METHOD FOR MANUFACTURING A SANITARY COMPONENT

Description

[0001] The present invention relates to a method for manufacturing a sanitary component, wherein the sanitary component is a toilet seat, toilet lid, or urinal lid. The invention further relates to a sanitary component obtained by the method.

[0002] Sanitary components, such as toilet seats, toilet lids, or urinal lids, are generally known in the state of the art. These well-known sanitary components are usually made of plastics, such as thermosets (also called thermoplastics), and are often white.

[0003] In contrast, colored sanitary components are manufactured using state-of-the-art technology by manually painting thermoset blanks with a spray gun. The associated manufacturing steps are complex, expensive, and extremely prone to errors, as manual painting frequently results in paint defects.

[0004] Alternatively, it is known from the prior art (DE 10 2013 005 990 A1) to color plastic objects by powder coating. In this process, the inherently non-electrically conductive plastic object is provided with a polar coating to achieve the static charge on the surface necessary for powder coating. After application to the plastic object, the polar coating must age for several hours to achieve the desired properties. The aging period is at least 12 hours, preferably up to 48 hours. For this reason, the known process is slow, requires extensive storage, and is therefore expensive.

[0005] Other state of the art documents are EP3 695 956 A1, DE 10 2019 105428 A1, US 2016 / 121361 A1, WO 201 5 / 054 770 A1 and DE 197 48 927 A1.

[0006] Against this background, the object of the present invention is to provide a method for producing sanitary components made of thermosets, with which the surfaces of the sanitary components can be quickly and easily designed in different colors. At the very least, the object of the invention is to provide a method alternative to the prior art.

[0007] This problem(s) is / are solved by a method according to claim 1. Preferred embodiments are the subject of the dependent claims.

[0008] The method according to the invention serves to manufacture a sanitary component, wherein the sanitary component is a toilet seat, a toilet lid or a urinal lid.

[0009] The method according to the invention comprises the following steps: a) Providing a blank sanitary component made of a thermoset material (thermoset material), wherein the provided blank (3a-c) was produced on the basis of a condensation resin, b) Preheating the blank in such a way that at least one surface of the blank is heated up, c) Spraying the sanitary component blank with an electrically charged powder coating, wherein the sanitary component blank is at a potential opposite to that of the electrically charged powder coating and the powder coating adheres to the sanitary component blank, and d) Baking of the powder coating to form a coating layer that constitutes an outer surface of the sanitary component.

[0010] The sanitary component to be manufactured can be a toilet seat, a toilet lid or a urinal lid.

[0011] The toilet seat refers to the part of a toilet seat assembly that is usually pivotally attached to a toilet bowl and on which a person sits directly while defecating. The toilet seat manufactured according to the inventive method is also colloquially referred to as a toilet seat or toilet lid.

[0012] The toilet seat manufactured according to the inventive method relates to the part of a toilet seat set which is also pivotably attached to the toilet ceramic - both in relation to the toilet ceramic and to a corresponding toilet seat - and which can be pivoted so that it rests on the toilet seat and thereby closes the toilet ceramic.

[0013] The lid of the urinal, ultimately produced according to the inventive method, is intended to be pivotably attached to a urinal mounted on a wall so that a user can open or close an opening of the urinal.

[0014] The blank of the sanitary component is an unfinished workpiece that already possesses the external shape of the sanitary component, but is still intended for further processing in the inventive method. In particular, the blank does not yet have an outer surface with the desired properties.

[0015] The blank of the sanitary component provided in step a) is formed according to the invention from a thermoset material. The corresponding shaping step of the blank, which can also be part of step a) of the method according to the invention, is carried out by pouring a condensation resin into a mold defining the shape of the blank and subsequently curing it under pressure and / or temperature. Reinforcing elements such as wood fibers and / or plastic fibers can be incorporated into the mold and encapsulated in the resin. These reinforcing elements increase the stability of the resulting sanitary component.

[0016] The shape used defines the sanitary component ultimately obtained, i.e., the toilet seat, the toilet lid, or the urinal lid.

[0017] During the development process, the inventor discovered that the surface of the blank acquires properties suitable for (electrostatic) powder coating when the blank is preheated in process step b). Preheating reduces the electrical surface resistance of the sanitary component made of thermoset material, which in turn allows the surface of the sanitary component to be brought to a potential suitable for powder coating.

[0018] It should be noted that the blank formed from the thermoset (thermoset) can remain untreated except for the preheating carried out in step b). This means that no coatings or agents need to be applied to the blank to create an electrically conductive surface for powder coating. This fact greatly accelerates and simplifies the process.

