Sanitary ware and its manufacturing method

Abstract

The present invention provides sanitary ware and a method for manufacturing the same, which can suppress defects such as breakage by making the weld lines of the ceramic non-linear. [Solution] The sanitary ware 1 of the present invention is a sanitary ware made by pressure molding of a slurry, and has confluence portions 18A and 18B formed by the confluence of the slurry flow, and is characterized in that these confluence portions are formed in a non-linear manner relative to the sanitary ware.

Description

Technical Field

[0001] The present invention relates to sanitary ceramics and a method for manufacturing the same, and particularly to sanitary ceramics by slurry pressure molding and a method for manufacturing the same.

Background Art

[0002] Conventionally, as a technique related to sanitary ceramics including flush toilets, urinals, wash basins, etc. and a method for manufacturing the same, for example, as described in Patent Document 1, a casting molding method for a ceramic molded body is described. In this casting molding method, a slurry in which ceramic raw material powder is dispersed in water and a plaster mold are used to form a ceramic molded body. The plaster mold has an injection port for injecting the slurry into the cavity, an exhaust hole for discharging the air in the cavity, and two paths that branch from the injection port and merge near the exhaust hole. And when the slurry branches from the injection port, vibration is not applied to the slurry, and vibration is applied to the slurry before it merges near the exhaust hole. In such a conventional manufacturing apparatus and manufacturing method for sanitary ceramics, by applying vibration to the slurry, it is attempted to prevent the occurrence of a linear merging line (so-called "weld line") in the molded body after casting molding.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, in the conventional sanitary ware manufacturing apparatus and method described above, simply vibrating the slurry while it is being poured into the mold is not sufficient to suppress the occurrence of weld lines in the molded product, and there is still a problem that weld lines occur. Furthermore, in conventional sanitary ware manufacturing apparatus and methods, for example, when slurry is injected into the cavity from two symmetrical paths, the slurry merges almost symmetrically with respect to the molded body, and a linear weld line is formed in that area. This can lead to problems such as cracks appearing in parts of the molded product if the influence of straight weld lines is too strong. Therefore, a recent challenge has been to find ways to make the linear weld lines formed on such molded bodies non-linear, thereby mitigating their impact on the ceramic's breakage and other issues.

[0005] Therefore, the present invention has been made to solve the problems of the prior art described above and the issues that have been requested in recent years, and aims to provide sanitary ware produced by slip pressure molding and a method for producing the same, which can suppress defects such as breakage by making the weld lines of the ceramic non-linear. [Means for solving the problem]

[0006] To solve the above-mentioned problems, the present invention provides a sanitary ware manufactured by pressure molding of a slurry, which has a confluence portion formed by the merging of the slurry flow, and the confluence portion is formed in a non-linear manner relative to the sanitary ware. In the present invention configured in this way, since the confluence portion formed by the merging of the slurry flow is formed in a non-linear manner relative to the sanitary ware, defects such as breakage that occur when the confluence line of the sanitary ware (the so-called "weld line") formed by the merging of the slurry becomes straight can be suppressed.

[0007] Furthermore, in the present invention, preferably, a pressure loss section that alters the flow of the slurry is formed near the confluence section. In the present invention configured in this way, a pressure loss section that alters the flow of the slurry is formed near the confluence, thereby effectively forming a non-linear weld line on the sanitary ware and suppressing defects such as breakage.

[0008] Furthermore, in the present invention, preferably, the pressure loss portion includes a convex portion that protrudes more than the confluence portion or a concave portion that is recessed more than the confluence portion. In the present invention configured in this way, the pressure loss section is provided with a convex portion that protrudes beyond the confluence section or a concave portion that is recessed beyond the confluence section, thereby more effectively making the weld line of the ceramic non-linear and suppressing defects such as breakage.

[0009] Furthermore, in the present invention, preferably, the pressure loss portion further comprises a recess provided adjacent to the convex portion. In the present invention configured in this way, by using adjacent convex and concave portions as pressure loss sections, phenomena such as so-called "shrinkage" caused by volume shrinkage of ceramics can be suppressed.

[0010] Furthermore, in the present invention, preferably, at least one of the convex portion and the concave portion is provided. In the present invention configured in this way, the presence of at least one convex and concave portion in the pressure loss section effectively suppresses phenomena such as shrinkage.

