Sanitary ceramic bonding forming process and bonding slurry

Abstract

The invention belongs to but is not limited to the technical field of ceramic bonding forming, and discloses a sanitary ceramic bonding forming process and bonding slurry, the mutual bonding surfaces of a plurality of parts produced by high-pressure grouting are optimally designed, and the original plane form of the bonding surfaces is optimized into an arc surface form; mixing the slurry and the glaze slip, and fully stirring to form bonding slurry with high bonding strength; prepared bonding slurry is smeared on the designed arc-shaped joint face; putting the bonded mud blank into a kiln for high-temperature sintering; and after firing, strict appearance and structure quality detection is performed on the bonded part to ensure that the product has no cracking and wind cracking phenomena. Through optimization of arc surface design and innovative combination of bonding slurry, the appearance quality, the bonding strength and the production stability of sanitary ceramic products are remarkably improved, multiple problems existing in a traditional plane bonding mode are solved, and powerful support is provided for efficient production of ceramic of a complex structure.

Description

Technical Field

[0001] The invention belongs to but is not limited to the technical field of ceramic bonding and forming, and in particular relates to a sanitary ceramic bonding and forming process and bonding slurry. Background Art

[0002] In the sanitary ceramic sanitary ware industry, the traditional gypsum mold production method can no longer meet the needs of modern production. 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. At present, the industry adopts the "planar" bonding bonding molding method, that is, the contact surfaces of the two parts are flat. This planar bonding method has multiple defects: ① It is difficult to accurately position the two parts when bonding, and there is a tendency for misalignment, which affects production efficiency and product yield; ② The bonding marks are visually obvious, affecting the appearance of the product; ③ The contact surface is small, the bonding strength is low, and it is easy to have wind cracks and bonding surface cracking problems.

[0003] The above problems have seriously restricted the market promotion of high-pressure grouting toilets, reducing product competitiveness and customer satisfaction. Existing technical status and existing defects:

[0004] As production competition becomes increasingly fierce, production costs need to be continuously controlled and reduced. At the same time, in order to reduce the labor intensity of production employees, the use of a highly mechanized production model has become a major trend. In the production process of sanitary ceramics, the molding process is the most labor-intensive and highly dependent on the skills of employees. The use of mechanized operations can provide efficiency and reduce the labor intensity of employees, but the complexity of the mold design must be reduced, and simplified block mold molding must be adopted. In this way, a bonding process must be used to bond several mechanically formed clay components together to form a finished product.

[0005] In the bonding process, the performance of the bonding mud is a key point. It is generally made of mud + returned mud. During high-temperature sintering, the bonding performance between the bonding mud and the mud blank is unstable, which is prone to wind cracking defects and even later wind cracking, causing the risk of market complaints.

[0006] In view of the above analysis, the technical problems that need to be solved urgently in the prior art are:

[0007] 1. Traditional plane bonding is difficult to position: Due to the simple contact surface of the plane bonding method, the bonded parts are prone to misalignment during production, affecting the bonding accuracy and production efficiency.

[0008] 2. Low bonding strength and easy to crack: The contact area of ​​traditional flat bonding is limited, the bonding strength is insufficient, and it is easy to cause wind cracking and seam cracking during high-temperature firing or later use.

[0009] 3. The bonding marks obviously affect the appearance: The joints of the flat bonding method have obvious visual marks, especially in high-end products, and the appearance quality is difficult to meet market demand.

[0010] 4. Unstable performance of bonding mud: Traditional bonding mud has unstable performance when fired at high temperature, has poor bonding effect with mud blank, and is prone to wind cracking in the later stage. Summary of the invention

[0011] In view of the problems existing in the prior art, the present invention provides a sanitary ceramic bonding molding process and bonding slurry.

