JP2002080286A - Method of manufacturing sanitary ware - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a sanitary ware whose stain is removed easily all the time. SOLUTION: The sanitary ware is manufactured by the process wherein the first coloring glaze layer is formed on the plain surface of the ware, then the second glaze layer whose surface roughness by a contact type-measuring apparatus (JIS-B0651) is <0.07 μm is formed on the first layer. The part of the manufacturing apparatus coming contact with the glaze for the second glaze layer contains little silica component.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a toilet bowl, a urinal, a toilet bowl, and a toilet bowl which maintain a function of easily removing dirt for a long period of time.
The present invention relates to a method for manufacturing sanitary ware such as a hand-washing machine and a wash basin, and more particularly, to a method for manufacturing a sanitary ware which can exhibit the above-mentioned characteristics with good reproducibility.

[0002]

2. Description of the Related Art The present inventors have previously used a stylus-type surface roughness measuring device (JIS-B06) to measure the surface roughness (Ra) of a ceramic surface.
51) proposed a sanitary ware which is less likely to adhere to dirt having a thickness of less than 0.07 μm and can easily remove dirt. (WO 99/61392). In one embodiment described above, the first colored glaze layer is provided on the sanitary ware substrate, and the second transparent glaze layer is further provided thereon. The second glaze layer has been prepared by applying a glaze that contains a pre-melted amorphous glaze raw material and does not contain an emulsifier such as zircon or pigment particles, and then fires it.

[0003]

However, in the above method, the surface smoothness may be slightly reduced depending on the preparation conditions of the second glaze. And WO99 / 613
As disclosed in Japanese Patent No. 92, the fluctuation of the surface roughness Ra on the sanitary ware surface on the order of 0.01 μm has a great effect on the difficulty of fixing dirt and the removability of dirt. In view of the above, the present invention provides a method for manufacturing sanitary ware capable of exhibiting excellent surface smoothness with good reproducibility, and thereby provides a sanitary ware with good reproducibility of sanitary ware having a property capable of easily removing dirt. An object of the present invention is to provide a method for manufacturing pottery.

[0004]

According to the present invention, in order to solve the above-mentioned problems, as one embodiment, a first colored glaze layer is formed on the surface of a pottery base material, and further a transparent first glaze layer is formed thereon. A second glaze layer is formed, and the surface roughness of the surface of the second glaze layer is measured by a stylus type surface roughness measuring device (JIS-
B0651), is a method for producing sanitary ware having a thickness of less than 0.07 µm, wherein the first glaze for forming the first glaze layer is mixed with the first glaze raw material using a mixing means or a crushing means. A step of preparing by pulverizing, a step of preparing the second glaze for forming the second glaze layer by mixing and pulverizing the second glaze raw material using a mixing means or a pulverizing means, pottery A step of applying the first glaze to the surface of the formed base or the ceramic firing base, and a step of applying the second glaze thereon, 800 to 1300 ° C.
Wherein the first glaze contains at least a particulate pigment or an emulsifier, and the second glaze contains at least an amorphous glaze and a particulate. At least a portion of the mixing means or pulverizing means in contact with the second glaze raw material or the second glaze in the step of preparing the second glaze, which is substantially free of pigments and emulsifiers, contains almost no silica component. The present invention provides a method for producing sanitary ware characterized by not including. WO 99/61
As disclosed in US Pat. No. 392, the decrease in surface smoothness during production is mainly caused by particles exposed on the surface of the second glaze layer. In the above manufacturing method, silica is hardly mixed from materials other than the raw material before the second glaze is applied, so that the amount of undissolved silica particles remaining after firing hardly varies from manufacturing lot to manufacturing lot. In addition, by adopting the above-described production method, the amount of undissolved silica particles remaining after firing is reduced, and the state is stabilized in a state where the amount is almost nil. Therefore, the surface roughness of the surface of the second glaze layer can be stably set to 0.07 μm.
m can be controlled to a value less than m, and thus a sanitary ware having a property of easily removing dirt can be produced with good reproducibility. In addition, although it is not limited to the following usage modes,
The mode in which the second glaze layer is transparent is particularly preferably used when the sanitary ware has a light-colored design such as white, yellow, light green, pink, light blue, and light brown. be able to.

