Sanitary fitting blank and method for manufacturing a sanitary fitting

Description

[0001] The invention relates to a sanitary tub with a metal tub body and an enamel coating arranged on the tub body. The invention further relates to a sanitary tub blank for shower trays or bathtubs for forming a sanitary tub according to the invention, as well as a method for its production.

[0002] Such combinations of a steel tub body and an enamel coating are generally referred to as steel enamel. Sanitary tubs made of steel enamel are characterized by high scratch, abrasion, and impact resistance, as well as being hygienic and dirt-repellent. Furthermore, the high-quality appearance of steel enamel is retained over time, with no color or surface changes occurring even under the influence of chemicals and heat.

[0003] The production of enamel and enameled products is well known to those skilled in the art. For further information, see the "Römpp Chemie Lexikon," Volume 2, 9th edition, 1990, pp. 1147 ff., and "Ullmanns Encyklopädie der technischen Chemie," Volume 10, 4th edition, 1975, pp. 436 to 447.

[0004] The raw materials used in enamel production are quartz, feldspar, soda, calcium carbonate, borax, sodium nitrate, and fluorspar, along with additives tailored to the specific application. The raw materials are mixed and melted at approximately 1200 °C, where they solidify, forming the frit in the form of granules or flakes.

[0005] The frit is ground and usually mixed with water to form a slurry, which is then applied to the steel surface to be coated, usually a steel sheet. The coating is dried before firing, and the dried layer is referred to as enamel biscuit or biscuit.

[0006] For the purposes of the invention, the blank is the intermediate product formed in this way before the final firing process. This also applies if, in a multi-layer, typically two-layer application of enamel with a base enamel and a top enamel, the base enamel layer has already been fired and the top enamel layer is present as a biscuit layer.

[0007] A bathtub or a shower tray can be considered as a sanitary tray. A tray is generally understood to be a body with a border and a vessel-shaped recess arranged between them. The vessel-shaped recess also primarily has a gradient that leads to a drain opening. For the purposes of the invention, the term "tub" also refers to bodies that deviate from the classic meaning of the word. For example, it is conceivable that a sanitary fixture exhibited as a shower tray consists of a substantially flat body that only has a specific gradient due to the installation situation, which is directed towards an edge-mounted drain. Sealing is achieved using special sealing tapes. In general, a broad interpretation of the term "tub" is therefore required.

[0008] With sanitary tubs made of steel enamel, there is always a risk for the user of slipping on the surface of the sanitary tub when exposed to moisture.

[0009] A thin film of water forms between the human skin and the surface, the formation of which is further promoted by surface-active substances contained in personal care products such as shower gels, bath additives, shampoos or skin care products.

[0010] In order to make a surface slip-resistant, it is already known to at least partially break through the surface film by creating edges and roughness.

[0011] In this context, US 2004 / 0105966 A1 describes a metal sanitary tub with an enameled surface, the enameled surface of which is provided in at least one section with an anti-slip coating. The anti-slip coating consists of a granular inorganic material that is firmly bonded to the enameled surface by firing.

[0012] Alternatively, DE 43 09 019 A1 describes a sanitary tub with a non-slip base surface created by roughening. Roughening is achieved by blasting with corundum or glass beads, etching, brushing, or grinding. The described method is primarily suitable for acrylic tubs, but should also be applicable to enameled steel tubs. However, mechanical material removal from enameled surfaces is very complex from a manufacturing perspective. Furthermore, mechanical material removal has the disadvantage of damaging the high-quality enameled surface.

[0013] In addition, anti-slip structures according to EP 0 825 917 B1 can also be created by generating microcraters using a laser.

[0014] FR 2 869 899 A1 describes the possibility of creating anti-slip structures on a sanitary tub by applying a mineral powder, which is sintered, for example, using a laser beam. WO 99 / 25562 A1 discloses a sanitary tub with laser marking.

[0015] Starting from a sanitary tub of the type described above, the object of the invention is to modify a sanitary tub in such a way that it is easy to manufacture and has particularly good anti-slip properties on the surface or on the area on which the user walks.

