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GB2134384A - A method of manufacturing sanitary ware - Google Patents
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GB2134384A - A method of manufacturing sanitary ware - Google Patents

A method of manufacturing sanitary ware Download PDF

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Publication number
GB2134384A
GB2134384A GB08302945A GB8302945A GB2134384A GB 2134384 A GB2134384 A GB 2134384A GB 08302945 A GB08302945 A GB 08302945A GB 8302945 A GB8302945 A GB 8302945A GB 2134384 A GB2134384 A GB 2134384A
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GB
United Kingdom
Prior art keywords
fiberglass
ceramic body
applying
mold
parts
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Withdrawn
Application number
GB08302945A
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GB8302945D0 (en
Inventor
Adriano S Alfonso
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Individual
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Individual
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Publication date
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Priority to GB08302945A priority Critical patent/GB2134384A/en
Publication of GB8302945D0 publication Critical patent/GB8302945D0/en
Publication of GB2134384A publication Critical patent/GB2134384A/en
Withdrawn legal-status Critical Current

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Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B28WORKING CEMENT, CLAY, OR STONE
    • B28BSHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B11/00Apparatus or processes for treating or working the shaped or preshaped articles
    • B28B11/04Apparatus or processes for treating or working the shaped or preshaped articles for coating or applying engobing layers

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  • Engineering & Computer Science (AREA)
  • Structural Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Laminated Bodies (AREA)

Abstract

This invention relates to a method of manufacturing sanitary ware and to sanitary ware manufactured by the method. The method comprises preparing a ceramic body, applying a glaze to the surfaces of the ceramic body which will be exposed in use, forming the partly glazed ceramic body, applying fiberglass to the unglazed surfaces of the body for reinforcement purposes, preparing the parts to which the ceramic body is to be connected from a plastics material reinforced with fiberglass, assembling the fiberglass reinforced plastics parts and the ceramic body and chemically welding them together.

