JP2003267774A - Method for manufacturing sanitary ware - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing sanitary ware capable of manufacturing the sanitary ware having a deep feel color tone without causing appearance defect. <P>SOLUTION: In the method for manufacturing the sanitary ware, after applying a transparent glaze on the surface of a formed body manufactured by a ware base in which a white pigment or a coloring pigment is added, the formed body is fired at 1,000-1,200°C. The raw material particle size of the ware base is set preferably in ≤7 μm as a median diameter. Further preferably, the transparent glaze layer is substantially amorphous, and SiO2 remaining after firing does not exist in the layer and also an emulsifier such as ZrSiO4, SnO2 and bone ash is not contained in the layer. <P>COPYRIGHT: (C)2003,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a urinal, a urinal, a handwasher, which has a color tone with a depth that has never been seen before.
The present invention relates to a method for manufacturing sanitary ware such as washbasins.

[0002]

2. Description of the Related Art Conventional sanitary ware has a slight coloring component (F
e, Ti, Ni, Mn, Cr, Co, Cu, Sb, etc.), a coloring agent for concealing the color of the base material and coloring it to give a design property to the brown clay base material due to its inclusion. The colored glaze added with an emulsifying agent or a pigment was glazed and then baked. For this reason, the overall appearance is flat and has a color tone with a poor sense of depth, and it is difficult to exhibit the high-class feel of translucent magnetic tableware.

On the other hand, a translucent magnetic tableware having a deep texture color tone is formed on a surface of a white ceramic base material formed of a base material having a median diameter of 10 to 20 μm as shown in, for example, Japanese Patent Publication No. 9-502689. It is obtained by applying a glaze if necessary and then firing at a temperature of 1250 to 1550 ° C.

[0004]

However, in sanitary ware, the median diameter 1 is the same as that of translucent magnetic tableware.
After glazing a transparent ceramic glaze on the surface of a white ceramic body formed from a base material of 0 to 20 μm, 1250 to 1550
When the method of firing at a temperature of ℃ is adopted, the sanitary ware is a large-scale, complicated-shaped, thick product and has a glazed portion on both sides of the base material, so glaze baldness, swelling, breakage, pinholes, etc. It was found that the appearance was poor. The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a method for manufacturing a sanitary ware capable of manufacturing a sanitary ware having a color tone with a deep texture without causing a defective appearance.

[0005]

In the present invention, in order to solve the above-mentioned problems, a transparent glaze is glazed on the surface of a molded body made of a white ceramic base material, and then baked at a temperature of 1000 to 1200 ° C. Characteristic sanitary ware manufacturing method,
Alternatively, after glazing a transparent glaze on the surface of a molded body made of a ceramic body to which a coloring pigment is added, 1000 to 1
Provided is a method for manufacturing sanitary ware, which comprises firing at a temperature of 200 ° C. By firing at 1000 to 1200 ° C., the gas generated from the base material is not generated all at once, and since it can be fired in a state where the melt viscosity is reasonably high, glaze, blisters, cuts, pinholes, etc. It becomes difficult to show a poor appearance.

In a preferred aspect of the present invention, the raw material particle size of the ceramic base material is 7 μm or less in median diameter. By doing so, it becomes easier to sinter the ceramic body, and the firing temperature can be lower than that of porcelain.

In a preferred embodiment of the present invention, the content of the flux component represented by Ca, Mg, K and Na contained in the ceramic body is 5 wt% to 1 in terms of oxide.
It should be 0% by weight. By doing so, it becomes easier to sinter the ceramic body, and the firing temperature can be lower than that of porcelain.

In a preferred embodiment of the present invention, the content of Al2O3 contained in the ceramic body is 26% or more, and Fe, Ti, Ni, Mn, Cr, Co and C are contained.
The content of the coloring component represented by u and Sb is set to 0.5% by weight or less in terms of oxide. Sanitary ware, where hygiene and cleanliness are of the utmost importance, is required to have particularly high lightness and whiteness, and white-based colors can give a high-class feeling, which is extremely effective. However, by making the above-mentioned, it is possible to suppress the coloring of the glaze surface due to the coloring component in the baking step as much as possible, and it is possible to obtain a product in a desirable category not only in lightness but also in chromaticity. More specifically, CIE197 conforming to JIS Z8729, which is not found in conventional sanitary ware.
Brightness L ^* measured by a color value measuring device using the 6 color system
Of 90 or more, chromaticity a ^* of −2 to +2, and chromaticity b ^* of −2 to 6 can be obtained.