[0016] This object is achieved by a sanitary tub according to claim 1, wherein the coating comprises macroscopic structures generated with a laser beam. Macroscopic structures, within the scope of the invention, mean a structure in the form of a notch having a length of at least 4 mm, preferably 10 mm or more, and / or a base area of ​​at least 1 mm².

[0017] The invention is based on the finding that such macroscopic structures can be used to specifically break up the water film. It is advantageous if the macroscopic structures are designed in such a way that the base area of ​​the notch is suitable for absorbing and / or draining at least part of the water.

[0018] In a preferred embodiment of the invention, the structures are formed in a continuous manner. For example, the macroscopic structures can then create a type of channel system, with the individual channels either branched or arranged one behind the other in a series. Furthermore, such an arrangement of macroscopic structures is also possible, forming a self-contained channel system, e.g., in the shape of a rectangle or a circle.

[0019] The tub body has a gradient, and the macroscopic structures can be aligned with this gradient. Through this alignment, the macroscopic structures serving as channels can transport the water in a targeted manner towards the drain opening. It is irrelevant whether the macroscopic structures are connected or not. If the macroscopic structures are not connected, an arrangement of several grooves arranged in a star shape around the drain opening, which are formed in the form of notches, is recommended. The grooves can be straight, wavy or zigzag-shaped, for example. When connected macroscopic structures are used, it can be provided that at least individual structures are aligned with the gradient or run in the direction of the drain opening.The macroscopic structures which do not run in the direction of the gradient can then preferably be branched off from at least one structure running in the direction of the outflow opening.

[0020] Often, however, the transport of water through the described macroscopic structures is not crucial. Rather, the provision of edges where the water film is locally interrupted is considered essential. Especially with linear structures, the effective edge length is crucial for a wavy pattern. In this context, it should also be observed that when macroscopic structures are created using a laser, the edges are usually not straight, but rather wavy. A certain wavy structure and the associated irregularity are particularly advantageous for interrupting a continuous water film. On the other hand, larger breakouts should be avoided.

[0021] To ensure that the macroscopic structures achieve a good anti-slip effect, it is advisable for the macroscopic structures to have a depth in the range of 10 µm to 150 µm. The depth of the macroscopic structures is particularly preferably between 20 µm and 50 µm, in particular between 30 µm and 40 µm.

[0022] In the case of a linear design of the macroscopic structures, the width can be, for example, between 35 µm and 250 µm, with a range between 70 µm and 130 µm being particularly preferred.

[0023] It should be noted that the specified values ​​refer to an average line width, with the edges not being straight, but rather with a certain wave or jagged shape. For example, if a linear macroscopic structure with a line width of 85 µm is formed, the line width variation can typically range between -8 µm and +15 µm. Such a line width variation can be readily accepted and is even advantageous because the irregular shape increases the effective edge length.

[0024] It is also advantageous if the macroscopic structures are spaced apart by a distance of 1 mm to 20 mm, preferably between 2 mm and 7 mm. This spacing is intended to ensure that a sufficient number of macroscopic structures can be arranged in a corresponding surface area of ​​the sanitary tub, so that the water volume can be effectively absorbed or transported away.

[0025] It is fundamentally within the scope of the invention that the macroscopic structures can be distributed over the entire surface of the sanitary tub. However, macroscopic structures are preferably provided only where an anti-slip effect is required. For example, the edge areas of a sanitary tub may, under certain circumstances, be able to do without such structures. The proportion of the surface of the sanitary tub that is provided with macroscopic structures is in the range of 5% to 100%, for example, between 40% and 50%. Especially with shower trays, however, it can actually be advantageous if the entire surface is provided with macroscopic structures.

[0026] The invention further relates to a sanitary tub blank according to claim 3 for forming a sanitary tub according to the invention, comprising a tub body made of steel and a coating applied to the tub body, wherein the coating comprises at least one unfired structural layer in the form of a biscuit layer. According to the invention, this sanitary tub blank is characterized in that the unfired structural layer is modified with a laser beam. Within the scope of the invention, the sanitary tub blank is to be understood as a semi-finished product from which an enameled sanitary tub can be formed.

