing, top round portlons of each rope or
the twistea bar 239a, 239b were spread toward their
diameter direction, thereby defining a border line
positioned on the same plane between the ad~acent ropes of
different color~. Thus, a long splral flow of mottled
pattern was defined.
Thereafter, in a drying and burning step S545, the
pressed body was drled at a temperature not more than 200~,
and then burned thirty hours at a temperature of 1200~,
thereby providing -a nonglazing tile 231 of lOOmm square
which had a mottled pattern of three dlfferent colors of
white, black and dark brown, as shown in FIG. 41.
- 48 -
210~33
In this embodiment, whlle the size of the tile 231 is
100mm square, it may be other desired slzes. The ~hape
thereof may be modified desirously such as a clrcle,
triangle, hexagon or octagon.
As mentloned above, the above embodlment o~ the tlle
is made by: preparlng three kinds of colored clay ~odies
which is of a predetermined moi~:ture content and added with
CMC as an adhesl~e; twlsting each two of the different
colors of bars or the whitish round bar 237a, the blackish
round bar 237b and the dark brownish round bar 237c;
disposing the twisted bar 239a and the twisted bar 239b in
a coiled manner on a hori~ontal plane ln the pressure
forming die 240; and pressingly forming, drying and burning
them.
According to the abo~e embodiment, a clear border llne
is defined in the pattern by the joint surfaces of the
whltish round bar 237a, blackish round bar 237b and dark
brownish round bar 237c which go through the tile in the
thickness direction. Thus, there is no problem that the
pattern i5 faded or vanished when the tile surface i~
abraded.
Since no glazes are used on the tlle surface, the tile
surface ls rough, so that it is hard to slip when got wet
ln a bathroom, a pavement or the like, and assures safety.
Since the tile is made wholly of the same raw material
and the clay bodies of equal density, and since the
adhesive is added to the clay bodies beforehand, there are
no cracks nor crazes in burning and no clearance generated.
The manufacturing method of the tile of this
embodiment compxlses: the raw material kneading step S541
for kneadlng the raw material mixed powders, plgments,
water and an adhesive to the raw material mixed powders to
prepare the colored clay bodies of a predetermined moi~ture
content; the bar forming step S542 for forming the whitlsh
round bar 237a, the blackish round bar 237b and the dark
brownish round bar 237c out of the colored clay bodies; the
twisting step S543 ~or twi~ting the whitish round bar 237a,
-- aS9 --
the blackish round bar 237b and the dark brownish bar 237c;
the pressure forming step S544 for disposing the twisted
bar 239a and the twisted bar 239b in a coiled manner on the
horizontal plane in the pressure formlng die 240 and
pressingly forming them; and the drying and burning qtep
S545 for drylng and burnlng the pressed body.
Accordingly, the tile can be manufactured by the
slmple steps from the step S541 to the step S545.
[TENTH EMBODIMENT]
Next, a tenth embodlment will be described referring
to FIGs. 49 to 52. A tile has a quadrant mottled pattern.
In FIG. 49, a tlle 251 has a pattern made of many
quadrant bars having mottles. Each quadrant bar is
composed, e.g. of whltish parts 251a, blacki~h parts 251b,
plnklsh parts 251c and blueish parts 251d. The quadrant
bars are arranged horizontally while twlsted, so that, when
the tlle ls sliced on any plane parallel to a tlle surface,
a pattern slightly different from that of the surface
appears.
Manufacturing steps of this tile will be described
hereunder.
In manufacturing the tile 251, in the same manner as
the ninth embodlment, ln a raw material kneadlng step S541
shown ln the ~lowchart of FIG. 42, an uncolored raw
materlal mixed powders and three klnds of colored raw
material mixed powders were prepared: uncolored raw
material mixed powders consisting of 50~ feldspar, 20%
china clay, 10~ kaolin and 20% clay; first colored raw
material mlxed powders obtained by addlng 1~ Fe2O3-Cr2O3-
CoO black plgment to the uncolored raw materlal mixed
powders; second colored raw materlal mlxed powders obtained
by addlns 2% A12O3-MnO plnk to the uncolored raw materlal
mixed body; and thlrd colored raw material mlxea body
obtained b~ addlng 2% zircon blue plgment. 1% CMC and 25%
water were added to each klnd of raw material mlxed
powders. Moreover, 2~ rock fibers 6mm long were added
- 50 -
2~ 3
thereto. Then, each of them WclS thrown and mixed in the
mlxer 233 of the continuous molding machine 232 of FIG. 43,
and sufficlently kneaded by the pug mill 234 to prepare
four ~inds of clay bodies. The uncolored raw material
mlxed powders become a whlte color after burning.
Next, in a bar forming step S542, each kind of clay
body obtalned in the step S5~1 was extruded from the
mouthpiece 236 of 6mm diameter by use of the extruder 235
of the continuous molding machine 232, thereby obtalning a
soft whitish round bar, a soft blackish round bar, a soft
plnkish round bar and a soft blueish round bar each of
which was lOOOmm long~
In a twistlng step S543, the whitish bar and the
blackish bar were put lnto each of the supply holes of the
twlster 238 and twisted thereby to obtain a twisted bar
252a of a mottled pattern of black and white as shown in
FIG. 50. Slmllarly, the pinkish bar and the blueish bar
were put ln the supply hole of the twister 238 and twisted
thereby to obtain a rope like twisted bar 252b of a mottled
pattern of pink and blue. Then, these twisted bars 252a
and 252b were further twisted to obtain a thlck double-
twisted bar 253 of approximately 20mm dlameter as shown in
FIG. 51.
Next, ln a pressure forming step S544, the double-
twlsted bar 253 having four colors was colled five tlme~
wlth lts one end as a start polnt, and cut off along one-
dot chain lineq lnto four quadrants, as shown ln FIG. 52.
The rests of the bar 253 in cutting were stored for packing
into spaces of corners of the die. Next, a guadrant cut
piece of the bar 253 was placed in the pressure forming die
240 o~ llOmm s~uare shown in FIG. 48. Then, the rests of
the bar 253 were fllled ln the spaces defined at the
corners of the die 240. Thereafter, the filled body was
pressed .
Then, ln a drying and burning step S545, the pressed
body was dried at a temperature not more than 200~, and
burned thir~y hours at a temperature of 1200~, thereby
- 51 -
i3 ~ ~
forming a nonglazing tlle 251 of 100mm square having a
mottled pattern of four colors of white, black, pink and
blue.
As mentioned above, the temth embodlment of the tlle
is made by: molding the coloxed clay bodles of a
predetermlned moisture content each of which i6 added wlth
CMC as an adheslve and rock flbers a~ reinforcing flbers to
obtain different colored bars or the whitish round bar, the
blackish round bar, the pinkish round bar and the blueish
round bar; twisting each two of them; further twisting the
twlsted bars 252a and 252b formed by twisting the above
bars to prepare the double-twisted bar 253; arranging lt
horizontally in the pressure forming die 240; and
presslngly forming and drying and burning.
Accordingly, ths same advantages are expected as the
ninth embodiment. Particularly, due to the double-twlsted
bar 253, more various patterns may be obtained. Since the
reinforcing flbers are added, a tensile strength in
twisting is lmproved so as to prevent rupture of the round
bars in double twisting.
[EL~V~Nl~ EM~ODIMENTl
An eleventh embodiment o~ the invention will be
descrlbed referring to FIG. 53. A tile has a mottled
strlpe pattarn.
In FIG. 53, a tile 261 has a mottled stripe pattern.
The pattern is composed, e.g. of whitish part 251a,
blackish parts 251b, plnklsh parts 251c and blueish parts
251d as in the tenth embodlment.
A manufacturing of this tile was carried out by use of
a double twisted bar 253 similar to that of the tenth
embodiment. Flrst, the double-twlsted bar 253 of four
colors was cut lnto a length of 105mm. A plurality of cut
pleces of the bar 253 were disposed in the same direc~lon
in the pressure forming die 240 and pressed. Then, they
were dried at a temperature of not more than 2~0~, and
burned thirty hours at a temperature of 1200~, thereby
- 52 -
2~ 3
obtalning a nonglazlng tile 261 having a mottled strlpe
pattern of four colors of white, black, plnk and blue.
Thus obtained tile has wlde uses as ln the tiles of
the fourth to eighth embodiments. Partlcularly, lt shows
outstandlng advantages when used for tiles for construction
use. Moreover, it can give a masslve feeling when used in
furniture or fixtures or the like.
In case the different colored barq made of the colored
clay bodles have an adhesive coated on the jolnt surfaces
and twlsted, a ~oinlng strength at the borders of the
dlfferent colors can be heightened in special.
In the ninth to eleventh embodiments, the clay bodies
may be obtalned by adding coloring pigments, water and, if
desired, an adhe~ive to the same materlal as common tlles
such as feldspar, chlna clay, kaolin, clay, etc., and
kneadlng th~m. In this case, the molsture content of the
clay body ls set so that, when the twisted bar is disposed
and pre sed in the dle, lt can flow to such a degree as
being filled up to the corners in the die thereby
preventlng lts destroy by expansion. By experiments, 20tS~
18 the best.