[0012] The present invention is achieved by a sanitary ceramic bonding molding process, comprising the following steps:

[0013] Step 1: Design of arc surface joint: Optimize the joint surfaces of multiple components produced by high-pressure grouting, and optimize the original plane shape of the joint surface into an arc surface shape;

[0014] Step 2, preparation of bonding slurry: mixing the slurry with the glaze slurry and stirring them fully to form a bonding slurry with high bonding strength;

[0015] Step 3: Applying the bonding slurry and joining the mud blank: Apply the prepared bonding slurry on the designed arc-shaped joint surface;

[0016] Step 4: Bonding and strengthening by high temperature firing: the bonded clay is placed in a kiln for high temperature firing;

[0017] Step 5: Quality inspection and post-optimization: After firing, the bonded parts are strictly inspected for appearance and structural quality to ensure that the product is free of cracks and wind cracks.

[0018] Furthermore, the design of the arc surface joint specifically includes:

[0019] During the design stage, the joint surfaces of the various parts of the sanitary ceramics were designed with curved surfaces. The two components, the panel and the outer barrel, were designed to be concave or convex arcs that can fit together, so that they can be completely fitted when joined; and the outer joint is located exactly where the R angle of the product ends to hide the seams and improve the appearance quality.

[0020] Furthermore, the preparation of the bonding slurry specifically includes:

[0021] Take an appropriate amount of mud in the molding workshop, weigh the glaze slurry according to the preset ratio, mix the two and add them into the mixer, ensure that they are fully stirred and evenly mixed to form a bonding mud with high bonding strength; after stirring, put the mud into a plastic bag or plastic bottle, and use it like squeezing toothpaste when ready, to facilitate construction operations.

[0022] Take the mud from the molding workshop, weigh it, add glaze slurry in a certain proportion, use a blender to mix evenly, then put it into a plastic bag or plastic bottle. When using it, apply it on the bonding position of the mud blank like squeezing toothpaste and perform normal bonding operations.

[0023] Furthermore, when applying the bonding slurry in step three, attention should be paid to uniform coverage of the slurry to avoid gaps that affect the bonding effect.

[0024] Concealed treatment of the bonding point: The curved surface design hides the joint at the end of the R angle of the product, and uses the visual characteristics of the curved surface to make the seam difficult to be visually detected, thereby further improving the appearance quality and high-end feel of the product.

[0025] Furthermore, in step 4, since glaze slurry components are added to the bonding slurry, it can be better melted with the green body at high temperature to form a strong bonding interface, thereby effectively improving the bonding strength and reducing the wind cracking problem.

[0026] Furthermore, in step five, the mud formula and arc surface design process are continuously optimized through data feedback to further improve the production efficiency and reliability of the product.

[0027] Another object of the present invention is to provide a sanitary ceramic bonding and molding system for a sanitary ceramic bonding and molding process, comprising:

[0028] The arc surface joint design module optimizes the joint surfaces of multiple components produced by high-pressure grouting, and optimizes the original plane shape of the joint surface to an arc surface shape;

[0029] The bonding mud preparation module mixes the mud and glaze slurry and stirs them fully to form a bonding mud with high bonding strength;

[0030] The bonding mud slurry application and mud blank jointing module applies the prepared bonding mud to the designed arc-shaped joint surface;

[0031] High temperature firing module, the bonded clay is placed in the kiln for high temperature firing;

[0032] Quality inspection and post-optimization module, after firing, the bonded parts are strictly inspected for appearance and structural quality to ensure that the product has no cracks or wind cracks.

[0033] Another object of the present invention is to provide a bonding slurry, such as the bonding slurry used in the above-mentioned sanitary ceramic bonding molding process;

[0034] Preparation method of bonding mud: Mix the mud and glaze slurry and stir them fully to form bonding mud with high bonding strength.

[0035] 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:

[0036] First, the present invention provides a bonding and forming process for sanitary ceramics. Compared with the existing planar bonding method in the industry, the curved bonding method has the following advantages in the actual production process:

[0037] ① The contact surface is a curved surface, which makes it easier to position the two parts during bonding; ② The bonding surface is a curved surface, the contact area of ​​the two parts is larger, and they are tighter after bonding. There is no cracking under a temperature difference of 85°C, which can effectively reduce the bonding cracks and later wind cracks that may exist in the subsequent production process; ③ The outer joint is exactly at the end of the R angle. After bonding, there is no obvious trace on the appearance of the product, which can effectively improve the grade of the product.

