Sanitary ceramic production process and closestool production process

Abstract

The invention belongs to but not limited to the technical field of ceramic production processes, and discloses a sanitary ceramic production process and a closestool production process, which comprise the following steps: preparing slurry with proper rheological property and uniform and fine glaze slip; prepared slurry is poured into a grouting mold, and demolding operation is carried out after molding; uniformly spraying or dip-coating the prepared glaze slip on the surface of the mud blank to ensure the coverage uniformity and thickness of a glaze layer; feeding the glazed green body into a kiln for high-temperature firing; the fired products are subjected to visual inspection and mechanical auxiliary detection, and the products with the appearance free of defects and the size meeting the requirement are screened out; carrying out reworking or waste treatment on unqualified products; and qualified products are cleaned and packaged, accessories are added, and then the products are stored in a warehouse and prepared to leave factories. The intelligent closestool produced through the technology is smooth in glaze surface, high in stain resistance and capable of meeting the high-end market requirement. The high-strength antibacterial closestool produced by the process has lasting antibacterial performance and higher structural strength, and is suitable for medical institutions and high-end residences.

Description

Technical Field

[0001] The present invention belongs to but is not limited to the technical field of ceramic production technology, and in particular relates to a sanitary ceramic production technology and a toilet production technology. Background Art

[0002] In the sanitary ceramics and sanitary ware industry, the traditional gypsum mold production method can no longer meet modern production needs. Many domestic ceramic factories have turned to high-pressure grouting technology to improve efficiency and reduce costs. However, this process requires the simplification of products, and products with complex structures, such as one-piece toilets and smart toilets, need to be split into multiple parts for high-pressure grouting production, and then bonded together. The technical problems that need to be solved urgently in the existing technology are: insufficient strength of the mud; poor adhesion of the glaze layer; deformation of the body during firing; and low production efficiency.

[0003] Therefore, a new sanitary ceramic production process is needed to solve these technical problems. Summary of the invention

[0004] In view of the problems existing in the prior art, the present invention provides a sanitary ceramic production process and a toilet production process.

[0005] The present invention is achieved by a sanitary ceramic production process, comprising the following steps:

[0006] Step 1, raw material processing: preparing mud with appropriate rheology and uniform and fine glaze slurry;

[0007] Step 2: Grouting: pour the prepared slurry into the grouting mold and perform demoulding after molding;

[0008] Step 3: Glazing: spray or dip the prepared glaze slurry evenly on the surface of the clay to ensure the uniformity and thickness of the glaze layer;

[0009] Step 4: Firing: The glazed body is sent into a kiln for high-temperature firing;

[0010] Step 5: Grading and sorting: The fired products are visually inspected and mechanically assisted to select products with no defects in appearance and meeting the size requirements; unqualified products are reworked or discarded;

[0011] Step 6: Packing and warehousing: Qualified products are cleaned, packaged, attached with accessories and stored in the warehouse, ready for shipment.

[0012] Further, the raw material processing specifically includes:

[0013] Mud preparation: The raw materials such as clay, quartz, feldspar, etc. are weighed in a certain proportion, and then water is added and ball-milled to prepare a mud with appropriate rheology;

[0014] Glaze slurry preparation: Kaolin, feldspar, zinc oxide and other materials are selected, mixed and ground into a uniform and fine glaze slurry to provide materials for the subsequent glazing process.

[0015] Further, the grouting molding specifically includes:

[0016] Pour the prepared mud into the grouting mold, form the toilet blank by grouting, control the grouting time and pressure to ensure uniform thickness of the mud blank;

[0017] After forming, demoulding operation is carried out to remove the wet blank and trim the surface to remove excess edges and smooth the seams.

[0018] Further, the glazed body is placed in a drying area and left to stand for a certain period of time to remove excess moisture and stabilize the glaze layer.

