Sanitary ware and method for producing the same

Abstract

To provide sanitary earthenware which can surely prevent the occurrence of cracks and breaks due to the shrinkage of the earthenware itself in an earthenware manufacturing process, and to provide a method for manufacturing the same.SOLUTION: A sanitary ware 1 according to the present invention includes a first wall portion 12 formed of a single wall made of a ceramic, and a second wall portion 14 formed of two walls 1618 and made of a ceramic, wherein the second wall portion includes a joint portion 20 at which at least one of the two walls is joined to the first wall portion, and a portion of the second wall portion adjacent to the joint portion 20 is provided with a through hole 24 for suppressing stress concentration during drying or firing in forming the sanitary ware.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to sanitary ware and a manufacturing method thereof, and more particularly to sanitary ware including flush toilets, urinals, washbasins, etc. made of ceramic, and a manufacturing method thereof. [Background technology]

[0002] Conventionally, sanitary ceramics including flush toilets, urinals, and washbasins made of ceramic have been known, such as the flush toilets described in Patent Documents 1-4, the urinal described in Non-Patent Document 1, and the washbasins described in Patent Documents 5 and 6. First, in the conventional sanitary ware (flush toilet) described in Patent Document 1, an inner communicating hole and an outer communicating hole are provided in the support wall portion and skirt portion, which are each made up of a single wall in the toilet body, through which a water supply hose can be inserted. Furthermore, in the conventional sanitary ware (flush toilet) described in Patent Document 2, communication holes for discharging leaked water are provided in the support wall and skirt of the toilet body. Furthermore, in the conventional sanitary ware (flush toilet) described in Patent Document 3, a through hole is provided in a single wall in the horizontal wall section that connects the toilet drain pipe section and the outer peripheral wall section, so that parts stored in the lower space section of the toilet body can be connected through the through hole. Furthermore, in the conventional sanitary ware (flush toilet) described in Patent Document 4, a first connection opening and a second connection opening are provided on the upper and lower inner walls of the toilet body, respectively, through which sheath pipes for inserting wiring, etc. are passed. Next, the conventional sanitary ware (urinal) described in Non-Patent Document 1 is a vertically long ceramic urinal, and since it shrinks significantly vertically due to its own weight during the ceramic molding process, the space between the floor material and the bowl is supported by a nearly straight wall. Furthermore, in the conventional sanitary ware (washbasin) described in Patent Document 5, a recess is provided at the boundary between the washbowl portion and its peripheral portion, and this recess is designed to disperse stress and reduce stress concentration. Furthermore, in the conventional sanitary ware (washbasin) described in Patent Document 6, if the connecting portion on the underside of the bowl portion that connects the outer surface of the bowl portion to the inner surface of the mounting portion shrinks during firing in the ceramic manufacturing process or if the connecting portion shrinks due to heat shock, the connecting portion can reduce the stress applied to the connecting portion between the curved portion of the bowl portion and the connecting portion.This makes it possible to prevent the washbasin from breaking or other problems caused by stress concentration during firing at the connecting portion between the curved portion of the bowl portion and the connecting portion. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 2023-110081 [Patent Document 2] Japanese Patent Publication No. 2022-131276 [Patent Document 3] Japanese Patent Application Publication No. 2017-210868 [Patent Document 4] Japanese Patent Application Publication No. 2017-089282 [Patent Document 5] Patent Publication No. 6899213 (Patent Publication No. 2018-89264) [Patent Document 6] Japanese Patent Application Publication No. 2023-184294

[0004] [Non-Patent Document 1] Japan Institute of Invention and Innovation, Disclosure of Technical Information, No. 2023-500897 Summary of the Invention [Problem to be solved by the invention]

[0005] However, the conventional sanitary ware described in the above-mentioned Patent Documents 1 to 6 and Non-Patent Document 1 has a problem in that loads due to shrinkage and the like are applied to the sanitary ware during the drying and firing processes in the manufacturing process of the sanitary ware, which causes stress concentration in specific locations of the sanitary ware, and may result in damage such as cracks and cuts. Therefore, damage such as cracks and cuts caused by such stress concentration and shrinkage leads to a decrease in yield, and so it has become an urgent issue to find ways to reduce the manufacturing costs of ceramics.

