JP2002187765A - Sanitary ware and method for manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide sanitary wares having good appearance and maintaining the function that it can easily remove soiling for a long period of time without depending on the product form, the position where a first coloring glaze layer is applied, or the like. SOLUTION: A first glaze layer containing color pigments is formed on the ceramic green body, and a second glaze layer is further formed thereon. An engobe having a higher porosity than that of the green body is formed between the green body and the first glaze layer.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a sanitary ware such as a urinal, a urinal, a hand-washing basin, a wash basin, and a method for producing the same, which maintains a function of easily removing dirt for a long period of time.

[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 to minimize the amount of residual quartz after sintering by using the obtained amorphous glaze and atomizing (Japanese Patent Application No. 10-1998)
No. 164177) and a method in which zircon and pigment are not added to the second glaze layer (Japanese Patent Application No. 10-37159).
9) was proposed.

As a result of further study of the above-mentioned invention, the present applicant has found that the surface roughness is 0.07 μm regardless of manufacturing variations.
It has been found that there is a method for reducing the appearance defect such as a spot pattern while maintaining the value less than m.

In a sanitary ware having a coloring first glaze layer formed on a surface of a pottery substrate and a transparent second glaze layer formed on the first glaze layer, the surface of the base and the first A sanitary ware, wherein an engobe having a higher porosity than that of the base material is formed between glaze layers, and a method for manufacturing the same. Such sanitary ware is very glossy, has a reduced appearance defect such as a spot pattern, and can maintain a surface roughness of less than 0.07 μm. Therefore, the function of easily removing dirt is maintained for a long time.

[0007] By forming the engobe, it is possible to make it less likely to be affected by the gas generated from the substrate during the firing process, to reduce the appearance defects such as spots and the like, and to smooth the surface of the second glaze layer. The property can be prevented from being impaired by the influence of the gas.

In particular, in the present invention, the engobe formed between the surface of the substrate and the first glaze layer is a layer having a higher porosity than the substrate. The porosity corresponds to the degree of promotion of sintering, and the higher the porosity, the greater the amount of residual grain boundaries. Part or most of the gas generated from the base material during the firing process is consumed in the reaction with the remaining grain boundaries in the engobe before reaching the first glaze layer, so that appearance defects such as spot patterns are less likely to occur. In addition, it is possible to prevent the smoothness of the surface of the second glaze layer from being impaired.

In a preferred aspect of the present invention, the engobe formed between the surface of the substrate and the first glaze layer is a layer having a higher sintering start temperature than the substrate. By increasing the sintering start temperature, the sintering start temperature of the reaction layer at the interface between the first glaze layer and the engobe also increases, and the gas generated due to the sintering of the base is the first glaze layer, Or, since it is easy to penetrate through the first glaze layer and the second glaze layer and open to the atmosphere, poor appearance such as a spot pattern is less likely to occur, and the second glaze It is possible to prevent the smoothness of the layer surface from being impaired.

In a preferred aspect of the present invention, the engobe formed between the surface of the substrate and the first glaze layer is a layer having a higher sintering end temperature than the substrate. By increasing the sintering end temperature, the gas generated from the substrate along with the non-equilibrium state near the maximum temperature of the firing process is generated by the first glaze layer, or the first glaze layer and the second glaze layer. And it is easy to open to the atmosphere through
It is possible to prevent appearance defects such as speckled patterns from occurring, and to prevent the smoothness of the surface of the second glaze layer from being impaired.

In a preferred aspect of the present invention, the engobe formed between the surface of the substrate and the first glaze layer is a layer having a smaller firing shrinkage than the substrate. By reducing the firing shrinkage, the firing shrinkage of the reaction layer at the interface between the base and the engobe also decreases, and a firing shrinkage gradient is generated inside the base. The firing shrinkage of the base material also decreases with the gradient, and the amount of generated gas also decreases, so that appearance defects such as spotted patterns are less likely to occur, and the smoothness of the surface of the second glaze layer is reduced. Damage can be prevented.

[0012] In a preferred aspect of the present invention, the portion where the engove is formed is a portion where the first glaze layer is formed on both front and back surfaces of the surface of the base material, and one side or both sides thereof Engobes are formed on the surface of. By doing so, it is possible to more effectively control the influence of the gas from the substrate even in a portion where the appearance defect is likely to occur in manufacturing.