[0027] The sanitary tub blank according to the invention is based on the finding that the unfired structural layer of enamel frits can be modified with a laser in such a way that after a final firing process, no further steps are required to create an anti-slip surface. In particular, laser processing of the fully fired surface can then be dispensed with. This avoids the problem that laser processing of an already fully fired covering layer could potentially damage it to such an extent that it is no longer watertight. According to the present invention, the sanitary tub blank is processed first, so that possible damage can be compensated for before the firing process. Furthermore, modifying a sanitary tub blank is also advantageous in terms of process control compared to modifying a fully fired sanitary tub.

[0028] According to the usual design, the coating is formed in at least one to three layers. In a three-layer structure, the coating consists of a primer layer, a top layer arranged thereon, and a structural layer arranged on the top layer, which is modified with a laser beam. In principle, however, it is also possible to form the coating in just two layers with a top layer and a structural layer, with the top layer then being formed from so-called direct white. This is particularly possible when the tank blank is made of nickel-plated steel. Finally, a single-layer structure is also possible, in which case the macroscopic structures are introduced with the laser in the as yet unfired layer of direct white.This is easily possible within the scope of the invention, especially with a tub blank made of nickel-plated steel and a sufficiently thick biscuit layer of the direct white that has not yet been fired.

[0029] The laser can then be used to make various types of modifications to achieve anti-slip structures in the unfired structural layer.

[0030] According to a first variant, the unfired structural layer has indentations created with the laser beam. The laser beam thus ablates ground enamel frits or the (dried) slip in the structural layer. For this to happen, the laser beam must have a sufficiently high energy. This is usually achieved using a pulsed laser, such as an Nd:YAG laser or a CO2 laser. The laser energy is concentrated into a short time pulse, so that a very high laser power is available for a brief moment.

[0031] The depth of the notch is generally limited to the thickness of the structural layer, with the structural layer having a thickness in the range of 100 µm to 200 µm. However, since the cover layer located beneath the structural layer, and optionally also a base layer, should not be damaged during laser beam modification, a smaller depth of the notch is advisable, with the structural layer having at least a residual layer thickness of, for example, 50 µm.

[0032] According to a further embodiment of the invention, modification by laser can also be provided in such a way that the structural layer is only fixed to the cover layer in certain areas using the laser beam. In contrast to a full-surface arrangement of a structural layer with introduced notches, according to this variant the structural layer is no longer arranged over the entire surface of the cover layer and thus forms an anti-slip surface in the form of elevations on the cover layer. In this case, too, both a structure with at least two layers with a cover layer of direct white and a three-layer structure with an additional primer layer are possible. The structural layer is fixed to the cover layer in such a way that the enamel frits of the structural layer are melted in certain areas using the laser beam and thereby solidified.The non-consolidated areas of the structural layer can then be removed, leaving the consolidated areas in the form of elevations on the top layer.

[0033] In contrast to modifications already known from the prior art, macroscopic structures, such as grooves, can be incorporated or applied directly into the sanitary tub blank, which are preferably formed in a continuous manner. This results in a complete modification of the sanitary tub blank, which is then formed into a finished sanitary tub through a final firing. Subsequent processing of the fired structural layer is not necessary.

[0034] In addition to a sanitary tub and a sanitary tub blank, a

[0035] Method for producing a sanitary bathtub according to claim 5 part of the invention. Here, a sanitary bathtub blank is first formed in such a way that an enamel coating with an unfired structural layer is applied to a steel body, wherein the unfired structural layer is then modified using a laser beam. For this purpose, the coating typically has a one- to three-layer structure. With a structure of at least three layers, a primer layer is first applied to the bathtub body and then a cover layer is applied to this primer layer. Between the application of the individual layers, a firing process usually takes place to fix the individual layers to the bathtub body. The unfired structural layer made of enamel frits is then applied to the cover layer and this is then modified with a laser beam.

[0036] If the coating is applied in two layers, the top coat can be applied directly to the tub body. An additional primer layer is therefore not required. This process uses a top coat of so-called direct white. Furthermore, the tub body must be made of nickel-plated steel. A two-layer construction is also possible if a primer layer is first applied and baked before the described structuring is applied in a sufficiently thick top coat. The top coat then coincides with the structuring layer.