[0006] Therefore, the present invention has been made to solve the above-mentioned problems of the conventional technology and problems that have been recently demanded, and has an object to provide sanitary ware that can reliably prevent the occurrence of cracks and cuts due to shrinkage of the sanitary ware itself during the sanitary ware manufacturing process, and a manufacturing method thereof. [Means for solving the problem]

[0007] In order to solve the above-mentioned problems, the present invention provides sanitary ceramics consisting of a flush toilet, urinal, or washbasin made of ceramic, which has a first wall portion made of ceramic and consisting of a single wall, and a second wall portion made of ceramic and consisting of two walls, wherein the second wall portion has a joint portion where at least one of the two walls is joined to the first wall portion, and a through hole is provided in a portion of the second wall portion adjacent to the joint portion to suppress stress concentration during drying or firing in the ceramic molding. In the present invention configured as described above, during drying and firing in the pottery molding process, the second wall portion consisting of two walls is particularly more likely to shrink than the first wall portion consisting of one wall. However, since a through hole is provided in the area of ​​the second wall adjacent to the joint with the first wall to suppress stress concentration during drying or firing in pottery molding, it is possible to suppress stress concentration at specific points of the pottery due to shrinkage during pottery molding. Therefore, it is possible to reliably prevent the occurrence of cracks or breaks due to shrinkage of the pottery itself during drying and firing of the pottery molding.

[0008] In the present invention, the through-hole is preferably provided in an unglazed or substantially unglazed portion of the second wall portion. In the present invention configured in this manner, the through holes are provided in the unglazed or nearly unglazed parts of the second wall portion, so that when providing the through holes there are no restrictions such as considerations regarding glazing, which simplifies the pottery structure and reduces manufacturing costs.

[0009] In the present invention, preferably, the sanitary ware includes a supporting wall portion supported on a base during drying or firing in ceramic molding, and the second wall portion provided with the through hole includes a first joint portion which is the joint portion joined to the first wall portion, and a second joint portion joined to the supporting wall portion, and a first distance from the first joint portion to the through hole is set to be equal to or shorter than a second distance from the second joint portion to the through hole. In the present invention configured in this manner, the second wall portion has a first joint joined to the first wall portion and a second joint joined to the support wall portion, and the first distance from the first joint to the through hole is set to be less than the second distance from the second joint to the through hole, so that the through hole can be provided in the second wall portion midway between the first joint with the first wall portion and the second joint with the support wall portion, or closer to the first joint with the first wall portion, which is more susceptible to shrinkage than the second joint. Therefore, it is possible to more reliably prevent the occurrence of cracks or breaks due to shrinkage of the pottery itself during drying or firing in the pottery molding process.

[0010] In the present invention, the sanitary ware is preferably the flush toilet, which has a bowl portion, the first joint portion being provided in a part of the bowl portion, and the through hole being positioned adjacent to the bowl portion. In the present invention configured in this manner, the sanitary ware is a flush toilet, the first joint is provided in part of the bowl portion, and the through-hole is positioned adjacent to the bowl portion, so it is possible to more reliably prevent cracks and cuts from occurring in the main bowl portion of the flush toilet due to shrinkage during drying or firing in the ceramic molding process.

[0011] The present invention also provides a method for producing the above-mentioned sanitary ware, comprising: a pouring step of pouring a slip into a mold; a filling step of filling a green body into the mold; a draining step of discharging excess slip from inside the green body after filling the mold; a demolding step of demolding the green body; a drying step of drying the green body after the demolding step; a glazing step of glazing the green body after the drying step; and a firing step of firing the green body after the glazing step, wherein the through hole is formed in the second wall portion during the filling step or before the drying step after the demolding step. In the present invention configured in this manner, the through holes are drilled in the second wall portion during the filling process of the ceramic molding or before the drying process after the demolding process, so that the drilling process can be carried out quickly. Furthermore, with the through holes drilled in the second wall portion, even when drying is performed in the subsequent drying step or firing is performed in the subsequent firing step, the through holes in the second wall portion can suppress stress concentration at the joint between the first and second wall portions of the sanitary ware, and can prevent cracks and cuts due to shrinkage. [Effects of the Invention]

[0012] According to the sanitary ware and the manufacturing method thereof of the present invention, it is possible to reliably prevent the occurrence of cracks and cuts due to shrinkage of the sanitary ware itself during the sanitary ware manufacturing process. [Brief explanation of the drawings]

