JP2002097068A - Sanitary ware - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a sanitary ware having less deformation in molding and firing, whose shape and dimensions after firing can be estimated precisely, sufficient mechanical strength, a space to put toiletries, sanitariness, durability and excellence in design. SOLUTION: The ware contains a sink with a drain and a flat part nearby and/or as a part of the sink, the latter of which comprises a hollow or a dense and hollow structure. The sink and the flat part are shaped as one body and a glaze layer is formed at necessary places. CaO components are segregated and scattered in the body.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a basin, a hand basin,
The present invention relates to sanitary ware such as a sink, a hair washer, a hair washer, and a baby bath.

[0002]

2. Description of the Related Art A basin, a hand basin, a sink and a shampoo, and a baby bath are daily necessities, and therefore, mechanical strength that can be used safely is required. In addition, design properties are also required. Furthermore, basins and hand washers and sinks and shampooers and baby baths also require chemical stability to be used around water. For this reason, glazed porcelain, especially for basins, hand-washers, sinks and shampoos, and baby baths, has been secured for a long time, and the degree of freedom of design based on the color and pattern of the glaze layer in one baking is also ensured. Easy to do 1
Glazed hard pottery base materials and fusible base materials that can be fired at a temperature of 100 to 1300 ° C. and can exhibit sufficient mechanical strength have been generally used.

[0003]

SUMMARY OF THE INVENTION A basin, a hand basin, a sink and a shampoo and a baby bath are used for the following purposes.
In many cases, cabinets, counters, shelves, etc. for storing daily necessities are provided. Therefore, there is a demand for the development of new ceramic products such as a washbasin, a handwasher, a sink, a hair washer, and a baby bath in which a space for placing objects and a flat portion satisfying the purpose are integrally formed. The space for placing objects is seamless with the basin and handwasher, the sink and the shampooer and the baby bath, and is integrally formed of a ceramic material, so that dirt does not accumulate at the seams and is easy to clean. For example, it is expected that hygiene is improved, that the space for placing objects is made of a ceramic material, the durability is improved, and that the design quality is improved due to the excellent texture of the ceramic material. However, when such a ceramic product is manufactured, the space for placing the object is integrally formed, so that the product itself becomes relatively large, so that the deformation becomes large. Especially about the space to put things,
The flatness is required for the purpose and the design, but the deformation is large and the demand cannot be satisfied. The causes of deformation are the following two points. One is deformation at the molding stage. Such ceramic products are generally molded by plastic molding such as casting.
The strength of the substrate at the molding stage is low, and the substrate is sagged and deformed by its own weight. In particular, the larger the product, the easier it is to deform the flat portion. This deformation occurs until the strength of the dried substrate exceeds a certain level. The other is deformation at the firing stage. In the case of hard pottery bases and melt bases, they are baked until they exhibit sufficient mechanical strength.
The amount of shrinkage during firing is large, and deformation due to sag is large.
Therefore, the product is deformed after firing. In particular, the larger the product, the easier it is to deform the flat portion. As described above, the deformation in the molding step and the firing step cannot be suppressed, and a space for placing objects, a basin and a hand basin integrally formed with a flat portion that satisfies the purpose, a sink and a hair wash New ceramic products such as bowls and baby baths could not be made.

On the other hand, in order to suppress the deformation at the firing stage,
It is possible to reduce the so-called flux components such as monovalent metal oxides and divalent metal oxides in the substrate as much as possible, or to set the firing temperature low and so-called baking to be sweet. Since the whole becomes a porous body which is porous and insufficiently melted, there is a problem that the strength is reduced.

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned problems, and an object of the present invention is to suppress the deformation of a product in a molding step and a firing step, while maintaining the mechanical strength required for sanitary ware, To provide sanitary ware made of porcelain with excellent hygiene, durability, and design, which allows the product shape and dimensions after firing to be accurately designed and has a space for daily necessities. With the goal.

[0006]

According to the present invention, in order to solve the above-mentioned problems, a sink having a drainage function, and a flat portion having a hollow structure in the vicinity of the sink and / or a part of the sink are provided. A sanitary ware having a flat portion having a solid structure and a hollow structure, a ceramic body in which the sink and the flat portion are integrally formed, and a glaze layer formed on a necessary portion of the base. A step of molding the raw material, and a step of glazing a necessary portion as necessary.
It can be manufactured by a method including a step of firing at a temperature of １1300 ° C., the firing shrinkage in the longitudinal direction of the base in the firing step is 6% or less, and the amount of softening deformation of the base in the firing step Is 10 mm or less, and the bulk density (Db) of the base is 1.6 to 2.1 g / c.
m ³ and the bulk density and bending strength (Sb) of the green body
And Sb> 60 × Db-60 (MPa). By making the flat portion a flat portion made of a solid structure, or a flat portion made of a solid structure and a hollow structure, the flat portion made of a solid structure minimizes sagging and deformation of the entire flat portion at the molding stage. While holding down
Furthermore, since the flat part and the sink part having a drainage function are integrally formed, a structure that is hardly contaminated and easy to clean is obtained.
If the firing shrinkage rate, softening deformation amount, bulk density, and the relationship between the bulk density and the bending strength of the base material satisfy the above-mentioned values, the firing shrinkage and deformation of the base portion are suppressed as much as possible, while the basin, the hand washing machine, the sink and the hair washing are performed. The product shape and dimensions after firing can be accurately designed while maintaining the mechanical strength required for a bowl and a baby bath. By doing so, at the practical level as sanitary ware, while suppressing the deformation of the product at the molding stage and firing stage,
Sanitary, durable, and design that can accurately design the shape and dimensions of the product after firing while maintaining the mechanical strength required for sanitary ware, and has a space for placing daily necessities etc. It is possible to provide a ceramic product having excellent properties.