[0019] Further, the sintering specifically includes:

[0020] The glazed body is sent into the kiln and fired at a high temperature of about 1200-1300℃ according to the set temperature curve;

[0021] During the firing process, the temperature and atmosphere are precisely controlled to ensure that the glaze layer is well bonded to the body and obtains the required strength and surface gloss.

[0022] Another object of the present invention is to provide a smart toilet production process based on a sanitary ceramic production process, comprising the following steps:

[0023] (1) Raw material processing

[0024] Mud preparation: Select high-quality clay, feldspar and quartz, mix them in a ratio of 60:25:15, add water, grind them in a ball mill for 8 hours, and filter to obtain uniform mud;

[0025] Preparation of glaze slurry: The glaze slurry is made of kaolin, zinc oxide, quartz powder and feldspar, which are mixed in a ratio of 50:20:15:15, and a small amount of viscosity enhancer and water are added, and the glaze slurry is ground in a ball mill for 6 hours to obtain a fine glaze slurry;

[0026] (2) Grouting

[0027] Mould grouting: inject mud into the smart toilet mould, and the grouting time is controlled within 20 minutes to ensure that the toilet wall thickness is uniform (about 10mm);

[0028] Demoulding and trimming: After taking out the wet blank, trim the water outlet and connection parts to ensure a smooth and flawless surface;

[0029] (3) Glazing and firing

[0030] Glazing: Use spraying equipment to spray glaze on the toilet body at multiple angles, and the thickness of the glaze layer is controlled at 0.5mm;

[0031] Firing: The glazed body is sent into the tunnel kiln and fired at a high temperature of 1250℃ for 12 hours to ensure that the glaze surface is evenly glossy and free of bubbles;

[0032] (4) Grading and packaging

[0033] Selection: Toilets with flawless glaze and accurate dimensions are selected through automated testing equipment;

[0034] Packaging: After being equipped with intelligent control components (such as heated seat rings, automatic flushing systems), they are packaged in multiple layers of foam for protection and stored in warehouses.

[0035] Another object of the present invention is to provide a high-strength antibacterial toilet production process based on a sanitary ceramic production process, comprising the following steps:

[0036] (1) Raw material processing

[0037] Slurry preparation: Add nano zinc oxide (accounting for 1% of the total slurry) to the slurry to improve the antibacterial properties of the green body;

[0038] Preparation of glaze slurry: Add silver ion antibacterial agent (accounting for 0.5% of the total glaze slurry) to the glaze slurry to enhance the antibacterial effect of the glaze surface, while ensuring that the glaze slurry fineness is less than 0.5μm;

[0039] (2) Grouting

[0040] Mould grouting: Use antibacterial special mould for grouting, and set the grouting time to 18 minutes to ensure uniformity inside and outside the blank;

[0041] Finishing and drying: After the wet blank is demoulded, the surface is carefully polished and placed in a low-temperature drying room for 12 hours;

[0042] (3) Glazing and firing

[0043] Glazing: A multi-layer dip coating process is used to make the glaze layer evenly cover each part, and the thickness of the antibacterial coating is controlled at 1mm;

[0044] Firing: Using precise temperature control technology in the kiln, firing at 1270°C ensures that the antibacterial material is firmly bonded to the ceramic body;

[0045] (4) Grading and packaging

[0046] Selection: Ensure the surface of toilet products is smooth and flawless through antibacterial performance testing and appearance inspection;

[0047] Packaging: Wrapped with antibacterial protective film to improve transportation safety.

[0048] Another object of the present invention is to provide a sanitary ceramic production system for a sanitary ceramic production process, comprising:

[0049] Raw material processing module, to prepare mud with appropriate rheology and uniform and fine glaze slurry;

[0050] Grouting molding module, pour the prepared slurry into the grouting mold, and perform demoulding operation after molding;

[0051] The glazing module evenly sprays or dips the prepared glaze slurry on the surface of the mud to ensure the uniformity and thickness of the glaze layer;

[0052] The firing module sends the glazed body into the kiln for high-temperature firing;

[0053] In the grading and sorting module, the fired products are visually inspected and mechanically assisted to select the products with no defects in appearance and meeting the size requirements; the unqualified products are reworked or discarded;

[0054] The packaging and warehousing module cleans and packages qualified products, adds accessories and stores them in the warehouse, ready for shipment.