[0037] Finally, when using nickel-plated steel and a sufficiently thick layer of direct white, a single layer and thus a single firing process is sufficient in a similar way.

[0038] The coating or individual layers of the coating can be applied using any known application method. Of course, as with the structural layer, the enamel can also be applied wet in the form of ground enamel frit or as a liquid slurry using a spraying process, dried, and then fired. To create anti-slip structures, the top layer is subsequently modified with a laser. Two different modification methods have proven useful, which were already described in connection with the sanitary tub.

[0039] According to the invention, material is removed by the laser beam, thereby creating indentations in the unfired structural layer. Lasers that generate a pulsed laser beam, such as Nd:YAG lasers or CO2 lasers, are preferably used for this purpose. In principle, it is possible to focus the laser beam and then direct it directly onto the unfired structural layer.

[0040] According to a non-stressed process variant, the laser beam melts and solidifies material from the unfired structural layer in certain areas. In contrast to the previous process, no material is removed, or even significantly removed, but rather the structural layer is merely fixed in certain areas due to the heat applied by the laser beam. This fixed area thus creates solidified and unsolidified areas in the unfired structural layer, with the unsolidified areas remaining mechanically sensitive to external influences.

[0041] To create anti-slip structures, the unconsolidated material is preferably removed, especially by blowing it off. However, rinsing with water or brushing is also possible.

[0042] By removing the unconsolidated material, the unfired structural layer forms raised areas on the top layer, which specifically break through the water film. It goes without saying that the unfired structural layer is then only applied to the top layer in those areas where the structural layer was previously consolidated. This allows the top layer to be exposed in certain areas, so that the coating, minus any primer layer, can be formed in one or two layers in certain areas.

[0043] In a preferred embodiment of the invention, the unfired structural layer is applied to the cover layer only in certain areas. In this approach, the considerations that the application of an unfired structural layer is only necessary where a slip-resistant structure is subsequently to be achieved by modifying the unfired structural layer are important. In this regard, special application masks are considered, for example, which allow the application of the structural layer only where a corresponding opening is provided. This allows for a particularly advantageous reduction in material consumption.

[0044] The unfired structural layer is then fired, resulting in a finished sanitary tub. In a preferred embodiment of the invention, the unfired structural layer is first heated to a temperature between the glass transition temperature and the softening point of the enamel before being fixed with the laser beam. This procedure offers the advantage that only a comparatively low amount of energy needs to be applied with the laser beam to fix the unfired structural layer, since a significant portion of the temperature increase is already achieved through the additional heating process. The laser beam then only exceeds the threshold for fixing, without any significant energy input being required for a temperature increase.

[0045] After the modification of the unfired structural layer either in the form of notches or, in the non-stressed variant, in the form of a partial fixation, the sanitary tub blank is then preferably finally fired so that a finished sanitary tub is formed.

[0046] In a preferred embodiment of the invention, the unfired structural layer is modified with the laser beam in such a way that macroscopic structures, in particular interconnected macroscopic structures such as branched or closed grooves, are created in the structural layer. Such structures can be created, for example, by guiding the laser or laser beam along a predetermined direction, thereby forming interconnected macroscopic structures in the form of grooves in the structural layer through indentations in the cover layer.

[0047] However, the formation of coherent macroscopic structures is not limited to the previously described process types, but can also be applied, for example, to a fully fired sanitary tub, in particular a steel enamel tub, in which case the coherent macroscopic structures are introduced into the fired covering layer by means of a laser.

[0048] The invention is explained in more detail below with reference to a drawing that represents only one exemplary embodiment. It shows: Fig. 1Shower tray with macroscopic structures, Fig. 2a, 2b, 2cThe process steps for forming a structural layer modified by means of notches, Fig. 3An alternative embodiment of a sanitary tray according to the Fig. 2a, 2b, 2c , Fig. 4a, 4b, 4c show the method steps according to a non-claimed embodiment for forming a structural layer partially fixed on a cover layer, Fig. 5 shows an alternative embodiment in a sectional view.

[0049] The Fig. 1 shows an example of a shower tray with a square base and a centrally located drain 11. The shower tray has a gradient from the edge 12 to the drain opening 11.

