JP2007325890A - Integrally formed bathtub made of ceramics - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of easily manufacturing a bathtub made of ceramics at a low cost which is lighter compared to conventional pottery products and has thermal insulation performance and waterproof performance. <P>SOLUTION: Admixture containing pearlite, Shirasu balloons, coal ash, etc. and fireproof aggregate, and a hydraulic castable comprising either one or both of alumina cement and hydraulic alumina or a mixture of them are slip-casted to form a hardened body. The hardened body is mold-released and then glazed and calcined to form the bathtub made of ceramics. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

The present invention relates to a ceramic bathtub and a method for manufacturing the same.

Conventionally, as described in Japanese Patent No. 2967256, a bathtub having an excellent design with a ceramic-like pattern is formed by spraying a transparent or lightly colored gel coat material on a mold to form a glossy layer. When the decorative layer or gloss layer is formed in a bathtub formed by spraying a colored gel coat material to form a decorative layer and laminating a reinforcing layer made of resin concrete, FRP or the like on the decorative layer, the mold The gel coat material is partially sprayed in a concentrated manner to hang down a part of the gel coat material along the mold to form a drooping pattern. It has been proposed to have a bathtub with a tone pattern.

However, in this method, although it has a pottery taste, it has insufficient hot water resistance and chemical resistance compared to pottery, causing deterioration of the resin during long-term use. There are obvious differences in their properties.
Japanese Patent Application Laid-Open No. 10-44115 discloses a method for manufacturing a large-sized integrally molded water tank made of ceramics, but its weight is quite heavy and practically difficult.

We provide ceramic bathtubs that have a water-resistant, chemical-resistant, lightweight ceramic bathtub. In addition, complex designs can be handled at low cost.

The present invention has been devised in view of the above-mentioned conventional problems, and aims to provide a method for producing a bathtub having a ceramic-like pattern and having excellent design characteristics. It is to mold a bathtub with a cured body in which etc. are mixed.
A mold is made in the required shape, and the slurry-like raw material is poured into the mold and cured, cured, glazed and fired after demolding.

Lightweight by mixing with foam aggregates such as perlite, shirasuba balloon, coal ash, etc. Also, it is coated with glaze and baked to form a glass layer on the surface. Therefore, it is possible to diversify the design, and it is possible to produce a profound feeling and luxury feeling unique to ceramics.

The present invention sprays a transparent or lightly colored glaze on a large-sized integral molded body casted with castable cement into a mold and bakes it to form a glass layer, presents a ceramic-like high-class feeling, and can greatly improve the design of a bathtub Has an effect.

In addition, since it is molded by so-called injection molding, in which slurry is poured into the mold, there is a degree of freedom in shape. It has become possible.

When hydraulic alumina is added to the aggregate prepared in a predetermined amount and this is set to 1, 20 wt% to 50 wt% of water is added, and the mixture is stirred for 5 to 10 minutes with a mixer and poured into a pre-installed mold.

Thereafter, the slurry is defoamed by vibration with a vibrator or the like, and at the same time the surface of the flowed slurry is flattened. After curing and curing sufficiently, remove from the mold and take out the molded body.

Further, glazing is performed by a method well known in the ceramic industry such as spray coating or dipping. Then it is fired to make a bathtub.

Embodiments of the present invention will be described below with reference to the drawings. First, an outer mold and an inner mold are installed in combination so as to obtain a predetermined thickness, thereby forming a cast mold.

The lightweight insulating castable is prepared by adding 20% by weight of water to the raw material 1 prepared with 80% by weight of aggregate and 20% by weight of a curing agent, and kneading with a mixer for about 5 to 10 minutes. Next, the slurry is poured into the first casting mold. At this time, if the outer mold and the inner mold are not firmly fixed, the slurry may flow out from the mold mating surface.

FIG. 1 shows a state in which slurry is poured into a mold.
If bubbles remain in the castable that has been constructed, the strength is reduced, and a steam explosion may occur during firing, so it is necessary to defoam. Various defoaming methods are used.

Here, in order to perform defoaming more effectively, it is necessary to perform it carefully in a short time by vibrator vibration. As a result, it is possible to prevent dangers such as rupture during firing, and the castable strength can also be obtained.

The molded and cured lightweight heat insulating castable is removed from the outer mold and the inner mold to form a lightweight heat insulating bathtub.
FIG. 2 shows a state where the mold is removed.

The molded lightweight heat insulating bathtub needs to be sufficiently dried because it needs to remove moisture. Drying methods include sun, heat, and dehumidification, and it is necessary to perform a method that matches the shape and size. In order not to cause any problems during the main firing, be sure to sufficiently dry and execute.

As with the pottery, it is necessary to apply glaze to the entire surface of the dried lightweight insulated tub except for the bottom. It has the characteristics that it can be made smoother and the inside of the bathtub is simple and hygienic and secure.

The glazed lightweight heat insulating bathtub needs to be fired at around 1250 ° C. in order to achieve gloss and smoothness. The fired lightweight heat insulating bathtub becomes a bathtub similar to pottery, and since it is lighter in weight, it is about 20% lighter than conventional pottery bathtubs, and it is difficult to cool due to the heat insulating effect and a comfortable bathing can be obtained. The fired lightweight heat insulating bathtub main body is sintered to obtain a strength slightly more than three times that of a conventional castable molded body.

In addition to bathtubs, it can also be applied as a method for manufacturing large tanks and satellite ceramics.

It is sectional drawing of the state which poured the castable into the outer type | mold and inner type | mold which manufacture a bathtub. Cross section of bathtub after demolding

Explanation of symbols

1 Outer mold 2 Inner mold 3 Molded body

Claims (3)

It consists of a castable heat insulating material made by mixing 45 to 90% by weight of refractory aggregate, 10 to 55% by weight of alumina cement as a binder, hydraulic alumina, or a mixture thereof. Coated and fired bathtub. 2. The bathtub according to claim 1, wherein the fire-resistant aggregate is made of at least one selected from chamotte aggregate, mullite aggregate, and foam aggregate. The bathtub according to claim 1, wherein the foamable aggregate is made of at least one selected from pearlite, shirasu balloon, and coal ash.

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