JP2002316885A - Sanitary ware and method for manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide sanitary ware which has appearance of high design characteristics and maintains the function to make dirt easily removable for a long period of time, regardless of product shapes and the application areas, or the like, of a first with glaze layer. SOLUTION: The sanitary ware is constituted by forming the first glaze layer of white on the surface of an earthenware surface and further forming a second while glaze layer consisting of amorphous glaze alone solutionized with 1 to 10% emulsion component or the amorphous glaze solutionized with 1 to 10% emulsion component and natural mineral particles thereon, and the surface roughness of the second glaze layer surface measured by a feeler type surface roughness measuring instrument (JIS-B 0651) is below 0.07 μm.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

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

[0002]

2. Description of the Related Art Conventionally, in the case of sanitary ware such as a toilet, a urinal, a hand-washing basin, and a basin, a glaze layer is generally applied to the surface of the porcelain substrate. Here, as a glaze raw material, natural raw materials such as silica sand (quartz) and feldspar were used as main raw materials, and in addition, an emulsifier and a pigment were added.

[0003]

However, in the conventional method as described above, quartz particles remain on the surface of the glaze layer without being completely vitrified and form recesses. Further, the emulsifier particles and the pigment particles are exposed on the surface to form projections. Therefore, the surface roughness (Ra) is measured by a stylus type surface roughness measuring device (JI
According to S-B0651), the thickness was 0.07 μm or more, and dirt easily adhered to the surface of the pottery and hardly fell off.

[0004]

Therefore, in order to solve this problem, the present applicant has provided a first glaze layer and a second glaze layer on a sanitary ware substrate, and the second glaze layer has A method in which the amount of residual quartz after firing is reduced as much as possible by using a molten amorphous glaze and atomizing (Japanese Patent Application No. 10-164).
177) and a method in which zircon and pigment are not added to the second glaze layer (Japanese Patent Application No. Hei 10-371599), and the surface roughness (Ra) of the pottery surface is measured by a stylus type surface roughness. 0.07 μm with a thickness measuring device (JIS-B0651)
Thus, a sanitary ware which is less likely to adhere to the dirt and which can easily remove the dirt has been completed.

[0005] However, in the above method, since the glaze is formed in two layers, the appearance may be different from the appearance obtained with the lower glaze alone. As a result of diligent studies, the present applicant has found that in a sanitary ware having a white appearance, the appearance obtained with the lower glaze alone is kept almost constant in production, and the surface roughness of the second glaze layer surface is 0.07 μm. It has been found that there is a method that makes it possible to reduce the value to less. The gist of the method is to form a solid solution of the emulsion component in the second glaze layer. The specific manufacturing method is a process of glazing a first glaze raw material having a white color after firing on a surface of a pottery molding base, and an amorphous glaze having an emulsion component in a solid solution of 1 to 10% thereon. A sanitary ware, comprising: a step of glazing a second glaze raw material comprising an amorphous glaze and natural mineral particles in which an emulsion component forms a solid solution of 1 to 10%, and a firing step. It is a manufacturing method of. By making the second glaze layer white, in a sanitary ware exhibiting a white appearance, the appearance obtained with the lower glaze alone can be kept almost constant in production. Furthermore, when providing a high-quality sanitary ware by expanding the area where the glaze is applied to the two layers, the two-layer interface due to the gas generated from the base material during firing becomes more likely to occur due to the accompanying production. Since the appearance defect such as a spot pattern generated on the surface is not visually recognized from the surface, it is possible to always obtain a product having a high design quality. Also, instead of adding the emulsion component of the second glaze layer to the glaze alone, by dissolving it in the amorphous glaze, it is possible to prevent tree-shaped emulsion particles from projecting to the outermost layer of the glaze. And a surface roughness of 0.07
It can be controlled to less than μm. Therefore, the sanitary ware can be easily cleaned.

In a preferred embodiment of the present invention, stannic oxide and zircon are used as the emulsion component. By doing so, the emulsion effect and whiteness of the second glaze layer are increased, and the design of the product is also enhanced.

[0007]

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.