[0011] Furthermore, in the present invention, preferably, the width of the recess is set to be narrower than the width of the protrusion. In the present invention configured in this way, by setting the width of the recess in the pressure loss section to be narrower than the width of the convex section, phenomena such as shrinkage can be suppressed more effectively.

[0012] Furthermore, in the present invention, preferably, one or more of the merging sections are provided, and if multiple merging sections are provided, each of the multiple merging sections is provided so as to be offset from one another. In the present invention configured in this way, one or more merging sections are provided, and if multiple merging sections are provided, each of the multiple merging sections is provided so as to be offset from one another. This effectively suppresses defects such as breakage that occur when the weld line of the sanitary ware formed by the merging of slurry becomes straight.

[0013] Next, the present invention relates to a method for manufacturing sanitary ware by slurry pressure molding, comprising: a pouring step of pouring slurry from one or more pouring ports provided in a casting mold; and a materialization step of pushing the slurry from the pouring ports at a predetermined pressure and for a predetermined time after the casting mold has been filled with slurry, wherein in the pouring step and the materialization step, a pressure loss section is provided that partially generates a pressure loss of the slurry at the confluence of the molded body where the slurry flows merge within the casting mold, and the pressure loss section is characterized in that the confluence of the molded body formed by the merging of the slurry is formed in a non-linear shape. In the present invention configured as described above, in a molded body formed by a casting mold for sanitary ware using slurry pressure molding, a pressure loss section is provided that partially generates a pressure loss of the slurry at the confluence point where the slurry flow merges within the casting mold. This makes it possible to make the confluence line (so-called "weld line") of the molded body formed by the confluence of the slurry non-linear, thereby suppressing defects such as breakage.

[0014] Furthermore, in the present invention, preferably, one or more of the above-mentioned merging sections are provided, and if there are multiple merging sections, each of the multiple merging sections is provided so as to be offset from one another. In the present invention configured as described above, one or more confluence parts are provided. When a plurality of confluence parts are provided, each of the plurality of confluence parts is provided so as to be offset from each other. Therefore, it is possible to effectively suppress defects such as breaks caused by the weld line of the sanitary ware formed by the confluence of the slurries becoming linear.

Effect of the Invention

[0015] According to the sanitary ware formed by slurry pressure molding and its manufacturing method of the present invention, the weld line of the ware can be made non-linear, and defects such as breaks can be suppressed.

Brief Description of the Drawings

[0016] [Figure 1] It is a partially enlarged plan view of the rear part of the sanitary ware (flush toilet) according to an embodiment of the present invention. [Figure 2] It is a cross-sectional view taken along line II-II of FIG. 1. [Figure 3] It is a diagram showing the overall configuration of a casting molding apparatus used in the manufacturing method of sanitary ware according to an embodiment of the present invention. [Figure 4] It is a perspective cross-sectional view of a casting mold provided in a casting molding apparatus used in the manufacturing method of sanitary ware according to an embodiment of the present invention. [Figure 5] It is a flowchart showing the procedure of the manufacturing method of sanitary ware according to an embodiment of the present invention. [Figure 6] It is a diagram schematically showing the manufacturing method of sanitary ware according to an embodiment of the present invention.

Mode for Carrying Out the Invention

[0017] Next, referring to the accompanying drawings, a sanitary ware according to an embodiment of the present invention and its manufacturing direction will be described. Figure 1 is a partially enlarged plan view showing the rear portion of the sanitary ware (flush toilet) according to this embodiment. Figure 2 is a cross-sectional view taken along line II-II in Figure 1. Figure 3 is a diagram showing the overall configuration of the casting apparatus used in the manufacturing method of sanitary ware according to this embodiment. Figure 4 is a perspective cross-sectional view of the casting mold provided in the casting apparatus used in the manufacturing method of sanitary ware according to this embodiment.