In the present invention, as another embodiment,
A first colorable glaze layer is formed on the surface of the ceramic body, and a second colorable glaze layer containing no particulate pigment and no particulate emulsifier is formed thereon; and The method for manufacturing sanitary ware, wherein the surface roughness of the surface of the second glaze layer is less than 0.07 μm by a stylus type surface roughness measuring device (JIS-B0651), wherein the first glaze layer is formed. Preparing a first glaze for mixing and grinding the first glaze raw material using a mixing means or a crushing means, and forming a second glaze for forming the second glaze layer in the second glaze layer Mix glaze raw materials using mixing means or crushing means.
A step of preparing by crushing, a step of applying the first glaze to the surface of the pottery molding base or the pottery fired base, and a step of applying the second glaze from above, 800-
Baking at a temperature of 1300 ° C., wherein the first glaze contains at least a particulate pigment or an emulsifier, and the second glaze contains at least an amorphous glaze and Substantially free of pigments and emulsifiers retained in particulate form after the firing step, and at least the second glaze material or the second glaze material of the mixing means or crushing means in the step of preparing the second glaze The present invention provides a method for manufacturing sanitary ware, characterized in that the portion in contact with the glaze contains almost no silica component. The decrease in surface smoothness is mainly caused by particles exposed on the surface of the second glaze layer.However, in the above-mentioned production method, silica is hardly mixed from materials other than raw materials before the second glaze is applied. The amount of undissolved silica particles remaining after firing is less likely to vary from production lot to production lot. In addition, by adopting the above-described production method, the amount of undissolved silica particles remaining after firing is reduced, and the state is stabilized in a state where the amount is almost nil. Therefore, it is possible to stably control the surface roughness of the surface of the second glaze layer to less than 0.07 μm, and to produce a sanitary ware having a property capable of easily removing dirt with good reproducibility. Become. In addition, although it is not limited to the following usage aspects, the aspect in which the second glaze layer is colored is that the sanitary ware is dark blue, black,
It can be particularly preferably used when it has a design property of a dark color system such as a reddish purple system or a dark brown system.

In a preferred aspect of the present invention, the mixing means or the crushing means in the step of preparing the second glaze is a ball mill equipment. When a ball mill is used, mixing and pulverization can be performed at the same time.

[0007] In a preferred embodiment of the present invention, at least two or more different types of spheres are mixed and used as spheres in the ball mill equipment, and one of them is formed of a non-silica material. Use the ball. By doing so, it is possible to reduce the mixing of silica particle components from spherulites, and the amount of undissolved silica particles remaining after firing is stably reduced.

[0008] In a preferred embodiment of the present invention, as the sphere in the ball mill equipment, a mixture of silica-based sphere and a ball whose surface is formed of a resin is used. By doing so, it is possible to reduce the mixing of silica particle components from spherulites, and the amount of undissolved silica particles remaining after firing is stably reduced.

[0009] In a preferred embodiment of the present invention, the spheres in the ball mill equipment are a mixture of silica spheres and alumina balls or zirconia balls. By doing so, it is possible to reduce the incorporation of the silica component from the cobblestone, and to stably reduce the amount of undissolved silica particles remaining after firing. In addition, by using these balls having high Young's modulus and high hardness, the pulverization efficiency is improved, and the mixing and pulverization time can be shortened.

[0010] In a preferred embodiment of the present invention, at least two or more different types of linings are mixed and applied to the inner surface of the mill in the ball mill equipment. Make sure that there is no lining of any material. By doing so, the mixing of the silica component from the inner surface of the mill can be reduced, and the amount of undissolved silica particles remaining after firing can be stably reduced.

In a preferred aspect of the present invention, the inner surface of the mill in the ball mill equipment is provided with a mixture of a silica-based lining and a rubber lining.
By doing so, the mixing of the silica component from the inner surface of the mill can be reduced, and the amount of undissolved silica particles remaining after firing can be stably reduced.

In a preferred aspect of the present invention, the inner surface of the mill in the ball mill facility is provided with a mixture of a silica lining and an alumina or zirconia lining. By doing so, the mixing of the silica component from the inner surface of the mill can be reduced, and the amount of undissolved silica particles remaining after firing can be stably reduced. In addition, by using such a material having a high Young's modulus and a high hardness, the pulverization efficiency is improved and the mixing and pulverization time can be shortened.

