JP2000319082A - Sanitary ware - Google Patents

Abstract

PROBLEM TO BE SOLVED: To maintain surface roughness at a specific value or below in spite of variations in production and to minimize the defects in production, such as appearance defects, by forming a first glaze layer having a specific compounded composition containing coloring pigment on the surface of an earthenware body and forming a second glaze layer having a specific compound composition free of the coloring pigment thereon. SOLUTION: The surface roughness of the resulted earthenware is suppressed to <0.07 μm. The components of the first glaze layer are, by weight % with respect to the glass components, 55 to 80 SiO2 component, 5 to 13 Al2O3 component, 10 to 25 bivalent metal oxide, 1.5 to 6.5 univalent metal oxide and 0.1 to 15 opacifier. The components of the second glaze layer are 52 to 76 SiO2 component, 6 to 14 Al2O3 component, 13 to 28 bivalent metal oxide and 1.5 to 6.5 univalent metal oxide. The first glaze layer 2 is applied on the sanitary ware body 1 and thereafter, the second glaze layer 3 is applied thereon.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a toilet bowl, a urinal bowl, a hand-washing bowl, and a basin, which have a function of easily removing dirt over a long period of time and have reduced appearance defects that occur during a firing process. And a method for manufacturing sanitary ware.

[0002]

2. Description of the Related Art Conventionally, in sanitary ware such as toilets, urinals, hand-washers, washbasins, etc., one layer of glaze is generally applied to a molding base by spraying or the like at a temperature at which the molding base is sufficiently sintered. It has been obtained by firing such that the glaze softens and adheres to the underlying pottery substrate. As a glaze material, natural materials such as silica stone and feldspar were used as main materials, and zircon, zirconia, tin oxide and the like were added as emulsifiers.

[0003]

However, in the conventional method as described above, the surface roughness (Ra) is measured by a stylus type surface roughness measuring device (JIS) due to the particles of quartz, zircon and pigment in the glaze layer. -B0651), it was 0.07 μm or more, and it was difficult to maintain the function of easily removing dirt over a long period of time.

[0004]

Therefore, in order to solve this problem, the present applicant has provided a first glaze layer and a second glaze layer on a molding base, and the second glaze layer has been previously melted. Method for minimizing the amount of residual quartz after firing by using an amorphous glaze that has been obtained and by atomization (Japanese Patent Application No. 16/1998)
No. 4177), and a method of not adding zircon and pigment to the second glaze layer (Japanese Patent Application No. 10-371599).

As a result of further study of the above-mentioned invention, the present applicant has found that the surface roughness is 0.07 mm regardless of manufacturing variations.
It has been found that there is a condition in which poor appearance such as a spotted pattern or a turtle pattern is less likely to occur while maintaining a value of less than.

In an embodiment of the present invention, a sanitary ware in which a first colored glaze layer is formed on the surface of the sanitary ware body and a transparent second glaze layer is formed thereon. In the above, the component of the first glaze layer is SiO2,
Al2O3, a divalent metal oxide, a monovalent metal oxide, and an emulsifier, wherein the weight% of the SiO2 to the glass component is 55 to 80%, and the weight% of the Al2O3 to the glass component is 5 to 13%. %, The weight% of the divalent metal oxide with respect to the glass component is 10 to 25%, the weight% of the monovalent metal oxide with respect to the glass component is 1.5 to 6.5%, and The weight% of the turbidity agent with respect to the glass component is 0.1 to 15%, and the component of the second glaze layer is composed of SiO2, Al2O3, divalent metal oxide and monovalent metal oxide. The weight percentage of the glass component is 52 to 76%, and the Al 2 O 3
Is 6 to 14% by weight based on the glass component, and 13 to 2% by weight based on the glass component of the divalent metal oxide.
A sanitary ware, which is 8%, and the weight% of the monovalent metal oxide with respect to the glass component is 1.5 to 6.5%.
Such sanitary ware can be very shiny and maintain a surface roughness of less than 0.07 μm, preferably less than 0.05 μm, more preferably less than 0.03 μm. Therefore, the function of easily removing dirt is maintained for a long time.