[0050] This is a shower tray made of steel enamel and thus has an enamel coating. Macroscopic structures created with a laser beam are also incorporated into this coating, whereby these macroscopic structures can be designed in various ways. Channel-shaped or linear structures are particularly preferred. According to the Fig. 1 In the sanitary tub shown above, this can be realized, for example, in the form of straight, linear structures, e.g. in the form of channels. If these are aligned with the gradient and run in the direction of the drain opening 11, the water can be transported in a targeted manner towards the drain opening 11. Furthermore, wave-shaped channels or channels with a zigzag structure are also conceivable. More important than the alignment along a gradient, however, is the formation of an edge which can locally break through a water film. In this context, the effective edge length is particularly crucial, whereby a slightly wavy or jagged edge of the macroscopic structures is also advantageous.

[0051] The Fig. 1 further shows macroscopic structures that are formed in a connected manner. According to the upper figure, the sanitary tub has exemplary linear macroscopic structures that are formed both in the direction of the drain opening 11 and parallel to it, whereby these structures can merge into one another or intersect.

[0052] The lower figure shows macroscopic structures that are closed, forming, for example, rectangles or circles. It also shows that the macroscopic structures can also be arranged only in certain areas on the surface of the sanitary tub.

[0053] The Fig. 2a, 2b, 2c In this context, show how these macroscopic structures can be formed.

[0054] According to the Fig. 2a A primer layer 2 is arranged on the tub body 1. In a first process step, the primer layer 2 is applied to the tub body 1 and then fired in a kiln. The primer layer 2 solidifies and is fixed to the tub body 1. In a next step, a cover layer 3 is applied to the primer layer 2 and fired again. Subsequently, a structural layer 4 made of ground enamel frit is applied to the cover layer 3 by means of a spraying process.

[0055] Then, according to Fig. 2b the modification of the structural layer 4 by means of a laser 5, which exposes the structural layer 4 to a laser beam 6 in such a way that notches 7 are formed within the structural layer 4. The material of the structural layer 4 is partially removed by the laser beam 6, wherein the laser beam 6 is pulsed to achieve a high energy density.

[0056] Depending on the power of the laser 5 or the strength of the laser beam 6 and the duration of the exposure time of the laser beam 6 in the structural layer 4, notches 7 of varying depths can be created, whereby the depth of the notches 7 is limited by the layer thickness of the structural layer 4. The proviso here is that the depth of the notches 7 may only be so great that a sufficient residual thickness remains in the area of ​​the notches 7 in the structural layer 4. If the structural layer 4 is intended to cover the underlying layer with color, a residual thickness of more than 80 µm is preferably provided. If color coverage is not necessary, the residual thickness can easily be smaller.

[0057] As soon as all notches 7 within the structural layer 4 have been created with the laser 5, the next process step can be carried out according to the Fig. 2c The sanitary tub blank, comprising the tub body 1, the primer layer 2, the cover layer 3, and the structural layer 4, is fired, whereby the structural layer 4 solidifies and, as it were, is fixed to the cover layer 3 with the notches 7. As a result, the firing process produces a ready-to-use sanitary tub with an anti-slip structure on its surface provided by the notches 7. To ensure the anti-slip structure is as effective as possible, the notches 7 have an average width in the range between 70 µm and 130 µm with a preferably (slightly) wavy edge, with the individual notches 7 being spaced from each other at a distance of 2 mm to 7 mm.

[0058] For reasons of better recognition, the Figuren 2b bis 3 not shown proportionally.

[0059] According to the Fig. 3 In such a process, in which the structural layer 4 is modified by introducing notches 7, a coating structure of only two layers is sufficient, so that a primer layer 2 can generally be dispensed with. In such a case, the tub body 1 made of steel is additionally nickel-plated on the surface, and the material used for the cover layer 3 is so-called direct white enamel.

[0060] The process steps for forming such a sanitary tub with a coating without a primer layer 2 essentially correspond to the steps already presented for a three-layer coating according to the Fig. 2a, 2b, 2c , whereby the application of a primer layer 2 and the subsequent firing of the primer layer 2 as shown in the figures are omitted.