[0019] The powder coating used in step c) can be flexibly selected depending on the specific requirements of the final sanitary component. In particular, powder coatings can be chosen that possess such properties that the outer surface of the sanitary component obtained after curing (step d)) meets requirements for hardness, scratch resistance, surface roughness and / or chemical resistance.

[0020] Powder coatings contain, as functional components, at least a polymer-based binder and color pigments. The latter give the powder coating its color. Additionally, the powder coating may contain additives and fillers.

[0021] Sanitary components in various colors can be produced using powder coatings. Decorative finishes that, for example, convey a wood grain or carbon fiber look are achieved by applying a sublimation film to the sanitary component after the powder coating process.

[0022] All common colors and / or color effects and / or decors can be achieved in this way.

[0023] Suitable powder coatings contain binders based on polyesters, such as unsaturated polyester resins, polyurethanes, acrylic resins, epoxy resins, or fluoropolymers. Hybrid powder coatings, which combine epoxy and polyester resins, are also possible.

[0024] Particularly preferred powder coatings are highly reactive polyester powder coatings, which are offered on the market by companies such as IGP under the following brand names: a. IGP-RAPID®< complete 88, in particular IGP-RAPID®< complete 881T, 8862, 8863 or 8864. Alternatively, the following powder coatings from IGP can also be used: b. IGP-RAPID®< top 381M powder, in particular IGP-RAPID®< top 381MA-A0 powder, or IGP-RAPID®< top 381ME-A1 powder.

[0025] The powder coating is preferably electrically charged at a spraying device. For example, the powder coating can be charged by high voltage (corona charging) or friction (triboelectric charging) at the spraying device. The powder coating charged in step c) is preferably positively charged, with the opposite potential to that of the sanitary component preheated in step b) being preferably ground potential.

[0026] The spraying device can be, for example, a manually operated powder spray gun or an automatic spray gun. The latter is guided precisely by an automatic or robotic system or installed in a fixed position, whereby the sanitary component is conveyed past the spraying device and sprayed with powder coating.

[0027] The process step c) is preferably divided into two sub-steps c1) and c2).

[0028] In step c1), the spraying device is arranged such that it sprays powder coating onto a surface of the sanitary component facing the spraying device. On the side facing away from the spraying device, a flat electrode (counter electrode) is preferably located in step c1), which preferably has larger surface dimensions than the sanitary component. The flat electrode is at the same potential as the spraying device and thus prevents the electrically charged powder coating from reaching a surface of the sanitary component facing away from the spraying device.

[0029] In step c2), the surface facing away from the spraying device in step c1) is sprayed with the powder coating. This can be achieved by moving the sanitary component, for example in a suspended state, to a different section of the powder coating system where another spraying device and another flat electrode (counter electrode) are positioned in the opposite direction compared to step c1). The additional spraying device and the additional flat electrode are preferably identical in design to those used in step c1).

[0030] Alternatively, the sanitary component sprayed in step c1) can be rotated without changing its position / remaining stationary, or the spray device and the flat electrode can be moved around the sanitary component. In this case, the additional spray device and the additional flat electrode are not necessary.

[0031] Preferably, suspensions, such as hooks, from which the sanitary component is suspended are insulated except for the section that is in contact with the sanitary component. This preferably prevents or at least reduces the migration / deflection of the sprayed powder coating towards the suspension in step c).

[0032] Preferably, the flat electrode and / or the additional flat electrode are designed in such a way that they can generate different potentials of varying strengths at different positions facing the sanitary component.

[0033] The charged powder coating adheres in step c) (c1), c2)) upon contact with the sanitary component preheated in step b), so that the corresponding layer does not run and the coating layer obtained in the subsequent step d) is uniform. This allows for reproducible achievement of good coating layers and visually flawless outer surfaces of the sanitary component – ​​and in different colors.

[0034] The coating layer produced in steps c) and d) is preferably a single layer (single-layer), especially when highly reactive polyester powder coatings such as those from IGP according to point a) above or the powder coating from IGP according to point b) above are used.

[0035] Furthermore, layers of varying thicknesses, preferably single-layer, can be produced, particularly uniformly. The thickness D of the coating layer obtained in step d) is preferably in the following range: 40 µm ≤ D ≤ OG, where OG is equal to 120 µm, 125 µm, 130 µm, 135 µm, 140 µm, 145 µm, 150 µm, 155 µm, 160 µm, 165 µm, 170 µm, 175 µm, 180 µm, 185 µm, 190 µm, 195 µm, or 200 µm. In step d), the powder coating is baked on. This is done by heating the sanitary component sprayed with the powder coating to a temperature T (which preferably corresponds to a specific melting temperature or is particularly preferably above it). The temperature T corresponds to a curing temperature. The powder coating begins to melt once its specific melting temperature is reached and hardens into a coating layer over a certain period of time.