[0038] The invention is to make a bold innovation on the bonding slurry in the bonding process of sanitary ceramic production, add a certain proportion of glaze slurry into the bonding slurry, and in the high-temperature firing process, the glazed bonding slurry can be better fused with the green body and have a stronger bonding force.

[0039] The use of the bonding slurry of the present invention can effectively solve the problem of wind cracking during firing of sanitary ceramics and the hidden danger of wind cracking in the later stage, and reduce market complaints about products and safety risks during use.

[0040] Second, the present invention solves the problem of difficult positioning by accurately positioning the bonding parts through the arc surface nesting design. The present invention significantly enhances the bonding strength by expanding the bonding area through the arc surface and adding glaze slurry to the bonding slurry. The present invention solves the problem of the joint marks affecting the appearance by designing the joint at the end position of the R angle to hide the seam. The present invention fundamentally improves the performance of the bonding slurry by adding glaze slurry to the slurry to make it melt better with the blank. The technical effects of the present invention specifically include:

[0041] 1. Improved bonding accuracy

[0042] Through the arc-shaped joint design, the clay parts can automatically fit together during bonding, limiting the multi-directional freedom, significantly improving the bonding accuracy and reducing the misalignment problem during the production process. The natural fit of the arc surface makes bonding more convenient and improves production efficiency.

[0043] 2. Significantly enhanced bonding strength

[0044] The curved bonding design expands the bonding area, and by adding glaze slurry to the bonding slurry, the high-temperature sintering and fusion effect between the mud blanks is enhanced. In the high and low temperature impact test after production, the product did not crack under the temperature difference of 85℃, and the bonding strength was much higher than the traditional flat bonding method.

[0045] 3. Improve product appearance quality

[0046] The curved surface design hides the bonding point at the end of the R angle, and the seam transitions naturally with the outer surface, with no obvious traces. This design enhances the grade of the product and makes the product more in line with the needs of the high-end market.

[0047] 4. Reduce production and use risks

[0048] Due to the high bonding strength of the curved surface design, the risk of wind cracking and later cracks is reduced, significantly reducing the product market complaint rate and improving the safety of use and customer satisfaction. BRIEF DESCRIPTION OF THE DRAWINGS

[0049] Figure 1 It is a process flow chart of the bonding and forming of sanitary ceramics provided by an embodiment of the present invention;

[0050] Figure 2 Schematic diagram of a planar bonding method provided by an embodiment of the present invention; (a) bonding schematic diagram; (b) enlarged cross-sectional diagram of the bonding surface;

[0051] Figure 3 Schematic diagram of the arc-surface bonding method provided by an embodiment of the present invention; (a) bonding schematic diagram; (b) enlarged cross-sectional diagram of the bonding surface;

[0052] Figure 4 is a structural diagram of a sanitary ceramic bonding and molding system provided by an embodiment of the present invention;

[0053] Figure 5 This is a comparison diagram of the cross-sections of the planar joint and the curved joint provided by the embodiment of the present invention;

[0054] Figure 6 This is a comparison diagram of the appearance of the planar joint and the curved joint provided by the embodiment of the present invention;

[0055] In the figure: 1, outer barrel; 2, panel; 3, joint surface; 21, R angle; 32, outer joint. DETAILED DESCRIPTION

[0056] 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.

[0057] like Figure 1 As shown, an embodiment of the present invention provides a sanitary ceramic bonding molding process, comprising the following steps:

[0058] Step 1: Design of arc surface joint: Optimize the joint surfaces of multiple components produced by high-pressure grouting, and optimize the original plane shape of the joint surface into an arc surface shape;

[0059] Step 2, preparation of bonding slurry: mixing the slurry with the glaze slurry and stirring them fully to form a bonding slurry with high bonding strength;

[0060] Step 3: Applying the bonding slurry and joining the mud blank: Apply the prepared bonding slurry on the designed arc-shaped joint surface;

[0061] Step 4: Bonding and strengthening by high temperature firing: the bonded clay is placed in a kiln for high temperature firing;

[0062] Step 5: Quality inspection and post-optimization: After firing, the bonded parts are strictly inspected for appearance and structural quality to ensure that the product is free of cracks and wind cracks.