In the present invention, the sink having a drainage function and the flat part having a hollow structure or a flat part having a solid structure and a hollow structure in the vicinity of the sink part and / or a part of the sink part are provided. A sanitary ware having a ceramic body and the glaze layer formed on a required portion of the body, wherein the sink portion and the plane portion are integrally formed, wherein the body is made of mullite and quartz. A crystal phase as a main component and S
It is a base material containing a glass phase containing iO ₂ and Al ₂ O ₃ as main components and a crystal phase composed of minerals selected from cristobalite, andalusite, sillimanite, kyanite, and corundum as required. Component is Si
O ₂ 50 to 65 wt%, Al ₂ O _{3 30 to} 45 wt%, 1
0.1 to 2 wt% of divalent metal oxide 0.1
-10 wt%, and as the divalent metal oxide component,
At least a CaO component is contained, and the Ca
Provided is a sanitary ware characterized by scattered CaO component segregated portions where O components are segregated. By making the plane part a plane part consisting of a solid structure, or a plane part consisting of a solid structure and a hollow structure, the plane part consisting of a solid structure,
Since the flat portion and the sink having a drainage function are integrally formed while minimizing the sagging and deformation of the entire flat portion at the molding stage, the structure is hardly soiled and easy to clean. CaO components segregated in the base material are scattered, so that the required mechanical strength is maintained, firing shrinkage becomes sufficiently small, and the product shape and dimensions after firing are accurately determined. Can be designed. The function of the CaO component is considered as follows. That is, the CaO component segregated portion where the CaO component is segregated is scattered,
In that portion, shrinkage due to liquid phase sintering is suppressed, and firing shrinkage is suppressed. Furthermore, due to the presence of CaO component segregation parts having different mechanical properties such as Young's modulus from the liquid phase part,
Since the crack deflection effect occurs, the mechanical strength can take a sufficient value. By doing so, at the practical level as sanitary ware, while suppressing the deformation of the product during the molding and firing stages, maintaining the mechanical strength required for sanitary ware, the product shape and dimensions after firing are accurate. Thus, it is possible to provide a sanitary ware made of ceramics, which can be designed in a short time, has a space for putting daily necessities and the like, and is excellent in hygiene, durability and design.

In a preferred aspect of the present invention, the crystal phase is dispersed in the glass phase, and a composition ratio of the glass phase to the base is less than 60 wt%. By controlling the ratio of the glass phase to less than 60 wt%, large shrinkage due to liquid phase sintering can be suppressed, and the firing shrinkage can be suppressed to 6% or less.

In a preferred embodiment of the present invention, the above C
The relationship between the abundance ratio (weight ratio) of Ca and Na, K, and Mg in the aO component segregation section is Ca> Na, Ca> K, Ca> M.
Make sure that all of g are satisfied. By doing so, the component of the CaO component segregation part is greatly different from the glass phase component, so that the effect of the CaO component segregation part being scattered is emphasized.

[0010] In a preferred aspect of the present invention, the amount of the CaO component in the substrate is 1 wt% or more. By setting the amount of the CaO component to 1 wt% or more, an excellent relationship between bulk specific gravity and strength can be obtained. CaO
It is considered that when the amount of the component is large, the shrinkage of the glass phase accompanying the liquid phase sintering can be suppressed to a small value.

In a preferred embodiment of the present invention, the relationship between the CaO component and the other divalent metal oxide component in the base material is such that the content of the other divalent metal oxide is 50 parts by weight or less based on 100 parts by weight of CaO. To be there. By doing so, an excellent relationship between bulk specific gravity and strength is obtained. It is considered that when the CaO component is large, the shrinkage accompanying the liquid phase sintering in the glass phase can be suppressed to be small.

In a preferred embodiment of the present invention, the base contains 100 parts by weight of a monovalent metal oxide component.
The content of the divalent metal oxide component should be 100 parts by weight or more. By doing so, the shrinkage during firing is suppressed to a small extent, and the effect of scattering CaO component segregated portions can be maximized.

[0013] In a preferred aspect of the present invention, the amount of quartz in the substrate is not more than 20 wt%. By doing so, it is possible to suppress an excessive increase in the coefficient of thermal expansion of the base material, and to reduce the temperature during firing in the manufacture of a large-sized and complicated wash basin, hand wash basin, sink, shampoo basin and baby bath. Cracks hardly occur in the process.

In a preferred embodiment of the present invention, when the base contains corundum, the amount of corundum is 20 wt.
%. By doing so, since corundum has a high Young's modulus, it is possible to obtain a great strength-improving effect by uniformly dispersing it in the substrate. If the base contains corundum, the corundum amount is 2
It is good to be 0 wt% or less. Corundum has a higher specific gravity than other minerals and glass phase and contains more than 20 wt%,
This is because the specific gravity of the base material increases and a burden is imposed during construction and the like.