[0018] Hereinafter, the term "ceramics" in this specification includes general sanitary ware materials such as porcelain and ceramics. First, as shown in Figures 1 to 4, in the manufacturing method of the flush toilet 1, which is a sanitary ware of this embodiment, a casting apparatus 2 is used to perform slurry pressure molding. Furthermore, this casting apparatus 2 includes a casting mold 4 for pressurizing a water-flushing toilet bowl 1, which is the molded body, and a pressurizing device 6 for pressurizing and injecting the slurry into the casting mold 4. Here, the casting mold 4 is provided with a pouring / sludge discharge port 4b and an exhaust port 4c, respectively, which communicate with the internal cavity 4a. Furthermore, the casting apparatus 2 is equipped with a pouring valve 8, a sludge discharge valve 10, an exhaust valve 12, and a control unit 14.

[0019] Here, the pouring valve 8 is configured to close or open the pouring passage f1, which is connected to the pouring / sludge discharge port 4b provided in the casting mold 4. Furthermore, the sludge discharge valve 10 is configured to close or open the sludge discharge passage f2, which is connected to the pouring / sludge discharge port 4b provided in the casting mold 4. Furthermore, the exhaust valve 12 is configured to open and close the exhaust port 4c for discharging air from inside the casting mold 4. Furthermore, the control unit 14 controls the pressurizing device 6, the inlet valve 8, the sludge discharge valve 10, and the exhaust valve 12.

[0020] Next, the casting mold 4 may be a resin mold made of resin, or a plaster mold made of plaster, etc., and a molded body is formed by pouring a slurry into a cavity 4a provided inside. In this embodiment, the pouring / sludge discharge port 4b is provided on the bottom surface of the casting mold 4, and the exhaust port 4c is provided on the top surface of the casting mold 4. Furthermore, a flow valve 8 is provided between the pressurizing device 6 and the flow passage f1 that connects the flow / sludge outlet 4b, a sludge discharge valve 10 is provided in the sludge discharge passage f2 that connects to the flow / sludge outlet 4b, and an exhaust valve 12 is provided in the exhaust port 4c.

[0021] Furthermore, the pressurizing device 6 pressurizes the slurry and causes it to flow through the pouring passage f1 and into the pouring / slurry outlet 4b of the casting mold 4. Furthermore, when sludge is introduced through the inlet / discharge port 4b, the inlet valve 8 located in the inlet passage f1 is opened. Furthermore, the opening and closing of the pouring valve 8 is controlled by a control signal from the control unit 14. The pressurizing device 6 causes the slurry to flow in from the pouring / discharge port 4b, so that the slurry fills the cavity 4a of the casting mold 4. Furthermore, once the casting mold 4 is filled with slurry, the pressurizing device 6 can be used to apply pressure to the slurry.

[0022] Next, the sludge discharge valve 10 is installed in the sludge discharge passage f2 which communicates with the pouring / sludge discharge port 4b of the casting mold 4, and is designed to close or open the pouring / sludge discharge port 4b. The opening and closing of the sludge discharge valve 10 is controlled by a control signal from the control unit 14, and by opening at a predetermined timing, the sludge inside the casting mold 4 is discharged.

[0023] Next, the exhaust valve 12 is provided at the exhaust port 4c of the casting mold 4 and is designed to open and close the exhaust port 4c. The exhaust port 4c is provided to discharge air that has been accumulating inside the casting mold 4 even before the injection of slurry into the casting mold 4 begins. Furthermore, the opening and closing of the exhaust valve 12 is controlled by a control signal from the control unit 14, and it is configured to open at a predetermined timing to discharge air from inside the casting mold 4.

[0024] Furthermore, the control unit 14 controls the pressurizing device 6, the pouring valve 8, the sludge discharge valve 10, and the exhaust valve 12 to execute the pouring process and the material application process in the manufacturing method of the flush toilet (molded body), which is sanitary ware in this embodiment. Specific control procedures for each process will be described later. Furthermore, the control unit 14 is specifically composed of a microprocessor, memory, interface circuitry, and software for operating these components (not shown above).

[0025] Next, with reference to Figures 5 and 6, the operation of the casting apparatus for molded articles according to this embodiment and the method for manufacturing molded articles will be described. Figure 5 is a flowchart showing the procedure for manufacturing the molded article according to this embodiment. Figure 6 is a schematic diagram showing the manufacturing method of the molded article according to this embodiment. First, in step S1 of the flowchart shown in Figure 5, the control unit 14 sends control signals to the sludge discharge valve 10, the exhaust valve 12, and the inlet valve 8, respectively, to close the sludge discharge valve 10 and open the exhaust valve 12 and the inlet valve 8 (see column I in Figure 6).