[0063] Furthermore, the design of the arc surface joint specifically includes:

[0064] During the design stage, the joint surfaces of the various parts of the sanitary ceramics were designed with curved surfaces. The two components, the panel and the outer barrel, were designed to be concave or convex arcs that can fit together, so that they can be completely fitted when joined; and the outer joint is located exactly where the R angle of the product ends to hide the seams and improve the appearance quality.

[0065] The concave and convex arc design can limit the freedom in multiple directions, so that the two parts can be accurately positioned and stably combined when they are joined. Compared with the flat shape, the arc design has a larger contact surface and a tighter joint. There is a turning point of the curved surface at the end of the R angle, and the joint is designed at the end of the R angle, which can hide the seam at the turning point of the curved surface and is less visible visually.

[0066] The embodiment of the present invention optimizes the design of the joint surfaces of multiple components produced by high-pressure grouting, and optimizes the original planar shape of the joint surface to an arc shape. Taking the smart toilet as an example, the two components of the toilet panel and the toilet outer barrel produced by grouting are arc-shaped at the joint. The joint surface of the toilet panel is an inward concave arc, while the joint surface of the toilet outer barrel is an outward convex arc. When the two components are joined, the inward concave and outward convex arcs can fit completely, and the outer joint is exactly at the end of the R angle of the product.

[0067] Furthermore, the preparation of the bonding slurry specifically includes:

[0068] Take an appropriate amount of mud in the molding workshop, weigh the glaze slurry according to the preset ratio, mix the two and add them into the mixer, ensure that they are fully stirred and evenly mixed to form a bonding mud with high bonding strength; after stirring, put the mud into a plastic bag or plastic bottle, and use it like squeezing toothpaste when ready, to facilitate construction operations.

[0069] Take the mud from the molding workshop, weigh it, add glaze slurry in a certain proportion, use a blender to mix evenly, then put it into a plastic bag or plastic bottle. When using it, apply it on the bonding position of the mud blank like squeezing toothpaste and perform normal bonding operations.

[0070] Furthermore, when applying the bonding slurry in step three, attention should be paid to uniform coverage of the slurry to avoid gaps that affect the bonding effect.

[0071] Concealed treatment of the bonding point: The curved surface design hides the joint at the end of the R angle of the product, and uses the visual characteristics of the curved surface to make the seam difficult to be visually detected, thereby further improving the appearance quality and high-end feel of the product.

[0072] Furthermore, in step 4, since glaze slurry components are added to the bonding slurry, it can be better melted with the green body at high temperature to form a strong bonding interface, thereby effectively improving the bonding strength and reducing the wind cracking problem.

[0073] Furthermore, in step five, the mud formula and arc surface design process are continuously optimized through data feedback to further improve the production efficiency and reliability of the product.

[0074] The present invention significantly improves the appearance quality, bonding strength and production stability of sanitary ceramic products through the optimization of arc surface design and the innovative combination of bonding slurry, solves many problems existing in traditional planar bonding methods, and provides strong support for the efficient production of complex structural ceramics.

[0075] like Figure 4 As shown, an embodiment of the present invention provides a sanitary ceramic bonding and molding system for a sanitary ceramic bonding and molding process, comprising:

[0076] The arc surface joint design module optimizes the joint surfaces of multiple components produced by high-pressure grouting, and optimizes the original plane shape of the joint surface to an arc surface shape;

[0077] The bonding mud preparation module mixes the mud and glaze slurry and stirs them fully to form a bonding mud with high bonding strength;

[0078] The bonding mud slurry application and mud blank jointing module applies the prepared bonding mud to the designed arc-shaped joint surface;

[0079] High temperature firing module, the bonded clay is placed in the kiln for high temperature firing;

[0080] Quality inspection and post-optimization module, after firing, the bonded parts are strictly inspected for appearance and structural quality to ensure that the product has no cracks or wind cracks.