Description

SPECIFICATION A method of manufacturing sanitary ware This invention relates to a method of manufacturing sanitary ware.
Conventional sanitary ware commonly known as vitreous ceramic sanitary ware is cast in plaster of paris molds, glazed and fired at high temperature to produce a glossy vitrified surface with a hardness of fifty five (55) barcel. Such sanitary ware is heavy and brittle, factors which contribute to the enormous cost of handling, packaging and transporting such products. Also, the conventional process of manufacturing sanitary ware makes technical control on hidden and unaccessible surfaces difficult particular ly when working on products with intricate configur ations such as water-closets; subsequently, wastage and rejects increase. The manufacture of sanitary ware entirely made of vitreous enamelled ceramics requires a big investment, consequently it becomes a captive business of a few enterpreneurs.Collectively, these factors increase the cost of production resulting in sanitary ware that is expensive.
It is an object of this invention to provide a method of manufacturing sanitary ware which overcomes or at least mitigates the above-mentioned disadvantages.
In one aspect, the present invention provides a method of manufacturing sanitary ware, comprising forming a ceramic body of the required shape for an article of sanitary ware, applying a glaze to the surfaces of the article which will be exposed during use of the article and applying fiberglass to the unglazed surfaces for reinforcement. Generally, the method further includes preparing parts to which the ceramic body is to be connected from plastics material reinforced with fiberglass, assembling the fiberglass reinforced plastics parts with the ceramic body and chemically welding the parts and the body together.
In a second aspect, the present invention provides a method of manufacturing sanitary ware, the method comprising the steps of: mixing weighed raw materials with water to form a slip; allowing the slip to age for at least a week; pouring the aged slip into a plaster mold having the required shape for an article of sanitary ware; allowing a build up wall around an inside surface of the mold to thicken to approximately 4.5 mm; removing the remaining slip from the mold; allowing the slip to dry to facilitate shrinking of the clay forming a bisque, the drying process being continued until the bisque has loosened completely from the inside surface of the mold; removing the bisque from the mold; drying the bisque further in a kiln to produce the ceramic body; glazing the surfaces of the ceramic body which will be exposed during use to a glaze thickness of approximately 0.3 mm; firing the partly glazed ceramic body at a temperature of about 1300"C in a kiln and allowing the fired ceramic body to cool; sanding the unglazed surfaces of the ceramic body, applying a first layer of fiberglass and then a second layer of fiberglass of twice the thickness of the first layer to the unglazed surfaces and using the hand lay-up method to impregnate the surface with resin after each application of fiberg lass.In a preferred embodiment, the method further comprises the steps of polishing a respective mold for each part to which the ceramic body is to be connected to a gloss finish with a soft cloth using a polishing compound; applying a separating film wax to each polished mold to ease removal of a molded part; applying two layers of a crystal-like resin to each mold followed by the three layers of true gel coat to serve as a protective coating of the finished part; applying a layer of fiberglass to the outer layer of the gel coat and impregnating the layer with resin by the hand lay-up method to produce a bubble free fiberglass reinforced plastics laminate; and assemb ling and chemically welding together the manufactured fiberglass reinforced plastics parts and the ceramic body.
For a better understanding of the present invention and to show how the same may be put into effect, an examplary embodiment thereof will now be described.
In general, the method of manufacturing sanitary ware like a water-closet comprises the steps of preparing the ceramic body, applying glaze to the functional surfaces, that is the surfaces which are exposed during use, of the ceramic body, firing the partly glazed ceramic body, reinforcing the unglazed parts of the ceramic body with fiberglass, preparing the other parts of the sanitary ware from fiberglass and plastic, assembling all the fiberglass reinforced plastic parts with the ceramic body, and chemically welding all the parts together.
The preparation of the ceramic body is done through the use of the slip casting method. Slip casting requires a fluid suspension of clay and other materials which will flow readily but will not settle in the molds. The ceramic body is prepared by weighing proportionally the raw materials as follows: ball clay 14 parts, China clay 11 parts, flint 4 parts, stone 5 parts and feldspar 4 parts. These raw materials are mixed with water preferably using a ball mill to form a slip. The slip is then allowed to age for at least a week before pouring it into plaster molds of the desired shape. Plaster of pairs molds are shaped using the outer surfaces of the sanitary wares such as sinks, urinals, bath tubs and toilet bowls as the design patterns. When the slip is poured into the plaster mold, water is adsorbed out of the slip and builds up a thickened wall around the inside surface of the mold.When the wall thickness reaches approximately 4.5 mm the remaining slip is removed from the mold. As the mold dries, the clay forms a bisque and shrinks until it has loosened completely from the inside surface of the mold. Then the bisque in clay form is removed and further dried preferably in a bisque kiln.