[0013] [Figure 1] 1 is a schematic side cross-sectional view of a flush toilet, which is a sanitary ware according to a first embodiment of the present invention, showing the state in which it is placed on a base during the drying process or firing process of shaping the ware. [Figure 2] FIG. 2 is a plan view taken along line II-II in FIG. [Figure 3] 10 is a schematic side cross-sectional view of a urinal, which is a sanitary ware according to a second embodiment of the present invention, showing the state in which the urinal is placed on a base during the drying process or firing process of shaping the ware. [Figure 4] 10 is a schematic side cross-sectional view of a washbasin, which is sanitary ware according to a third embodiment of the present invention, showing the state in which the washbasin is placed on a base during the drying process or firing process of shaping the ware. DETAILED DESCRIPTION OF THE INVENTION

[0014] First, with reference to Figs. 1 and 2, a flush toilet, which is a sanitary ware according to a first embodiment of the present invention, will be described. FIG. 1 is a schematic cross-sectional side view of a flush toilet, which is a sanitary ware according to this embodiment, and shows the state in which it is placed on a base during the drying process or firing process of shaping the ware. As shown in FIG. 1, the flush toilet 1, which is sanitary ware according to this embodiment, is a so-called "floor-mounted flush toilet" that is installed so as to contact the floor surface inside a toilet room.

[0015] The flush toilet 1 also has a toilet body 2 made of ceramic. The toilet body 2 has a bowl portion 4 that receives waste, a drain trap portion 6 with an inlet portion 6a connected to the bottom of the bowl portion 4 to discharge waste inside the bowl portion 4, and a skirt portion 8 that covers the outer casings of the bowl portion 4 and the drain trap portion 6 from the sides. In this specification, "ceramics" includes common sanitary ware materials such as porcelain and ceramics. Furthermore, the bottom 2a of the toilet body 2 is designed to be grounded to a base 10 arranged in the kiln space or drying space K during the drying and firing steps in the pottery molding process. The toilet body 2 may be positioned on the base 10 in any orientation other than the bottom 2a thereof when placed on the base 10 during the drying and firing steps of ceramic molding. Furthermore, the floor-standing flush toilet 1 of this embodiment may be a so-called "wash-down" flush toilet, in which waste within the bowl portion 4 is washed away by the difference in height of the bowl portion 4 within the toilet body 2, or it may be a so-called "siphon" flush toilet, in which waste within the bowl portion 4 is sucked up using the siphon action and discharged to the outside through the drain trap portion 6, or other types of flush toilet.

[0016] Next, the manufacturing process for the ceramic toilet body 2 of the flush toilet 1 of this embodiment will be briefly explained. The ceramic molding process for the toilet body 2 includes a pouring process in which slip is poured into a mold made of plaster or resin to form the shape of the ceramic, a filling process in which the molded body is filled into the mold, a mud draining process in which excess slip is discharged from inside the molded body after it has been filled into the mold, a compaction process in which the moisture content of the molded body is reduced to improve its shape retention and demoldability, a demolding process in which the molded body is demolded, a drying process in which the molded body is dried after the demolding process, a glazing process in which the molded body is glazed after the drying process, and a firing process in which the molded body is fired after the glazing process. In this embodiment, particularly with regard to the molding (pouring molding) in the pouring process described above, pouring molding that forms a molded body (solid molded body) that does not have a hollow area is defined as "double molding," and the ceramic wall formed by this double molding is defined as "single wall." On the other hand, the pouring process to form a hollow body is defined as "single-layer molding," and the ceramic wall formed by this single-layer molding is defined as "two walls." As a result, the complex shaped portions of the ceramic toilet body 2 of the flush toilet 1 of this embodiment are formed using ceramic molding that appropriately combines single-layer molding and double-layer molding.

[0017] Next, as shown in Figures 1 and 2, in the flush toilet 1 of this embodiment, the lower part of the bowl portion 4 of the toilet body 2 is provided with a first wall portion 12 consisting of a single wall made of ceramic. The toilet body 2 also includes a second wall 14 that is joined to the first wall 12 and is made of ceramic. The second wall 14 is made up of two walls 16 and 18 that are also made of ceramic. Furthermore, one wall 16 of the two walls 16, 18 in the second wall portion 14 forms part of the skirt portion 8, and its lower end 16a serves as a support wall portion supported on a base 10 in the kiln space or drying space K. On the other hand, the other wall 18 of the two walls 16, 18 of the second wall portion 14 serves as a support wall portion that connects the wall 16 to the first wall portion 12, which is made up of a single wall of the bowl portion 4.