[0026] Next, in step S2, the control unit 14 sends a control signal to the pressurizing device 6 to activate it, and the slurry pouring process begins. As a result, the slurry S flows in from the pouring / draining port 4b of the casting mold 4, and the filling of the cavity 4a of the casting mold 4 with the slurry S begins. When the slurry S flows into the cavity 4a of the casting mold 4, as shown in column II of Figure 6, the slurry S hits the inner wall surface of the cavity 4a and spreads outwards from the pouring / draining port 4b.

[0027] As the pouring continues, the slurry S splits into two branches from the pouring / discharge port 4b and spreads within the cavity 4a, as shown in column III of Figure 6. In addition, the air A that was trapped in the cavity 4a of the casting mold 4 is pushed out by the inflow of the slurry S and discharged from the exhaust port 4c.

[0028] On the other hand, in step S3 of the flowchart shown in Figure 5, it is determined whether a predetermined pouring time has elapsed after the pouring process has started. If the predetermined pouring time has not elapsed, the process in step S3 is repeated. Once the pouring time has elapsed, the process in the flowchart proceeds to step S4.

[0029] Furthermore, after the start of the pouring process and after a predetermined pouring time has elapsed, the slurry S, which had split into two and spread within the cavity 4a, collides with each other inside the mold 4, as shown in column IV of Figure 6, filling the gaps within the cavity 4a. In the example shown in Figure 6, the slurry S poured in through the pouring passage f1 and the pouring / discharge port 4b splits into two paths as it moves through the annular cavity 4a, collides and merges near point P on the opposite side of the pouring / discharge port 4b. In the schematic diagram in Figure 6, a collision occurs at point P, but inside an actual three-dimensional casting mold, collisions between slurry particles S generally occur in non-linear regions.

[0030] Furthermore, traces of the slurry colliding and merging inside the casting mold 4 remain on the molded body 16 as a merging section 18 (a so-called "weld line"). When the weld lines 18 remaining on the molded body 16 are formed directly, they can cause cracks, bulges, and other defects in the ceramic after firing, resulting in defective products and a decrease in quality.

[0031] Next, in step S4, the control unit 14 sends a control signal to the sludge discharge valve 10 to close the sludge discharge valve 10 (see column IV in Figure 6). Furthermore, the control unit 14 applies pressure to the slurry S filled inside the casting mold 4 by continuing the operation of the pressurizing device 6. In other words, after the casting mold 4 is filled with slurry S, the control unit 14 starts a material filling process in which the slurry S is pushed through the casting / discharge port 4b via the casting passage f1 at a predetermined pressure and for a predetermined time, with the discharge valve 10 closing the discharge passage f2 which communicates with the pouring / discharge port 4b of the casting mold 4, while the pouring valve 8 is open.

[0032] Furthermore, in step S5 of Figure 5, it is determined whether a predetermined meating time has elapsed since the meating process began. If the predetermined meat settling time has not elapsed, the process in step S5 is repeatedly executed. Once the meat settling time has elapsed, the process in the flowchart proceeds to step S6. After a predetermined buildup time has elapsed, the slurry S inside the mold 4 is built up on the walls of the cavity 4a inside the mold 4, and the molded body 16 is formed inside the mold 4.

[0033] Next, in step S6, the control unit 14 sends a control signal to the pressurizing device 6 to stop its operation. The control unit 14 also sends a control signal to the sludge discharge valve 10 to open the sludge discharge valve 10 (see column V in Figure 6). This triggers the sludge discharge process, and the sludge S that did not adhere to the mold 4 is discharged from the pouring / sludge discharge port 4b through the sludge discharge passage f2.

[0034] Furthermore, in step S7, the molded body 16 is demolded from the mold 4, and the molded body 16 is completed (see column VI in Figure 6). In this embodiment, the casting mold 4 is composed of two molds, and the molded body can be removed from the casting mold 4 by separating them. The completed molded body 16 then undergoes drying, glazing, firing, and other processes to become a ceramic product. In addition, in the manufacturing method of the flush toilet 1, which is sanitary ware according to this embodiment, the control unit 14 may be omitted, and in terms of equipment, it is not limited to the high-pressure molding method using a resin mold 4 as described above, but may also be a casting molding method using a plaster mold 4, or any other casting molding method may be adopted regardless of the mold material.

