JP2021134133A - Sanitary earthenware excellent in cleanability - Google Patents

Abstract

To provide sanitary earthenware including a matted glaze layer, the sanitary earthenware being excellent in texture and cleanability.SOLUTION: Sanitary earthenware includes: an earthenware base material; and a glaze layer provided on a surface thereof, wherein: a 60° glossiness of the surface is 20 or more but less than 50; when Rz and Rsk specified according to JIS B0601(2001) are measured under conditions specified according to JIS B0633(2001), 1.40 μm≤Rz<2.40 μm and -1.14<Rsk<0.40 are satisfied; and when a maximum valley depth specified according to ISO 25178-2(2012) is measured under conditions specified according to ISO 25178-3(2012), 1.0 μm<Sv<4.0 μm is satisfied. The sanitary earthenware is excellent in cleanability while having an excellent matted surface.SELECTED DRAWING: None

Description

The present invention relates to a matte surface sanitary ware that is excellent in cleanability, that is, can easily remove stains on the surface.

The appearance of sanitary ware is generally glossy and glossy, giving it a texture that evokes a sense of luxury and cleanliness. On the other hand, matte sanitary ware, which is not glossy as opposed to glossy, is being evaluated in the market. This is because the matte finish enhances the appearance (design) of the product and makes it possible to harmonize with the texture of the walls and fixtures in the same space, expanding the variety of designs.

The matte tone of sanitary ware is basically obtained by scattering light by forming irregularities on the surface. Since this unevenness sometimes lowers the cleanability of sanitary ware, it is necessary to appropriately control the surface texture so as not to lower the cleanability. However, the surface shape of the surface of the sanitary ware may be disturbed by gradually eroding the glassy surface of the glaze due to use. The surface must be designed and manufactured to handle such situations.

Japanese Unexamined Patent Publication No. 2012-46364 (Patent Document 1) discloses a technique for precipitating crystal particles during glaze firing to form a matte surface. It is said that it is possible to achieve both antifouling property and matte tone by using a surface with specific physical properties.

Further, Japanese Patent Application Laid-Open No. 2018-104272 (Patent Document 2) describes a technique for obtaining a matte-like and antifouling surface by blasting the glazed surface.

Including these, the conventional mat-like sanitary ware is further improved, and there is still a demand for a mat-like sanitary ware with excellent cleanability.

Japanese Unexamined Patent Publication No. 2012-46364 JP-A-2018-104272

The present inventors have recently found that the surface of a glaze layer having a specific surface texture is a source of a matte tone having excellent cleanability.

Therefore, an object of the present invention is to provide a sanitary ware provided with a matte-like glaze layer having excellent cleanability.

The sanitary ware according to the present invention is a sanitary ware provided with a pottery base and a glaze layer on the surface.
The 60 ° glossiness of the surface of the Yuraku layer is 20 or more and less than 50.
When the Rz and Rsk specified in JIS B0601 (2001) are measured under the conditions specified in JIS B0633 (2001),
1.40 μm ≤ Rz <2.40 μm, -1.14 <Rsk <0.40,
When the maximum valley depth Sv specified by ISO 25178-2 (2012) is measured under the conditions specified by ISO 25178-3 (2012),
It is characterized in that 1.0 μm <Sv <4.0 μm.

It is a schematic diagram explaining the cross-sectional structure of the sanitary ware according to this invention.

Sanitary ware In the present invention, "sanitary ware" means pottery products used around toilets and washrooms, specifically toilet bowls, urinals, toilet bowl sana, toilet tanks, washbasin washbasins, etc. It means a hand wash basin.

FIG. 1 is a schematic view showing a cross-sectional structure near the surface of the sanitary ware according to the present invention. The sanitary ware 100 has a surface layer structure in which the glaze layer 10 is formed on the pottery base 80, and both are joined at an interface 80a. Further, the glaze layer 10 has a surface 10a thereof. Further, there may be another glaze layer (not shown) between the glaze layer 10 and the pottery base 80.

Surface properties The glaze layer (10) provided in the sanitary ware according to the present invention has the properties of the surface (10a).
(1) The 60 ° glossiness of the surface is more than 20 and less than 50.
(2) When the Rz and Rsk specified by JIS B0601 (2001) on the surface are measured under the conditions specified by JIS B0633 (2001),
1.40 μm ≤ Rz <2.40 μm, -1.14 <Rsk <0.40,
(3) When the maximum valley depth Sv specified by ISO 25178-2 (2012) on the surface is measured under the conditions specified by ISO 25178-3 (2012),
It satisfies the three requirements of 1.0 μm <Sv <3.4 μm.