[0081] 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 bonding molding process, characterized in that: The following steps are involved: Step 1: Design of arc surface joint: Optimize the joint surfaces of multiple components produced by high-pressure grouting, and optimize the original plane shape of the joint surface into an arc surface shape; Step 2, preparation of bonding slurry: mixing the slurry with the glaze slurry and stirring them fully to form a bonding slurry with high bonding strength; Step 3: Applying the bonding slurry and joining the mud blank: Apply the prepared bonding slurry on the designed arc-shaped joint surface; Step 4: Bonding and strengthening by high temperature firing: the bonded clay is placed in a kiln for high temperature firing; Step 5: Quality inspection and post-optimization: After firing, the bonded parts are strictly inspected for appearance and structural quality to ensure that the product is free of cracks and wind cracks.

2. The sanitary ceramic bonding molding process according to claim 1, characterized in that: The design of the arc surface joint specifically includes: During the design stage, the joint surfaces of the various parts of the sanitary ceramics were designed with curved surfaces. The two components, the panel and the outer barrel, were designed to be concave or convex arcs that can fit together, so that they can be completely fitted when joined; and the outer joint is located exactly where the R angle of the product ends to hide the seams and improve the appearance quality.

3. The sanitary ceramic bonding molding process according to claim 1, characterized in that: The preparation of the bonding slurry specifically includes: Take an appropriate amount of mud in the molding workshop, weigh the glaze slurry according to the preset ratio, mix the two and add them into the mixer, ensure that they are fully stirred and evenly mixed to form a bonding mud with high bonding strength; after stirring, put the mud into a plastic bag or plastic bottle, and use it like squeezing toothpaste when ready, to facilitate construction operations. Take the mud from the molding workshop, weigh it, add glaze slurry in a certain proportion, use a blender to mix evenly, then put it into a plastic bag or plastic bottle. When using it, apply it on the bonding position of the mud blank like squeezing toothpaste and perform normal bonding operations.

4. The sanitary ceramic bonding molding process according to claim 1, characterized in that: In step 3, pay attention to even coverage of the bonding slurry when applying it to avoid gaps that affect the bonding effect; Concealed treatment of the bonding point: The curved surface design hides the joint at the end of the R angle of the product, and uses the visual characteristics of the curved surface to make the seam difficult to be visually detected, thereby further improving the appearance quality and high-end feel of the product.

5. The sanitary ceramic bonding molding process according to claim 1, characterized in that: In step 4, since glaze slurry is added to the bonding slurry, it can be better melted with the green body at high temperature to form a strong bonding interface, thereby effectively improving the bonding strength and reducing wind cracking problems.

6. The sanitary ceramic bonding molding process according to claim 1, characterized in that: In step five, the mud formula and curved surface design process are continuously optimized through data feedback to further improve the production efficiency and reliability of the product.

7. A sanitary ceramic bonding and molding system for the sanitary ceramic bonding and molding process according to any one of claims 1 to 6, characterized in that: include: The arc surface joint design module optimizes the joint surfaces of multiple components produced by high-pressure grouting, and optimizes the original plane shape of the joint surface to an arc surface shape; The bonding mud preparation module mixes the mud and glaze slurry and stirs them fully to form a bonding mud with high bonding strength; The bonding mud slurry application and mud blank jointing module applies the prepared bonding mud to the designed arc-shaped joint surface; High temperature firing module, the bonded clay is placed in the kiln for high temperature firing; Quality inspection and post-optimization module, after firing, the bonded parts are strictly inspected for appearance and structural quality to ensure that the product has no cracks or wind cracks.

8. A bonding slurry, characterized in that: The bonding slurry for the bonding and molding process of sanitary ceramics according to any one of claims 1 to 7; The bonding slurry preparation method comprises the following steps: mixing the slurry and the glaze slurry and stirring them sufficiently to form a bonding slurry with high bonding strength.

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