[0061] Instead of notches 7, the structural layer 4 can also be modified in a different way by means of a laser beam 6, whereby slip-resistant structures are also formed in the coating. For this purpose, according to Fig. 4a analogous to Fig. 2a First, a primer layer 2 is applied to the tub body 1 and then fired. A top layer 3 is then applied to the fired primer layer 2, fired, and finally, a structural layer 4 is applied. Here, the structural layer 4 also consists of enamel frits. The result is a three-layer coating consisting of a fired primer layer 2, a fired top layer 3, and an unfired structural layer 4.

[0062] In the next step, the Fig. 4b A laser beam 6 is generated by the laser 5 and directed onto the surface of the structural layer 4. The type of laser and the choice of the laser radiation power are selected such that no significant material removal occurs, but rather that the structural layer 4 is heated and fixed by the action of the laser radiation 6. Thus, starting from the point of impact of the laser beam 6, regions are formed in which material 8 is solidified by the laser radiation 6, and regions that are not under the influence of the laser beam 6 and thus contain unsolidified material 9.

[0063] Subsequently, in a process step according to Fig. 4c the removal of the non-solidified material 9 of the structural layer 4. The removal takes place, for example, by blowing off with air or another gaseous medium, by rinsing with water, or by brushing. The structural layer 4 then only consists of the material 8 solidified by laser 5 or laser beam 6, whereby complete removal of the non-solidified material 9 is not absolutely necessary. In principle, it is also possible for the structural layer 4 to be only partially freed of the non-solidified material 9, so that the non-solidified material 9 is then fixed in a final firing process. In the present case, however, the non-solidified material 9 has been completely removed, and the structural layer 4 forms a partially present structure on the cover layer 3.

[0064] The Fig. 5Finally, the figure shows a design of the sanitary tub in which the coating is formed in only a single layer. For this purpose, the enamel known as direct white is applied as a slip in sufficient thickness and dried, with the structuring then taking place directly in the resulting biscuit layer. The cover layer 3 thus simultaneously forms the structural layer 4 with the notch 7.

Claims

1. A sanitary device having a device body (1), which consists of steel, and a coating, which is arranged on the device body (1) and consists of enamel, wherein the coating has macroscopic structures in the form of indentations (7), which are produced with a laser beam, wherein the proportion of the surface that is provided with macroscopic structures is within the range of 5% to 100%, and the macroscopic structures have a depth within the range of 10 µm to 150 µm.

2. The sanitary device according to Claim 1, characterised in that the structures are cohesive.

3. A sanitary device blank for shower trays or bath tubs to form a sanitary device according to one of Claims 1 to 2, having a device body (1), which consists of metal, and a coating, which is arranged on the device body and consists of enamel, wherein the coating has at least one unfired structural layer (4), wherein the unfired structural layer (4) is modified with a laser beam (6) and has indentations (7) made with the laser beam, wherein the structural layer has a thickness of 100 µm to 200 µm, and the depth of the indentations (7) is limited to the structural layer (4).

4. The sanitary device blank according to Claim 3, characterised in that the coating has a covering layer (3) on which the unfired structural layer (4) is arranged.

5. A method for producing a sanitary device according to one of Claims 1 to 2, wherein first a sanitary device blank is formed such that an enamel coating with an unfired structural layer (4) is applied to a device body (1) consisting of steel, wherein the unfired structural layer (4) is modified with a laser beam (6), wherein, by means of the laser beam (6), material is removed and indentations (7) are produced in the unfired structural layer (4).

6. The method according to Claim 5, wherein the coating has a covering layer (3), which is arranged either on a primer layer (2) or on the device body (1), wherein first the covering layer (3) is applied and fired, and then the unfired structural layer (4) is applied to the covering layer (3).

7. The method according to Claim 5 or 6, wherein the unfired structural layer is applied to the covering layer only in some regions.

8. The method according to one of Claims 5 to 7, wherein the sanitary device blank is finally fired.

9. The method according to one of Claims 5 to 8, wherein the unfired structural layer (4) is modified with the laser beam (6) such that macroscopic structures are produced in the unfired structural layer (4).

10. The method according to Claim 9, wherein the structural layer (4) also forms the covering layer (3) in a single firing process.