As the colorlng pigments, pigments for kneading may be
used such as chromlum oxide, lron oxide or Mn-Al pink, ln
addltlon to natural pigments like chromite or loess. The
added amount ls one to two percent usually.
As an adhesive ~oining the molded bodles mutually,
e.g. a cellulose ether like CM (methyl cellulose), CMC
(carboxymethyl cellulose sodium), ethyl cellulose or benzyl
cellulose, or a synthetlc resln may be used. In addition,
as the adheslve of the nlnth to eleventh embodlments, any
one may do as long as lt prevents cracks or the like ln
burnlng as in the fourth to elghth embodlments. Of course,
inorganlc adhesives may be used in addltlon to the organic
adhesives like a synthetic resin.
The drylng and burnlng after pressing may be carried
out in accordance with a manufacturing condition for
generally known nonglazing tlles.
- 53 -
2 ~ 3
While, in the nlnth to eleventh embodiments, the
adhesive is beforehand added to the raw material mlxed
powders for preventing cracks by burning, peellng off
between different colored parts or the like, other
modifications are posslble. For example, the adhesive may
be coated on the contact surfaces of every colors of bars
after they are extruded in the bar forming step S542. In
partlcular, thls is more effectlve for prevention of
peellng off at the borders o~ different colored portlons.
The adhesive may be added beforehand to the raw material
mixed powders, and further coated on the contact surfaces
of the bars in the bar formlng step S542.
In the ninth to eleventh embodiments, whlle the
twisting of the ~ars is done by the twister 238, ~ machine
or means therefor ls not limited thereto, but any means for
giving an even twisting to the round bars may do instead.
For example, twisting by hand is possible.
Whlle, in the nlnth to eleventh embodiments, the
twisted bar ls obtalned by one tlme or two times twisting,
the twlsting times are not limited thereto. Mottles of the
pattern can be increased by uslng thinner round bars and
multiplying the twisting tlmes. The colors or color
arrangem~nt are not limlted to those of the above
embodiments, but they may be chosen from various kinds of
colors or color arrangements. The size of the tile may be
set in desired one.
While the tenth and eleventh embodiments use the rock
flbers as the reinforcing fibers, other reinforcing ~ibers
like whlsker may be used. Moreover, depending on the
material of the tile, any types of reinforcing materlal
that can keep lts fibrou~ state at any burning temperatures
can be used such as glass wool, metal fibers, etc.
Glazlng treatment of the tile surface may be freely
adopted according to its use.
Twelfth to slxteenth embodiments of the invention will
be described hereunder.
- 54 -
2 1 ~ 3
FIGs. 54(a) to 54(d) illustrate respectively examples
of angle tlles having various colored patterns which are
obtalned in each of the twelfth to sixteenth embodiments.
The angle tlle 260, 270, 280, 290 only as an example of
these embodiments ~ 8 composed o~ long and short tiles
Joined by a rectangular corner 263, 273, 283, 293. They
may bP used for stepped parts of stalrs or roads or the
like. In the followlng description, the long tile is
called a main plate 261, 271, 281, 291. The short one ls
called a bent plate 262, 272, 282, 292.
In FIG. 54(a), the main plate 261 of the tile 260 has
two palrs of triangle parts of different colors while each
palr shows symmetry. The bent plate 252 is the same color
as that of the ad~acent trtangle. In FIG. 54(b), the main
plate 271 of the tile Z70 has a pair of symmetrically
arranged semicircular parts and other parts of different
colors. The bent plate 272 is the same color as that of
the other parts. In FIG. 54(c), both of the main plate 281
and the bent plate 282 of the tile 280 has a spread mottled
pattern. In FIG. 54(d), the main plate 291 of the tile 290
has the same color arrangement as that of the tlle of FIG.
54(a). The bent plate 292 has a color arrangement
correspondlng to a half of the above color arrangement.
These are the appearances of the tiles in each embodiment.
lTWELFTH EMBODIMENT]
The twelfth embodiment will be described referring to
FIGs. 55 to 60, taking the angle tile 260 as an example.
In FIG. 54(a), the angle tlle 260 has the main plate
261 and the bent plate 262 formed at both sldes of the
corner 263. The main plate 2~1 has one pair of triangles
provlded with llght blue spots on a whlte background and
the other pair provided wlth light gray spots on a black
background. The bent plate 262 has light blue spots on a
whlte bacXground like the one triangle pair of the main
plate 261.
This angle tile 260 was manufactured according to a
- 55 -
2 ~ 3
process of FIG. 55 by use of the followlng devlce.
FIG. 56 shows a plate tlle press machine 410 used in a
preformed ~ile body forming step S551. FIG. 57 shows a
preformed tlle body 300 made by this plate tlle press
machine 400. Thls preformed tlle body lncludes a preformed
main plate body 301 forming the main plate 261 and a
preformed bent plate body 302 forming the bent plate 262.
Each preformed tlle body 301, 302 has a trlmmed part 304.
FIG. 58 shows a bar press machine 420 used in a joining bar
forming step S552 of FIG. 55. FIG. 59 shows a joining bar
303 formed hy the bar press machine 420 of FIG. 58. FIG.
60 shows a press die in an angle tlle pressing machine used
in an angle tile body formlng step S554, a lower mold 431
and an upper mold 432 thereof.
To begin with, in a preformed tile body forming step,
colored granules used for preparing the preformed tile ~ody
300 were prepared as follows. A crashed mix raw material
consistlng of 50~ feldspar, 20% china clay, 10% kaolin and
20~ clay was used herein. Three kinds of colored crashed
mix raw materials were prepared: a flrst material adding 5%
black pigment (belonging to a group of CoO, Cr2O3, Fe2O3)
to the above crashed mix raw materlal; a second materlal
addlng 5~ blue plgment (belonging to a group of ZrSiO4(V)~;
and a third materlal without any plgment added. Water was
added to each kind of these materials. They were then
mixed and ground by a trommel or the like into a slip, and
granulated by a spray drier into granules of a fixed
moisture content (granule diameter of about 70~m). Thus,
black, blue and uncolored (white) granules were prepared.
The preformed tile body 300 was prepared using these
colored granules (including white ones) as mentioned below.
First, a partition plate (not shown) was dlsposed
diagonally in a forming space 412 (103mm wide, 120mm long
and 13mm deep) of the lower mold 411 of the plate tile
press machlne 410 shown in fig. 56. Thus, the forming
space 412 was divlded lnto four isosceles right triangles.
Then, a mlxture of the uncolored or white granules and the
- 56 -
2 1 ~
blue granules was filled ln the facing one pair of the
~rlangle spaces. A mlxture of the whlte granules and the
black granules was filled in the other pair of the triangle
spaces. Thereafter, the partl~lon plate was removed, and
the granules were pressed by the plate tile press machine
410 to make the preformed main plate tlle body 301 havlng a
colored pattern shown in FIG. 57. ~ mixture of the white
granules and the blue granules was filled in the forming
space 412 (103mm long, 55mm wlde and 13mm thick) of the
lower mold 411. They were similarly pressed to obtain the
preformed bent plate body 302. The pressing was carried
out at a pressure of 200kg/cm2.
As mentioned above, the trlmmed part 304 ls provlded
in a length of about 20mm on a part unnecessary in a
finished tile or outside ends of the preformed main plate
body 301 and the preformed bent plate body 302. This
trimmed part 304 is cut off in a following s~ep.
Therefore, uncolored or white granules were filled at a
part correspondlng to the trimmea part 304. Accordlngly,
ln forming the preformea main pla~e body 301, the partition
plate was diagonally dlsposed only in a square part (103mm
square) of the forming space 412 while excepting a part for
forming the trimmed part 304 (about 20mm wide).
Next, in a ~oining bar forming step S552, a joinlng
bar 303 was formed. This joining bar 303 had a cross
section of 13mm square and a length of 103mm and was made
by filling a mixture of the white granules and the blue
granules used ln forming the pre~ormed tile body in the bar
press machine 420 shown ln FIG. 58, and presslng it. FIG.
59 shows thus obtalned ~oining bar 303 which has a pattern
of light blue spots scattered on a white background.
In a preformed tlle body and ~oining bar disposing
step S553, two kinds of preformed tlle bodies 301 and 302
obtained in the ~tep S551 and the ~oining bar 303 obtained
in the step S552 were respectlvely disposed in the lower
mold 431 of the press die 430 of the angle tile presslng
machlne which molded an angle product. Speclfically, the
- 57 -
21 0 ~
joining bar 303 was dlsposed along a lowermost rectangular
corner of the V-shaped lower mold 431. At thls tlme, since
the corner of the joinlng bar 303 and the corner of the
lower mold 431 are rectangular, respectively, the ~oinlng
bar 303 can be disposed in close contact therewlth. Next,
the preformed main plate body 301 and the preformed bent
plate body 302 were disposed at both sldes of the ~oining
bar 303 on both slopes of the lower mold 431. Here, they
were disposed so that one end or the side of the trimmed
part 304 was positioned outslde and that the other end
surface was touched vertically with the ~oining bar 303.
At this time, a size of one part, for the main plate, of
the lower mold 431 is 105mm wide, 120mm long and 13mm deep.