In the present invention, a sink having a drainage function and a flat portion having a hollow structure or a flat portion having a solid structure and a hollow structure in the vicinity of the sink portion and / or a part of the sink portion are provided. A sanitary ware having a ceramic body in which the sink portion and the plane portion are integrally formed and a glaze layer formed on a necessary portion of the base material, wherein a step of forming the base material is required. It can be produced by a method including a step of glazing a necessary portion according to the conditions, and a step of firing at a temperature of 1100 to 1300 ° C., wherein the base material is a clay mineral, quartz, a monovalent metal-containing material, and a divalent metal-containing material. A raw material, and the clay mineral is a mineral containing at least one selected from kaolinite, dickite, halloysite, sericite, and pyrophyllite. At least wollastonite or limestone or anorthite is contained, the amount of the quartz is 30 wt% or less based on the raw material, and the amount of the clay mineral is 30 to 90 wt% based on the raw material. The base material is provided with sanitary ware, the particle size of which is adjusted to have an average particle size of 3 to 10 μm based on a laser diffraction particle size analyzer. By making the flat portion a flat portion made of a solid structure, or a flat portion made of a solid structure and a hollow structure, the flat portion made of a solid structure minimizes sagging and deformation of the entire flat portion at the molding stage. In addition, since the flat portion and the sink having the drainage function are integrally formed, the structure is less likely to be soiled and is easier to clean. Ca
By using limestone or wollastonite or feldspar as a raw material used to introduce O, these materials may have a CaO component in solid solution with components such as MgO, Na ₂ O, and K ₂ O. Since no compound is formed, a portion where the CaO component is segregated in the fired body is easily formed and scattered. By doing so, at the practical level as sanitary ware, while suppressing the deformation of the product during the molding and firing stages, maintaining the mechanical strength required for sanitary ware, the product shape and dimensions after firing are accurate. Thus, it is possible to provide a sanitary ware made of ceramics, which can be designed in a short time, has a space for putting daily necessities and the like, and is excellent in hygiene, durability and design.

In the present invention, a sink having a drainage function and a flat portion having a hollow structure or a flat portion having a solid structure and a hollow structure in the vicinity of the sink portion and / or a part of the sink portion are provided. A sanitary ware having a ceramic body in which the sink portion and the plane portion are integrally formed and a glaze layer formed on a necessary portion of the base material, wherein a step of forming the base material is required. It can be produced by a method including a step of glazing a necessary portion according to the conditions, and a step of firing at a temperature of 1100 to 1300 ° C., and the base material is a clay mineral, quartz, a monovalent metal oxide-containing raw material, divalent It contains a metal oxide-containing raw material and a raw material having a small loss on ignition, and the clay mineral is a mineral containing at least one selected from kaolinite, dickite, halloysite, sericite, and pyrophyllite. The amount of quartz is 30 wt% or less based on the base material, the clay mineral is 30-90 wt% based on the base material, and the raw material having a small ignition loss is 5-50 wt% based on the base material. The raw material has an average particle diameter of 3 based on a laser diffraction particle sizer.
Provided is a sanitary ware characterized in that the particle size is adjusted to be 10 μm to 10 μm. By making the flat portion a flat portion made of a solid structure, or a flat portion made of a solid structure and a hollow structure, the flat portion made of a solid structure minimizes sagging and deformation of the entire flat portion at the molding stage. While holding down,
Since the flat part and the sink part having the drainage function are integrally formed, the structure is hard to be soiled and easy to clean. By containing a raw material having a small ignition loss, firing shrinkage based on the ignition loss is reduced. By doing so, at the practical level as sanitary ware, while suppressing the deformation of the product during the molding and firing stages, maintaining the mechanical strength required for sanitary ware, the product shape and dimensions after firing are accurate. Thus, it is possible to provide a sanitary ware made of ceramics, which can be designed in a short time, has a space for putting daily necessities and the like, and is excellent in hygiene, durability and design.

In a preferred embodiment of the present invention,
At least wollastonite or limestone or anorthite is contained as the valent metal-containing raw material. By the synergistic effect of the effect of using a small raw material of ignition loss and the effect of using limestone or wollastonite or anorthite as a base material used to introduce CaO,
In addition, excellent shrinkage due to firing can be obtained and excellent strength can be obtained.

In a preferred embodiment of the present invention, the raw material having a small loss on ignition is chamotte, and the main mineral of the chamotte is at least one mineral selected from mullite, cristobalite, quartz and corundum,
The amount of CaO in the chamotte is set to 1% by weight or more. By using a crystalline chamotte having an amount of CaO of 1 wt% or more, the mechanical strength is improved by the crack deflection effect, and the firing shrinkage can be reduced by reducing the ratio of the glass phase.

In a preferred embodiment of the present invention, the raw material having a small ignition loss is a hollow glass mainly composed of SiO ₂ and Al ₂ O ₃ . By doing so, the pores of the hollow glass remain as closed pores in the substrate, so that a substrate having a low bulk specific gravity is obtained for the strength.

In a preferred embodiment of the present invention, the raw material having a small ignition loss is at least one kind selected from shirasu balloons, expanded perlite, and expanded shale. By doing so, since the pores remain as closed pores in the substrate, a substrate having a low bulk specific gravity is obtained for the strength.

In a preferred aspect of the present invention, in the drying step of drying the formed base in the step of forming the base material, the flat part of the formed base has the same shape as the flat part. Allow to dry in contact with the receiver. By doing so, the flat part comes into contact with the drying tray and dries, so that the flat part in the drying stage is unlikely to set or deform, and there is a space on the flat part where household goods can be placed. The obtained sanitary ware is obtained.

In a preferred aspect of the present invention, the bulk density (Db) of the green body is 1.6 to 2.1 g / cm ³ , and the relationship between the bulk density of the green body and the bending strength (Sb) is Sb>
60 × Db−60 (MPa). By doing so, the balance between weight reduction and mechanical strength is maintained at a practical level as sanitary ware.

In a preferred aspect of the present invention, the glaze layer has a coefficient of thermal expansion of 0 to 30 × 10 ⁻⁷ more than that of the base material.
/ ° C Make the glaze smaller. By forming a glaze layer having a coefficient of thermal expansion of 0 to 30 × 10 ⁻⁷ / ° C. smaller than that of the base material on the base surface, fine cracks due to aging of the glaze surface are less likely to occur.

In a preferred embodiment of the present invention, the element
The coefficient of thermal expansion of the ground is 50-90 × 10 ^-7(/ ° C) (50 ~
600 ° C.). 90 × 10^-7Less than
This makes it possible to burn large and complex sanitary ware
Cracks are less likely to occur during the cooling process during formation. Also,
50 × 10^-7By doing the above, defects such as cracks
It is possible to ensure the freedom of design of the glaze layer under difficult conditions
it can.