The raw material formulation for the ceramic body varies depending upon the cost and chemical composition of the locally available raw materials. The raw material formulation must be prepared with the view of producing bisques that are relatively porous and soft in order to facilitate the impregnation thereof with resin and to facilitate the sanding process.
After the preparation of the ceramic body, a glaze is applied. The glaze is sprayed on the functional surfaces of the body to a glaze thickness of approximately 0.3 mm. The glaze is prepared using the following proportions: feldspar 20 parts, flint glass 14 parts, white lead 14 parts, stone 3 parts, oxide of zinc 3 parts, whiting 11/2 parts and plaster 1 part.
These raw materials are ground together in a ball mill with the correct amount of water until the required particle size is attained.
Some of the raw materials for the glaze contain soluble and volatile substances hence,fritting is necessary. Fritting is the process of subjecting materials to intense heat until they melt to form a glass in orderto remove the soluble and volatile components of the materials before use.
Also, it should be noted that the formulation for glaze varies depending on the cost and composition of locally available materials. The glaze that should be prepared should be hard, chemically resistant and have a very low water permeability.
The partly glazed body is then fired at a high temperature of approximately 1300 C in a kiln, preferably a gloss kiln, and then allowed to cool. The unglazed back surface of the ceramic body is sanded to make it rough for better adherence with a fiberglass impregnated resin. With a relatively porous body, the penetration of the resin will extend up to the inner surface of the glaze layer. Athree quarter (3/4) of an ounce (21g) layer and a one and one half (1/2) ounce (42g) layer of fiberglass mat are applied to the sanded unglazed surface of the body, impregnating the fiberglass with resin by the hand lay-up method after each application. This will lead to the resilient and practically unbreakable characteristic of the sanitary wares.
The resin used is a mixture ofthirty percent (30%) styrene monomer and seventy percent (70%) general purpose unsaturated polyester resin by weight.
Then 0.02% cobalt napthenate (6% concentration), or a substitute, is added to the mixture which is then stirred to accelerate hardening. To initiate the chemical reaction, 0.02% catalyst is added to the mixture. The catalyst is fifty percent (50%) of methyl ethyl ketone and fifty percent (50%) hydrogen peroxide (50% concentration).
In manufacturing the other parts of the sanitary ware, individual molds having the configuration of the pattern are prepared. The molds could be made either of fiberglass reinforced plastic or chrome plated metal. The molds are polished to gloss finish with soft cloth using Johnson polishing compoung.
Johnson lubricant wax No. 111 or carnauba wax is further applied to ease the removal of the molded parts. The wax is applied three times allowing the film to dry after every application before polishing the surface with soft cloth.
Two layers of crystal-like resin are then sprayed onto the molds followed by three layers of a true colour gel coat. The crystal-like resin serves as protective coating on the surface of the finished product. Afterwards three quarters (3/4) of an ounce (21g) of fiberglass mat is evenly placed onto the gel coat and impregnated with resin by the hand lay-up method to produce a bubble free fiberglass reinforced plastic laminate. Several layers of three fourth (1/4) (219) and one and one half (11/2) ounce (429) of fiberglass are applied until the thickness approximates one eighth (1/8) of an inch (3 mm). After one hour, the fiberglass reinforced plastic parts are removed from the molds and then trimmed.
After manufacturing the ceramic body and the various parts of the sanitary ware, they are assembled and chemically welded. The base gel coat is used in welding all the joints in order to conceal all connections and to provide a uniform colour and shade for aesthetic beauty. Since the sanitary wares are manufactured by parts, it is possible to produce wares in two or multi-tone colour two add to its beauty. The finished product is then polished and tested. The sanitary ware is allowed to cure to two weeks while in storage, then packed, weighed and labelled for shipment. The curing time can be accelerated by subjecting the product to annealing at 120"F (50 C) for one hour.
It is also possible to produce sinks, urinals, bath tubs and toilet bowls solely utilizing the fiberglass reinforced ceramic as the material and using separate molds, each part can be manufactured using the aforementioned procedure. Ideally, for very light sanitary wares, only the functional outer exposed surfaces shall be made of fiberglass reinforced ceramic, the rest shall be made of fiberglass reinforced plastic.
Thus, sanitary ware produced by a method in accordance with the invention is aesthetically beautiful, chemically resistant, light weight, practically unbreakable, durable and cheap.
Moreover, the sanitary ware has an almost monolithic structure with the brittleness of the ceramic compensated for by the elasticity of fiberglass resulting in sanitary ware that can absorb to some extent any impact caused by accidental dropping and rough usage. Also, the sanitary ware is light and hence can be packed in corrugated carton boxes and freighted even by air. Advantageously, a method in accordance with the invention facilitates technical control during the manufacturing process thus minimizing rejects resulting in a considerable reduction in the manufacturing cost.