A size of the other part, for the bent plate, of the lower
mold 431 is 105mm long, 55mm wlde and 13mm deep. Uncolored
granules were filled in contact surfaces between the
preformed tile bodles 301 and 302 and the ~olning bar 303
in a small amount, and also in a gap at contact parts
between the preformed tile bodies 301 and 302 and the upper
mold 432 ln a thlckness of the preformed tile body. FIG.
60 shows the state of each material on the lower mold 431.
In an angle tile body forming step S554, the reversed
V-shaped upper mold 432 corresponding to the shape of the
lower mold 431 was pressed against the materials on the
lower mold 431 at a pressure of 300kg/cm2. Thus, the
materlals were lntegrally pressed and the angle tile body
was obtalned. The angle tlle body wa8 taken out by pulling
up the upper mold 432 and pushed up the lower mold 431 up
to a take-up level.
As mentloned above, the trimmed parts 304
approximately 20mm wide were provided on both ends of the
angle tlle body or unnecessary parts ~or ~inished tiles.
These trlmmed parts 304 were removed by cutting by a cutter
along cutting lines shown ln FIG. 60. Since the angle tile
body ls a pressed body molded by a sufficient presslng
force, it has enough strength to bear any works by hand to
a sufficient degree, unless it ls intended to destroy lt.
- 58 -
2 ~ 3
In a burnlng step S555, the angle tile bodies obtained
in the step S554 were arrangecl in a chamotte sagger at
appropriate intervals therebetween. They were burned four
hours at a temperature o~ 1200~ and slntered.
Thus, the angle tile 260 was ob~alned. AS ~hown ln
FIG. 54(a), this tlle 260 has the main plate 261 lOOmm
wide, lOOmm long and lOmm thlck and the bent plate 262
lOOmm long, 50mm wide and lOmm thick at opposite sides of
the rectangular corner 263. The main plate 261 ls
diagonally divided into two pairs of triangles one pair of
which has the light blue spotted pattern on the white
background and the other pair of which has light gray
spotted pattern on the black background. The bent plate
262 has the light blue spotted pattern on the white
background whlah is the same as the pattern of the ad~acent
part of the maln plate 261.
As mentioned above, thls embodiment of the angle tile
260 ls made by: disposing the plate shaped preformed tile
bodies 301 and 302 having the spotted pattern respectively
on the opposite slopes of the lower mold 431 of V-section;
disposing the ~oining bar 303 of the same materlal as the
preformed tlle body 301, 302 between the facing end
surfaces of the preformed tlle bodies 301 and 302 along the
edge of the lower mold 431; and pressing them between the
lower mold 431 and the upper mold 432 into one body, and
then burning them.
According to the present embodlment, slnce the plate
shaped preformed tile bodies 301 and 302 are given colored
patterns on thelr surfaces beforehand, such patterns appear
on the surface of the angle tile as they are, so that it ls
possible to obtain the above mentioned patterns that would
be difflcult to provide in conventional molds for angle
tiles. Moreover, slnce the preformed tlle bodles 301, 302
are ~oined by the ~olning bar 303 of the same material into
the anyle molded body without any ~olnt line, so that the
finlshea tile has a good appearance and sufficient corner
strength.
- 5g -
5~ 3
The manufacturing method of the angle tile comprises:
the preformed tile body forming step S551 ~or forming the
plate shaped preformed tile bodies 301, 302 havlng the
colored spotted pattern on their surfaces; the ~oining bar
forming step S552 for forming the ~oining bar 303 of the
same material as the preformed tile body 301, 302; the
preformed tlle body and joining bar dlsposing step S553 for
disposing the preformed tile bodies 301, 302 respectively
on the opposi~e slopes of the lower mold 431 of V-section
and the ~oining bar 303 between the end surfaces of ~he
preformed tile bodles 301, 302 along the edge of the lower
mold 431; the angle tile body forming step S554 for
pre~sing the preformed tlle bodie~ 301, 302 and the ~oin~ng
bar 303 between the lower mold 431 and the upper mold 432
to form the angle tile body as one body; and the burning
step S555 for burning the angle tile body.
According to this embodiment, the angle tile having
the colored spotted pattern can be obtained by the simple
steps from the step S551 to the step S555.
[THIR~L~ L~ EMBODIMENT]
The thirteenth embodiment o~ the in~entlon will be
described referrlng to FIGs. 61 to 63(b), taking the angle
tile 270 of FIG. 54(b) as an example.
In FIG. 54(b), the angle tile 270 has the main plate
271 and the bent plate 272 at both sides of the rectangular
corner 273. The main plate 271 has a pattern composed of a
pair of semiclrcles, one of which is yellow and the other
of whlch is green, and the other parts which is white. The
bent plate 272 has a pattern of the same white color as the
ad~acent part of the main plate 271.
Thls angle tile 270 was manufactured as follows.
FIG. 62 shows a preformed tlle body 311 formed in a
preformed tile body forming steps S561. FIG. 63 shows an
aluminium frame 435 of the press die 430 of the angle tile
pressing machine used in the angle tile body forming step
S554. The frame 435 defines guide walls ln filling jolning
- 60 -
5 3
granules at the edge of the lower mo~d 431 o~ V-section. A
pair of trlmmlng metal fittings 436, 437 are disposed at
such positlon~ a~ trimmed parts are to be pro~lded on each
end of the preformed tile bodies 311, 312 which are placed
on the slopes of the lower molcl 431. The flttings 436 ls
situated agalnst the outslde end of the preiormed maln
plate body 311. The other fittlngs 437 ls sltuated against
the outslde end of the preformed bent plate body 312.
Firs~, in the preformed tile body formlng step S561,
three klnds of colored crashed mlx raw materials were
prepared from the same uncolored crashed mix raw material
as the twelith embodlment: first colored materials obtained
by adding 5% yellow plgment (titan yellow) to the uncolored
materlal; second colored materlal obtained by adding 5%
green plgment (chromlum oxlde) to the uncolored materlal;
and the uncolored crashed mix raw material as lt is though
it ls called a colored crashed mix raw materlal herein for
convenlence sake. Each of them was added with water and
granulated lnto particles o~ about 70~m diameter, thereby
preparing thr~e klnds of colored granules or yellow, green
and uncolored ~white) granulesO
Then, in the preformed tile body forming step S56l,
two partltlon plates (not shown) were disposed in the
forming space 412 of the lower mold 411 of the plate tile
press machlne 410. Each partitlon plate is semicircular
and has a dlameter equal to a length of a side of the
forming space 412. Thus, the partltion plates divided the
formlng space 412 lnto three spaces (two semicircular
spaces and the rest). The yellow granules and the gre2n
granules were filled respectively in the two semicircula~
spaces and the whlte granules were iilled in the rest oi
the space. Then, the partltion walls were removed and the
colored granules were pressed by the plate tile press
machine 410 to form the preformed main tile body 311. On
the other hand, using another plate tile press machine
whlch was substantially the same construction as the press
machine 410 but different in size and had a lower die and a
- 61 -
2 1 ~ 3
formlng space, the preformed bent plate body 312 was
prepared. For convenience sake, the press die and its
elements are given the same reference numerals as those of
the press dle 410. Namely, the white granules were filled
in all the ~orming space 412 and pressed similarly to the
above, thereby formlng the preformed bent plate body 312.
FIG. 62 shows the preformed tlle body 311 molded as above.
~ere, the size o~ the formlng space 412 for the preformed
main plate body 311 was 308mm wide, 308mm long and 25mm
deep. The size of the forming space 412 for the preformed
bent plate body 312 wa~ 308mm long, 35mm wide and 25mm
deep. The pressure was 200kg/cm2.
In the twelfth embodiment, the tri~med part 304 is
formed at the end of each preformed tlle body 301, 302, and
the formlng space 412 includes a space for such trimmed
part. However, in this embodiment, as mentioned below, the
trimming metal fittings 436, 437 of substantially a similar
shape to the trimmed part 304 is placed in moldlng the
angle tlle body. Thus, the forming space 412 in this
embodiment includes no space for such trimmed part.
Next, in a Joining granule forming step S562, ~oining
granules were prepared by adding 1% CMC to the whlte
granules, whlch were used in formlng the preformed tile
body 311, 312.
Then, in a preformed tile body and joining granule
dlsposing step S563, each preformed tile body 311, 312 and
the ~oinlng granules were dlsposed on the lower mold 431 of
V-sectlon. Specifically, the alumlnium frame 435 (305mm
long, 50mm high and 30mm wide) for guiding the ~oining
granules as packed material was disposed ln the lower mold
431 so that its opening was contacted with t he edged area
of the lower mold 431. Thereafter, the ~oining granules
were put lnto the frame 435. Then, as shown ln FIG. 63(a),
the preformed maln plate body 311 and the preformed bent
plate body 312 were disposea in the lower mold 431 so that
they were contacted to the frame 435. Then, the frame 435
was removed, and simultaneously, each preformed tlle body
- 62 -
2 1 ~ 3
311, 312 was pushed toward the edge of the lower mold 431
(ln a dlrection of arrow of FIG. 63 (~) ) along the slope
thereo~, th~r~by maklng the preeormed tile bodies 311, 312
nearer. Next, the trimming metal fittings 436, 437 were
placed so as to touch the ends of the preformed tile bodies
311, 312 in such posltlons as the trlmmed parts were
placed. FIG. 63~b) shows a st.ate obtained by the above
operation. At this time, as shown in FIG. 63(b), the
~olnlng granules were densely packed ln a bar shaped space
of 25mm s~uare sectlon which was defined by the end
surfaces of the two preformed tlle bodles 311, 312.