[0035] Next, as shown in Figures 1, 2, and column VI of Figure 6, the molded body 16 is provided with a plurality (for example, two) confluence sections 18 (first confluence section 18A, second confluence section B) formed by the merging of the slurry flow. These junctions 18A and 18B are formed non-linearly with respect to the sanitary ware flush toilet 1 in the plan view shown in Figure 1. Furthermore, as shown in Figure 1, each junction 18A and 18B is positioned so as to be offset from each other with respect to the left-right central axis C1 of the left and right molded bodies 16 in a plan view.

[0036] Next, as shown in Figure 2, pressure loss sections 20A and 20B (first pressure loss section 20A and second pressure loss section 20B) are provided near each confluence section 18A and 18B, respectively, formed by changing the flow of the slurry. Furthermore, each pressure loss section 20A, 20B includes a plurality (for example, two) of protrusions 22, 24 that protrude beyond each confluence section 18A, 18B, and a plurality (for example, two) of recesses 26, 28 provided adjacent to each of the protrusions 22, 24. Furthermore, the widths (short side widths) W1 and W2 of each recess 26 and 28 are set to be narrower than the widths (short side widths) W3 and W4 of each protrusion 22 and 24 (W1, W2 <W3、W4)。 In this embodiment, a configuration in which multiple (two each) protrusions 22, 24 and recesses 26, 28 are provided is described, but it is sufficient if at least one of the multiple protrusions 22, 24 and recesses 26, 28 is provided.

[0037] Next, with reference to Figures 1 and 2, the operation of the flush toilet 1, which is a sanitary ware of this embodiment, and its manufacturing method will be described. First, in the case of the flush toilet 1, which is a sanitary ware of this embodiment, the confluence sections 18A and 18B formed by the merging of the slurry flow are formed in a non-linear manner relative to the flush toilet 1, which is a sanitary ware. Therefore, defects such as breakage that occur when the confluence line (so-called "weld line") of the sanitary ware (flush toilet 1) formed by the merging of slurry becomes straight can be suppressed.

[0038] Next, according to the flush toilet 1, which is a sanitary ware of this embodiment, pressure loss sections 20A and 20B that change the flow of slurry are formed near the confluence sections 18A and 18B, so that the weld lines 18A and 18B of the sanitary ware (flush toilet 1) can be effectively formed in a non-linear shape, and defects such as breakage can be suppressed.

[0039] Furthermore, according to the flush toilet 1, which is sanitary ware of this embodiment, the pressure loss sections 20A and 20B are provided with protrusions 22 and 24 that protrude beyond the confluence sections 18A and 18B, and recesses 26 and 28 that are recessed beyond the confluence sections 18A and 18B. This makes it possible to more effectively make the weld lines 18A and 18B of the ceramic (flush toilet 1) non-linear and suppress defects such as breakage.

[0040] Furthermore, according to the flush toilet 1, which is a sanitary ware of this embodiment, by using the convex portions 22, 24 and concave portions 26, 28, which are provided adjacent to each other as pressure loss portions 20A, 20B, phenomena such as so-called "shrinkage" that occur due to the volume contraction of the ceramic can be suppressed.

[0041] Furthermore, according to the flush toilet 1, which is a sanitary ware of this embodiment, by providing multiple protrusions 22, 24 and recesses 26, 28 in each of the pressure loss sections 20A, 20B, phenomena such as shrinkage can be effectively suppressed.

[0042] Furthermore, according to the flush toilet 1 which is the sanitary ware of the present embodiment, with respect to the lateral widths (short-side widths) W1 and W2 of the concave portions 26 and 28 in the pressure loss portions 20A and 20B, by setting them to be narrower than the lateral widths (short-side widths) W3 and W4 of the convex portions 22 and 24 (W1, W2 < W3, W4), phenomena such as sink marks can be more effectively suppressed.