[0055] Another object of the present invention is to provide a toilet using the above-mentioned sanitary ceramic production process.

[0056] In combination with the above technical solutions and the technical problems solved, the advantages and positive effects of the technical solutions to be protected by the present invention are as follows:

[0057] First, the technical problem solved by the present invention

[0058] 1. Insufficient strength of the mud: By adding reinforcing agent to the mud, the strength of the wet and dry blanks after molding can be improved to reduce cracking and deformation problems.

[0059] 2. Poor adhesion of the glaze layer: Optimize the glaze slurry formula and glazing process to ensure that the glaze layer is tightly bonded to the body after high-temperature firing to prevent the glaze from peeling off.

[0060] 3. Deformation of the green body during firing: By optimizing the kiln temperature curve and support structure design, the warping or deformation problems during firing can be effectively reduced.

[0061] 4. Low production efficiency: The introduction of automated grouting equipment and precise control systems can greatly improve production efficiency and product consistency.

[0062] Second, the technical effect of the present invention

[0063] 1. Improved product quality: By optimizing the mud and glaze slurry formula, the toilets produced have higher impact resistance, stain resistance and glaze gloss.

[0064] 2. Reduce production costs: Improve molding process and firing control, reduce defective product rate, and save raw materials and energy consumption.

[0065] 3. Adapt to diverse needs: By adjusting process parameters, we can quickly respond to market demands for toilets of different specifications, colors and functions, and improve market competitiveness.

[0066] 4. Environmentally friendly manufacturing: reduce waste emissions, use recyclable raw materials and clean energy, and comply with green manufacturing requirements. BRIEF DESCRIPTION OF THE DRAWINGS

[0067] Figure 1 It is a process flow chart of sanitary ceramic production provided by an embodiment of the present invention;

[0068] Figure 2 It is a schematic diagram of the mud blank bonding process provided by an embodiment of the present invention.

[0069] Figure 3 It is a structural diagram of a sanitary ceramic production system provided in an embodiment of the present invention. DETAILED DESCRIPTION

[0070] In order to make the purpose, technical solution and advantages of the present invention more clearly understood, the present invention is further described in detail below in conjunction with the embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention.

[0071] like Figure 1 As shown, an embodiment of the present invention provides a sanitary ceramic production process, comprising the following steps:

[0072] Step 1, raw material processing: preparing mud with appropriate rheology and uniform and fine glaze slurry;

[0073] Step 2: Grouting: pour the prepared slurry into the grouting mold and perform demoulding after molding;

[0074] Step 3: Glazing: spray or dip the prepared glaze slurry evenly on the surface of the clay to ensure the uniformity and thickness of the glaze layer;

[0075] Step 4: Firing: The glazed body is sent into a kiln for high-temperature firing;

[0076] Step 5: Grading and sorting: The fired products are visually inspected and mechanically assisted to select products with no defects in appearance and meeting the size requirements; unqualified products are reworked or discarded;

[0077] Step 6: Packing and warehousing: Qualified products are cleaned, packaged, attached with accessories and stored in the warehouse, ready for shipment.

[0078] Further, the raw material processing specifically includes:

[0079] Mud preparation: The raw materials such as clay, quartz, feldspar, etc. are weighed in a certain proportion, and then water is added and ball-milled to prepare a mud with appropriate rheology;

[0080] Glaze slurry preparation: Kaolin, feldspar, zinc oxide and other materials are selected, mixed and ground into a uniform and fine glaze slurry to provide materials for the subsequent glazing process.