Moreover, the rest of the ~olnlng gran~lles burled an inside
part deflned by touching edges of the two preformea tlle
bodies 311, 312.
Then, in an angle tile body forming step S564, the
upper mold of reversed V-section corresponding to the
sectlon of the lower mold 431 is pressed agalnst the lower
mold 431 at a pressure of 400kg/cm , thereby obtaining an
angle tile body wlthout any cutting works needed. Since
the thlckness of the trlmmlng metal fittlngs 436, 437 as an
alternate of the trimmed part is set lnto 80% that of each
preformed tile body 311, 312, they never hinders the
presslng work of the angle tlle body into one body.
Thereafter, in a burning step S565, as in the twelfth
embodiment, the angle tlle body was kurned to obtain the
angle tile 270. The angle tile 270 has the main plate 271
300mm wide, 300mm long and 20mm thlck and the bent plate
272 300mm long, 50mm wlde and 20mm thick at opposlte sldes
of the rectangular corner 273 shown in FIG. 54(b). The
maln plate 271 has a pattern composed of a palr of
symmetrically arrange~ semlcircles, one of whlch ls yellow
and the other of which is green, and the rest part whlch is
whlte. The be~t plate 272 has a pattern of whlte color
which is the same as the ad~acent part of the main plate
271.
As mentioned above, this embodiment of the angle tile
270 is made by: disposing the plate llke preformed tile
- 63 -
2 1 ~ 3
bodles 311, 31Z having colored patterns thereon on both the
slopes of the lower mold 431 of V-section; disposing the
~oinlng granules of the same material ~etween the end
surfaces of the preformea tile bodies 311, 312 along the
lowermost corner of the lower mold 431; and pressing them
between the upper mold 432 and the lower mold 431 into one
body, and burning it.
According to this embodiment, as in the twelfth
embodiment, it ls posslble to provide an angle tile which
has a colored pattern and a good apearance.
The manufacturlng method of the angle tile in this
embodiment comprlses: the preformed tile body forming step
S561 for forming the plate ~haped preformed tile bodles
311, 312 having the colored patterns thereon; the Joining
granules forming step S562 for forming the joining granules
which are the same material as those of the preformed tile
body 311, 312; the preformed t~le body and ~oining granule
disposing step S563 for disposing the preformed tlle bodies
311, 312 on bo~h the slopes of the lower mold 431 and the
~olning granules between the end surfaces of the preformed
tile bodies 311, 312 along the corner of the lower mold
431; the angle tile body formlng step S564 for pressing the
preformed tile bodies 311, 312 and the joining granules
between the upper mold 432 and the lower mold 431 to form
the angle tlle body; and the burning step S565 for burning
the angle tile body.
According to this embodlment, it is possible to
provide an angle tile having a colored pattern with simpla
steps. Moreover, in thls embodiment, slnce the trimming
metal fittings are used, there ls no need to provide the
trlmmed part on the preformed ~ile body.
[FOUR~ l~ EMBODIMENT]
Next, the fourteenth embodiment of the invention will
be described referrlng to FIGs. 64 to 67, taking the angle
tile 280 of FIG. 54tc) as an example.
In FIG. 54(c~, the angle tile 280 has the main plate
- 64 -
2 1 ~ 3
281 and the bent plate 282 at opposite sldes of the
rectangular corner 283. Each of the main plate 281 and the
ben~ plate 282 i9 provlded with a spread mottled pattern
continually.
This angle tile 280 was manufactured as below,
according to the manufacturing steps simllar to those of
the twelfth embodiment.
FIG. 64 shows an extruder 440 used ln the preformed
~ile body forming step S551 and the ~olning bar forming
step S552. FIG. 65 shows a preformed tile body 320 formed
ln the preformed tile body formlng step S551. FIG. 66
shows a ~oining bar 323 molded ln the ~olning bar forming
step S552. FIG. 67 shows a press dle 430 in the angle tlle
press machlne used in the angle tlle body formlng step
S554.
First, ~n the preformed tile body forming step SS51,
the preformea tlle body 320 was fabricated as follows.
Three kinds of colored granules (white, dark brown and
blue) were prepared by: adding 5% white plgment (zircon),
5~ dark brown pigment (Fe2O3-ZnO) and 5% blue pigment
(zirc~n blue or the like) respectlvely to three crashed mlx
raw materials similar to that of the twelfth embodiment;
further adding water to each of them so that the moisture
content ~ecame 20~; and kneading each of them. ~he three
kinds of colored clay bodies were respectively put into the
extruder 440 shown in FIG~ 64. Then, each clay body was
extruded from a mouthpiece of 25mm diameter (not shown)0
thereby moldlng white, dark brown and blue bars each of
which is lO~Omm long and of a circular section.
Thereafter, three kinds of colored round bars were gathered
and piled in four rows and four llne~ while arranging the
colors at random. Then, the gathered body was vertically
cut at 25mm lntervals in the longitudinal direction. The
cut pieces were half-dried by air drying at a temperature
of not more than 50~. The half-dried cut pieces were
disposed in the forming space 412 of the lower mold 411 of
the plate tile press machine 410 while their cut surfaces
- 65 -
2 ~
belng faced above. Then, they were pressed at a pressure
of 40kg/cm2 thereby formlng nondrled body of the preformed
tile ~ody 320. At the time of pressing, the cut pieces
were deformed and spread, thereby providlng the preformed
tile body 320 which had a flowing mottled pattern on lts
surface.
In the twelfth embodlment, two kinds of preformed tlle
bodle~ 311 and 312 of dlfferent slzes were prepared ~or the
maln plate and the bent plate. ~owever, ln this
embodiment, two preformed tlle bodles 320 of the same slze
were ~oined, and one of them was cut off ln half to make a
bent plate 282. Therefore, in thls embodiment, only one
size of preformed tile body 320 was prepared which had a
dlmension subtracting the dimension of the trimmed part
from the dimension of the preformed main plate body 301 o~
the twelfth embodiment.
Thus o~talned nondried preformed tile body 320 was
further air-dried at a temperature of not more than 50~,
thereby forming the preformed tlle body 320 shown in FIG.
65. ~hus dried preformed tile body 320 contracted to 105mm
square due to evaporatlon of molsture in comparison with
the nondried one.
A preqs die 430 for formlng an angle tile body has a
lower mold of reversed V-section. So, ln a ~olning bar
forming step S552, a ~oining bar 323 was formed into a
sectlon that was fitted in a space of generally V-shape
defined between end surfaces of the preformed t~le bodles
320, when two tile bodies 320 were disposed on opposlte
slopes of the lower mold 431. A making process thereof
wlll be descrlbed hereunder.
In making the ~olnlng bar 323, the three kinds of
colored round bars used ln forming the preformed tile body
320 were cut respectively lnto a length of 25mm. The same
number of the cut pieces of each color were mixed and
kneaded until they made mottled pattern. Thereafter, they
were put lnto the extruder of FIG. 64. ~he kneaded
materlal was extruded from a mouthpiece ~not shown) whlch
- 66 -
2 1 ~ 3
had a shape composed of a semicircle of 30mm diameter and
an lsosceles right triangle of 15mm side wlth its bottom
connected to a chord of ~he semlclrcle. The extruded body
was cut lnto a length of llOmm, then drled 24 hours at a
temperature of not more than 50~. Thus, The joining bar
323 havlng a spread mottled pattern was obtained as shown
ln FIG. 66.
Next, ln a preformed tile body and ~olning bar
dlsposing step S553, two preformed tile bodies 320 were
disposed respectively on opposlte slopes (107mm wide, 107mm
long and 15mm deep~ of the lower mold 431 of reversed V-
sectlon of the press die 430. A V-sectlon space was
defined by the upper end surfaces of thus disposed two
preformed tile bodles 320. Next, the ~oining bar 323
having the spread mottled pattern was disposed and fitted
ln the space between the two preformed tile bodies 320.
Then, ln an angle tile body forming step S554, as
shown ln FIG. 67, the upper mold 432 of a V-section
corresponding to the section of the lower mold 431 was
pressed against the materials on the lower mold 431 at a
pressure of 60kg/cm2, thereby making an angle tlle body.
This angle tlle body was dried sufficiently at a
temperature of not more than 100~, and cut off by a cutter
at such a positlon (a position shown by a two-dot chain
line of FIG. 67) as the length of the bent plate 282 was
50mm.
In the present embodlment, the bent plate 282 was
obtalned by cutting the preformed tile body 320, because
the pattern on the preformed tile body 320 ls a spread
mottled one and lt is hard to obtaln the same pattern
except the square shape. The cut parts were used for
manufacturing another angle tiles.
In a burning step S555, the angle tile body was burned
under the same condition as the twelfth embodiment, thereby
maklng the angle tile 280 shown in FIG. 54~c). The tile
280 has the main plate 281 lOOmm wide, lOmm long and lOmm
thlck and the bent plate 282 lOOmm long, 50mm wlde and lOmm
- 67 -
2 1 ~ 3
thick at both sides o~ the rectangular corner 283. Both
the main plate 281 and the bent plate 282 have the tricolor
spread mottled pattern of white, blue and dark brown
continually formed on thelr surface.