[0013]

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. As the raw material of the first glaze layer, a mixture of natural mineral particles such as quartzite, feldspar, and limestone, an amorphous glaze, or a raw material containing a mixture thereof to which a pigment and / or an emulsifier is added is used. Used. As the raw material of the second glaze layer, any of an amorphous raw material, a mixture of an amorphous raw material and natural mineral particles, and a finely divided natural mineral particle can be suitably used. The amorphous raw material refers to a raw material obtained by previously melting a raw material composed of a mixture of the above-mentioned natural mineral particles and the like at a high temperature and vitrifying the raw material. As engobe raw materials,
A raw material having a composition whose sintering start temperature is higher than that of the base material is used. Specifically, although not limited to the following, for example,
Use a mixture of at least two of pottery stone, clay, feldspar, dolomite, lime, BaCO3, SrCO3, chamotte, zinc white, quartzite, spinel compounds, alumina, mullite, and aluminum hydroxide that can be used as an engobe raw material. The mixing ratio of alumina, mullite, aluminum hydroxide, or the like, which acts as a component for increasing the sintering start temperature, is made larger than that of the raw material.

In the present invention, first, a raw material powder for forming an engobe is prepared. In this method, the target material is obtained by mixing the above raw materials with a ball mill or the like and pulverizing the raw materials as necessary.

Next, a coloring glaze is prepared. This includes
The glaze raw material and the pigment and / or emulsifier may be mixed by a ball mill or the like, and crushed if necessary.
A commercially available coloring glaze to which a pigment and / or an emulsifier is added may be purchased.

Next, in order to prepare a transparent glaze containing no pigment and no emulsifier, the ratio of the amorphous glaze to the sum of the natural mineral particles and the amorphous glaze is desirably 50 to 50. 99% by weight, more desirably 60 to 95%, to prepare a transparent glaze raw material. This is mixed with a ball mill or the like and, if necessary, crushed to obtain the desired product.

Next, the engobe raw material is applied to at least a part of the surface of the sanitary ware molded body prepared by a general sanitary ware manufacturing process. Here, the term "at least a part" means, for example, both a ball surface, a trap portion, a rim back, etc. of a toilet bowl, which is easily soiled or a part on the back side thereof, and an entire toilet. In addition, well-known methods such as spray coating, flow coating, and printing can be used as the application method.

Next, a coloring glaze is applied to a required portion of the surface of the sanitary ware molded article on which at least a part of the engobe raw material has been applied, and a transparent glaze is applied at least partially on the glaze to form a surface smoothing function layer. I do.
Here, at least a portion of the transparent glaze coating layer refers to, for example, both application to a portion of a 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 coating,
Known methods such as flow coating and printing can be used.

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

[0020]

Example (Comparative Example 1)

[0021]

[Table 1]

2 Kg of 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 diameter (D50) was about 6.5 μm. The glaze slurry obtained here is used as the first glaze A.

Next, an under-counter basin without the need for glazing on the back side of the ball surface was prepared using a sanitary ware base slurry prepared from silica sand, feldspar, clay, etc. as a raw material. Was applied by a spray coating method, and then fired at 1100 to 1200 ° C. to obtain a sample.

The obtained basin was measured for glaze surface roughness (Ra) and confirmed for appearance defects in production. The surface roughness is measured by a stylus type surface roughness meter (JIS-B06
51), the center line surface roughness (Ra) was measured. The appearance defect in the production was visually confirmed. (Comparative Example 2)

[0025]

[Table 2]

The raw material having the composition shown in Table 2 and the amorphous glaze were mixed at a ratio of 50 to 9 to the total sum of the two.
2 kg of the transparent glaze raw material, 1 kg of water, and 4 kg of cobblestone adjusted to 9% by weight were put into a 6-liter pottery pot, and the transparent glaze slurry after pulverization using a laser diffraction type particle size distribution analyzer was used. The particles were pulverized by a ball mill so that the particle size measurement result was 10% or less of 67% and the 50% average particle size (D50) was 6.0 μm. The glaze slurry obtained here is referred to as a second glaze B.

Next, a wall-mounted basin, which needs to be glazed on the back side of the ball surface, is prepared using a sanitary ware base slurry prepared from silica sand, feldspar, clay, or the like as a raw material. A is applied by a spray coating method,
Further, a second glaze B was applied thereon as an upper layer by a spray coating method. Then 1100-12
A sample was obtained by firing at 00 ° C.

With respect to the obtained wash basin, the glaze surface roughness (Ra) was measured, and the appearance defects in production were confirmed. The surface roughness is measured by a stylus type surface roughness meter (JIS-B06
51), the center line surface roughness (Ra) was measured. The appearance defect in the production was visually confirmed.

(Example 1) 10-90% pottery stone, clay 10
2Kg of engobe raw material, 2Kg of water and 4Kg of cobblestone adjusted to become ~ 50%, feldspar 1-20% and alumina 10-80% are put into a pottery pot having a volume of 6 liters,
The particle size measurement result of the pulverized engobe raw material slurry using a laser diffraction type particle size distribution analyzer is
% And a 50% average particle diameter (D50) of about 7 μm were crushed by a ball mill. The engobe raw material slurry obtained here is referred to as slurry C.