In the present invention, a glaze raw material is defined as a raw material containing a mixture of natural mineral particles such as quartz sand, feldspar, limestone, etc., an amorphous glaze, or a mixture thereof. In the present invention, the white first glaze layer refers to the glaze raw material to which a pigment and / or an emulsifier is added. In addition, the white second glaze layer includes (1) an amorphous glaze in which an emulsion component is solid-dissolved in a concentration of 1 to 10%, and (2) a non-aqueous glaze in which an emulsion component is solid-dissolved in a concentration of 1 to 10%. A mixture of crystalline glaze and natural mineral particles (in this case,
The ratio of the amorphous glaze to the sum of the two is preferably 5
0-99% is preferable, and more preferably 60-95%). The pigment is
For example, there are a cobalt compound, an iron compound, a chromium compound, a nickel compound and the like. Amorphous glaze refers to a raw material of glaze consisting of a mixture of emulsifiers such as natural mineral particles as described above.
It refers to a glaze melted and vitrified at a high temperature of 00 ° C. to 1700 ° C. For example, a frit glaze can be suitably used.

In the present invention, first, a white first glaze is prepared. For this, the glaze raw material and the pigment and / or emulsifier may be mixed by a ball mill or the like and ground if necessary, or a commercially available white pigment to which the pigment and / or emulsifier is added may be used. You may purchase glaze.

Next, to prepare a second white glaze,
The natural mineral particles and the amorphous glaze in which the emulsion component is in a solid solution of 1 to 10%, the ratio of the amorphous glaze to the total sum of the two is preferably 50 to 99% by weight, more preferably 60 to 99% by weight.
Mix so as to be ~ 95% to prepare a white glaze raw material. Alternatively, an amorphous glaze in which the above-mentioned emulsion component is in a solid solution of 1 to 10% may be used alone. This is mixed with a ball mill or the like and, if necessary, crushed to obtain the desired product.

Next, a white first glaze is applied to a required portion of the surface of the sanitary ware molded body prepared by a general sanitary ware manufacturing process, and at least a part of the white second glaze is further applied thereon. By glazing, a surface smoothing functional layer is formed. Here, at least a portion of the white second glaze coating layer is, for example, a ball surface in a toilet bowl,
It refers to both the application to parts that are easily soiled, such as the trap section and the rim back, and the application to the entire toilet bowl. In addition, well-known methods such as spray coating, flow coating, and printing can be used as the application method.

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.

[0013]

EXAMPLES (Comparative Example 1) Glaze raw material 2 having the composition shown in Table 1
Kg, 1 Kg of water and 4 Kg of cobblestone were put into a 6-liter pottery pot, and the particle size measurement result of the colored glaze slurry after grinding using a laser diffraction type particle size distribution analyzer was 10 μm.
m = 65%, 50% average particle size (D50): 6.5 μm
The powder was pulverized by a ball mill so as to have a particle size of about m.
The glaze slurry obtained here is designated as glaze A.

[0014]

[Table 1]

Next, using a sanitary ware body slurry prepared from silica sand, feldspar, clay or the like as a raw material, a wall-mounted high-quality toilet bowl that needs to be glazed on the back side of the ball surface is prepared.
Is applied by a spray coating method.
A sample was obtained by firing at 100 to 1200 ° C.

With respect to the obtained toilet, the glaze surface roughness (Ra) was measured, and the appearance defect in the 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.

Comparative Example 2 A raw material having the composition shown in Table 2
An amorphous glaze, 2 kg of a transparent glaze raw material, 1 kg of water and 4 kg of cobblestone, adjusted so that the ratio of the amorphous glaze to the total sum of the two is 50 to 99% by weight, was added to a 6 liter pottery. Put in a pot, the particle size measurement result of the transparent glaze slurry after grinding using a laser diffraction particle size distribution meter,
Pulverization was performed by a ball mill so that the particle size of 10 μm or less was 67% and the 50% average particle size (D50) was 6.0 μm. The glaze slurry obtained here is designated as glaze B.

[0018]

[Table 2]

Next, using a sanitary ware body slurry prepared from silica sand, feldspar, clay, or the like as a raw material, a wall-mounted high-quality toilet bowl that needs to be glazed on the back side of the ball surface is prepared, and glaze A is used as a lower layer. The coating was applied by a spray coating method, and the glaze B was further applied as an upper layer by the spray coating method. Then, the sample was obtained by firing at 1100 to 1200 ° C.

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.