As mentioned above, this embodiment of the tile 280 is
made by: disposlng the plate shaped preformed tile bodies
320 havlng ~he spread mottled pattern respectively on the
opposite slopes of the lower mold 431 of reversed V-
section; dlsposlng the ~oining bar 323 of the same material
as those of the preformed tile body 320 between the end
surfaces of these preformed tile bodles 32Q along the peak
of the lower mold 431; pressing them between the upper mold
~32 and the lower mold 431 lnto one body; and burning i~.
The manufacturing method of this embodlment of the
tile comprlses: the preformed tlle body forming step S551
for forming the plate shaped preformed tile body 320 having
the spread mottled pattern thsreon; the ~olning bar forming
step S552 for forming the ~oining bar 323 of the same
material as the preformed tile body 320; the preformed tile
body and ~oining bar disposing step S553 for disposing the
preformed tile bodies 320 respectively on the opposite
slopes of the lower mold 431 of reversed V-section ana the
~oining bar 323 between the end surfaces of the preformed
tile bodles 320 along the peak of the lower mold 431; the
angle tile body forming step S554 for pressing the
preformed tlle bodles 320 and the ~oining bar on the lower
mold 431 by the upper mold 432 into one body so as to make
the angle tile body; the burning step S555 for burning the
angle tile body.
According to the angle tile and its manufacturing
method of thls embodiment, the same advantageous effects
can be obtalned as the twelfth and thlrteenth embodlment.
[FI~ ~ EMBODIMENT]
The fifteenth embodiment of the inventlon will be
described referring to FIG. 68, taking the angle tlle 290
of FIG. 54(d) as an example.
- 68 -
21~53
In FIG. 54(d), the angle tile 290 has the main plate
291 and the bent plate 292 at both sides of the rectangular
corner 293. The main plate 291 has the same pattern as
that of the angle tlle 260 of FIG. 54(a). The bent tile
292 haR a pattern similar to that of the maln plate 291 ~a
pattern obtained by cutting the pattern of the preformed
main plate body 301 ln half). The patterns on the main
plate 291 and the bent plate 292 are continuously provided.
This angle tile 290 was manufactured as below
according to steps similar to those of the thlrteenth
embodlment.
First, ln a preformed tlle body forming step S561, a
pre~ormed maln plate body 301 was made by use of the plate
tlle press machine 410 used in the twelfth embodiment. A
preformed bent tlle body 332 was made by use of a partition
plate lnot shown) 50 that the pattern became a pa~tern
obtained by cutting the pattern of the preformed main plate
body 301 in half. The thickness of the preformed tile
bodies 301, 332 was lOmm.
In a ~olning granule forming step S562, joining
granules were prepared by adding 1~ CMC to the black
granules used in formlng the preformed tlle body 301, 332.
Next, in a preformed tile ~ody and ~oining granule
dlsposing step S563, the preformed tile bodies 301, 332 and
the ~oining granules were dlsposed on the lower mold 431 of
V-sectlon, as ln the thirteenth embodiment. However, in
this embodiment, the black granules were filled by use of
the aluminium frame 435 103mm long, ~Omm high and lOmm
wide. Moreover, the black granules were disposed as a
linlng materlal over the preformed tile bodies 301, 332 in
a uniform thickness o~ 6mm.
Then, ln an angle tile body forming step S564, as
shown ln FIG. 68, the materlals on the lower mold 431 were
pressed by the upper mold 432 to form an angle tlle body.
The thlckness of the angle tile body was ~3mm.
Thereafter, vla simllar steps to those of the
thirteenth embodlment, the angle tlle 290 was obtained as
- 69 -
2 ~
shown ln FIG. 54(d). The angle tlle 29~ has the maln plate
291 and the bent plate 292 of the same dlmension as those
of the twelfth embodlment. The main plate 291 has the same
pattern as that of the main plate 261 of the twelfth
embodiment. The bent plate 292 has the pattern similar to
that of the maln plate 291 (the pattern cuttlng the pattern
of the maln plate 291 in half). ~he patterns of the main
plate 291 and the bent plate 292 are continuously provided.
As mentioned above, the present embodiment of the tlle
290 ls made by: disposlng the preformed tile bodies 301,
33~ having the colored pattern respectively on the opposite
slopes of the lower mold 431 of V-section; disposing the
~olning granules of the same material between the end
surfaces of these preformed tile bodles 301, 332 along the
corner of the lower mold 431; and pressing them by the
upper mold 432 into one body and burning it.
The manufacturing method of the present embodiment of
the tile comprises: the preformed tile body forming step
S561 for formlng the plate shaped preformed tlle bodies
301, 332 havlng the colored pattern thereon; the jolning
granules formlng step S562 for formlng the joining granules
of the same material as that of the preformed tile body
301, 332; the preformed tile body and joinlng granule
disposing step S563 for disposing the preformed tile bodies
301, 332 on the opposlte slopes of the lower mold 431 of V-
section an~ the ~oining granules between the end suxfaces
of the preformed tile bodies along the edge of the lower
mold 431; the angle tile body ~orming step S564 for
pressing the preformed tlle bodles 301, 332 and the ~oining
granules between the lower mold 431 and the upper mold 432
lnto one body thereby obtaining the angle tile body; the
burning step S565 for burning the angle tile body.
Accordingly, it is possible to provide an angle tile
having a colored pattern and a good appearance as in the
twelfth embodiment. It is also possible to provlde an
angle tile rein~orced by lining, since the granules are
used as a lining materlal.
.
- 70 -
1 SIX'l ~'L~ EM~ODIMENT]
The angle tile 260 of FIG. 54(a) may be manufactured
as follows. Such modification will be descrlbed referring
to FIG. 69.
Thls angle tile 260 was manufactured as below
according to the steps of ~he thirteenth embodiment.
First, in the preformed tile body forming step S561,
only a preformed main plate body 301 was formed as in the
twelfth embodlment.
Then, in the ~oining granule formlng step S562,
~oining granules were prepared by adding 1% CMC to the
mixture of the white granules and the blue granules whlch
were used in manufacturing the preformed main plate body
301.
Next, ln the preformed tlle body and ~oining granule
dlsposlng step S563, the preformed tile body 301 was
dlsposed on one slope of the lower mold 431 of V-section.
On the other hand, the ~oining granules were disposed and
filled on the other slope of the lower mold 431 as well as
the corner of the lower mold 431, as shown in FIG. ~9.
This filled layer of the ~oining granules had a thickness
twice that of tha preformed main plate body 3~1.
Particularly, the ~olning granules were filled over the
corner o~ the lower mold ~31 up to a ~x1 , thlckness of
lOmm.
Then, in ~he angle tile body forming step S564, the
upper mold 432 of reversed V-sectlon corresponding to the
sectlon of the lower mold 431 was pressed agalnst the lower
mold 431 to form an angle tile body. Trimmed parts 304
were cut off as ln the twelfth embodiment.
The burning step S565 was carrled out under ~he same
condltion as the twelfth embodlment, thereby obtaining the
angle tlle 260 shown in FIG. 54(a) as in the twelfth
embodlment.
As mentioned above, this modification of the angle
tile is maae by: disposing the plate shaped preformed tlle
2 ~ 5 ~
body 301 havlng the colored pattern on ~he one slope of the
lower mold 431 and the jolnlng granules o~ the same
materlal a~ th~t o~ the pre~ormed tlle ~ody 3 01 on the
other slope and the corner of the lower mold 431~ and
presslng them by the upper mold 432 into one body and
burning lt.
The manufacturlng method of this modification
comprises: the preformed tile body formlng step S561 for
formlng the plate shaped preformed tile body 301 having the
colored pattern; the ~oining granule formlng step S562 for
forming the joinlng granules of the same material as that
of the preformed tlle body 301; the preformed tlle body and
~oining granule disposing step S563 for disposlng the
preformed tile body 301 on one slope of the lower mold ~31
of V-sectlon and the ~oining granules on the other slope
and the corner of the lower mold 431; the angle tile body
forming step S564 for pressing the pre~ormed tile body 301
and the ~oining granules between the lower mold 431 and the
upper mold 432 into one body, thereby forming the angle
tlle body; and the burning step S565 for burning the angle
tlle body.
According to this modlficatlon, the same advantages
can be obtalned, too, as in the twelfth embodiment.
In the above embodlments, the dlsposlng works of the
materials ln the preformed tile body and joining bar
disposlng step S553 and the preformed tile body and ~olning
granule disposing tep S563 may be carried out as follows.
FIGs. 70(a) and 70(b) respectively show the case in
which a ~olning bar is used. Specifically, FIG. 70(a)
shows the case in which linlng powders were di~posed over a
contact portlon or border line of two preformed tlle bodies
340 and the ~olning bar 343. FIG. 70(b) shows the case in
whlch llnlng powders were dlsposed ln a uniform thlckness
over all the two preformed tile bodies 340. Such angle
tile has a corner made stronger.