Next, using a sanitary ware body slurry prepared from silica sand, feldspar, clay, or the like as a raw material, a wall-mounted basin in which the back side of the ball surface needs to be glazed with a coloring glaze is prepared. Was coated as an engobe by a spray coating method.

Further, the first glaze A having a coloring property is applied to a necessary portion including both the front and back surfaces of the ball surface by a spray coating method, and furthermore, a transparent portion is applied to a necessary portion excluding the back side of the ball surface. The second glaze B was applied by a spray coating method. Then, 1100-1200
A sample was obtained by firing at ℃.

The obtained wash basin was measured for glaze surface roughness (Ra) and confirmed for appearance defects in production. The surface roughness is measured by a stylus type surface roughness meter (JIS-B06
51), the center line surface roughness (Ra) was measured. The appearance defect in the production was visually confirmed.

(Example 2) 10-90% pottery stone, clay 10
2Kg of engobe raw material, 2Kg of water and 4Kg of cobblestone adjusted to become ~ 50%, feldspar 1-20% and alumina 10-80% are put into a pottery pot having a volume of 6 liters,
The particle size measurement result of the pulverized engobe raw material slurry using a laser diffraction type particle size distribution analyzer is
% And a 50% average particle diameter (D50) of about 7 μm were crushed by a ball mill. The engobe raw material slurry obtained here is referred to as slurry C.

Next, using a sanitary ware body slurry prepared from silica sand, feldspar, clay, or the like as a raw material, a wall-mounted wash basin in which the back side of the ball surface needs to be coated with a colored glaze is prepared. Was applied by spray coating to both sides of the film as an engobe.

Further, the first glaze A having a coloring property is applied to a necessary portion including the front and back surfaces of the ball surface by a spray coating method, and furthermore, a transparent portion is applied to a necessary portion excluding the back side of the ball surface. The second glaze B was applied by a spray coating method. Then, 1100-1200
A sample was obtained by firing at ℃.

With respect to the obtained wash basin, the glaze surface roughness (Ra) was measured, and the appearance defect in production was confirmed. The surface roughness is measured by a stylus type surface roughness meter (JIS-B06
51), the center line surface roughness (Ra) was measured. The appearance defect in the production was visually confirmed.

As shown in Table 3, as shown in Table 3, by forming engobes on the surface of the pottery substrate, no spot pattern is generated regardless of the product shape, the application site of the first coloring glaze layer, and the like. That was confirmed.

[0038]

[Table 3]

[0039]

According to the present invention, sanitary ware having a good appearance and a function of easily removing dirt over a long period of time irrespective of the product shape, the application site of the first coloring glaze layer, and the like. Can be provided.

[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) 4. Engobe layer

 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Tomoyasu Ichiki 2-1-1 Nakajima, Kokurakita-ku, Kitakyushu-shi, Fukuoka Prefecture Totoki Equipment Co., Ltd. (72) Inventor Katsuhiro Kawakami Nakajima, Kitakyushu-shi, Fukuoka 2-1-1, Totoki Kiki Co., Ltd.

Claims (9)

[Claims] 1. A first glaze layer containing a coloring pigment is formed on a ceramic substrate, and a second glaze layer is further formed thereon, and between the base and the first glaze layer. Is a sanitary ware characterized by forming engobes having a higher porosity than the base material. 2. The sanitary ware according to claim 1, wherein the engobe has a composition whose sintering start temperature is higher than the composition of the base. 3. The sanitary ware according to claim 1, wherein the engobe is a layer having a higher sintering end temperature than a base material. 4. The sanitary ware according to claim 1, wherein the engobe is a layer having a smaller firing shrinkage rate than the base material. 5. The portion where the engove is formed is a portion where the first glaze layer is formed on both front and back surfaces of the surface of the base material, and the engobe is formed on one surface or both surfaces thereof. The sanitary ware according to any one of claims 1 to 4, wherein the sanitary ware is provided. 6. The method for producing sanitary ware according to claim 1, wherein a step of producing a pottery molding base is performed for forming an engobe having a composition having a sintering start temperature higher than the composition of the base. A step of applying a raw material to a molding substrate of a sanitary ware substrate, a step of applying a coloring glaze raw material for forming a first glaze layer on the engobe, or both on the engobe and the molding substrate, A process for applying a transparent glaze material for forming a glaze layer on the first glaze layer and a firing step. 7. The fired engobe has a thickness of 0.0
The method for producing sanitary ware according to claim 6, wherein the length is 2 mm or more. 8. The fired engobe has a thickness of 0.4.
The method for producing sanitary ware according to claim 6, wherein the length is less than 0 mm. 9. The portion where the engove is formed is a portion where the first glaze layer is formed on both front and back surfaces of the base material surface, and the engobe is formed on one surface or both surfaces thereof. The method for producing sanitary ware according to claim 6, wherein the sanitary ware is manufactured.