Claims (13)

1. A method of manufacturing sanitary ware, comprising forming a ceramic body of the required shape for an article of sanitary ware, applying a glaze to the surfaces of the article which will be exposed during use of the article and applying fiberglass to the unglazed surfaces for reinforcement.
2. A method according to claim 1, wherein the step of applying fiberglass to the ungiazed surfaces comprises applying a first layer of fiberglass and then a second layer of fiberglass to the unglazed surfaces using the hand lay-up method and impregnating the unglazed surfaces with resin after each application of fiberglass.
3. A method according to claim 1 or 2, further comprising sanding the unglazed surfaces before applying the fiberglass.
4. A method according to claim 1,2 or 3, further including preparing parts to which the ceramic body is to be connected from plastics material reinforced with fiberglass, assembling the fiberglass reinforced plastics parts with the ceramic body and chemically welding the parts of the body together.
5. A method according to claim 4, wherein the step of preparing the parts to which the article is to be connected comprises: polishing a respective mold for each part and applying a layer of wax to each mold surface: applying one or more layers of a plastics material to each mold followed by one or more layers of a protective coating and applying a layer of fiberglass to each outer layer of gel coat to produce a respective fiberglass reinforced plastics laminate.
6. A method according to claim 5, wherein each layer of fiberglass is applied to the respective outer layer of gel coat is impregnated with resin by the hand lay-up method.
7. A method according to claim 5 or 6, wherein two layers of plastics material in the form of a crystal-like resin are applied to each mold followed by three layers of a protective true gel coat.
8. A method of manufacturing sanitary ware, the method comprising the steps of: mixing weighed raw materials with water to form a slip; allowing the slip to age for at least a week; pouring the aged slip into a plaster mold having the required shape for an article of sanitary ware; allowing a build up wall around an inside surface of the mold to thicken to approximately 4.5 mm; removing the remaining slip from the mold; allowing the slip to dry to facilitate shrinking of the clay forming a bisque, the drying process being continued until the bisque has loosened completely from the inside surface of the mold; removing the bisque from the mold; drying the bisque further in a kiln to produce the ceramic body; glazing the surfaces of the ceramic body which will be exposed during use to a glaze thickness of approximately 0.3 mm; firing the partly glazed ceramic body at a temperature of about 1300"C in a kiln and allowing the fired ceramic body to cool; sanding the unglazed surfaces of the ceramic body, applying a first layer of fiberglass and then a second layer of fiberglass of twice the thickness of the first layer to the unglazed surfaces and using the hand lay-up method to impregnate the surface with resin after each application of fiberglass.
9. A method according to claim 8, further including the steps of polishing a respective mold for each part to which the ceramic body is to be connected to a gloss finish with a soft cloth using a polishing compound; applying a separating film wax to each polished mold to ease removal of a molded part; applying two layers of a crystal-like resin to each mold followed by the three layers of true gel coat to serve as a protective coating of the finished part; applying a layer of fiberglass to the outer layer of gel coat and impregnating the layer with resin by the hand lay-up method to produce a bubble free fiberglass reinforced plastics laminate; and assemb ling and chemically welding together the manufacture fiberglass reinforced plastics parts and the ceramic body.
10. A method according to claim 8 or 9, wherein the ceramic body is prepared using 14 parts ball clay, 4 parts China clay, 4 parts flint, 5 parts stone and 4 parts feldspar.
11. A method of manufacturing sanitary ware substantially as hereinbefore described.
12. Sanitary ware whenever produced in accordance with the method of any one of the preceding claims.
13. Any novel feature or combination of features described herein.
GB08302945A 1983-02-03 1983-02-03 A method of manufacturing sanitary ware Withdrawn GB2134384A (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
GB08302945A GB2134384A (en) 1983-02-03 1983-02-03 A method of manufacturing sanitary ware

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
GB08302945A GB2134384A (en) 1983-02-03 1983-02-03 A method of manufacturing sanitary ware

Publications (2)

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GB8302945D0 GB8302945D0 (en) 1983-03-09
GB2134384A true GB2134384A (en) 1984-08-15

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GB08302945A Withdrawn GB2134384A (en) 1983-02-03 1983-02-03 A method of manufacturing sanitary ware

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Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN117303933B (en) * 2023-11-29 2024-02-06 佛山东鹏洁具股份有限公司 Notch repairing process for ceramic glaze

Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1541444A (en) * 1975-10-20 1979-02-28 Hodgetts A C Encased and/or decorated sanitary units
US4209862A (en) * 1978-05-11 1980-07-01 Cortes Garza Rodrigo Bathroom fixtures and process of manufacture

Patent Citations (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1541444A (en) * 1975-10-20 1979-02-28 Hodgetts A C Encased and/or decorated sanitary units
US4209862A (en) * 1978-05-11 1980-07-01 Cortes Garza Rodrigo Bathroom fixtures and process of manufacture

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Publication number Publication date
GB8302945D0 (en) 1983-03-09

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