In a preferred embodiment of the present invention, the element
The impact strength of the ground is 2 × 10^-1J / cm ^TwoAs above
I do. By doing so, the mechanical strength is at a practical level
To keep the daily life at a practical level.
Even if it is lowered, cracks, scratches, etc. are less likely to occur.

In a preferred embodiment of the present invention, the forming method is a slip casting method. By doing so, large and complex sanitary ware can be easily manufactured at low cost.

[0027] In a preferred aspect of the present invention, a part of and / or the entire periphery of the flat part formed of the hollow structure is formed with respect to the flat part formed of the hollow structure. The vertical and / or substantially vertical hollow structure has at least one standing plate. By doing so, the upright portion having the hollow structure serves as a reinforcing structure for preventing the flat portion from deforming or deforming at the molding stage.

In a preferred aspect of the present invention, a part of and / or the entire periphery of the plane part having the solid structure or the plane part having the solid structure and the hollow structure is perpendicular to the plane part. And / or at least one or more uprights having a substantially vertical solid structure and / or hollow structure. By doing so, the upright portion made of the solid structure and / or the hollow structure serves as a reinforcement structure for preventing the flat portion from being set or deformed in the forming stage and the firing stage.

[0029] In a preferred aspect of the present invention, the total area of the sanitary ware including the sink portion and the flat portion is 15%.
% Or more is the area of the plane portion. By doing so, it is possible to obtain a sanitary ware having a space where a daily necessity article can be sufficiently placed on the flat surface.

In a preferred aspect of the present invention, at least 10% of the total area of the flat portion is the area of the flat portion having the solid structure. By doing so, the flat portion made of the solid structure is hardly deformed or deformed at the stage of forming the nearby flat portion made of the hollow structure, and the mechanical strength of the flat portion is maintained at a practical level. As a result, it is possible to obtain a sanitary ware having a space on which a daily life article can be placed on a flat surface.

[0031]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS First, main terms in the present invention will be described. In the crystalline phase present invention, a particular mineral and crystalline phase refers to a portion having a regular diffraction pattern in X-ray diffraction.
The amount of the crystal phase was quantified by an internal standard method from a calibration curve using a standard substance of each crystal phase, and expressed as a weight ratio.

[0032] In the glass phase present invention, the glass phase refers to regular show no diffraction pattern portions other than the crystalline portion in the X-ray diffraction.

In the present invention, the ratio of the glass phase in the base is defined by the weight ratio of the glass phase to the whole base. In particular,
It is the amount excluding the amount of the crystal phase determined by X-ray diffraction.

Components of the base ceramic components include oxides and solid solutions of a plurality of metal species, such as a complex oxide crystal and a glass phase represented by mullite, and these are also determined by fluorescent X-ray analysis. It is defined in terms of weight ratio in terms of a quantified single component metal oxide.

As a result of elemental analysis by the CaO component segregation part EPMA,
A region having a high concentration is defined as a CaO component segregated portion. Ca
In the O component segregation part, based on the elemental analysis by EPMA,
It is more preferable that the Mg concentration, the Na concentration, and the K concentration are not significantly changed or are lower than those in the periphery in order to reduce firing shrinkage.

Dispersion of CaO component segregation part “ Dispersion ” refers to a state where regions are present not only in one place but in many places. In such a state, a crack deflection effect is effectively exerted.

The bulk density of the green body is measured by the Archimedes method. Width 2
After drying a test piece (baked body) having a thickness of 5 mm, a thickness of 5 mm and a length of 20 mm at 105 ° C. for 24 hours, the test piece is cooled to room temperature in an environment where the test piece does not absorb moisture, and the mass W1 is measured. Next, the test piece is kept in a vacuum for one hour to release bubbles. Further, under the same environment, the test piece is kept in water for 1 hour and then returned to room temperature. Next, the test piece is weighed while freely hanging in water with a thin thread, and the mass W2 is measured. Thereafter, this is taken out of the water, the water droplets on the surface are quickly wiped off with a squeezed compress, and the mass W3 is measured immediately. Bulk density is water density, W1, W2, W
It is obtained from the following equation from 3. Bulk density = water density × W1 / (W3-W2)

The bending strength of the green body is measured by a three-point bending method using a baked test piece of φ13 × 130 mm under the conditions of a span of 100 mm and a crosshead speed of 2.5 mm / min.

The unfired test piece having a width of 30, a thickness of 15 and a length of 260 mm was marked with a length of 150 mm, and the percentage of the change in length after firing divided by 150 mm was calculated as the percentage of the substrate. The firing shrinkage was used.

The amount of softening deformation of the green body The unfired test piece having a width of 30, a thickness of 15, and a length of 260 mm is fired while being supported by a span of 200 mm, and the amount of deflection at the center of the fired test piece and the thickness of the test piece are determined. Measure. Since the amount of deflection at this time is inversely proportional to the square of the thickness of the test piece, the amount of deflection converted when the thickness is 10 mm was defined as the amount of softening deformation of the substrate by the following equation. Softening deformation of the matrix = deflection amount measurement value × (thickness of test piece after baking) ^{2/10 2}

The coefficient of thermal expansion of the green body was measured using a calcined diameter of 5 mm,
Using a test piece having a length of 20 mm, the coefficient of linear thermal expansion was measured by a differential dilatometer using a compression load method or a measurement temperature range of 50 to 600 ° C.

The impact strength of the green body was measured with a Charpy tester using a fired test piece of φ13 × 130 mm.

The thermal shock resistance of the substrate was measured by holding a test piece having a width of 25 × thickness of 10 × length of 110 mm at a predetermined temperature for 1 hour or more, then throwing it into water and quenching it to determine whether cracks were generated. Checked and evaluated. It showed the maximum temperature difference where no cracks occurred.