The surface of the glaze layer having the above-mentioned properties according to the present invention has a matte tone and is excellent in cleanability. According to the findings obtained by the present inventor, regarding the unevenness of the glaze layer for realizing a matte surface, the stain removing property is not significantly reduced on a glossy surface having a glossiness of more than 80, but the glossiness is obtained. When the degree is smaller than 50, a matte appearance is exhibited, but the stain removing property tends to be deteriorated. Presumably, dirt gets into the uneven shape, making it difficult to remove, or a high cleaning load must be applied to remove it. In the present invention, even on the surface of the glaze layer having a low glossiness of less than 50, as described above, there are few particles in the vicinity of the surface, and the Rz and Rsk of the surface are set within a predetermined range. , It has been found that it has high cleanability, that is, it can be easily removed even if it gets dirty once. According to the present invention, the degree of cleanability is not inferior to that of a glossy surface having a glossiness of more than 80.

The properties of the above (2) provided in the glaze layer of the sanitary ware according to the present invention are preferably 1.90 μm ≦ Rz <2.44 μm and −0.20 <Rsk <0.40. Further, the property of the above (3) provided in the glaze layer of the sanitary ware according to the present invention is preferably 2.0 μm ≦ Sv ≦ 3.2 μm. By setting these ranges, it is possible to provide better cleanability.

Glaze Layer According to the present invention, various glaze layers, that is, those generally understood by those skilled in the art as glaze layers, can realize a matte surface having the above-mentioned properties. In the present invention, the glaze layer 10 may have a composition generally understood by those skilled in the art as a glaze layer, as long as the above-mentioned properties can be realized on the surface thereof.

According to a preferred embodiment of the present invention, the composition of the glaze layer comprises the composition described in the following table in terms of oxide.

Further, according to still one aspect of the present invention, in addition to the components in the above table, Fe ₂ O ₃ , TiO ₂ , BaO, B ₂ O ₃ , Li ₂ O, Sb ₂ O ₃ , CuO, MnO, NiO, CoO, MoO ₃ , SnO ₂ , PbO and the like may be included.

In the present invention, the glaze layer 10 may contain particles. The particles include crystalline particles contained in the raw material and crystalline particles precipitated by firing. Materials include zircon, quartz, diopside, anorthite and the like.

Pottery Base According to the present invention, the pottery base 80 is not particularly limited, and a known pottery base used for sanitary ware can be used. Further, an intermediate layer made of another base material having a property different from that of the pottery base material may be provided in the lower layer of the glaze layer having the surface texture and in the upper layer of the pottery base material 80. As a result, it is possible to suppress air bubbles that infiltrate into the glaze layer from the pottery base during the firing process during production, and it is possible to form a glaze layer that is not only excellent in appearance but also excellent in cleanability.

Manufacture of Sanitary Pottery The sanitary ware according to the present invention can be manufactured by forming a glaze layer on the base of the pottery and further processing the surface of the glaze layer so as to have the above-mentioned surface texture. Specifically, it can be produced by the following method.

First, a molded body to be used as a base for pottery is prepared. This is made by casting and molding a conventionally known slurry for sanitary ware prepared from silica sand, feldspar, limestone, clay, etc. with a mold such as gypsum. The molded product is dried and then glazed.

In the present invention, the raw material of the glaze forming the glaze layer is not particularly limited as long as the composition of the glaze layer can be realized, but in general, the raw material of the glaze is a mixture of natural mineral particles such as silica sand, feldspar, and limestone. Minerals such as cobalt compounds and iron compounds, emulsifying agents such as zirconium silicate and tin oxide are used. A glaze layer can be obtained by melting the glaze raw material at a high temperature and then quenching and vitrifying it. The preferred composition of the glaze raw material in the present invention is, for example, 10 wt% to 30 wt% of feldspar, 15 wt% to 40 wt% of silica sand, 10 wt% to 25 wt% of calcium carbonate, and 10 wt% of corundum, talc, dolomite, and zinc oxide, respectively. Hereinafter, the total amount of the emulsion and the pigment is 15 wt% or less. The above-mentioned glaze is applied to a dried molded product, and then dried and fired to obtain an article having a glaze layer. The firing temperature is preferably 1,000 ° C. or higher and 1,300 ° C. or lower at which the glaze softens.

The properties (1), (2) and (3) provided in the glaze layer of the sanitary ware according to the present invention are preferably realized by a wet blast treatment as described later.

In the present invention, the surface properties of the glaze layer described above can be preferably realized by a wet blast treatment. The wet blast treatment is a method of simultaneously injecting a mixture of water, an abrasive, and compressed air onto the surface of the glaze layer to scrape the surface and form a desired surface state. A matte surface according to the present invention can be obtained by appropriately selecting the type of abrasive, the average particle size, the supply pressure of compressed air, the projection distance, the projection angle, the projection time, and the like. According to a preferred embodiment of the present invention, it is preferable to use non-spherical alumina particles as the abrasive and to use those having a particle size range of 1 μm to 100 μm.

Preparation of samples used in Examples 1 to 14 Prepare a sanitary ware (manufactured by TOTO Ltd., color product number: # NW1) equipped with a glaze layer containing glass and pigment on the outermost surface, and make the flat surface about. A sample was obtained by cutting out 10 cm.