FIGs. 70~c), 70(d) and 70(e) respectlvely show the
case in which ~olning granules are used. Speclfically,
- 72 -
2 ~ 3
FIG. 70tc) shows the case in whlch the jolning granules
were dlsposed as a linlng mater:Lal over the facing ends of
the two preformed tlle bodles 340, in addltlon to belng
filled therebetween. FIGs. 70(d) and 70(e) respectlvely
show the case in which an inside end of a preformed tlle
body 340 is slanted so as to facilitate fllling the ~oinlng
granules between end surfaces of the preformed tile bodles
340. More ln detall, FIG. 70(cl) shows the case ln whlch
the ~olning granules were filled as a lining materlal over
the facing lnside end surfaces thereof. FIG. 7~(e) shows
the case ln which the ~oining granule~ were ~illed over all
the preformed tile bodles 340 as a liner.
FIG. 70(f) show~ the case in which the preformed tile
body 340 was disposed on one slope of the lower mold 431
and the lining powders were dlsposed on the other slope and
the corner of the lower mold 431, over the preformed tile
body 340 and the joined part of-the preformed tile body 340
and the lining powders.
In the twelfth to sixteenth embodiments, the preformed
tile body may be any other fo.rms so long as it ls plate
shaped. The pattern on its surface may be desirously
changed, and lf desired, it may be a plain pattern of one
color. This preformed tile body may be formed by presslng
a powder material or a clay body, for example, as in
generally known tiles. In this case, it is preferable to
set a pressure in pressing ~nto a relatlvely low value.
Thereby, the preformed tile body is further compressed when
finally belng pressed into an angle shape, so as to be
s~rongly ~oined to the ~oining bar or granules. However,
it is not pre$erable to mold it at an excessively low
pressure, slnce the obtalned colored pattern change ln
presslng it lnto the angle shape. Generally, lt is
preferable to set the pressure in formlng the preformed
tlle body lnto one half to two thlrds of a pressure in
maklng finally the angle tile body. The pressure ln
presslng lt into the angle shape ls equal to a pressure for
presslng common tlles or angle tlles. Preferably, the
2 1 ~
preformed tile body ls formed into a ~idth a little smaller
than that of the lower mold so as to facilltate its
disposing on the lower mold.
The ~oinlng bar and the ~oining yranules are ~oined
integrally with the preformed tile body to define the
corner of the angle tile, so that they may be made of any
material inasmuch as it has the same quallty as that of the
preformed tile body. "The same quality" means that the
material is substantlally the same in terms of composition
so that there arlse no remarkable differences in slnterlng
t~mpera~ure or the like. Preferably, the ~oinlng bar or
granules have the same composition, lncludlng the component
of the pigment, as that of the preformed tlle body so tha~
the colored pattern of the angle tlle ls made continuous
including the corner. It ls preferable to add an adhesive
to thase ~oining bar or granules so as to improve a ~oining
property at the time of pressure forming wlth the preformed
tile body as well as to prevent cracks at the time of
burning. A cellulose ether like CMC or a synthetic resln
or the llke may be used.
The ~oining bar of such materlal may be ~ormed by any
desired method like extruding of a clay body or pressure
forming of powdars or the llke. It is preferable to make
its density approxlmately the same as that of the preformed
tile body in view of unlformity of the angle tile when it
is flnlshed. Therefore, lt ls most preferable to form lt
by a method and under a condition similar to those of the
preformed tile body. The ~olning bar needs to have such a
section as to be filled as close as possible between the
end surfaces of the preformed tile bodies on the slopes of
the lower mold.
A normal powder materlal may be used as it 18 for the
~olnlng granules. However, it ls advant~geous to use a
materlal ln the form of pelletized granules. These
granules can be made by addlng water to a powder material,
mlxlng and crushlng it by a trommel or the like lnto a
slip, and then pelletizlng it lnto granules of a
- 74 -
21~53
predetermined molsture content by a spray drler or the
like. Since the granules are nonstlcky and smooth, lt
lmproves workabllity. Moreover, the granules can flow
easlly to be filled over all bletween the end surfaces of
the preformed tile bodies which are disposed on the
opposite surfaces of the lower mold. In case the preformed
tlle body is made by pressure forming of a powder materlal,
the ~olning granules may be the same as the powder
material. The ~oining granules can be auxiliarily used in
case a filllng state of the ~oining bar is not satisfactory
between the end surfaces of the preformed tile bodles.
Whlle the preformed tile body and the jolning bar or
granules are dlsposed on the lower mold of the press die
which defines a pressure forming space of angle shape, the
lower mold may be a V-section or a reversed V-section. In
case the lower mold is a reversed V-sectlon, lt is not
preferable to use the ~oining granules. In case of
providing an angle tlle of relatively large size, the lower'
mold ls preferably a V-sectlon. A llning powder material
may be further disposed on these materials on the lower
mold. Thls provides an an~le tile reinforced by the liner.
While, the angle tlle and its manufacturing method of
the twelfth to sixtePnth embodiments were described, mainly
taking as an example the angle tile composed of short and
long tiles ~oined integrally by the rectangular corner,
other modifications are posslble. For example, The tiles
~oined by the corner may have the same length or other
desired length3. The corner may have a desired angle other
than the right angle or may be curved.
The devlce used ln the twelfth to sixteenth
embodlments is not limited to the above descrlbed one. Any
type of device which has been already used in a ceramlc
industry or the like may be chosen for the use. Or some
change to the conventlonal device ls possible.
[ .~ V~ EMBODIMENT]
A seventeenth embodiment of the inventlon will be
- 75 -
2 ~ 3
described referrlng to FIGs. 71 to 76. A tile of this
embodlment ls also applicable to stepped parts of stairs or
roads.
In FIG. 71, An angle tlle 601 has a pair of plate
tlles 602a, 602b and a corner 603 ~oining them at right
angle. This tile 601 is used at the stepped part while
putting the long plate tile 602a horizontally and the short
plate tlle 602b vertically. The corner 603 has a surface
that ls gently curved. The plate tlles 602a, 602b and the
corner 603 have thelr surfaces uniformly colored as a
whole. In thls embodiment, the angle tlle 601 has a
spotted pattern of a light tone that green granules are
scattered on a white background in a spotted manner.
In thi~ embodlment of ~he angle tile 601, a colored
pattern 604 for distingulshing the corner ls provlded on
the surface of each plate tile 602a, 602b. As shown in
FIG. 71, a long strip of colored pattern extends in a width
direction of the tile near the corner 603, in the plate
tile 602a. Short strips of colored pattern extend at rlght
angle to the corner 603 and are dlsposed in parallel in the
width direction of the tile, ln the plate tile 602b. These
patterns are colored into dark brown. These colored
patterns 604 go through the tile in lts thlckness
directlon, so that they are never faded nor vanished if the
tile ls abraded.
In case of tiling the stepped parts of the stalrs or
the roads using the angle tiles 601, the colored patterns
604 are arranged along a corner of the stepped part,
thereby defining a marking for distinguishing the corner
from a fla~ par~ in terms of color difference. Thus, such
colored patterns 604 attract atten~ion of walkers, so that
the walkers can be kept away from danger such as stumbling
or the llke when they go up and down the stepped parts like
stairs, thereby improvlng qafety in such going up and down.
Thls embodiment of the angle tlle 601 is manufactured
by a slmllar manufacturing method to tha~ of the twelfth
embodlment, ln accordance wlth the process shown in FIG.
- 76 -
2 1 ~ 3
55.
[PREFORMED TILE BODY FORMING STEP]
In thls embodlment, a preformed tile body is
presslngly formed by use of a pressure forming machlne 610
shown in FIG. 72 and a partltlon plate 620 shown in FIG.
73. The pressure forming machine 610 ls composed of a
pressure formlng dle 611, a vertically movable lower mold
612, a vertically movable upper mold 613 and a fixed frame
614.
The partltion plate 620 is composed of a square outer
frame 621, a partition wall 622 disposea inside thereof and
~olnts 623 ~oining the partitlon wall 622 to the outer
frame 621. The outer frame 621 ~s made lnto such a shape
as to be fitted ln the pressure forming die 611 without
clearance. The ~oint 623 ls made by a plate. A lower end
of the ~oint 623 does not reach a lower end of the outer
frame 621 and the partition wall 622. Thls partition wall
622 may be modifled in various forms accordlng to a desired
patternO Depending on a form of the pattern, at least one
of the outer frame 621 and the partition wall 622 may be
omltted, and the partltlon plate 620 may be composed o~ the
partltion wall 622 and the outer frame 621 or the ~oints
623. The partltlon plate 620 may be composed of only the
partitlon wall 622.
The paxtitlon plate 6~0 may be formed by molding a
synthetic resln, for example.
Such partition plate 620 was disposed in the pressure
forming die 611. As shown in FIG. 72, colored granules
615a, 615b of dlfferent colors were fllled respectlvely in
formlng spaces up to substantlally the same helght. In
thl fllling, a proper hopper was used, since openlngs of
the partitlon plate 6~0 were small.