[0081] Further, the grouting molding specifically includes:

[0082] Pour the prepared mud into the grouting mold, form the toilet blank by grouting, control the grouting time and pressure to ensure uniform thickness of the mud blank;

[0083] After forming, demoulding operation is carried out to remove the wet blank and trim the surface to remove excess edges and smooth the seams.

[0084] Further, the glazed body is placed in a drying area and left to stand for a certain period of time to remove excess moisture and stabilize the glaze layer.

[0085] Further, the sintering specifically includes:

[0086] The glazed body is sent into the kiln and fired at a high temperature of about 1200-1300℃ according to the set temperature curve;

[0087] During the firing process, the temperature and atmosphere are precisely controlled to ensure that the glaze layer is well bonded to the body and obtains the required strength and surface gloss.

[0088] Example 1: Smart toilet production process

[0089] 1. Raw material processing

[0090] Mud preparation: Select high-quality clay, feldspar and quartz, mix them in proportion (60:25:15), add water, grind them in a ball mill for 8 hours, and filter to obtain uniform mud;

[0091] Preparation of glaze slurry: The glaze slurry is made of kaolin, zinc oxide, quartz powder and feldspar, which are mixed in a proportion of (50:20:15:15), and a small amount of viscosity enhancer and water are added. The glaze slurry is ground in a ball mill for 6 hours to obtain a fine glaze slurry.

[0092] 2. Grouting

[0093] Mould grouting: inject mud into the smart toilet mould, and the grouting time is controlled within 20 minutes to ensure that the toilet wall thickness is uniform (about 10mm);

[0094] Demoulding and trimming: After taking out the wet blank, trim the water outlet and connection parts to ensure a smooth and flawless surface.

[0095] 3. Glazing and firing

[0096] Glazing: Use spraying equipment to spray glaze on the toilet body at multiple angles, and the thickness of the glaze layer is controlled at 0.5mm;

[0097] Firing: The glazed body is sent into the tunnel kiln and fired at a high temperature of 1250℃ for 12 hours to ensure that the glaze surface is evenly glossy and free of bubbles.

[0098] 4. Grading and packaging

[0099] Selection: Toilets with flawless glaze and accurate dimensions are selected through automated testing equipment;

[0100] Packaging: After being equipped with intelligent control components (such as heated seat rings, automatic flushing systems), they are packaged in multiple layers of foam for protection and stored in warehouses.

[0101] Effect

[0102] The smart toilets produced by this process have a smooth glaze and strong stain resistance, which can meet the needs of the high-end market.

[0103] Example 2: High-strength antibacterial toilet production process

[0104] 1. Raw material processing

[0105] Slurry preparation: Add nano zinc oxide (accounting for 1% of the total slurry) to the slurry to improve the antibacterial properties of the green body;

[0106] Preparation of glaze slurry: Add silver ion antibacterial agent (accounting for 0.5% of the total glaze slurry) to the glaze slurry to enhance the antibacterial effect of the glaze surface, while ensuring that the fineness of the glaze slurry is less than 0.5 μm.

[0107] 2. Grouting

[0108] Mould grouting: Use antibacterial special mould for grouting, and set the grouting time to 18 minutes to ensure uniformity inside and outside the blank;

[0109] Finishing and drying: After the wet blank is demoulded, the surface is carefully polished and left to stand in a low-temperature drying room for 12 hours.

[0110] 3. Glazing and firing

[0111] Glazing: A multi-layer dip coating process is used to make the glaze layer evenly cover each part, and the thickness of the antibacterial coating is controlled at 1mm;

[0112] Firing: Use precise temperature control technology in the kiln and fire at 1270℃ to ensure that the antibacterial material is firmly bonded to the ceramic body.

[0113] 4. Grading and packaging

[0114] Selection: Ensure the surface of toilet products is smooth and flawless through antibacterial performance testing and appearance inspection;

[0115] Packaging: Wrapped with antibacterial protective film to improve transportation safety.