[0013]

BEST MODE FOR CARRYING OUT THE INVENTION The manufacturing method of the present invention can be used for manufacturing sanitary ware such as toilets, urinals, washbasins, handwashers, and the like. In addition, the second glaze layer may be applied to a necessary portion, for example, in a toilet bowl, a ball surface,
For urinals such as traps and rim backs, the ball surface,
In a basin or a hand basin such as a trap portion, a sana, and the like, it is also effective to apply to a portion of a ball surface or the like where dirt easily adheres.

In the present invention, the glaze for forming the colorable first glaze layer is a mixture of natural mineral particles such as quartz sand, feldspar, limestone and / or an amorphous glaze, and a pigment and / or an amorphous glaze.
Alternatively, it refers to one prepared by mixing with an emulsifier and pulverizing as necessary. The first glaze raw material refers to individual raw materials before preparing the above glaze. The basic composition of the solid content of the first glaze is SiO2: 52 to 80 parts by weight,
Al2O3: 5 to 14 parts by weight, CaO: 6 to 17 parts by weight, MgO: 0.5 to 4.0 parts by weight, ZnO: 3 to 11 parts
Parts by weight, K2O: 1 to 5 parts by weight, Na2O: 0.5 to
2.5 parts by weight, emulsifier: 0.1 to 15 parts by weight, pigment:
0.001 to 20 parts by weight. The first glaze may further contain a sizing agent, a dispersant, a preservative, an antibacterial agent, and the like.

In the present invention, pigments include, for example, cobalt compounds and iron compounds, and emulsifiers include, for example,
Zircon, tin oxide and the like. The amorphous glaze refers to a glaze obtained by melting a glaze raw material composed of a mixture of the above-described natural mineral particles and the like at a high temperature and vitrifying it. For example, frit glaze can be suitably used.

[0016] The glaze for forming the transparent second glaze layer is an amorphous glaze and, if necessary, natural mineral particles such as silica sand, feldspar, limestone and the like, and mixtures or fine particles thereof. , Which is prepared by adding, mixing and pulverizing. In addition, the glaze for forming the coloring second glaze layer includes an amorphous glaze, a pigment that is not easily retained in particles after firing, and a natural mineral such as quartz sand, feldspar, and limestone, if necessary. It is prepared by adding and mixing particles, a mixture thereof, and an atomized product, and pulverizing the mixture. The second glaze raw material refers to individual raw materials before preparing the above glaze.

As the pigment which is not easily retained in the form of particles after firing, a navy blue pigment mainly composed of cobalt, a black pigment mainly composed of iron, cobalt, chromium and nickel can be suitably used.

The surface roughness Ra is measured according to JIS-B060
JIS-B according to the definition and labeling of
The measurement is performed by a stylus type surface roughness measuring device based on 0651 (1996).

In the present invention, first, a first glaze for forming a colorable first glaze layer is prepared. For this purpose, the first glaze raw material may be mixed by a ball mill or the like and ground if necessary, or a commercially available colored glaze to which a pigment and / or an emulsifier is added may be purchased. You may.

Next, a second glaze for forming a transparent second glaze layer containing no pigment and emulsifier or a second glaze for forming a colored second glaze layer is provided. prepare.

The second glaze for forming the transparent second glaze layer is, for example, a mixture of natural mineral particles such as silica sand, feldspar, limestone and the like, and an amorphous glaze, which is the sum of the two. The proportion of the amorphous glaze is desirably 50 to 99% by weight,
More desirably, in order to become 60 to 99%, in addition to siliceous spheres, alumina, zirconia balls, etc., and / or silica, lining as rubber lining, alumina, zirconia, etc. And then pulverized if necessary.

The second glaze for forming the colorable second glaze layer is, for example, a mixture of natural mineral particles such as silica sand, feldspar, limestone and the like, and an amorphous glaze, which is the sum of the two. The proportion of the amorphous glaze is desirably 50 to 99% by weight,
More desirably, it is adjusted to 60 to 99%, and a desired amount of the above pigment is added in an external ratio, and in addition to the siliceous spheres, alumina, zirconia balls or the like, and / or In addition to the siliceous lining, rubber, alumina, zirconia and the like are mixed in a ball mill and pulverized if necessary.