If the weight percentage of SiO2 relative to the glass component in the second glaze layer component is less than 52%, glaze accumulation occurs particularly in the trap portion of the toilet and the trap portion of the urinal. Glaze surface cannot be obtained. This is probably because the viscosity of the second glaze layer at the highest temperature is too low compared to the viscosity of the first glaze layer at the highest temperature. This suggests that the SiO2 particles may completely dissolve in the surrounding glass due to the decrease in the amount of SiO2, and thus may completely exhibit the behavior as a Newtonian fluid.

When the weight percentage of SiO2 in the glass component of the second glaze layer is 76% or more, a turtle pattern is formed on the ball surface of a toilet bowl, the ball surface of a urinal, and the like. Glaze surface cannot be obtained. This is probably because the viscosity of the second glaze layer at the maximum temperature is too high compared to the viscosity of the first glaze layer at the maximum temperature. The reason for this is that, due to an increase in the amount of SiO2, the SiO2 particles cannot be completely dissolved in the glass but remain in a considerable amount as undissolved silica, so that friction may be acting between the glass and the undissolved silica. Is suggested.

[0009] Among the components of the second glaze layer, Al2O3
When the weight% of the glass component is less than 6%, a mat-like pattern is generated, and a desired glaze surface cannot be obtained. This is probably because the viscosity of the second glaze layer at the maximum temperature is too high compared to the viscosity of the first glaze layer at the maximum temperature. The reason for this is that the SiO2 particles relatively increased due to the decrease in the amount of Al2O3 cannot be completely dissolved in the glass but remain in a considerable amount as undissolved silica, so that friction acts between the glass and the undissolved silica. It is suggested that there is a possibility.

[0010] Among the components of the second glaze layer, Al2O3
When the weight% of the glass component is 14% or more,
A mat-like pattern is generated, and a desired glaze surface cannot be obtained. This is probably because the viscosity of the second glaze layer at the maximum temperature is too high compared to the viscosity of the first glaze layer at the maximum temperature. The reason for this suggests that friction may be acting between the mullite crystals precipitated by increasing the amount of Al2O3 and the glass.

If the weight percentage of the divalent metal oxide relative to the glass component in the second glaze layer component is less than 13%, a mat-like pattern is generated and a desired glaze surface cannot be obtained. This is probably because the viscosity of the second glaze layer at the maximum temperature is too high compared to the viscosity of the first glaze layer at the maximum temperature. The reason is that the SiO2 particles relatively increased due to the decrease in the amount of the divalent metal oxide cannot be completely dissolved in the glass and remain in a considerable amount as undissolved silica. It is suggested that may be working.

If the weight percent of the divalent metal oxide in the glass component of the second glaze layer is 28% or more, a mat-like pattern is generated, and a desired glaze surface cannot be obtained. This is probably because the viscosity of the second glaze layer at the maximum temperature is too high compared to the viscosity of the first glaze layer at the maximum temperature. The reason for this is that the crystals precipitated due to the increase in the amount of the divalent metal oxide, particularly Z
It is suggested that friction may be acting between willemite and glass that precipitate when nO is used.

When the weight% of the monovalent metal oxide to the glass component is less than 1.5% of the components of the second glaze layer, a turtle pattern occurs and a desired glaze surface cannot be obtained. . This is probably because the viscosity of the second glaze layer at the maximum temperature is too high compared to the viscosity of the first glaze layer at the maximum temperature. The reason is that a large amount of SiO2 cannot be dissolved in the glass due to the decrease in the amount of the monovalent metal oxide,
It is suggested that friction may be acting between the remaining undissolved silica and the glass.