The colored granules as a tlle forming material were
prepared as follows. Namely, three klnds of crushed m~x
raw materlals were prepared: a first materlal obtained by
addlng 5~ whlte pigment (zircon) to a base crushed mlx raw
materlal consistlng of 50% feldspar, 20% china clay and 30
- 77 -
2 1 ~ 3
kaolln; a second materlal obtained by adding 2% green
plgment (chromlum oxlde) to the basP crushed mix raw
material; a thlrd materlal obtained by addlng 2% dark brown
plgment (red oxide) to the base materlal. These materlals
were mixed further with 0.5~ CMC and water, and mlxed ln a
trommel lnto a sllp. This slip was fed to a spray drler to
be granulated and drled. Thus, there were provided whlte,
green and dark brown granules which had an average grain
diameter of 500ym and a moisture content of about 6%.
Simllarly, uncolored granules were prepared which had no
pigments.
A mixture of 70~ white granules and 30% green granules
were used for the colored granules 615a which formed
whole surface of the tile. The dark brown granules were
used for the colored granules 615b filled into the
partition wall 622.
Thereafter, the partltion wall was ralsed and removed
out of the pressure forming die 611. Then, the colored
granules 615a, 615b were gently pressed to make their
surface flat. The uncolored granules were further filled
as a linlng material over the colored granules.
The granules in the pressure forming die 611 were
pressed ~nd molded into one body between the lower mold 612
and the upper mold 613 at a pressure of 200kg/cm2. Next, a
preformed tlle body which was obtalned by thls pressure
forming was taken out by pulllng up the upper mold 613 and
pushing up the lower mold 612 up to a take-up le~el.
Thus obtained plate shaped preformed tile body 606 is
composed of a surface layer 606a made of the mlxture of
colored granules 615a, a colored pattern 606b made of the
colored granules 615b and a llnlng layer 606c made of the
uncolored granules, as shown in FIG. 74(a).
A short preformed tlle body 606 was fabriaated by use
of the same material as the preformed tile body 606 of FIG.
74(a) and a similar method thereto.
The preformed tile body 606 of FIG. 74(b) has a length
of one half of the length of the one 606 of FIG. 74(a), and
- 78 -
21 ~'3~
forms the short plate tlle 602b of the tile 601 of FIG. 71.
A partltion plate 620 used in making the short pre~ormed
tlle body 606 has three partltion walls 622 corresponding
to the colored patterns 606b. Whlle the short preformed
tlle body 606 was fabrlcated by a pressure formlng die of a
dlmension correspondlng to a dlmenslon thereof, the
pressure formlng dle 611 for maklng the long preformed tile
body 606 can be used as it is. In this case, the short
preformed tile body 606 is obtalned by cuttlng the long
preformed tlle body 606 in half.
[JOINING BAR FORMING STEP]
A ~oinlng bar 607 was fabricated by use of the mlxture
of color~d granules conslstlng of 70% whlte granules and
30~ green granules which were used for making the surface
layer 606a of the preformed tlle body 606.
As shown in FIG. 75, the ~oinlng bar 607 has such a
section as a bottom of an lsosceles right triangle ls
formed into an arc. This sectlon is substantially equal to
a sectlon of a space that is deflned between end s~rfaces
of a palr of pre~ormed tlle bodles when they are dlsposed
respectlvely on opposlte slopes of a lower mold of an angle
tile press die described later. A length of the jolnlng
bar 607 is substantially equal ~o a width of the preformed
tile body 606.
The ~oining bar 607 was pressed and formea at a
pressure of about 100kg/cm2 by use of a pressure forming
die of a shape corresponding thereto. This pressure is
lower than a pressure in presslng the preformed tile body,
so that the ~oinlng bar 607 has relatlvely a llttle larger
dlmension.
[PREFORMED TILE BODY AND JOINING BAR DISPOSING STEP]
The short and long pair of preformed tile bodies 606
and the Joinlng bar 607 were dlsposed on the lower mold of
the angle tlle press dle.
As shown in FIG. 76, an angle tlle press dle 630 is
- 79 -
2 ~ 5 3
composed of a lower mold 631 of reversed V~sec~lon and an
upper mold 632 of V-section.
The short and long pre~ormed t lle bodies 606 were
dlsposed respectively on opposite slopes of the lower mold
631 while havlng the colored patterns 606b faced upside and
placed near a peak of the lower mold 631. The joinlng bar
607 was disposed between the preformed tile bodies 606
along the peak Qf the lower mold 631. Trimmlng metal
flttings 640 define a formlng space over the lower mold 631
correspondingly to a shape of an angle tile to be
fabricated.
In thls step, lf there ls made a gap or clearance
between the ~olning bar 607 and the preformed tile bodies
606, granules used for forming the ~olning bar 607 are
preferably filled in such a gap.
. .
lANGLE TILE BODY FORMI~G STEP ]
The preformed tile bodies 606 and the ~oining bar 607
were pressed lnto one body between the lower mold 631 and
the upper mold 632 to form an angle tile body. A pressure
in this pressing ls approximately the same level as thP
presslng of common tiles or angle tlles, but made higher
than pressures in presslng the preformed tile body and the
~olnlng bar. In this pres~ing, the preformed tlle bodles
606 and the ~olnlng bar 607 were further compre~sed to be
~oined lntegrally. In this embodlment, the pre~sure
forming was carried out at a pressure of 400kg/cm2 to make
the angle tile body as one body without any ~oint line.
[BURNING STEP~
The angle tile bodies were put in a chamotte sagger
with a distance therebetween, and burned and ~intered in a
shuttle kiln under a condition of a burning temperature o~
1250~ and a burning time of 30 hours, thereby making angle
tiles as finlshed products.
Thus, the angle tile 601 shown ln FIG. 71 was
obtalned.
- 80 -
2 1 ~ 3
While, in thls embodiment, the joining bar 607 ls the
same color as the ~ur~ace layer 606a of the preformed ~ile
body 606, it may be a dlfferent color so as to deflne a
colored pattern at the corner of the angle tile for
dlstingulshlng it. While, in thls embodlment, the surface
layer 606a of the preformed tile body 606 has only the
spotted pattern, a variety of patterns may be provided on
the surface of the tlle by use of a plurality of colors of
granules and a partition plate accordlng to a color
arrangement.
[EI~n~ EMBODIMENT]
An eighteenth embodiment of the invention will bq
descrlbed referrlng to FIGs. 77 to 81.
As shown in FIG. 77, an angle tlle 701 of this
embodlment ls composed of a long and short pair of plate
tiles 702a, 702b and a corner 703 ~oining them at right
angle, as in the seventeenth embodlment of the angle tile
601. Colored patterns 704 for dlstinguishlng the corner
are providsd respectively on the pla~e tiles 702a, 70~b.
The colored pattern 704 of the long plate tile 702a has a
relatively large width and is formed successively from one
end to the other end ln the width direction of the tlle.
These plate tiles 702a, 702b and the corner 703 have their
surfaces colored unlfo~mly and provided with a spotted
pattern of llght whitish gray tone that llght black
~ranules are scattered to make spots on a white background.
On the other hand, the colored pattern 704 is a spotted one
of a slmllar color tone to the above color tone, but is
made a ~potted pattern of relatively dark tone that the
li~ht black granules are mixed ln larger amount on a white
background, thereby being distlnguishable by a dlfference
of lightness of the colors.
In this embodiment, a protruded area 708 is further
formed on the colored pattern 704 of the long plate tlle
702a ln order to prevent slip. In the illustrated example,
the protruded area 708 has a plurality of ribs each of
- 81 -
21~53
whlch contlnuously extends in the width dlrection of the
tlle and which have a cross sectlon of a saw ~hape as a
whole. The corner 703 has a curved shape whlch ls bulged
out of the surface of the plate tlles 702a, 702b. Thls
bulged corner 703 is provided with a plurality of grooves
709a for drainage along a curved sur~ace thereof. These
grooves 709a are continuous respectlvely with grooves 709b
which are formed on the ribs of the protruded area 708.
Slnce the present embodiment of the angle tlle 701 has
the protruded area 708 for preventing slippage, lt ls
posslble to assure more safety in going up and down stepped
parts. Moreover, shade by the protruded area 708 makes the
colored pattern 704 more conspicuous, thereby facilitating
the corner distlngulshing effects of the colored pattern
704. Slnce the corner 703 is curved and bulged from the
surface of the tile plates 702a, 702b, lt enlarges the
corner strength of the angle tile. Moreover, the bulged
curved shape of the corner 703 itself can give
distingulshlng effects of the corner. Since the grooves
709a for dralnage are formed on the bulged corner 703, they
draln water on the plate tile 702a ln cooperation with the
grooves 709b of the plate tlle 702a. These grooves 709a,
709b also enlarge the dlstlnguishing effects of the corner
due to their concavo-convex shapes.
Next, a manufacturlng method of the angle tlle ln the
elghteenth embodiment of the invention wlll be described
according to the process shown ln FIG. 61. It is basically
the Rame as the manufacturing steps of the seventeenth
embodiment, except the ~oining bar is substituted by
~olning granules.
[PREFORMED TILE BODY FORMING STEP]
A preformed tlle body was prepared by presslngly
formlng colored granules as a tlle materlal, a~ ln the
preformed tlle body forming step of the seventeenth
embodlment.
FIG. 78 shows a pressure forming machine 710 used ln
- 82 -
2 1 ~ 3
the pressing work. ~he pressure forming machine 710 is
composed of a pressure forming die 711, a vertically
movable lower mold 712, a vertically movable upper mold 713
and a fixed frame 714.