Next, a second glaze layer is formed by coating the surface of the sanitary ware molded article with the first glaze and glazing at least a part of the second glaze. Here, the term "at least a portion" refers to, for example, both application to a portion of the toilet bowl that is easily soiled, such as a ball surface, a trap portion, and a rim back, and application to the entire toilet bowl. The application method is spray coat, flow coat,
Known methods such as printing can be used.

Thereafter, by firing at a temperature of 800 to 1300 ° C., the molded body sinters and the two glaze layers are fixed, thereby obtaining a sanitary ware having excellent surface smoothness.

[0025]

Example (Comparative Example 1)

[0026]

[Table 1]

1000 kg of a glaze raw material having the composition shown in Table 1
And 485 kg of water and 1200 kg of siliceous cobblestone, a ball mill with an internal volume of 1850 liters (silica lining)
And the particle size of the colored glaze slurry after pulverization using a laser diffraction particle size distribution analyzer
Pulverization was performed by a ball mill so that the 5% and 50% average particle diameters (D50) became about 6.5 μm. The glaze slurry obtained here is designated as glaze A.

Next, one toilet bowl was prepared using a sanitary ware base slurry prepared from a mixture of natural mineral particles such as silica sand, feldspar, and clay, and a glaze A was applied by a spray coating method. A sample was obtained by firing at 1100 to 1250 ° C.

With respect to the obtained toilet, the glaze surface roughness (Ra) was measured, and the number of remaining silica particles of 5 μm or more which were not vitrified in a fixed field of view of the surface of the sanitary ware was confirmed. Surface roughness can be measured with a stylus type surface roughness meter (J
Using IS-B0651), the number of sampling points was set to 10, and the center line surface roughness (Ra) was measured. The number of remaining silica particles which were not vitrified on the surface of the sanitary ware was confirmed by visual inspection using a magnified image of a microscope with a magnification of 1000 times and a sampling point of 10 points.
(Comparative Example 2)

[0030]

[Table 2]

The ratio of the amorphous glaze to the total sum of the raw material composed of the mixture of the natural mineral particles having the composition shown in Table 2 and the amorphous glaze having the composition shown in Table 2 is 50 to 99% by weight. 1000kg of glaze raw material and water 48
5 kg and 1200 kg of siliceous cobble stones are filled with an internal volume of 185
Put into a 0 liter ball mill (silica lining)
A particle size measurement result of the colored glaze slurry after grinding using a laser diffraction type particle size distribution analyzer showed that 67%
Pulverization was performed by a ball mill so that the 0% average particle size (D50) was about 6.0 μm. The glaze slurry obtained here is designated as glaze B.

Next, one toilet bowl was prepared using sanitary ware body slurry prepared from a mixture of natural mineral particles such as silica sand, feldspar, and clay, and glaze A was applied as a lower layer by spray coating. Furthermore, glaze B was applied thereon by spray coating as an upper layer.
Then, it fired at 1100-1250 degreeC and obtained the sample.

With respect to the obtained toilet, the glaze surface roughness (Ra) was measured, and the number of remaining silica particles of 5 μm or more which were not vitrified in a fixed field of view of the surface of the sanitary ware was confirmed. Surface roughness can be measured with a stylus type surface roughness meter (J
Using IS-B0651), the number of sampling points was set to 10, and the center line surface roughness (Ra) was measured. The number of remaining silica particles which were not vitrified on the surface of the sanitary ware was confirmed by visual inspection using a magnified image of a microscope with a magnification of 1000 times and a sampling point of 10 points.

(Example 1) The ratio of the amorphous glaze to the total sum of the raw material composed of the mixture of the natural mineral particles having the composition shown in Table 2 and the amorphous glaze having the composition shown in Table 2 was 5%.
Glaze raw material prepared to be 0-99% by weight
kg of water, 485 kg of water, 598 kg of siliceous cobblestone, and 815 kg of alumina balls are placed in a 1850 liter ball mill (silica lining), and the particle size measurement of the colored glaze slurry after pulverization using a laser diffraction type particle size distribution analyzer. The pulverization was performed by a ball mill so that the result was 67% for 10 μm or less and about 50 μm average particle diameter (D50) of about 6.0 μm. The glaze slurry obtained here is used as glaze C.