[0036] The temperature T to which the sanitary component is heated is, for example, in the range between 120°C and 200°C, 130°C and 200°C, 140°C and 200°C, 150°C and 200°C, 160°C and 200°C, 170°C and 200°C, 180°C and 200°C, or 190°C and 200°C. A temperature between 125°C and 150°C is particularly preferred.

[0037] When using highly reactive polyester powder coatings, such as those from IGP according to point a above, the temperature T is between 125°C and 140°C, and for the powder coating from IGP according to point b above, it is between 130°C and 150°C.

[0038] The lower the temperature, the longer step d) takes.

[0039] The sanitary component is preferably kept at a constant temperature T in step d).

[0040] The corresponding period of time over which the sanitary component is preferably kept at a constant temperature ranges from a few minutes, for example 2 min, to ten minutes or more, for example 20 min, and is longer the lower the temperature. Preferably, step d) includes the following sub-steps:

[0041] d1) a preheating step in which the blank sprayed in step c), to which the powder coating adheres, is heated to the curing temperature by a preheating device, and d2) a firing step in which the blank preheated in step d1), to which the powder coating adheres, passes through a firing oven in which the coating layer forming the outer surface of the sanitary component is formed.

[0042] The preheating step d1) is, in particular, a rapid heating process, which is carried out, for example, by a heating device positioned in front of the kiln. This heating device is, for example, an infrared heater that preferably irradiates the sanitary component from both sides in order to quickly heat it to the temperature prevailing in the kiln.

[0043] In firing step d2), the final coating of the sanitary component is formed, which can have different colors depending on the powder coating used. The temperature prevailing in the kiln has the temperature values ​​T already mentioned above.

[0044] The inventive method is designed such that the blank of the sanitary component provided in step a) was produced on the basis of a condensation resin, wherein a corresponding condensate released during hardening of the blank is preferably water.

[0045] The condensation resin is, for example, a urea resin (HF), a melamine resin, or a phenolic resin. It has been shown that the process according to the invention yields particularly good results with these resins, especially with melamine resins or urea resins. Melamine resins or urea resins are particularly preferred in combination with the aforementioned highly reactive polyester powder coatings, such as those from IGP according to point a. above or the powder coating from IGP according to point b. above. This combination leads to a very good bond between the substrate and the coating layer.

[0046] The method according to the invention is preferably designed such that the blank is preheated in step b) with an infrared emitter by irradiating the blank with infrared radiation, wherein the infrared radiation is preferably in a wavelength range of 3,000 nm to 50,000 nm (IR-C (mid-infrared, long-wave)). The irradiation in step b) preferably takes place over 40 seconds to 120 seconds, whereby the surface of the blank is heated to 80°C to 100°C.

[0047] The infrared emitter preferably irradiates the sanitary component from both sides and, in particular, evenly irradiates the surfaces of the sanitary component from both sides.

[0048] Furthermore, the invention relates to a sanitary component obtainable according to the described method. This sanitary component is preferably characterized by the fact that no polar or electrically conductive coatings are located between the final coating and the surface of the blank.

[0049] A preferred embodiment of the method according to the invention is explained below with reference to the accompanying figure. It shows: Figure 1 a schematic sequence of the method according to the invention;

[0050] Figure 1Figure 1 shows a schematic representation of the manufacturing process according to the invention for producing a sanitary component. The sanitary component to be produced is, in particular, a toilet lid, a toilet seat, or a urinal lid.

[0051] The method according to the invention is essentially divided into four steps, namely: a) Providing a blank sanitary component made of a thermoset material (thermoset material), wherein the provided blank (3a-c) was produced on the basis of a condensation resin, b) Preheating the blank in such a way that at least one surface of the blank is heated up, c) Spraying the sanitary component blank with an electrically charged powder coating, wherein the sanitary component blank is at a potential opposite to that of the electrically charged powder coating and the powder coating adheres to the sanitary component blank, and d) Baking of the powder coating to form a coating layer that constitutes an outer surface of the sanitary component.

[0052] The aforementioned step a) takes place in Figure 1 In section I of a coating system 1 set up for carrying out the process according to the invention, preforms made of thermoset (thermoplastic) of the sanitary component to be manufactured are provided. According to the invention, the preforms are made from a condensation resin, which is preferably cured to form the thermoset preform by releasing water under heat and pressure.