Blasting The surface of the above sample glaze layer was treated using a commercially available wet blasting device. Non-spherical alumina particles were used as the abrasive, the particle size range of the abrasive was selected from 1 μm to 100 μm, and the supply pressure of compressed air, the projection distance, the projection angle, and the projection time were appropriately selected for the treatment. The evaluation samples thus obtained were designated as Examples 1 to 14.

Measurement of surface texture

(1) Measurement of surface shape 1 (Rsk, Rz, RSm, Rc)
For the obtained evaluation sample, each surface was used according to the definition and indication by JIS B0601 (2001) using a stylus type surface roughness measuring device (SV-3200 manufactured by Mitutoyo Co., Ltd.) conforming to JIS B0651 (2001). Roughness parameters (Rsk, Rz, RSm, Rc) were calculated. The measurement conditions are the evaluation length 4 mm, cutoff values λc 0.8 mm, λ s 0.0025 mm, filter type Gaussian, and inclination correction (overall) according to the regulations of JIS B0633 (2001), and the line roughness at 10 points in total. Was measured, and the average value thereof was adopted as the value of the roughness parameter of the sample. The results are as shown in Table 2 below.

(2) Surface shape measurement 2 (Sv)
For the obtained evaluation sample, the maximum valley depth Sv specified in ISO25178-2 (2012) was measured using a laser microscope LEXT OLS4500 (manufactured by Olympus) under the conditions specified in ISO25178-3 (2012). .. The measurement was performed by analyzing the image obtained under the following observation conditions under the following analysis conditions.

As the observation conditions, a magnification of 1071 times and a high precision mode (pitch 0.2 μm) were selected, and an image of 258 μm × 258 μm was taken per field of view.

The analysis conditions were such that the evaluation area was 258 μm × 258 μm, and as image correction, horizontal correction (automatic) and noise removal were performed using the analysis software attached to the laser microscope. In the filter processing, the cutoff value (λc) of the L filter was set to 30 μm, and the cutoff value (λs) of the S filter was not set. "Roughness" was selected as the measurement parameter. Under the above conditions, the maximum valley depth Sv was measured.

The configuration of the laser microscope and analysis software used for the measurement is shown below.
Laser microscope device: OLS4500
Product version: 1.1.8
Light source: 405nm semiconductor laser Detection system: Photomultiplier Objective lens: OLYMPUS MPlan APO N 50X / 0.95 LEXT
Analysis software OLS4500 application (version: 1.1.8.3)

For one sample, measurements were taken at three points so that the fields of view did not overlap, and the average value of them was taken as the Sv of the sample. The results are as shown in Table 2 below.

(3) Measurement of glossiness The 60 ° glossiness of the obtained sample was measured with a gloss meter (GM-268plus manufactured by Konica Minolta Co., Ltd.) based on JIS Z8741. The results are as shown in Table 2 below.

(4) Evaluation of Cleanability for Oily Dirt The cleanability of the surface of the obtained evaluation sample for oily solids was evaluated by the following method. A SPECTROPHOTOMETER CM-2600d (manufactured by Konica Minolta) was used as the color difference meter. The measurement conditions are set using the color system: L * a * b *, mask / gloss: S / I + E, UV setting: UV100%, light source: D65, observation field: 10 degrees, display: absolute color difference. The a * value displayed on the SCI including the positively reflected light was used as the average value of the three measurements at the same location.
(A) a * on the surface of the sample was measured with a color difference meter, and the value was set to a0 *. Including the following, when measuring a *, a white mask having a width of 5 mm was put on the line to prevent measurement variation due to bleeding.
(B) A line having a width of 3 mm was drawn on the sample with a red pastel (registered trademark), a * on the line was measured with a color difference meter, and the value was taken as a1 *.
(C) Using a commercially available toilet cleaning sheet (trade name: Toilet Quickle, manufactured by Kao Corporation, "Quickle" is a registered trademark of Kao Corporation), 25 g / cm ^{2 in} the direction perpendicular to the line. With the load applied, it was wiped 30 times back and forth.
(D) The color on the line of the crepuscular of the sample after sliding was measured with a color difference meter, and the value was taken as a2 *.
(E) Dirt removability was calculated from the following formula.
Dirt removal property (%) = (a1 * -a2 *) / (a1 * -a0 *)
The results obtained were as shown in Table 2 below.

Claims (3)

It is a sanitary pottery with a pottery base and a glaze layer on the surface.
The 60 ° glossiness of the surface of the glaze layer is 20 or more and less than 50.
When the Rz and Rsk specified in JIS B0601 (2001) are measured under the conditions specified in JIS B0633 (2001),
1.40 μm ≤ Rz <2.40 μm, -1.14 <Rsk <0.40,
When the maximum valley depth Sv specified by ISO 25178-2 (2012) is measured under the conditions specified by ISO 25178-3 (2012),
A sanitary ware, characterized in that 1.0 μm <Sv <4.0 μm. The sanitary pottery according to claim 1, further comprising an intermediate layer between the glaze layer and the pottery base. The method for manufacturing sanitary ware according to claim 1 or 2.
Prepare an article with a glaze layer,
A method comprising treating the surface of the glaze layer with a wet blast.

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