Next, one toilet bowl was prepared using a sanitary ware base slurry prepared from a mixture of natural mineral particles such as silica sand, feldspar, and clay, and glaze A was applied as a lower layer by spray coating. Further, glaze C was applied thereon by spray coating as an upper layer.
Then, it fired at 1100-1250 degreeC and obtained the sample.

With respect to the toilet bowl obtained, the surface roughness (Ra) of the glaze was measured, and the remaining number of silica particles of 5 μm or more which were not vitrified in a fixed field of view of the sanitary ware surface was confirmed. Surface roughness can be measured with a stylus type surface roughness meter (J
Using IS-B0651), the number of sampling points was set to 10, and the center line surface roughness (Ra) was measured. The number of remaining silica particles which were not vitrified on the surface of the sanitary ware was confirmed by visual inspection using a magnified image of a microscope with a magnification of 1000 times and a sampling point of 10 points.

(Example 2) The ratio of the amorphous glaze to the total sum of the raw material comprising a mixture of natural mineral particles having the composition shown in Table 2 and the amorphous glaze having the composition shown in Table 2 was 5%.
Glaze raw material prepared to be 0-99% by weight
kg, 485 kg of water, 598 kg of siliceous spheres, and 815 kg of alumina balls are put into a 1850 liter ball mill (lining is a mixture of siliceous and rubber).
A particle size measurement result of the colored glaze slurry after grinding using a laser diffraction type particle size distribution analyzer showed that 67%
Pulverization was performed by a ball mill so that the 0% average particle size (D50) was about 6.0 μm. The glaze slurry obtained here is used as glaze D.

Next, one toilet bowl was prepared by using a sanitary ware base slurry prepared from a mixture of natural mineral particles such as silica sand, feldspar, and clay, and glaze A was applied as a lower layer by spray coating. Further, glaze C was applied thereon by spray coating as an upper layer.
Then, it fired at 1100-1250 degreeC and obtained the sample.

With respect to the toilet bowl thus obtained, the glaze surface roughness (Ra) was measured, and the remaining number of non-vitrified silica particles of 5 μm or more in a fixed field of view of the surface of the sanitary ware was confirmed. Surface roughness can be measured with a stylus type surface roughness meter (J
Using IS-B0651), the number of sampling points was set to 10, and the center line surface roughness (Ra) was measured. The number of remaining silica particles which were not vitrified on the surface of the sanitary ware was confirmed by visual inspection using a magnified image of a microscope with a magnification of 1000 times and a sampling point of 10 points.

(Example 3) The ratio of the amorphous glaze to the total sum of the raw material consisting of the mixture of the natural mineral particles having the composition shown in Table 2 and the amorphous glaze having the composition shown in Table 2 was 5%.
Glaze raw material prepared to be 0-99% by weight
kg, 485 kg of water, 598 kg of siliceous cobblestone and 815 kg of alumina balls are placed in a 1850 liter ball mill (lining is a mixture of siliceous and alumina), and a colored glaze after grinding using a laser diffraction type particle size distribution analyzer. When the particle size of the slurry was 10 μm or less,
% And a 50% average particle diameter (D50) of about 6.0 μm. The glaze slurry obtained here is designated as glaze E.

Next, one toilet bowl was prepared using a sanitary ware body slurry prepared from a mixture of natural mineral particles such as silica sand, feldspar, and clay, and glaze A was applied as a lower layer by spray coating. Further, glaze C was applied thereon by spray coating as an upper layer.
Then, it fired at 1100-1250 degreeC and obtained the sample.

With respect to the obtained toilet, the glaze surface roughness (Ra) was measured, and the remaining number of silica particles of 5 μm or more which were not vitrified in a fixed field of view of the sanitary ware surface was confirmed. Surface roughness can be measured with a stylus type surface roughness meter (J
Using IS-B0651), the number of sampling points was set to 10, and the center line surface roughness (Ra) was measured. The number of remaining silica particles which were not vitrified on the surface of the sanitary ware was confirmed by visual inspection using a magnified image of a microscope with a magnification of 1000 times and a sampling point of 10 points.