When the weight% of the monovalent metal oxide with respect to the glass component among the components of the second glaze layer is 6.5% or more, a spot pattern is generated and a desired glaze surface cannot be obtained. . This is probably because the viscosity of the second glaze layer at the highest temperature is too low compared to the viscosity of the first glaze layer at the highest temperature. The reason for this suggests that a large amount of SiO2 can be dissolved in the glass due to the increase in the amount of the monovalent metal oxide. Therefore, it is suggested that undissolved silica does not remain and may exhibit a behavior as a Newtonian fluid.

[0015]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention can be used for sanitary ware such as toilets, urinals, washbasins, handwashers, and the like. In the case of toilet bowls, ball surfaces, traps, rim back, etc., in the case of urinals, ball surfaces, traps, sana, etc. Application is also effective. The components of the first glaze layer are mainly composed of a SiO2 component, an Al2O3 component, a divalent metal oxide component, a monovalent metal oxide component, and an emulsifier, but may be TiO2, V2O5, cobalt oxide, or the like. May be contained. The components of the second glaze layer are mainly composed of a SiO2 component, an Al2O3 component, a divalent metal oxide component and a monovalent metal oxide component.
2, V2O5 and the like may be contained. As the divalent metal oxide component, alkaline earth metal oxides such as CaO and MgO, ZnO, CuO and the like can be used. As the monovalent metal oxide component, Na2O, K2O, Li2O, or the like can be used.

[0016]

【Example】

[Table 1]

[0017]

[Table 2]

2 kg of a glaze raw material having the composition shown in Table 1 and water 1
Kg and 4 Kg of cobblestone were placed in a 6-liter pottery pot, and the particle size of the colored glaze slurry after pulverization using a laser diffraction type particle size distribution analyzer was 10 μm or less.
Pulverization was performed by a ball mill so that the 5% and 50% average particle diameters (D50) became about 6.5 μm, to obtain a first colorable glaze slurry.

Separately, a glaze raw material having the composition shown in Table 2 and an amorphous glaze having the same composition were adjusted so that the ratio of the amorphous glaze to the total sum of the two was 50 to 99% by weight. 2 kg of raw material for glaze, 1 kg of water and 4 kg of cobblestone are added in a volume of 6
Of the transparent glaze slurry after pulverization using a laser diffraction type particle size distribution meter in a ceramic liter of 10 liters.
Pulverization is performed by a ball mill so that 0) becomes 6.0 μm, and a transparent second glaze slurry (described below)
I got

Separately, Na2 was added to the composition shown in Table 2.
2 kg of glaze raw material obtained by adjusting a glaze raw material having a composition to which O and K2O are added by 2% each and an amorphous glaze having the same composition so that the ratio of the amorphous glaze to the total sum of the two is 50 to 99% by weight. And 1 kg of water and 4 kg of cobblestone are placed in a 6 liter pottery pot, and the particle size of the transparent glaze slurry after pulverization using a laser diffraction type particle size distribution analyzer is 67% for 10 μm or less and 50% average. Particle size (D50)
Was crushed by a ball mill to obtain a transparent second glaze slurry (hereinafter described).

Separately, for the compositions shown in Table 2, SiO 2
The ratio of the amorphous glaze to the total sum of the glaze raw material having the composition of 2% and the amorphous glaze having the same composition is 50 to 50%.
2 kg of glaze raw material and water 1 adjusted to 99% by weight
Kg and 4 Kg of cobblestone are put into a 6-liter pottery pot, and the particle size of the transparent glaze slurry after pulverization using a laser diffraction type particle size distribution analyzer is 6 μm when the particle size is 10 μm or less.
Pulverization was performed by a ball mill so that the 7% and 50% average particle diameters (D50) became 6.0 μm, to obtain a transparent second glaze slurry (described below).

Next, a 70 × 150 mm plate-shaped test piece and a toilet bowl were prepared using a slurry of sanitary ware body prepared from silica sand, feldspar, clay and the like, and the coloring property obtained as described above was obtained. The first glaze slurry was applied to a plate-shaped test piece by a spray coating method, and a transparent second glaze slurry (〜) was further applied thereon by a spray coating method. Then, 1100-1200 ° C
The sample (-) was obtained by baking with.