[0018] Next, FIG. 2 is a plan view taken along the line II-II in FIG. As shown in FIG. 1, wall 18 of second wall portion 14 has a first joint portion 20 where a rear end 18a thereof is joined to first wall portion 12 of bowl portion 4, which is made up of a single wall. The wall 18 of the second wall portion 14 also has a second joining portion 22 where its front end 18b is joined to the wall 16 of the skirt portion 8. Furthermore, as shown in Figures 1 and 2, a through hole 24 is provided in the wall 18 of the second wall portion 14 in a portion adjacent to the first joint portion 20 to suppress stress concentration during drying or firing in the pottery molding process.

[0019] Here, as shown in Figure 2, the through hole 24 is provided in the unglazed or almost unglazed portion A1 of the wall 18 of the second wall portion 14, and has a roughly arc-shaped elongated hole shape when viewed from the lower side of the toilet body 2. Incidentally, in this specification, the term "almost no glaze part" refers to areas where glaze is not intentionally applied by spraying or the like, but where a small amount of glaze may be applied. In such cases, the area where a small amount of glaze is applied is also considered to be an "almost no glaze part." However, the shape of the through-hole 24 may be set to a round hole, an elliptical hole, an elongated hole, a polygonal hole, or the like, other than the above-mentioned arc-shaped elongated hole. In addition, a first distance L1 in the front-rear direction from the first joint portion 20 to the center O1 of the through hole 24 is set to be smaller than a second distance L2 in the front-rear direction from the second joint portion 22 to the center O1 of the through hole 24 (L1 <L2)。 Incidentally, the through holes 24 are drilled in the wall 18 of the second wall portion 14 during the casting process of ceramic molding, or before the drying process after the demolding process.

[0020] Generally, sanitary ceramic products such as flush toilets are produced through a series of ceramic molding processes, including the pouring process, filling process, sludge removal process, compaction process, demolding process, drying process, glazing process, and firing process, as described above, in which the slip is filled in a mold, dried for a predetermined period of time, and then fired at a predetermined temperature. During each process, the ceramic's own weight F0 (see Figure 1) generates reaction forces F1 and F2 (see Figure 1) due to the balance of forces caused by the ceramic's unique shape and friction with the base that occurs when the sanitary ware shrinks against the sanitary ware in the kiln space or drying space K. During the drying and firing processes, stress tends to concentrate, particularly in the area adjacent to the first joint 20 between the first wall portion 12, which consists of a single wall, and the second wall portion 14, which consists of two walls 16 and 18, causing cracks and cuts, resulting in a decrease in yield rate. In other words, during drying and firing in the pottery molding process, the second wall portion 14, which consists of two walls 16, 18, is more likely to shrink and develop cracks and cuts than the first wall portion 12, which consists of a single wall. However, with the flush toilet 1, which is a sanitary ceramic product according to the present embodiment described above, a through hole 24 is provided in the second wall portion 14 at a location adjacent to the first joint 20 with the first wall portion 12, which prevents stress concentration during drying or firing when the ceramic is molded, making it possible to prevent stress concentration at specific locations on the ceramic due to shrinkage during molding. Therefore, it is possible to reliably prevent the occurrence of cracks or breaks due to shrinkage of the pottery itself during drying and firing of the pottery molding.

[0021] Furthermore, with the flush toilet 1, which is sanitary ceramic according to this embodiment, the through-hole 24 is provided in the unglazed or nearly unglazed portion A1 of the wall 18 of the second wall portion 14, so that when providing the through-hole 24 there are no restrictions such as considerations regarding glazing, simplifying the ceramic structure and reducing manufacturing costs.

[0022] Furthermore, the flush toilet 1, which is sanitary ceramic according to this embodiment, has a first joint 20 where the second wall portion 14 is joined to the first wall portion 12, and a second joint 22 where it is joined to the support wall portion 16. In addition, the first distance L1 from the first joint 20 to the center O1 of the through hole 24 is set to be smaller than the second distance L2 from the second joint 22 to the center O1 of the through hole 24 (L1 <L2)。 As a result, a through hole 24 can be provided in the second wall portion 14, midway between the first joint 20 with the first wall portion 12 and the second joint 22 with the support wall portion 16, or on the side closer to the first joint 20 with the first wall portion 12, which is more susceptible to shrinkage than the second joint 22. Therefore, it is possible to more reliably prevent the occurrence of cracks or breaks due to shrinkage of the pottery itself during drying or firing in the pottery molding process.