As shown in Table 3, the results of Examples 1 to 3 were very stable and excellent surface smoothness was observed. The remaining number of silica particles that are not vitrified
, And also in the pulverization time, the improvement of the pulverization efficiency was confirmed.

[0044]

[Table 3]

[0045]

According to the production method of the present invention, it is possible to provide a method for producing sanitary ware having a property of easily removing dirt with good reproducibility.

[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 Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) E03D 13/00 E03D 13/00

Claims (9)

[Claims] 1. A colorable first glaze layer is formed on a surface of a pottery substrate, and a transparent second glaze layer is further formed thereon, and a surface roughness of the second glaze layer surface is provided. Using a stylus type surface roughness measuring device (JIS-B0651)
A method for producing sanitary ware that is less than 0.07 μm,
A step of preparing a first glaze for forming the first glaze layer by mixing and pulverizing the first glaze raw material using a mixing means or a pulverizing means, to form the second glaze layer; A step of preparing the second glaze by mixing and pulverizing the second glaze raw material using a mixing means or a pulverization means, a step of applying the first glaze to a pottery molding base or a pottery firing base surface, A step of applying the second glaze thereon, and a step of firing at a temperature of 800 to 1300 ° C., wherein the first glaze contains at least a particulate pigment or an emulsifier, The second glaze contains at least an amorphous glaze and is substantially free of particulate pigments and emulsifiers, and at least the mixing means or the pulverizing means in the step of preparing the second glaze. Raw material for glaze There the method for producing sanitary ware portion in contact with the second glaze, characterized in that the substantially free of silica components. 2. A colorable first glaze layer is formed on the surface of the pottery substrate, and a colorable second glaze layer containing no particulate pigment and no particulate emulsifier is formed thereon. And the surface roughness of the surface of the second glaze layer was 0.07 by a stylus type surface roughness measuring device (JIS-B0651).
A method for producing sanitary ware having a particle size of less than μm, wherein the first glaze for forming the first glaze layer is prepared by mixing and pulverizing the first glaze raw material using a mixing means or a pulverizing means. Preparing a second glaze for forming the second glaze layer by mixing and pulverizing a second glaze raw material using a mixing means or a pulverizing means; Applying the first glaze to the surface, further applying the second glaze thereon, and firing at a temperature of 800 to 1300 ° C., wherein the first glaze is at least particulate. The second glaze contains at least an amorphous glaze and is substantially free of pigments and emulsifiers that are retained in a particulate form after the baking step, And adjust the second glaze At least said second glaze material or a portion in contact with the second glaze manufacturing method of sanitary ware, characterized in that substantially free of silica components of the mixing means or grinding means in the process of. 3. The method for producing sanitary ware according to claim 1, wherein the mixing means or the crushing means in the step of preparing the second glaze is a ball mill facility. 4. The cobblestone in the ball mill equipment includes:
The ball according to claim 3, wherein a mixture of at least two or more different types of cobblestones is used, and one of them is a ball formed of a non-silica material. Manufacturing method of sanitary ware. 5. The cobblestone in the ball mill equipment includes:
The method for producing sanitary ware according to claim 3, wherein a mixture of a silica-based sphere and a ball whose surface is formed of a resin is used. 6. The cobblestone in the ball mill equipment includes:
The method for producing sanitary ware according to claim 3, wherein a mixture of silica-like spheres and alumina balls or zirconia balls is used. 7. The inner surface of the mill in the ball mill equipment is provided with a mixture of at least two kinds of different materials, and one of them is provided with a non-silica material. The method for producing sanitary ware according to any one of claims 3 to 6, wherein the sanitary ware is manufactured. 8. The method for producing sanitary ware according to claim 3, wherein a silica lining and a rubber lining are mixed and applied to the inner surface of the mill in the ball mill equipment. 9. The mill inner surface of the ball mill facility is provided with a mixture of a silica lining and an alumina or zirconia lining.
7. The method for producing sanitary ware according to any one of Items 6 to 6.