[0116] Effect

[0117] The high-strength antibacterial toilet produced by this process has long-lasting antibacterial properties and higher structural strength, and is suitable for medical institutions and high-end residences.

[0118] like Figure 2 As shown, the schematic diagram of the mud bonding process:

[0119] (1) Seal ring clay blocks;

[0120] (2) Separation of mud blocks for the bladder bag and the sewage pipe;

[0121] (3) Dividing the clay blocks into blocks;

[0122] (4) Bonding of the seat ring block and the bladder bag sewage pipe block;

[0123] (5) The barrel clay and other parts are bonded in blocks to complete an integrated product. The red coordination position is the hardening position;

[0124] (6) Illustration of the wind crack locations of the product.

[0125] like Figure 3 As shown, an embodiment of the present invention provides a sanitary ceramic production system for a sanitary ceramic production process, comprising:

[0126] Raw material processing module, to prepare mud with appropriate rheology and uniform and fine glaze slurry;

[0127] Grouting molding module, pour the prepared slurry into the grouting mold, and perform demoulding operation after molding;

[0128] The glazing module evenly sprays or dips the prepared glaze slurry on the surface of the mud to ensure the uniformity and thickness of the glaze layer;

[0129] The firing module sends the glazed body into the kiln for high-temperature firing;

[0130] In the grading and sorting module, the fired products are visually inspected and mechanically assisted to select the products with no defects in appearance and meeting the size requirements; the unqualified products are reworked or discarded;

[0131] The packaging and warehousing module cleans and packages qualified products, adds accessories and stores them in the warehouse, ready for shipment.

[0132] Embodiment 3: A toilet is manufactured by adopting the above-mentioned sanitary ceramic production process.

[0133] The above description is only a specific implementation mode of the present invention, but the protection scope of the present invention is not limited thereto. Any modifications, equivalent substitutions and improvements made by any technician familiar with the technical field within the technical scope disclosed by the present invention and within the spirit and principle of the present invention should be covered by the protection scope of the present invention.

Claims

1. A sanitary ceramic production process, characterized in that: The following steps are involved: Step 1, raw material processing: preparing mud with appropriate rheology and uniform and fine glaze slurry; Step 2: Grouting: pour the prepared slurry into the grouting mold and perform demoulding after molding; Step 3: Glazing: spray or dip the prepared glaze slurry evenly on the surface of the clay to ensure the uniformity and thickness of the glaze layer; Step 4: Firing: The glazed body is sent into a kiln for high-temperature firing; Step 5: Grading and sorting: The fired products are visually inspected and mechanically assisted to select products with no defects in appearance and meeting the size requirements; unqualified products are reworked or discarded; Step 6: Packing and warehousing: Qualified products are cleaned, packaged, attached with accessories and stored in the warehouse, ready for shipment.

2. The sanitary ceramic production process according to claim 1, characterized in that: The raw material processing specifically includes: Mud preparation: The raw materials such as clay, quartz, feldspar, etc. are weighed in a certain proportion, and then water is added and ball-milled to prepare a mud with appropriate rheology; Glaze slurry preparation: Kaolin, feldspar, zinc oxide and other materials are selected, mixed and ground into a uniform and fine glaze slurry to provide materials for the subsequent glazing process.

3. The sanitary ceramic production process according to claim 1, characterized in that: The grouting molding specifically comprises: Pour the prepared mud into the grouting mold, form the toilet blank by grouting, control the grouting time and pressure to ensure uniform thickness of the mud blank; After forming, demoulding operation is carried out to remove the wet blank and trim the surface to remove excess edges and smooth the seams.

4. The sanitary ceramic production process according to claim 1, characterized in that: The glazed body is placed in a drying area and left to stand for a certain period of time to remove excess moisture and stabilize the glaze layer.

5. The sanitary ceramic production process according to claim 1, characterized in that: The sintering specifically includes: The glazed body is sent into the kiln and fired at a high temperature of about 1200-1300℃ according to the set temperature curve; During the firing process, the temperature and atmosphere are precisely controlled to ensure that the glaze layer is well bonded to the body and obtains the required strength and surface gloss.