[0053] The blanks for the sanitary component are objects that already have the shape of the sanitary component to be manufactured and are to be coated in the further process, as will be explained below.

[0054] The coating system 1 includes a conveyor 2, which is loaded in section 1 by hanging blanks 3a-c of the sanitary components, for example, on corresponding hooks. The hooks are preferably coated with an insulating layer except for the section that is in contact with the blank 3a-c.

[0055] Blanks 3a-c of various sanitary components are in Figure 1suspended on the conveyor device 2. A blank 3a, 3b of a toilet lid and a toilet seat are located in section I. Blanks 3c of a urinal lid are already in section III. The blanks 3a-c are preferably untreated except for a preliminary cleaning step not shown, i.e., preferably no electrically conductive coating or other substances influencing conductivity are separately applied to the thermoset surface of the blanks 3a-c.

[0056] Conveyor system 2 includes electrically conductive structures designed such that the sanitary component blanks 3a-c are electrically contacted. Figure 1The electrically conductive structures are preferentially at ground potential, which is why the suspended blanks 3a-c of the sanitary components are also at ground potential. The electrical potential or ground potential of the electrically conductive structures and the suspended blanks 3a-c is in Figure 1 schematically represented with dashed lines.

[0057] Conveyor system 2 is set up, the supplied and suspended blanks 3a-c of the sanitary components are moved towards the in Figure 1 to convey the blanks 3a-c of the sanitary components in the direction shown by the arrow. The direction FR corresponds to the conveying direction of the blanks 3a-c of the sanitary components. The conveying device 2 transports the blanks 3a-c of the sanitary components from section I to a section II, in which step b) of the method according to the invention is carried out.

[0058] In section II, the conveying device 2 includes a radiator, in particular an infrared radiator, which preferably irradiates the surfaces of the sanitary components 3a-c uniformly. The irradiation leads to a preheating of the surfaces of the sanitary components 3a-c, resulting in a reduction of the electrical surface resistance. The surfaces of the sanitary components 3a-c are preferably heated to a temperature between 80°C and 100°C in section II. The dwell time of the sanitary components 3a-c in section II is between 40 seconds and 120 seconds.

[0059] The blanks 3a-c then proceed to section III. In section III, the sanitary component blanks 3a-c are sprayed with an electrically charged powder coating 4. The spraying is preferably carried out in two partial steps c1) and c2).

[0060] In sub-step c1), preferably a front surface of the sanitary component is sprayed with powder coating. The front surface is in Figure 1 visible and lies in the drawing plane.

[0061] Facing the front surface is an automatic spray gun 5. The electrical charging of the powder coating 4 takes place at the automatic spray gun 5 arranged in section III, for example by friction (triboelectric charging) or by applying a high voltage (corona charging).

[0062] The charged powder coating 4 impacts the front surface of the sanitary component blanks 3a-c and adheres to them, particularly due to the reduced surface resistance resulting from step b) and the opposite mass potential on which the blanks 3a-c are located. The thickness of the powder layer formed on the sanitary component blanks 3a-c is determined by the conveying speed of the sanitary component blanks 3a-c in section III and / or the amount of powder coating 4 sprayed.

[0063] Perpendicular to the plane of the drawing, behind the sanitary component, i.e. on the side of the sanitary component 3c facing away from the front surface, there is an electrode 6 (counter electrode).

[0064] Electrode 6 is at the same potential as the automatic spray gun 5, at least with respect to the corresponding polarity relative to ground potential. The field generated between electrode 6 and the sanitary component ensures that the powder coating sprayed by the automatic spray gun 5 does not reach the surface of the sanitary component 3c facing electrode 6.

[0065] Preferably, the electrode 6 is divided into different areas, for example nine equally sized areas that can assume different potentials. This allows the field between electrode 6 and sanitary component 3c to be "shaped" in order to prevent, as effectively as possible, the powder coating from transferring to the side facing electrode 6.

[0066] After sub-step c1), sub-step c2) is carried out, in which the side surface (rear surface) facing away from the automatic spray gun 5 in sub-step c1) is sprayed with powder coating.

[0067] The coating system preferably has for sub-step c2) in section III a further automatic spray gun 5' and a further electrode 6', which are only reversed in their positions compared to those for sub-step c1).

[0068] The other electrode 6' is therefore located in Figure 1 in front of sanitary component 3c and obscures it in this view. For this reason, sanitary component 3c is shown as a dashed line in sub-step c2).