[0023] Furthermore, with the flush toilet 1, which is sanitary ceramic according to this embodiment, the sanitary ceramic is a flush toilet 1, the first joint 20 is provided in part of the bowl portion 4, and the through-hole 24 is positioned adjacent to the bowl portion 4, so it is possible to more reliably prevent cracks and cuts from occurring in the main bowl portion 4 of the flush toilet 1 due to shrinkage during drying or firing when the ceramic is formed.

[0024] Furthermore, with the flush toilet 1, which is sanitary ware according to this embodiment, the through-holes 24 are drilled in the wall 18 of the second wall portion 14 during the casting process of the ware molding, or before the drying process after the demolding process, allowing for quick drilling. Furthermore, with the through holes 24 drilled in the wall 18 of the second wall portion 14, even when drying is performed in the subsequent drying process or firing is performed in the subsequent firing process, the through holes 24 in the second wall portion 14 can suppress stress concentration at the first joint 20 between the first wall portion 12 and the second wall portion 14 of the sanitary ware, and can prevent cracks and cuts due to shrinkage.

[0025] Note that the flush toilet 1, which is the sanitary ware according to this embodiment, has been described as being in the form of a so-called "floor-standing flush toilet", which is installed so as to come into contact with the floor surface inside the toilet room, but it is not limited to this form and may also be a so-called "wall-hung flush toilet", in which the bottom 2a of the toilet body 2 is positioned so as to be spaced above the floor surface inside the toilet room, and the rear end of the toilet body 2 is fixed to the wall surface behind it. Furthermore, when a "wall-hung flush toilet" is used, for example, the drying and firing processes are carried out in the kiln space or drying space K during ceramic molding, with the rear end of the toilet body 2 installed in the toilet room positioned on the base.

[0026] Next, a urinal as a sanitary ware according to a second embodiment of the present invention will be described with reference to FIG. FIG. 3 is a schematic cross-sectional side view of a urinal, which is sanitary ware according to a second embodiment of the present invention, showing the state in which the urinal is placed on a base during the drying process or firing process of shaping the ware. As shown in Figure 3, the urinal 100 of this embodiment comprises a toilet body 102 made of ceramic. The toilet body 102 comprises a bowl portion 104 for receiving waste, a drain trap portion 106 having an inlet portion 106a connected to the bottom of the bowl portion 104 for discharging waste within the bowl portion 104, and a skirt portion 108 that covers the outer peripheries of the bowl portion 104 and the drain trap portion 106 from the sides. Furthermore, the bottom 102a of the toilet body 102 is designed to be grounded to a base 110 arranged in the kiln space or drying space K during the drying and firing steps in the pottery molding process. The toilet body 102 may be positioned on the base 110 in any orientation other than the bottom 102a thereof during the drying and firing steps of ceramic molding.

[0027] Next, as shown in FIG. 3, in the urinal 100 of this embodiment, the lower part of the bowl part 104 of the toilet body 102 is provided with a first wall part 112 consisting of a single wall made of ceramic. The toilet body 102 also includes a second wall 114 that is joined to the first wall 112 and is made of ceramic. The second wall 114 is made up of two walls 116 and 118 that are also made of ceramic. Furthermore, one wall 116 of the two walls 116, 118 in the second wall portion 114 has its upper end 116a joined to the first wall portion 112 and its lower end 116b supported by the base 110, forming a support wall portion. On the other hand, the other wall 118 of the two walls 116, 118 in the second wall portion 114 has its rear end 118a joined to the first wall portion 112, which consists of a single wall of the bowl portion 4, and its front end 118b forms a support wall portion connected to the skirt portion 108.

[0028] Next, as shown in FIG. 3, an upper end 116a of a wall 116 of the second wall portion 114 forms a first joint portion 120 joined to the first wall portion 112 of the bowl portion 4, which is made up of a single wall. On the other hand, the lower end 116b of the wall 116 of the second wall portion 114 forms a second joint portion 122 that is joined to the bottom portion 102a of the toilet body 102. Furthermore, as shown in FIG. 3, a through hole 124 is provided in the wall 116 of the second wall portion 214 at a portion adjacent to the first joint portion 120, for suppressing stress concentration during drying or firing in the pottery molding.