6. A smart toilet production process based on sanitary ceramic production process as claimed in any one of claims 1 to 5, characterized in that: The following steps are involved: (1) Raw material processing Mud preparation: Select high-quality clay, feldspar and quartz, mix them in a ratio of 60:25:15, add water, grind them in a ball mill for 8 hours, and filter to obtain uniform mud; Preparation of glaze slurry: The glaze slurry is made of kaolin, zinc oxide, quartz powder and feldspar, which are mixed in a ratio of 50:20:15:15, and a small amount of viscosity enhancer and water are added, and the glaze slurry is ground in a ball mill for 6 hours to obtain a fine glaze slurry; (2) Grouting Mould grouting: inject the slurry into the smart toilet mould, the grouting time is controlled within 20 minutes, and ensure that the toilet wall thickness is uniform, about 10mm; Demoulding and trimming: After taking out the wet blank, trim the water outlet and connection parts to ensure a smooth and flawless surface; (3) Glazing and firing Glazing: Use spraying equipment to spray glaze on the toilet body at multiple angles, and the thickness of the glaze layer is controlled at 0.5mm; Firing: The glazed body is sent into the tunnel kiln and fired at a high temperature of 1250℃ for 12 hours to ensure that the glaze surface is evenly glossy and free of bubbles; (4) Grading and packaging Selection: Toilets with flawless glaze and accurate dimensions are selected through automated testing equipment; Packaging: After being equipped with intelligent control components, the intelligent control components including the heated seat ring and automatic flushing system are packed with multiple layers of foam protection and stored in the warehouse.

7. A high-strength antibacterial toilet production process based on a sanitary ceramic production process as claimed in any one of claims 1 to 5, comprising the following steps: (1) Raw material processing Slurry preparation: Add nano zinc oxide to the slurry, accounting for 1% of the total slurry, to improve the antibacterial properties of the green body; Preparation of glaze slurry: Add silver ion antibacterial agent to the glaze slurry, accounting for 0.5% of the total glaze slurry, to enhance the antibacterial effect of the glaze surface, while ensuring that the glaze slurry fineness is less than 0.5μm; (2) Grouting Mould grouting: Use antibacterial special mould for grouting, and set the grouting time to 18 minutes to ensure uniformity inside and outside the blank; Finishing and drying: After the wet blank is demoulded, the surface is carefully polished and placed in a low-temperature drying room for 12 hours; (3) Glazing and firing Glazing: A multi-layer dip coating process is used to make the glaze layer evenly cover each part, and the thickness of the antibacterial coating is controlled at 1mm; Firing: Using precise temperature control technology in the kiln, firing at 1270°C ensures that the antibacterial material is firmly bonded to the ceramic body; (4) Grading and packaging Selection: Ensure the surface of toilet products is smooth and flawless through antibacterial performance testing and appearance inspection; Packaging: Wrapped with antibacterial protective film to improve transportation safety.

8. A sanitary ceramic production system according to any one of claims 1 to 5, characterized in that: include: Raw material processing module, to prepare mud with appropriate rheology and uniform and fine glaze slurry; Grouting molding module, pour the prepared slurry into the grouting mold, and perform demoulding operation after molding; The glazing module evenly sprays or dips the prepared glaze slurry on the surface of the mud to ensure the uniformity and thickness of the glaze layer; The firing module sends the glazed body into the kiln for high-temperature firing; In the grading and sorting module, the fired products are visually inspected and mechanically assisted to select the products with no defects in appearance and meeting the size requirements; the unqualified products are reworked or discarded; The packaging and warehousing module cleans and packages qualified products, adds accessories and stores them in the warehouse, ready for shipment.

9. A toilet, characterized in that: The sanitary ceramic production process as described in any one of claims 1 to 8 is adopted.

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