[0069] Furthermore, the additional automatic spray gun 5' and the additional electrode 6' are preferably constructed identically to those for sub-step c1), which is why reference is made to corresponding descriptions.

[0070] The division of section III into the two sub-steps c1) and c2) results in a very uniform application of the powder coating on the blanks 3a-c.

[0071] The powder coating 4 sprayed in section III can be selected depending on desired properties or requirements, such as chemical resistance, scratch resistance, and color of the final sanitary component.

[0072] The conveying device 2 then transports the powder-coated blanks 3a-c of the sanitary components from section III to a section IV, in which a preferred step d1) of the process is carried out.

[0073] The coating system 1 has a rapid preheating device in section IV, which rapidly preheats the powder-coated blanks 3a-c to the temperature T (curing temperature) prevailing in the subsequent dryer (section V). The rapid preheating device is preferably an infrared radiator.

[0074] A heating device or dryer forms section V, in which step d2) is carried out.

[0075] In section V, or in step d2), the powder-coated blanks 3a-c of the sanitary components, which were preheated in section IV, are kept at temperature T for a specific period of time, preferably constant. If section IV and step d1) are not present, the dryer in section V heats the powder-coated blanks 3a-c to temperature T.

[0076] The powder coating adhering to the blanks 3a-c of the sanitary components melts in section V and cross-links to form a coating layer that hardens.

[0077] The coating layer formed on the blanks 3a-c of the sanitary components forms the outer surface or visible surface.

[0078] The time period of step d2), during which the sanitary component blanks 3a-c are located in section V, varies depending on the powder coating 4 used and / or the temperature T prevailing in section V. The preferred section IV is therefore adjustable. The temperature T is between 120°C and 200°C depending on the powder coating used.

[0079] The blanks 3a-c of the sanitary components are coated after passing through section V and can be removed from the coating system 1 by detaching them from the conveyor system 2.

[0080] Powder coatings enable the production of sanitary components in all common colors through the use of appropriate color pigments. Color effects, such as metallic or pearlescent effects, can also be easily achieved by adding effect pigments.

[0081] If the sanitary components removed from coating plant 1 are to be given a decorative finish, for example a wood or carbon look, the corresponding sanitary components are subjected to a preferred further manufacturing step, which is in Figure 1 The product undergoes a sublimation process, which is not shown. In the next manufacturing step, a sublimation film is applied to the coated sanitary component. The color of the sanitary component, together with the applied sublimation film, creates the desired decorative effect.

[0082] It should be emphasized that sanitary components made of thermoset material can be produced using the method according to the invention without the need to provide the corresponding blanks with an electrically conductive layer. Step b) is particularly essential to the invention. Step d1) is merely preferred.

[0083] The statements in the general section before the figure description apply equally to the embodiment described and vice versa.

Claims

1. A method of manufacturing a sanitary component, wherein the sanitary component is a toilet seat, a toilet lid or a urinal lid, the method comprising the following steps: a) providing a blank (3a-c) of the sanitary component made of a duromer material (duroplast material), the blank (3a-c) provided having been produced on the basis of a condensation resin, b) preheating the blank (3-c) in such a way that at least a surface temperature of the blank is increased, c) spraying the blank (3a-c) of the sanitary component with an electrically charged powder coating (4), the blank (3a-c) of the sanitary component being at a potential opposite to that of the electrically charged powder coating (4) and the powder coating (4) adhering to the blank (3a-c) of the sanitary component, and d) baking the powder coating (4) to form a coating layer forming an outer surface of the sanitary component.

2. The method according to claim 1, wherein the blank (3a-c) of the sanitary component provided in step a) has been produced on the basis of the condensation resin, a corresponding condensate split off during curing of the blank being water.

3. The method according to claim 1 or 2, wherein the blank (3a-c) is preheated in step b) with an infrared radiator by irradiating the blank with infrared radiation, the infrared radiation preferably being in a wavelength range from 3,000nm to 50,000nm.

4. The method according to one of the claims 1 to 3, wherein in step b), only the surface of the blank (3a-c) is heated.

5. The method according to claim 4, wherein in step b) the surface of the blank (3a-c) is heated to a temperature between 100°C and 120°C in 40s to 120s.

6. The method according to one of the claims 1 to 5, wherein step d) comprises: d1) a preheating step in which the sprayed blank (3a-c) to which the powder coating adheres is heated to a stoving temperature by a preheating device, and d2) a firing step in which the blank (3a-c) preheated in step d1), to which the powder coating adheres, passes through a kiln in which the coating layer forming the outer surface of the sanitary component is formed.