In a preferred embodiment of the present invention, the transparent glaze layer is substantially amorphous, and S which remains after firing.
No iO2 is present and no emulsion such as ZrSiO4, SnO2, bone ash is included. Sanitary ware The amorphous part of the glaze is uniformly eroded by long-term use, especially on the part of the glaze surface that is constantly in contact with water. However, SiO2 that remains as a crystalline material, ZrSiO4, SnO as an emulsifying agent
2. The erosion rate of bone ash and other parts is different from the erosion rate of amorphous parts, so that unevenness will eventually occur on the surface.
As a result, the smoothness of the glaze surface deteriorates, causing problems in stain resistance and hygiene. By making the transparent glaze layer amorphous, the smoothness of the glaze surface can be maintained for a long period of time, and it is possible to provide sanitary ware with high cleanability and hygiene. Also,
By applying the transparent and highly smooth glaze to the white base material in this way, it is possible to give a high-grade feeling not possible with conventional sanitary ware. The high-class feeling has two factors: the glossiness of the surface increases, and the fact that the glaze is transparent causes reflection of visible light not only on the surface of the glaze but also on the surface of the white pigment background, so that the so-called depth feeling is increased. It is due to.

In a preferred aspect of the present invention, the surface roughness Ra of the surface of the transparent glaze layer is set to less than 0.07 μm by a stylus type surface roughness measuring device (JIS-B0651). By doing so, the surface of the sanitary ware glaze will have an unprecedented smoothness, and dirt will not adhere firmly, and as a result, even if it adheres, it can be lifted by contact with water and lifted. Dirt can be removed by running water.

[0011]

BEST MODE FOR CARRYING OUT THE INVENTION The present invention can be used for sanitary ware such as a toilet bowl, urinal, washbasin, hand basin, baby bath, toilet sana, sink and toilet tank.

In the present invention, the base material is kaolin,
It is defined as a mixture of natural mineral particles such as pottery stone, mica, clay and feldspar. In the present invention, the glaze raw material, silica sand, feldspar,
It is defined as a raw material containing a mixture of natural mineral particles such as limestone, an amorphous glaze, or a mixture thereof. The pigment is, for example, a cobalt compound, an iron compound or the like, and the emulsifying agent is, for example, ZrSiO4, SnO2 or the like. Amorphous glaze is a raw material for glaze consisting of a mixture of the above-mentioned natural mineral particles and the like, which is melted at a high temperature of 1400 ° C to 1700 ° C.
It refers to a vitrified glaze, and for example, frit glaze can be preferably used. Further, in the present invention, the particle size of the raw material and the glaze is a laser diffraction type particle size distribution meter (Nikkiso,
It is a median diameter measured by a Microtrac laser type particle size meter FRA). As a method for forming the base material, slurry casting, pressure forming, extrusion forming, etc., which are generally applied to sanitary ware, can be applied. Further, as the glaze application method, a commonly used spray coating method, dipping coating method, brush coating, roller coating or the like can be applied.

In the present invention, a base material is first prepared.
For this purpose, the above raw materials may be mixed with a ball mill or the like, or may be pulverized if necessary.

Next, in order to prepare a transparent glaze which does not contain a pigment and an emulsifier, the ratio of the amorphous glaze to the total sum of the above glaze raw material and the amorphous glaze is preferably 50 to 50.
99% by weight, more preferably 60 to 90%, are mixed to prepare a transparent glaze raw material. This is mixed with a ball mill or the like and, if necessary, pulverized to obtain the desired product. .

Next, the above-mentioned base material is prepared according to the general manufacturing process of sanitary ware, and the above-mentioned slurry casting molding, pressure molding,
A sanitary ware molding is produced by extrusion molding or the like.

Then, the surface glaze layer is formed by glazeing the necessary portion of the surface of the sanitary ware molding with the transparent glaze. Further, as the glaze method, a well-known method such as spray coating, flow coating and printing can be used.

After that, by firing at a temperature of 1000 to 1200 ° C., a sanitary ware having a lightness and whiteness and a high-grade feeling, which are not available in conventional sanitary ware, is obtained.