This pressure forming machine 710 is dlfferent from
the pressure forming machine 610 of FIG. 72 in that a
concavo-convex mold surface 715 is provided on an upper
surface of the lower mold 712 or a bottom surface of the
pressure formtng die 711. The concavo-convex mold surface
715 serves to form rlbs for preventing slippage on a tile
surface. In this embodiment, the mold surface 715 has
three lines of crests extending from one lateral end to the
other lateral end of the pressure forming die 711. Th~
mold surface 715 iR arranged near one longitudinal snd of
the pressure formlng die 711. The mold surface 715 is
further provided with pro~ections (not shown) at bottoms
between the crests in order to form grooves for drainage.
The mold surface 715 is structured in an exchangeable
manner on a main body of the lowsr mold 712.
A partition plate 720 shown in FIG. 79 was used in
fllling the colored granules as a tile material into the
pressure forming die 711, as ln the seventeen~h embodiment.
The partition plate 720 is composed of an outer frame 721
and two partition walls 722, and divided into three spaces
by the two partition walls 722. ~he space deflned between
the two partltion walls 722 ha~ its width and position
determined so as to accommodate the concavo-convex mold
surface 715 thereln.
The partition plate 720 was dlsposed ln the pressure
formlng die 711. Then, colored granules 705a were fllled
lnto the two outslde spaces each deflned between the outer
frame 722 and the partitlon walls 722, as shown in ~IG. 78.
Colored granules 705b were fllled in the center space
deflned between the two partitlon walls 722. The two kinds
of colored granules 705a, 705b were fllled up to
substantially the same height. Next, the partltion plate
720 was taken up and removed out o~ the pressure forming
- 83 -
~ 3~;~
dle 711. Thereafter, the colored granules 705a, 705b were
gently pressed so as to make their surfaces even. Then,
llning granules were further filled over them.
The colored granules 705a, 705b were prepared as
follows, ln the same manner as those of the seventeenth
embodiment. Namely, a base crushed mlx raw material
consisting of 50% feldspar, 20% china clay and 30% kaolln
was added with 5% white plgment (zircon) as a coloring
pigment. ~hey were further added wlth 0.5% CMC and water
and mlxed ln a trommel into a sllp. This sllp was put lnto
a spray drier and granulated and arled. Thus, white
granules of an average particle diameter of about 400~m
were prepared. Similarly, 2~ black pigment (chromite) was
mixed in the above base material to prepare llght black
granule~ of an average partlcle dlameter of about 700pm.
Moreover, linlng granules were prepared with no pigments
added lnto an averaga partlcle dlameter of about 500~m.
Each kind o~ the granules has a molsture content of about
6~.
The color~d granules 705a were composed of 80~ white
granules and 20% light black granules. The colored
granules 705b were composed of 60~ whlte granules and 40
light black granules.
The colored granules 705a, 705b and the lining
granules were pressed and molded into one body ln the
preqsure forming die at a pressure of 200kg/cm2 betwean the
lower mold 712 and the upper mold 713, as in the
seventeenth embodiment.
Thu~ obtained preformed tile ~ody 706 has a surface
layer 706a made of the mixed colored granules 705a, a
colored part 706b made of the colored granules 705b and a
linlng layer 706c made of the llning granules, as shown in
FIG. 80. The colored part 706b has a protruded area 706d
for preventing slippage formed by the mold surface 715 of
the pressure formlng die 711. The colored part 706b i~
further provided with grooves 706e for dralnage.
On the other hand, there was prepared a short
- 84 -
2 ~ .3 3
preformed tile body constituting the short plate tile 702b
ln the angle tlle 701 of FIG. 77. Here, the short
preformed tile body has a structure corresponding to that
of the long one 706 of FIG. 80, so the same reference
numerals as the long preformed tlle body 706 will be
attached to the corresponding parts for convenience sake
(see FIG. 81). The short preformed tile body was
fabricated in the same manner as that of the preformed tlle
body 606 of FIG. 74(b). Still, a surface layer 706a was
made of mixed colored granules of 80% whlte granules and
20~ llght black granules, and colored parts 706b were made
of mixed colored granules of 60% whlte granules and 40
llght black granules.
[JOINING GRANULE FORMING STEP]
The mixed colored granules of 80~ white granules and
20~ light black granules which were used in fabricating the
preformed tile body 706 and the surface layer 706a were
used for ~olning granules as they were.
~PR~FORMED TILE BODY AND JOINING GRANULE DISPOSING STEP]
The long and short preformed tlle bodies 706 and the
~olnlng granules were alsposed on a lower mold of an angle
tile press die.
In FIG. 81, an angle tile press die 730 is composed of
a lower mold 731 of V-section and an upper mold 732 of
reversed V-sectlon.
The lower mold 731 has a mold surface 733 that i9 the
same shape as that of the concavo-convex mold surface 715
of the pressure forming die 711. Thls concavo-convex mold
surface 733 has ribs whlch correspond to the 811p
preventlng protruded area 706d of the long preformed tile
body 706. Thus, lt prevents the protruded area 706d from
deformlng at the time of pressing step. Compressed
deformation of the preformed tile body 706 ls not very
large ln pressing, so that such a concavo-convex mold
surface 733 is not always necessary depending on a shape of
- 85 -
2 ~ 5 3
the protruded area 706d. Whlle, ln this embodlment, the
mold surface 733 is integrally formed on a sur~ace o~ the
lower mold 731, it may be ln such a form as to pack dents
of the protruded pattern 706 and deflne a flat surface.
A lowermost edge part or a bottom 734 of the lower
mold 731 has a cross section that is curved and bulged
downward. Protruslons 735 are provlded along a curved
surface of the bottom 734 so as to form the grooves 709a
for drainage. Though not shown ln FIG. 81, one of the
slopes of the lower mold 731 has protrusions formed
continuously with the protruslons 735. These protruslons
(not shown) have a shape corresponding to that of the
draining grooves 706e of the long preformed tile body 70~
and fitted thereln. These protrusions (not shown) are
provlded princlpally for preventing the ~oining granules
from lntruding lnto the dralning grooves 706e. Therefore,
these protrusions need not be formed over all the full
length of the groove 706e.
As shown in FIG. 81, a pair of long and short
preformed tlle bodles 706 were disposed on the opposlte
surfaces of the lower mold 731 whlle their colored surface
situated downward. Then, the ~oinlng granules were fllled
between the end surfaces of the preformed tile bodles 706
along the bottom 734 of the lower mold 731.
In thls fllling the Joinlng granules, the short
preformed tile body 706 was moved upward a little along the
slope of the lower mold 731 whlle the end metal fittings
640 was removed. Then, the ~oinlng granules were thrown
lnto between the pre~ormed tile bodies 706 through a hopper
or a slmllar frame. Thereafter, the short preformed tlle
body 7~6 was pushed downward along the slope of the lower
mold 731. The Joining granules were disposed in an
excesslve amount over the bottom 734 of the lower mold 731,
taking compression in pressing lnto account.
lANGLE TILE BODY FORMING STEP, BURNING STEP]
An angle tlle body ~ormlng step and a burniny step are
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2~ ~3~3
~ust the same as the seventeenth embodlment.
Thus, the angle tile 70:l shown ln FIG. 77 was
obtained. The angle tlle 701 has the colored pattern 704
formed up to a sufficient depth in the thickness directlon
thereof and made into one body with the other part thereof.
Accordingly, lf the tile is abraded strongly, the colored
pattern 704 is never vanished nor peeled off.
In this embodiment, the colored granules for the
surface layer 706a of the preformed tile body 706 are used
for the ~oining granules as they are so that the same color
ls given to the area from the corner to the plate tiles o~
the tlle. However, the ~oinlng granules may be a different
color tone from that of the colored granules, so that
corner distlngui~hlng colored pattern is provided on the
corner of the tlle. While, in this embodiment, the surface
layer 706a of the preformed tile body 706 is g~ven a simple
spotted pattern, plural colors of granules and an
appropriate partition plate may be used so that varlous
patterns are formed on the tile surface.
This embodlment provides an angle tile having a thick
corner distlngulshing colored pattern, that is difficult to
obtain ln conventlonal angle tile press dies, and slip
preventlng protrusions.
While, ln thls embodiment, the sllp preventing
protruded area 708 ls formed lnto a section of a saw, it
may have any other shapes. Some modifications will be
shown ln FIGs. 82(a) to 82(c). FIG. 82(a) lllustrates a
sllp preventing protruded area 801 which has rectangular
protruslons provlded in two row~, while each row belng
arranged along a width direction of a tile. The
protruslons of one row are posltloned diagonally to those
of the other row. FIG. 82(b) lllustrates a slip preventing
protruded area 802 whlch haq clrcular protruslons provlded
ln two rows, while each row belng arranged along a wldth
directlon of a tlle. The pro~ruslons of one row are
diagonally dlsposed to those o~ the other row. FIG~ 82(c)
shows a sllp preventlng protruded pattern 803 which has
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210~3
.,
grooves of V-section provided laterally and longitudinally
o~ a tile, thereby forming concaves and convexes.
The preferred embodiments descrlbed herein are
therefore illustratlve and not restrictive, the scope of
the lnvention being lndlcated in the appended claims and
all variatlons whlch come wlthin the meaning of the claims
are intended to be embraced therein.
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