Next, an example of a method of manufacturing the basin, the hand-washing device, the sink and the hair-washing device, and the baby bath of the present invention will be described. As the raw material starting material, a clay mineral and a Ca-containing material are essential components, and in addition, quartz, a monovalent metal-containing material, and a material having a small ignition loss may be added. The above-mentioned raw materials are mixed and, if necessary, ground with a ball mill or the like to obtain a raw material. The average particle size of the raw material based on a laser diffraction particle size analyzer is preferably adjusted to 3 to 10 μm. When the casting method is used in the subsequent forming step, the raw material is dispersed in water and used as a suspension. In the suspension, a dispersant, a preservative, a sizing agent, an antibacterial agent and the like may be added. Kaolinite, dickite, halloysite, sericite, and pyrophyllite can be suitably used as the clay mineral. Sericite, feldspar, and nepheline can be suitably used as the monovalent metal-containing raw material. Limestone and wollastonite can be suitably used as the Ca-containing raw material. As for the composition of each raw material, the clay mineral is preferably used in an amount of 30 to 90 parts by weight, and the Ca-containing raw material is preferably used in an amount of 1 to 15 parts by weight. The monovalent metal-containing raw material can be used in a range where the total amount of monovalent metal oxides does not exceed 2 wt% with respect to the whole substrate. When a quartz raw material is used, the content is preferably 30 parts by weight or less, and when a raw material having a small ignition loss is used, it is preferably used within a range of 5 to 50 parts by weight.

Manufacturing method The raw material is molded by a casting method or the like, and after demolding and drying, glaze is applied to necessary portions and fired. A plaster mold, a resin mold, or the like can be used for the casting mold, and any of pressure application, vacuum suction, mold suction, and head pressure can be used as the pressure application method. Drying can be performed, for example, at room temperature to about 110 ° C. In the drying step, when the flat part of the formed base is brought into contact with a drying tray having the same shape as the flat part and dried, the product having the integrated drain part and the flat part having the drainage function and the drying tray are Then, the front and / or back surface of the flat part of the product is brought into contact with the drying receiver. The angle of the product in which the drying tray and the flat portion contact each other can be any angle. However, the drying tray
In the product in the drying stage, it is preferable that the contact be made on the flat portion side where the flat portion is easily set or deformed. FIGS. 1 to 5 exemplify a preferred method of contacting the drying receiver according to the surface angle of the flat portion of the basin. For the glaze, a method such as a wet spray or a dry spray can be used. As the glaze, natural raw materials such as feldspar, quartz, limestone and the like, amorphous raw materials such as frit glaze and the like added with a pigment and an emulsifier can be used. As glaze,
It is preferable to use a raw material having a coefficient of thermal expansion of 0 to 30 × 10 ⁻⁷ / ° C. smaller than that of the base material. Firing is 1100-1300
It can be performed at a temperature of ° C. For firing, a continuous firing furnace,
Any of the batch furnaces can be used.

Structure of Planar Portion There are two types of structure of the flat portion, a flat portion having a solid structure and a flat portion having a hollow structure. The flat portion having a solid structure has advantages in that the flat portion having a hollow structure has higher mechanical strength and is less likely to be set or deformed in a molding stage. On the other hand, the flat part having the hollow structure has an advantage that the flat part having the hollow structure is less likely to be deformed in the firing step because of the presence of the upright part having the hollow structure. Therefore, it is preferable that the structure of the flat portion is a structure in which the flat portion having the solid structure and the flat portion having the hollow structure are combined. As a reinforcement structure to make it difficult for the flat part to be deformed or deformed at the molding stage,
It is preferable that at least one or more uprights having a solid structure and / or a hollow structure perpendicular and / or substantially perpendicular to the plane are provided around a part and / or the entire periphery of the plane. The term “substantially perpendicular” may be any angle as long as it has the effect of making the upright portion having a solid structure and / or a hollow structure less likely to be set or deformed in the flat portion in the forming step and the firing step. The position, number, and combination of the uprights made of a solid structure and / or a hollow structure are possible in any case, but the uprights made of a solid structure and / or a hollow structure are located on the back surface of the flat surface. Is preferred. FIGS. 6 to 10 illustrate a preferred planar structure in which one of the basins has an upright portion having a solid structure and / or a hollow structure.

[0047]

Embodiments of the present invention will be described below with reference to the accompanying drawings. FIG. 14 shows the chemical composition and the mineral content of the raw material of the base used in the examples. FIG. 15 shows the base composition and the base properties according to the present invention.

The total amount of monovalent metal oxides in the base composition is the total amount of monovalent metal oxides such as Na ₂ O and K ₂ O in the chemical composition of the base, and the total amount of divalent metal oxides is the M in chemical composition
Shows the total amount of divalent metal oxides such as gO and CaO.

FIG. 15 shows a wollast made of pottery stone, kaolin and clay as main raw materials, in which the amount of a sintered flux component such as a monovalent metal oxide is reduced so as to reduce the amount of shrinkage and softening deformation during firing. It is a base material of the present invention in which a CaO unevenly distributed portion is formed in the base material using knight, and the base material contains about 3.8 wt% of CaO.

The firing shrinkage, softening deformation during firing, and bending strength of the green body of the present invention were 2.8%, 5.5 mm, and 64.7.
Mpa, while keeping the firing shrinkage and deformation to the utmost, while sufficiently maintaining the mechanical strength required for sanitary ware.

FIG. 16 shows the chemical composition of the glaze used in the present invention. This glaze is called Bristol Glaze and is a glaze generally used for sanitary ware.

Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. FIG. 11 is an external perspective view showing an embodiment of a basin according to the present invention.