The surface roughness (Ra) of the glaze was measured and the appearance defect was confirmed for the obtained plate-shaped test piece. Surface roughness is measured by a stylus type surface roughness meter (JIS-B0651)
Was used to measure the center line surface roughness (Ra). The appearance defect was confirmed visually.

The results, as shown in Table 3, show that as SiO2 increases with respect to the composition of the second transparent glaze, a turtle pattern starts to appear and a manufacturing defect in appearance begins to occur.

On the other hand, with respect to the composition of the transparent second glaze, when the monovalent metal oxide is increased, a spot pattern is generated, and a manufacturing defect in appearance starts to occur. In addition, the same check was performed for the toilet bowl, and it was confirmed that the tendency was the same as that of the test piece.

[0026]

[Table 3]

[0027]

According to the present invention, the surface roughness (Ra) can be maintained at less than 0.07 m irrespective of manufacturing variations, and manufacturing defects such as poor appearance are minimized. It becomes possible to provide sanitary ware that has been improved.

[Brief description of the drawings]

FIG. 1 is a diagram showing an embodiment of the present invention.

[Explanation of symbols]

 1. Sanitary ware base 2. First glaze layer (colorable glaze layer) 3. Second glaze layer (transparent glaze layer)

 ──────────────────────────────────────────────────続 き Continuing from the front page (72) Inventor Shigeyuki Yamada 2-1-1 Nakajima, Kokurakita-ku, Kitakyushu-shi, Fukuoka Touchi Kiki Co., Ltd. (72) Inventor Toru Ueno 2 Nakajima, Kokurakita-ku, Kitakyushu-shi, Fukuoka 1-1-1 Totoki Kiki Co., Ltd. (72) Inventor Hiroyuki Takada 2-1-1 Nakajima, Kokurakita-ku, Kitakyushu-shi, Fukuoka Tochiki Kiki Co., Ltd. (72) Inventor Yukinari Matsumoto Kokura, Kitakyushu-shi, Fukuoka 2-11-1, Nakajima, Kita-ku, Totoki Equipment Co., Ltd. (72) Inventor Minoru Suda 2-1-1, Nakajima, Kokurakita-ku, Kitakyushu-shi, Fukuoka Totoki Equipment Co., Ltd. (72) Katsuhiro Kawakami, Inventor 2-1, 1-1 Nakajima, Kokurakita-ku, Kitakyushu-shi, Fukuoka

Claims (2)

[Claims] 1. A sanitary ware having a first glaze layer containing a color pigment formed on a surface of a pottery substrate, and a second glaze layer not containing a color pigment formed thereon. The glaze layer comprises SiO2, Al2O3, a divalent metal oxide, a monovalent metal oxide, and an emulsifier.
The weight percentage of iO2 to the glass component is 55 to 80%, and the weight percentage of Al2O3 to the glass component is 5 to 80%.
13%, the weight% of the divalent metal oxide with respect to the glass component is 10 to 25%, the weight% of the monovalent metal oxide with respect to the glass component is 1.5 to 6.5%, and The weight% of the emulsifier with respect to the glass component is 0.1 to 15%, and the component of the second glaze layer is SiO2, Al2O.
It is composed of a trivalent metal oxide and a monovalent metal oxide, and the weight percentage of the SiO2 to the glass component is 52 to 50%.
76%, the weight% of the Al2O3 with respect to the glass component is 6-14%, the weight% of the divalent metal oxide with respect to the glass component is 13-28%, and the glass component of the monovalent metal oxide 1.5% to 6.5% by weight
A sanitary ware characterized by being. 2. The surface of the second glaze layer has a surface roughness of 0.5.
The sanitary ware according to claim 1, wherein the sanitary ware is less than 07 µm.