[0043] Also, according to the flush toilet 1 which is the sanitary ware of the present embodiment and its manufacturing method, one or more confluence portions are provided. When a plurality of confluence portions are provided, each of the plurality of confluence portions is provided so as to be offset from each other. Thereby, defects such as breaks generated when the weld lines 18A and 18B of the sanitary ware (flush toilet 1) formed by the confluence of the slurry become linear can be effectively suppressed.

[0044] Furthermore, according to the manufacturing method of the flush toilet 1 which is the sanitary ware of the present embodiment, in the molded body 16 formed by the casting mold in the sanitary ware (flush toilet 1) by slurry pressure molding, pressure loss portions 20A and 20B for partially generating the pressure loss of the slurry are provided with respect to the confluence portions 18A and 18B where the flow of the slurry converges in the casting mold 4. Thereby, the weld lines 18A and 18B which are the confluence lines of the molded body 16 formed by the confluence of the slurry can be made non-linear, and defects such as breaks can be suppressed.

[0045] In the flush toilet 1 which is the sanitary ware according to the above-described present embodiment, it may be in the form of a so-called "floor-mounted flush toilet" installed so as to contact the floor surface in the toilet room, or the bottom of the flush toilet 1 may be arranged to be spaced upward from the floor surface in the toilet room, and the rear end portion of the toilet body may be fixed to the wall surface behind it, that is, a so-called "wall-mounted flush toilet".

[0046] Furthermore, in the embodiment described above, a flush toilet 1 was used as an example of sanitary ware, but other forms such as urinals and washbasins may also be used as long as they are sanitary ware. [Explanation of symbols]

[0047] 1 Flush toilet (sanitary ware, molded body) 2 Cast molding equipment 4. Casting mold 4a cavity 4b Inlet / Sludge Outlet 4c exhaust port 6. Pressurizing device 8. Inlet valve 10. Sludge discharge valve 12 Exhaust valve 14 Control Unit 16 Molded body 18. Confluence, Weldline 18A First Junction, Weldline 18B Second Junction, Weldline 20 Pressure loss section 20A First pressure loss section 20B Second pressure loss section 22 Convex part 24 Convex part 26 recesses 28 recesses A air C1: Center axis in the left-right direction f1 pouring passage f2 Sludge removal passage S Sludge W1 Width of the recess, short side width W2 Width of the recess, short side width W3 Width of the protruding part, width of the shorter side W4 Width of the protruding part, width of the shorter side

Claims

1. Sanitary ware made by pressure molding of slip, It has a confluence section formed by the merging of slurry flows, The above-mentioned confluence is characterized by being formed in a non-linear manner relative to the sanitary ware.

2. The sanitary ware according to claim 1, wherein a pressure loss section that alters the flow of slurry is formed near the above-mentioned confluence section.

3. The sanitary ware according to claim 2, wherein the pressure loss portion has a protrusion that extends beyond the confluence portion or a recess that is recessed beyond the confluence portion.

4. The sanitary ware according to claim 3, wherein the pressure loss portion further comprises a recess provided adjacent to the convex portion.

5. The sanitary ware according to claim 4, wherein at least one of the above-mentioned protrusions and recesses is provided.

6. The sanitary ware according to claim 4, wherein the width of the recess is set to be narrower than the width of the protrusion.

7. The sanitary ware according to claim 1, wherein one or more junctions are provided, and if multiple junctions are provided, each of the multiple junctions is provided so as to be offset from one another.

8. A method for manufacturing sanitary ware by pressure molding of slip, A pouring process in which slurry is poured through one or more pouring openings provided in the casting mold, The process includes a step of filling the above-mentioned mold with slurry, and then pushing the slurry through the pouring opening at a predetermined pressure and for a predetermined time, A method for manufacturing sanitary ware, characterized in that, in the above-mentioned pouring step and the above-mentioned material application step, a pressure loss section is provided that partially generates pressure loss of the slurry at the confluence of the molded body where the slurry flows merge within the mold, and the pressure loss section is such that the confluence of the molded body formed by the merging of the slurry is formed in a non-linear shape.

9. The method for manufacturing sanitary ware according to claim 8, wherein one or more of the above-mentioned junctions are provided, and if there are multiple junctions, each of the multiple junctions is provided so as to be offset from one another.

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