[0029] Here, the through-hole 124 is provided in the unglazed or nearly unglazed portion A101 of the wall 116 of the second wall portion 114, and has a generally arc-shaped elongated hole shape when viewed from the front-to-rear direction of the toilet body 102. However, the shape of the through-hole 124 may be set to a round hole, an elliptical hole, an elongated hole, a polygonal hole, or the like, other than the above-mentioned arc-shaped elongated hole. Furthermore, a first distance L101 in the up-down direction from the first joint 120 to the center O101 of the through hole 124 is set to be smaller than a second distance L102 in the front-rear direction from the second joint 122 to the center O101 of the through hole 124 (L101 <L102)。 Furthermore, the through holes 124 are drilled in the wall 116 of the second wall portion 114 during the casting process of the ceramic molding, or before the drying process after the demolding process.

[0030] According to the urinal 100, which is a sanitary ware according to the present embodiment described above, a through hole 124 is provided in the wall 116 of the second wall portion 114 at a location adjacent to the first joint 120 with the first wall portion 112, which prevents stress concentration during drying or firing in the ceramic molding process, thereby preventing stress concentration at specific locations on the ceramic due to shrinkage during ceramic molding. Therefore, it is possible to reliably prevent the occurrence of cracks or breaks due to shrinkage of the pottery itself during drying and firing of the pottery molding.

[0031] Furthermore, in the urinal 100, which is a sanitary ware according to this embodiment, the through-hole 124 is provided in the unglazed or nearly unglazed portion A101 of the wall 116 of the second wall portion 114, so that when providing the through-hole 124 there are no restrictions such as considerations regarding glazing, and the ware structure can be simplified and manufacturing costs can be reduced.

[0032] Furthermore, the urinal 100, which is sanitary ware according to this embodiment, is provided with a first joint 120 where the second wall portion 114 is joined to the first wall portion 112, and a second joint 122 where the bottom 102a of the toilet body 102 and the lower end 116b of the support wall portion 116 are joined. In addition, the first distance L101 from the first joint 120 to the center O101 of the through hole 124 is set to be smaller than the second distance L102 from the second joint 122 to the center O101 of the through hole 124 (L101 <L102)。 As a result, a through hole 124 can be provided in the support wall portion 116 of the second wall portion 114, midway between the first joint portion 120 and the second joint portion 122, or on the side closer to the first joint portion 120 with the first wall portion 112, which is more susceptible to shrinkage than the second joint portion 122. Therefore, it is possible to more reliably prevent the occurrence of cracks or breaks due to shrinkage of the pottery itself during drying or firing in the pottery molding process.

[0033] Furthermore, in the urinal 100, which is the sanitary ware of this embodiment, the through-holes 124 are drilled in the wall 116 of the second wall portion 114 during the casting process of the ware molding or before the drying process after the demolding process, so that the drilling process can be carried out quickly. Furthermore, when the through-holes 124 are drilled in the wall 116 of the second wall portion 114, even when drying is performed in the subsequent drying process or firing is performed in the firing process, the through-holes 124 in the second wall portion 114 can suppress stress concentration at the first joint 120 between the first wall portion 112 and the second wall portion 114 of the sanitary ware, and can prevent cracks and cuts due to shrinkage.

[0034] Next, a washbasin as sanitary ware according to a third embodiment of the present invention will be described with reference to FIG. FIG. 4 is a schematic cross-sectional side view of a washbasin, which is sanitary ware according to a third embodiment of the present invention, in a state where it is placed on a base during the drying process or firing process of shaping the ware. As shown in Figure 4, the washbasin 200 according to this embodiment includes a washbasin body 202 made of ceramic. The washbasin body 202 includes a bowl portion 204, a drain outlet 206 provided below the bowl portion 204, and a skirt portion 208 that covers the outer periphery of the bowl portion 204 from the side.

[0035] Next, as shown in FIG. 4, in the washbasin 200 of this embodiment, the lower part of the bowl portion 204 of the washbasin body 202 is provided with a first wall portion 212 consisting of a single wall formed of ceramic. The washbasin body 202 also includes a second wall portion 214 that is joined to the first wall portion 212 and is made of ceramic. The second wall portion 214 is made of two walls 216 and 218 that are also made of ceramic. Furthermore, one wall 216 of the two walls 216, 218 in the second wall portion 214 has its upper end 216a joined to the first wall portion 212 and its lower end 216b joined to the bottom 202a of the washbasin body 202, forming a support wall portion supported on a base 210 in the kiln space or drying space K, and forms part of the skirt portion 208. On the other hand, the other wall 218 of the two walls 216, 218 in the second wall portion 214 has its upper end 218a joined to the first wall portion 212 consisting of a single wall of the bowl portion 4, and its lower end 218b joined to the bottom 202a of the washbasin body 202, forming a support wall portion connecting this bottom 202a and the first wall portion 212 of the bowl portion 204.