As shown in FIG. 11, the basin is equipped with a sink 7.
And a flat portion 8 and a wall plate portion 9 integrally formed with the sink portion 7 in the vicinity of the sink portion 7.

The wash basin was fabricated by molding using a gypsum mold by a slip casting method, followed by finishing, drying, glaze steps, and then firing. Glaze is Fig. 16
The materials shown in Table 1 were used. The thermal expansion coefficient of the glaze is 51 × 10
^-7 / ° C. These prototype washbasins were glazed on all areas that contact water or drainage to prevent the base from absorbing water. That is, the inside of the overflow 10 was also a glazed portion.

When the prototype wash basin was fired, no kiln sharks were generated. Kiln sharks are cuts caused by heat shock during which the product is cooled during the firing process. In addition, when the prototype wash basin was subjected to a rapid heat test,
No cutting occurred. The rapid heat test means that the basin is 80 ° C.
Is a test for confirming whether or not breakage due to thermal shock occurs when a temperature difference of? The temperature difference of 80 ° C. is performed by a method of pouring cold water of 10 ° C. into the sink 7 and keeping the basin at 13 ° C., and then immediately draining the hot water of 93 ° C. into the sink 7 after extracting the cold water. Was.

In general, a product having a more complicated structure is more likely to have a cut called kiln shark during firing, and a smaller thermal expansion coefficient of the base material is less likely to cause kiln shark. For this reason, it is necessary to consider setting the thermal expansion coefficient according to the shape of the product to be produced. The prototype wash basin has a coefficient of thermal expansion of 70
If it is not more than × 10 ⁻⁷ / ° C., a wash basin can be manufactured without generating kiln sharks. In order to lower the coefficient of thermal expansion, there are a method of lowering the quartz content in the base material and a method of increasing the firing shrinkage. In the present invention, a method of lowering the quartz content in the base material is particularly preferable. In the wash basin having the prototype shape, the quartz content is preferably 20% by weight or less.

The relationship between bulk density and strength is improved by adjusting the particle size of the raw material to a finer particle size. Also,
The effect of reducing the amount of softening deformation during firing is also obtained. In order to obtain a good basin, it is preferable to adjust the average particle size of the raw material to 10 μm or less.

If a raw material containing a large amount of Ca and having a small ignition loss is used, it is possible to manufacture a basin having a sufficiently small firing shrinkage and firing deformation and an excellent bulk density to strength.
In order to obtain a good basin, it is preferable to use a raw material containing a large amount of Ca and having a small loss on ignition.

The flat portion 8 includes a flat portion 3 having a solid structure, a flat portion 4 having a hollow structure, and an upright portion 5 having a hollow structure. The flat portion 3 having the solid structure has advantages that the mechanical strength is higher than the flat portion 4 having the hollow structure, and that the flat portion 3 is less likely to be set or deformed in the molding stage. On the other hand, the flat portion 4 having the hollow structure is different from the flat portion 3 having the solid structure in the upright portion 5 having the hollow structure.
Due to this, there is an advantage that deformation is less likely to occur in the firing step. Therefore, it is preferable that the structure of the flat part 8 is a structure in which the flat part 3 having a solid structure and the flat part 4 having a hollow structure are combined. Further, the flat portion 3 having the solid structure is less likely to be set or deformed in the molding stage of the portion 4 having the hollow structure in the vicinity thereof.
It is preferable to make the plane part 3 having a solid structure as large as possible at the center of the plane part 8. Further, a part of the flat portion 4 having the hollow structure of the flat portion 8 is provided with a standing plate portion 5 having a hollow structure substantially perpendicular to the flat portion 3 having the solid structure.
Are three, so that it becomes a reinforcement structure for making it difficult for the flat portion 4 having the hollow structure to be set or deformed at the firing stage. The larger the product and the larger the flat portion, the easier it is to deform during the forming and firing steps, so that a further reinforcing structure may be required. In this case, there should be at least one or more stand-up portions composed of a solid structure and / or a hollow structure that is perpendicular and / or almost perpendicular to the plane portion around a part and / or the entire periphery of the plane portion. Thus, reinforcement becomes possible.

Since the sink portion 7 and the flat portion 8 are integrally formed, the boundary between the sink portion 7 and the flat portion 8 is eliminated, so that the dirt does not accumulate at the seam and the sanitary property is improved, such as easy cleaning. A ceramic washbasin is obtained. In addition, since the flat portion 8 and the wall plate portion 9 are integrally formed, the boundary between the flat portion 8 and the wall plate portion 9 is eliminated, so that dirt does not accumulate at the seams and cleaning is facilitated, thereby improving hygiene. A ceramic basin is obtained. To obtain a good basin, the sink 7
It is preferable to take appropriate R dimensions at the boundary between the flat portion 8 and the boundary between the flat portion 8 and the wall plate portion 9.

In the drying step of the base on which the basin is formed, if the surface of the flat part 8 is dried immediately after demolding, the flat part 8 is liable to be set or deformed by its own weight. . In the prototype wash basin, immediately after removal from the mold, the flat portion 8 is brought into contact with the trial dry receiver 11 having the same shape as the flat portion 8, and the flat portion 8 and the trial dry receiver 11 are formed.
The surface of the flat portion 8 is fixed and dried at an angle such that the surface of the flat portion 8 is obliquely downward while contacting, and after the strength of the base material has reached a certain level or more, the basin is set up at an angle where the surface of the flat portion 8 is vertical. After fixing, the trial-made drying tray 11 was removed, and the basin was completely dried. By doing so, a basin having a space in which the flat portion 8 was not set or deformed in the drying stage and a space for daily necessities or the like could be placed was obtained.