(Example 1) The ratio of the amorphous glaze having the composition shown in Table 3 and the natural mineral particles having the composition obtained by removing ZrSiO ₄ from the composition shown in Table 2 to the total sum of the two. 2Kg of white glaze raw material, 1Kg of water, and 4Kg of cobblestone adjusted to 50-99% by weight are put into a 6-liter pottery pot, and the transparent glaze is ground using a laser diffraction type particle size distribution meter. The particle size measurement result of the slurry is
Pulverization was performed by a ball mill so that the particle size of 10 μm or less was 67% and the 50% average particle size (D50) was 6.0 μm. The glaze slurry obtained here is designated as glaze C.

[0022]

[Table 3]

Next, using a sanitary ware body slurry prepared from silica sand, feldspar, clay, or the like as a raw material, a wall-mounted high-quality toilet bowl that needs to be glazed on the back side of the ball surface is manufactured, and glaze A is used as a lower layer. The coating was applied by a spray coating method, and a glaze C was further applied thereon as an upper layer by a spray coating method. Then, the sample was obtained by firing at 1100 to 1200 ° C.

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.

(Example 2) The ratio of the amorphous glaze having the composition shown in Table 4 and the natural mineral particles having the composition obtained by removing SnO ₂ from the composition shown in Table 2 with respect to the total sum of the two. 2Kg of white glaze raw material, 1Kg of water, and 4Kg of cobblestone adjusted to 50-99% by weight are put into a 6-liter pottery pot, and the transparent glaze is ground using a laser diffraction type particle size distribution meter. When the particle size measurement result of the slurry is 10
μm or less is 67%, and 50% average particle size (D50) is 6.0.
Pulverization was performed by a ball mill so that the particle size became μm. The glaze slurry obtained here is designated as glaze D.

[0026]

[Table 4]

Next, using a sanitary ware body slurry prepared from silica sand, feldspar, clay, or the like as a raw material, a wall-mounted high-quality toilet bowl that needs to be glazed on the back side of the ball surface is manufactured, and glaze A is used as a lower layer. The coating was applied by a spray coating method, and the glaze D was further applied thereon as an upper layer by a spray coating method. Then, the sample was obtained by firing at 1100 to 1200 ° 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.

The results are shown in Table 5. As shown in Table 5, a second white glaze layer made of an amorphous glaze in which an emulsion component is dissolved is formed on the first white glaze layer. By doing so, it is possible to obtain a sanitary ware having a surface roughness Ra of less than 0.07, hardly adhering dirt, and easily removing dirt without substantially impairing the design. It could be confirmed.

[0030]

[Table 5]

[0031]

According to the present invention, regardless of the product shape, the application site of the first white glaze layer, etc., it has the function of having a high design appearance and easily removing dirt for a long period of time. It is possible to provide sanitary ware to be maintained.

[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 (white glaze layer) 3. Second glaze layer (white glaze layer containing amorphous glaze in which emulsion component is solid solution)

 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Shingo Kasahara 2-1-1 Nakajima, Kokurakita-ku, Kitakyushu-shi, Fukuoka Totoki Equipment Co., Ltd. (72) Inventor Katsuhiro Kawakami 2 Nakajima, Kokurakita-ku, Kitakyushu-shi, Fukuoka No. 1-1 Toto Kiki Co., Ltd. (72) Inventor Tomoyasu Ichiki 2-1-1 Nakajima, Kokurakita-ku, Kitakyushu-shi, Fukuoka Prefecture Toko Kiki Co., Ltd. (72) Inventor Shin Hayakawa Kitakyushu, Fukuoka 2-1-1 Nakajima, Kokurakita-ku Totoki Equipment Co., Ltd.

Claims (3)

[Claims] 1. A first glaze layer having a white color is formed on a surface of a pottery substrate, and a second glaze layer in which an emulsion component is dissolved as a solid is formed on the first glaze layer. A sanitary ware having a surface roughness of less than 0.07 μm by a stylus type surface roughness measuring device (JIS-B0651). 2. The sanitary ware according to claim 1, wherein stannic oxide or zircon is used as the emulsion component. 3. The method for producing sanitary ware according to claim 1, wherein a step of applying a first glaze raw material having a white color after firing on the surface of the ceramic molding base, and an emulsion component thereon. Applying a second glaze raw material consisting of an amorphous glaze in which 1 to 10% is a solid solution or an amorphous glaze in which an emulsion component is in a solid solution of 1 to 10% and natural mineral particles, Baking a sanitary ware.