[0036] Here, the bottom 202a of the washbasin body 202 is designed to be grounded to a base 210 arranged in the kiln space or drying space K during the drying process and firing process in pottery molding. Furthermore, the posture of the washbasin body 202 placed on the base 210 during the drying process and firing process in ceramic molding may be such that all parts of the washbasin body 202 other than the bottom 202a are placed on the base 210.

[0037] Next, as shown in FIG. 4, an upper end 218a of the wall 218 of the second wall portion 214 forms a first joint portion 220 joined to the first wall portion 212 of the bowl portion 4, which is made up of a single wall. On the other hand, the lower end 218b of the wall 218 of the second wall portion 114 forms a second joint portion 222 joined to the bottom portion 202a of the washbasin body 202. Furthermore, as shown in FIG. 4, a through hole 224 is provided in the wall 218 of the second wall portion 214 in a portion adjacent to the first joint portion 220, for suppressing stress concentration during drying or firing in the pottery molding.

[0038] Here, the through-hole 224 is provided in the unglazed or nearly unglazed portion A201 of the wall 218 of the second wall portion 214, and has a generally arc-shaped oblong hole shape when viewed from the front-to-rear direction of the washbasin body 202. However, the shape of the through-hole 224 may be set to a round hole, an elliptical hole, an elongated hole, a polygonal hole, or the like, other than the above-mentioned arc-shaped elongated hole. In addition, a first distance L201 in the up-down direction from the first joint portion 220 to the center O201 of the through hole 224 is set to be smaller than a second distance L202 in the front-rear direction from the second joint portion 222 to the center O201 of the through hole 224 (L201 <L202)。 Furthermore, the through holes 224 are formed in the wall 218 of the second wall portion 214 during the casting process of the ceramic molding, or before the drying process after the demolding process.

[0039] According to the washbasin 200, which is a sanitary ware according to the present embodiment described above, a through hole 224 is provided in the wall 218 of the second wall portion 214 adjacent to the first joint 220 with the first wall portion 212, which prevents stress concentration during drying or firing in the ceramic molding process, thereby preventing stress concentration at specific locations on the ceramic due to shrinkage during ceramic molding. Therefore, it is possible to reliably prevent the occurrence of cracks or breaks due to shrinkage of the pottery itself during drying and firing of the pottery molding.

[0040] Furthermore, according to the washbasin 200, which is a sanitary ceramic product of this embodiment, the through hole 224 is provided in the unglazed or nearly unglazed portion A201 of the wall 216 of the second wall portion 214, so that when providing the through hole 224, there are no restrictions such as considerations regarding glazing, and the ceramic structure can be simplified and manufacturing costs can be reduced.

[0041] Furthermore, according to the washbasin 200, which is sanitary ceramic according to this embodiment, the second wall portion 214 has a first joint 220 where the upper end 218a of the wall 218 is joined to the first wall portion 212, and a second joint 222 where the lower end 218b of the wall 218 is joined to the bottom 202a of the washbasin body 202. Also, the first distance L201 from the first joint portion 220 to the center O201 of the through hole 224 is set to be smaller than the second distance L202 from the second joint portion 222 to the center O201 of the through hole 224 (L201 < L202). Thus, in the wall 218 of the second wall portion 214, the through hole 224 can be provided at the middle between the first joint portion 220 and the second joint portion 222, or on the side closer to the first joint portion 220 of the first wall portion 212 where shrinkage is more likely to occur than the second joint portion 222. Therefore, during drying or firing in pottery forming, it is possible to more reliably prevent the occurrence of cracks and breaks due to the shrinkage of the pottery itself.