The wash basin made as a trial was equipped with a sink portion 7 and a flat portion 8.
Approximately 45% of the total area of the basin including the wall plate portion 9 and the flat plate portion 8 was used as the area. The area where the daily necessities and the like can be sufficiently placed on the flat portion 8 depends on the area of the sink portion 7. However, when the size of the sink portion 7 is general, the sink portion 7 and the flat portion are used. It is preferable that 15% or more of the total area of the basin including the wall portion 8 and the wall plate portion 9 is the area of the flat portion 8.

The basin made as a prototype has a flat part 8 composed of a flat part 3 having a solid structure and a flat part 4 having a hollow structure. Approximately 40% of the total area. The flat portion 3 having a solid structure is less likely to be set or deformed at the stage of forming the flat portion 4 having a hollow structure, and the mechanical strength of the flat portion 8 is maintained at a practical level. In order to provide a space in which articles and the like can be placed, it is preferable that the area of the flat portion 3 having the solid structure is 10% or more of the total area of the flat portion 8.

[0064]

According to the present invention, it is an object of the present invention to suppress the deformation of the product in the molding stage and the firing stage, maintain the mechanical strength required for sanitary ware, and adjust the shape and dimensions of the product after firing. It is possible to provide a sanitary ware made of porcelain, which can be accurately designed and has a space for placing daily necessities and the like, and is excellent in hygiene, durability, and design.

[Brief description of the drawings]

FIG. 1 is a schematic view of a method of contacting a drying receiver when the surface of a flat portion is set upright.

FIG. 2 is a schematic view of a method of contacting a drying tray when the surface of the flat portion is obliquely downward.

FIG. 3 is a schematic diagram of a method of contacting a drying receiver when the surface of the flat portion is obliquely upward.

FIG. 4 is a schematic view of a method of contacting a drying receiver when the surface of the flat portion is directed downward.

FIG. 5 is a schematic diagram of a method of contacting a drying receiver when the surface of the flat portion is directed upward.

FIG. 6 is a schematic view of a planar structure having two upright portions having a hollow structure in the planar portion.

FIG. 7 is a schematic diagram of a planar structure having six uprights having a hollow structure in the planar portion.

FIG. 8 is a schematic view of a planar structure having a single upright portion having a solid structure in the planar portion.

FIG. 9 is a schematic view of a planar structure having two upright portions having a solid structure in the planar portion.

FIG. 10 is a schematic diagram of a planar structure in which two planar uprights having a hollow structure and two uprights having a solid structure are provided on a planar portion.

FIG. 11 is an external perspective view of a wash basin experimentally manufactured in the embodiment.

FIG. 12 is a schematic cross-sectional view of a wash basin experimentally manufactured in the embodiment.

FIG. 13 is an external perspective view of a prototype of the drying receiver manufactured in the embodiment.

FIG. 14 shows the chemical composition and the mineral content of the raw material of the base used in the examples.

FIG. 15 shows a base composition and a base property according to the present invention.

FIG. 16: Chemical composition of the glaze used.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 ... Basin 2 ... Drying receiver 3 ... Plane part which has a solid structure 4 ... Plane part which has a hollow structure 5 ... Stand part part which has a hollow structure 6 ... Stand part part which has a solid structure 7 ... Sink part 8 ... Plane part 9 ... Wall plate part 10 ... Overflow 11 ... Prototype drying tray

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) C04B 33/24 C04B 33/24 Z 33/28 33/28 (72) Inventor Naoki Koga Kokura, Kitakyushu, Fukuoka Prefecture 2-1-1 Nakajima, Kita-ku Toto Kiki Co., Ltd.

Claims (26)