[0018]

Example (Comparative Example 1)

[0019]

[Table 1]

50 kg of the base material having the composition shown in Table 1, 24 kg of water and 80 kg of spheroids were put into a ball mill having a volume of 100 liters, and the particle size of the ground slurry after crushing was measured using a laser diffraction type particle size distribution meter, and the particle size was 10 μm. The following was crushed so that the 58% and 50% average particle diameter (D50) was about 9.0 μm. The substrate slurry obtained here is referred to as substrate A.

Next, after adjusting the fluidity of the base material A, a wall-mounted wash basin was formed and manufactured by a slurry casting molding method using a gypsum mold.

[0022]

[Table 2]

2 kg of glaze raw material having the composition shown in Table 2 and 1 part of water
Kg and 4 Kg of spheroids were placed in a ceramic pot having a volume of 6 liters, and the particle size measurement result 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 referred to as a glaze A.

Glaze A was applied to the washbasin prepared above by a spray coating method, and thereafter 1170 to 119.
A sample was obtained by firing at 0 ° C.

With respect to the obtained wash basin, the color value, the glaze surface roughness (Ra), and the appearance were evaluated. Color value is measured by Minolta spectrophotometer CM-370
0d, CIE197 according to JIS Z8729
The color value of L ^* a ^* b ^* was measured by 6 color system. Here, as the measurement conditions, a visual field of 10 ° and a light source D65 were used. The surface roughness is a stylus type surface roughness measuring device (JIS-B06
51) was used to measure the center line surface roughness (Ra). The appearance was visually evaluated.

(Comparative Example 2)

[Table 3]

A raw material having the composition shown in Table 3 and an amorphous glaze were used, and the ratio of the amorphous glaze to the total sum of both was 50 to 9.
2 kg of transparent glaze raw material adjusted to be 9% by weight, 1 kg of water, and 4 kg of boulder were placed in a ceramic pot having a volume of 6 liters, and a transparent glaze slurry after crushing using a laser diffraction type particle size distribution meter was prepared. The particles were pulverized by a ball mill so that the particle size measurement result was 67% when the particle size was 10 μm or less and the 50% average particle size (D50) was 6.0 μm. The glaze slurry obtained here is referred to as a glaze B.

Next, using the above-mentioned base A, a wall-mounted wash basin was formed and manufactured by a slurry casting molding method using a gypsum mold, and a glaze B was applied by a spray coating method.
Then, the sample was obtained by baking at 1170 to 1190 ° C.

With respect to the obtained wash basin, the color value, the glaze surface roughness (Ra), and the appearance were evaluated. Color value is measured by Minolta spectrophotometer CM-370
0d, CIE197 according to JIS Z8729
The color value of L ^* a ^* b ^* was measured by 6 color system. Here, as the measurement conditions, a visual field of 10 ° and a light source D65 were used. The surface roughness is a stylus type surface roughness measuring device (JIS-B06
51) was used to measure the center line surface roughness (Ra). The appearance was visually evaluated.

(Example)

[0031]

[Table 4]

50 kg of the base material having the composition shown in Table 4, 24 kg of water and 80 kg of spheroids were placed in a ball mill having a volume of 100 liters, and the particle size of the ground slurry after crushing was measured using a laser diffraction type particle size distribution meter to obtain a particle size of 10 μm. The following was pulverized so that 63% and 50% average particle diameter (D50) were about 6.5 μm. The substrate slurry obtained here is referred to as substrate B.

Next, after adjusting the fluidity of the base material B, a wall-mounted wash basin was formed and manufactured by a slurry casting molding method using a gypsum mold.

2 kg of glaze raw material having the composition shown in Table 3 and 1 water
Kg and 4 Kg of spheroids were placed in a ceramic pot having a volume of 6 liters, and the particle size measurement result of the colored glaze slurry after pulverization using a laser diffraction type particle size distribution analyzer was 10 μm or less.
Glaze B obtained by grinding with a ball mill so that the 5% and 50% average particle diameter (D50) is about 6.5 μm.
Was applied to the wall-mounted washbasin using the above-mentioned base B by the spray coating method. After that, 1170-11
A sample was obtained by baking at 90 ° C.