[0042] Furthermore, according to the washbasin 200 which is a sanitary pottery according to the present embodiment, since the through hole 224 is drilled in the wall 218 of the second wall portion 214 during the build-up process of pottery forming or before the drying process after the demolding process, the drilling process can be performed promptly. Also, in the state where the through hole 224 is drilled in the wall 218 of the second wall portion 214, even if drying is performed during the subsequent drying process or firing is performed during the firing process, the through hole 224 of the second wall portion 214 can suppress the stress concentration on the first joint portion 220 etc. between the first wall portion 212 and the second wall portion 214 of the sanitary pottery, and prevent the occurrence of cracks and breaks due to shrinkage.

Explanation of Signs

[0043] 1 The washlet toilet which is a sanitary pottery according to the first embodiment of the present invention 2 The toilet body 2a The bottom of the toilet body 4 The bowl portion 6 The drain trap portion 6a The inlet portion of the drain trap portion 8 The skirt portion 10 The base 12 The first wall portion 14 The second wall portion 16 One wall of the double wall, the support wall portion 16a The lower end of the wall 18 The other wall of the double wall, the support wall portion 18a The rear end 18b Front end 20 1st joint 22 Second joint 24 through holes 100 Urinal, which is sanitary ware according to the second embodiment of the present invention 102 Toilet body 102a Bottom of toilet bowl 104 Bowl section 106 Drain trap section 106a Inlet of drain trap 108 Skirt Club 110 Foundation 112 1st wall section 114 2nd wall section 116 One wall of two walls, supporting wall 116a Top of the wall 116b Bottom of wall 118 The other wall of a double wall, supporting wall 118a rear end 118b Front end 120 1st joint 122 Second joint 124 through hole 200 A washbasin which is sanitary ware according to the third embodiment of the present invention 202 Washbasin body 202a Bottom of the washbasin body 204 Bowl 206 Outlet 208 Skirt Club 210 Foundation 212 1st wall section 214 2nd wall section 216 One wall of a double wall, supporting wall 216a Top of the wall 216b Bottom of wall 218 The other wall of a double wall, supporting wall 218a Top of the wall 218b Bottom of the wall 220 1st joint 222 Second joint 224 through hole A1 Unglazed or almost unglazed area A101 Unglazed or almost unglazed parts A201 Unglazed or almost unglazed parts F0 Self-weight F1 Reaction Force F2 reaction force K Kiln space or drying space L1: The first distance in the front-to-rear direction from the first joint to the center of the through hole L2 Second distance in the front-to-rear direction from the second joint to the center of the through hole L101 First distance in the vertical direction from the first joint to the center of the through hole L102 Second distance in the vertical direction from the second joint to the center of the through hole L201: The first distance in the vertical direction from the first joint to the center of the through hole L202: Second distance in the vertical direction from the second joint to the center of the through hole O1 Center of through hole O101 Center of through hole O201 Center of through hole

Claims

1. Sanitary ware consisting of a flush toilet, urinal, or washbasin made of ceramic, a first wall portion formed of a single wall made of ceramic; a second wall portion formed of ceramic and consisting of two walls; The second wall portion has a joint portion where at least one of the two walls is joined to the first wall portion, and a through hole is provided in a portion of the second wall portion adjacent to the joint portion to suppress stress concentration during drying or firing in the ceramic molding.

2. 2. The sanitary ware according to claim 1, wherein the through-hole is provided in an unglazed or substantially unglazed portion of the second wall portion.

3. 2. The sanitary ware according to claim 1, wherein the sanitary ware comprises a support wall portion supported by a base during drying or firing in shaping the sanitary ware, the second wall portion provided with the through hole comprises a first joint portion which is the joint portion joined to the first wall portion, and a second joint portion which is joined to the support wall portion, and a first distance from the first joint portion to the through hole is set to be equal to or shorter than a second distance from the second joint portion to the through hole.

4. The sanitary ware according to claim 3, wherein the sanitary ware is a flush toilet, the flush toilet having a bowl portion, the first joint portion being provided in a part of the bowl portion, and the through hole being positioned adjacent to the bowl portion.

5. A method for manufacturing the sanitary ware according to any one of claims 1 to 4, A pouring process in which the slip is poured into a mold; a molding step of molding a molded body into the mold; a slurry draining step of draining excess slurry from inside the molded body after the molding has been completed; a demolding step of demolding the molded body; a drying step of drying the molded body after the demolding step; a glazing step of glazing the molded body after the drying step; A firing step of firing the molded body after the glazing step, The manufacturing method is characterized in that the through hole is drilled in the second wall portion during the inlaying step or before the drying step after the demolding step.

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