[Claims] 1. A sink having a drainage function, and a flat part having a hollow structure or a flat part having a solid structure and a hollow structure in the vicinity of the sink part and / or a part of the sink part, A sanitary ware in which a glaze layer is formed on a required portion of the ceramic body and the base body in which the sink portion and the plane portion are integrally formed, and a step of forming the base material, if necessary. It can be manufactured by a method including a step of glazing a necessary portion and a step of firing at a temperature of 1100 to 1300 ° C., wherein the firing shrinkage in the longitudinal direction of the base in the firing step is 6% or less. The amount of softening deformation of the substrate in the step of performing is 10 mm or less, and the bulk density (Db) of the substrate
Is 1.6 to 2.1 g / cm ³ , and the relationship between the bulk density and the bending strength (Sb) of the substrate is Sb> 60 × Db −
A sanitary ware characterized by being 60 (MPa). 2. A sink having a drainage function, and a flat portion having a hollow structure or a flat portion having a solid structure and a hollow structure in the vicinity of the sink portion and / or a part of the sink portion, It is a sanitary ware in which a glaze layer is formed on a required portion of the ceramic body and the base body in which the sink portion and the flat surface portion are integrally formed, and the base material includes mullite and quartz as main components. A base material including a crystal phase, a glass phase containing SiO ₂ and Al ₂ O ₃ as main components, and a crystal phase composed of a mineral selected from cristobalite, andalusite, sillimanite, kyanite, and corundum, if necessary. major component of the green body SiO ₂ 50~65wt%, Al ₂ O
₃ 30-45 wt%, monovalent metal oxide 0.1-2 wt
%, A divalent metal oxide is 0.1 to 10 wt%, and at least a CaO component is contained as the divalent metal oxide component, and CaO component segregated portions in which the CaO component is segregated in the base material are scattered. Sanitary ware characterized by doing. 3. The sanitary ware according to claim 2, wherein the crystal phase is dispersed in the glass phase, and a composition ratio of the glass phase to the base is less than 60 wt%. 4. Ca and N in said CaO component segregation part
The relation of the abundance ratio (weight ratio) of a, K, and Mg is Ca> N.
The sanitary ware according to claim 2 or 3, wherein a, Ca> K, and Ca> Mg are all satisfied. 5. The sanitary ware according to claim 2, wherein the amount of the CaO component in the substrate is 1 wt% or more. 6. The relationship between the CaO component in the substrate and the other divalent metal oxide component is such that the other divalent metal oxide is 50 parts by weight or less based on 100 parts by weight of CaO. The sanitary ware according to claim 2. 7. The monovalent metal oxide component 1
The sanitary ware according to any one of claims 2 to 6, wherein the divalent metal oxide component is present in an amount of 100 parts by weight or more based on 00 parts by weight. 8. The wash basin, the hand wash, the sink and the shampoo, and the baby bath according to claim 2, wherein the amount of quartz in the substrate is 20 wt% or less. 9. The sanitary ware according to claim 2, wherein when the base contains corundum, the amount of corundum is 20 wt% or less. 10. A sink having a drainage function, and a flat part having a hollow structure or a flat part having a solid structure and a hollow structure in the vicinity of the sink part and / or a part of the sink part, A sanitary ware in which the sink portion and the flat surface portion are integrally formed, and a glaze layer is formed on a necessary portion of the base material, wherein a step of forming a base material and, if necessary, It can be produced by a method including a step of glazing on various parts and a step of firing at a temperature of 1100 to 1300 ° C., wherein the base material contains a clay mineral, quartz, a monovalent metal-containing material, and a divalent metal-containing material. The clay mineral is a mineral containing at least one selected from kaolinite, dickite, halloysite, sericite, and pyrophyllite. As the divalent metal-containing raw material, at least warast And Ito, or limestone or anorthite is contained, the amount of the quartz is less than 30 wt% relative to the matrix material, the amount of the clay mineral 30~90w relative to the matrix material
The sanitary ware, wherein the base material is adjusted in particle size such that the average particle size based on a laser diffraction particle size analyzer is 3 to 10 μm. 11. A sink having a drainage function, and a flat part having a hollow structure or a flat part having a solid structure and a hollow structure in the vicinity of the sink part and / or part of the sink part, A sanitary ware in which a glaze layer is formed on a required portion of the ceramic body and the base body in which the sink portion and the plane portion are integrally formed, and a step of forming the base material, if necessary. It can be produced by a method including a step of glazing a necessary portion and a step of firing at a temperature of 1100 to 1300 ° C., wherein the base material is a clay mineral, quartz, a monovalent metal oxide-containing raw material, and a divalent metal oxide. The raw material contains a raw material having a small loss on ignition, and the clay mineral is a mineral containing at least one selected from kaolinite, dickite, halloysite, sericite, and pyrophyllite, and the quartz. The amount is not more than 30 wt% relative to the matrix material, wherein the clay mineral is 30 to 90 wt% relative to the matrix material, a small feed of the loss on ignition to matrix material 5~50w
The sanitary ware, wherein the base material is adjusted in particle size such that the average particle size based on a laser diffraction particle size analyzer is 3 to 10 μm. 12. The sanitary ware according to claim 11, wherein the bivalent metal-containing raw material contains at least wollastonite, limestone, or feldspar. 13. The raw material having a small ignition loss is chamotte, and the main mineral of the chamotte is at least one mineral selected from mullite, cristobalite, quartz and corundum, and the amount of CaO in the chamotte is The sanitary ware according to claim 11, wherein the amount is 1 wt% or more. 14. The raw material having a small ignition loss is SiO 2
_2. The sanitary ware according to claim 11, wherein the sanitary ware is hollow glass containing Al ₂ O ₃ as a main component. 15. The sanitary ware according to claim 11, wherein the raw material having a small ignition loss is at least one selected from shirasu balloon, expanded perlite, and expanded shale. 16. In the drying step of drying the formed base in the step of forming the base material, the flat part of the formed base is brought into contact with a drying tray having the same shape as the flat part for drying. The sanitary ware according to any one of claims 10 to 15, wherein the sanitary ware is used. 17. The bulk density (Db) of the green body is 1.6.
２．１2.1 g / cm ³ , and the relationship between the bulk density of the substrate and the bending strength (Sb) is Sb> 60 × Db-60 (MPa).
The sanitary ware according to claim 2, wherein: 18. The sanitary ware according to claim 1, wherein the glaze layer is a glaze having a coefficient of thermal expansion smaller by 0 to 30 × 10 ⁻⁷ / ° C. than the base material. 19. The thermal expansion coefficient of the substrate is 50 to 90 ×
The sanitary ware according to any one of claims 1 to 18, wherein the temperature is 10 ^-7 (/ ° C) (50 to 600 ° C). 20. The impact strength of the substrate is 2 × 10 ⁻¹ J /
The sanitary ware according to any one of claims 1 to 19, wherein the sanitary ware is not less than cm ² . 21. The method according to claim 10, wherein the forming method in the forming step is a slurry casting method.
20. The sanitary ware according to 20. 22. A part of and / or the entire periphery of the flat part composed of the hollow structure and the plane part composed of the solid structure and the hollow part are perpendicular to and / or perpendicular to the plane part composed of the solid structure.
22. The sanitary ware according to claim 1, wherein there is at least one standing plate portion having a substantially vertical hollow structure. 23. A part perpendicular to and / or substantially perpendicular to the flat part around the flat part made of the solid structure or a part and / or the whole of the flat part made of the solid structure and the hollow structure. 2. The device according to claim 1, wherein there is at least one standing plate portion having a solid structure and / or a hollow structure.
The sanitary ware according to any one of to 22. 24. The sanitary ware according to claim 1, wherein at least 15% of the total area of the sanitary ware including the sink portion and the flat portion is the area of the flat portion. 25. At least 10% of the total area of the plane portion is:
The sanitary ware according to any one of claims 1 to 24, wherein the sanitary ware has an area of a plane portion having the solid structure. 26. The sanitary ware according to claim 1, wherein the sanitary ware is any of a wash basin, a hand wash, a sink, a hair washer, and a baby bath.