With respect to the obtained wash basin, the color value, the glaze surface roughness (Ra), and the appearance were evaluated. Color value is measured by Minolta spectrophotometer CM-370
0d, CIE197 according to JIS Z8729
The color value of L ^* a ^* b ^* was measured by 6 color system. Here, as the measurement conditions, a visual field of 10 ° and a light source D65 were used. The surface roughness is a stylus type surface roughness measuring device (JIS-B06
51) was used to measure the center line surface roughness (Ra). The appearance was visually evaluated.

As shown in Table 5, each of the results shows that the coloring component was eliminated as much as possible, and an amorphous transparent glaze layer was formed on the surface of sanitary ware in which the amount of Al2O3 and the amount of flux were controlled.
By making a sanitary ware under the firing condition of the sanitary ware of 0 to 1190 ° C, the CI compliant with JIS Z8729 can be obtained.
The lightness L ^* measured by a color value measuring device using the E1976 color system is 90 or more, the chromaticity a ^* is -2 to +2, and the chromaticity b ^* is -2 to 6, which is not found in conventional sanitary ware. It was confirmed that it was possible to obtain sanitary ware having a whiteness, and it was possible to obtain sanitary ware with a very high-grade appearance, and a stylus-type surface roughness measuring device (JIS-B065).
According to 1), it was confirmed that it was less than 0.07 μm, and that it was possible to obtain a sanitary ware in which dirt was less likely to adhere and dirt could be easily removed.

[0037]

[Table 5]

[0038]

As described above, according to the present invention, it is possible to provide a method for manufacturing a sanitary ware capable of manufacturing a sanitary ware having a color tone with a deep texture without causing a defective appearance.

[Brief description of drawings]

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

[Explanation of symbols]

1 ... Sanitary ware substrate of the present invention 2 ... Transparent glaze layer (amorphous glaze layer)

   ─────────────────────────────────────────────────── ─── Continued front page    (72) Inventor Shingo Kasahara             2-1-1 Nakajima, Kokurakita-ku, Kitakyushu City, Fukuoka Prefecture             No. Totoki Equipment Co., Ltd. (72) Hidemi Ishikawa, inventor             2-1-1 Nakajima, Kokurakita-ku, Kitakyushu City, Fukuoka Prefecture             No. Totoki Equipment Co., Ltd. (72) Inventor Tomoyasu Ichiki             2-1-1 Nakajima, Kokurakita-ku, Kitakyushu City, Fukuoka Prefecture             No. Totoki Equipment Co., Ltd. (72) Inventor Katsuhiro Kawakami             2-1-1 Nakajima, Kokurakita-ku, Kitakyushu City, Fukuoka Prefecture             No. Totoki Equipment Co., Ltd. (72) Inventor Shin Hayakawa             2-1-1 Nakajima, Kokurakita-ku, Kitakyushu City, Fukuoka Prefecture             No. Totoki Equipment Co., Ltd.

Claims (7)

[Claims] 1. A surface of a molded body made of a white ceramic body is glazed with a transparent glaze, and then 1000 to 1200 ° C.
A method for manufacturing sanitary ware, which comprises firing at a temperature of. 2. A transparent glaze is applied to the surface of a molded body made of a ceramic base material to which a color pigment is added, and then 100
A method for producing sanitary ware, which comprises firing at a temperature of 0 to 1200 ° C. 3. The method for producing sanitary ware according to claim 1, wherein the raw material particle size of the ceramic base is a median diameter of 7 μm or less. 4. Ca, Mg, which is contained in the ceramic body,
The method for producing a sanitary ware according to claim 1, wherein the content of the flux component represented by K and Na is 5% by weight to 10% by weight in terms of oxide. 5. The content of Al2O3 contained in the ceramic body is 26% or more, and Fe, Ti, Ni, and M are contained.
The content of the coloring component represented by n, Cr, Co, Cu, Sb is 0.5% by weight or less in terms of oxide, and the sanitary ware according to claim 1, 3, or 4. Production method. 6. The transparent glaze layer is substantially amorphous, has no residual SiO2 after firing, and has a ZrSi content.
The method for producing a sanitary ware according to any one of claims 1 to 5, wherein an emulsifying agent such as O4, SnO2 or bone ash is not contained. 7. The surface roughness Ra of the surface of the transparent glaze layer is less than 0.07 μm according to a stylus type surface roughness measuring device (JIS-B0651). Sanitary ware manufacturing method.