JPS6344707B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for adhering green substrates for sanitary ware (toilet bowls), and more particularly to an in-mold bonding method for green substrates in which the green substrate is bonded while being held in a mold.

Generally, when manufacturing large ceramics such as sanitary ware,
Instead of integrally molding the entire pottery at once, we divided the sanitary ware into a body and a rim, and then glued the separately molded bodies and rims together using slurry to integrate them. We are hiring.

Conventionally, this bonding work was done manually. That is, the body material and the rim material are molded by casting slurry into a mold, the removed body material and the rim material are placed in a position where they can be easily bonded to each other, and the rim is formed. Let only the rim material harden to the extent that it can be lifted by hand, apply slurry to the surface of the body material to be bonded, and with two people lift the rim material and rotate it 180 degrees in the air to attach the body material. Place the rim raw material on top of the body raw material along the raw material, and after confirming that the rim raw material and the body raw material are completely overlapped, press the adhesive surface from above and below with your hands. I was going there because of this.

Generally, when bonding a torso material and a rim material that have been molded by pouring slurry into a mold, in order to improve their adhesion, it is necessary to ensure that both are still soft, that is, to remove the mold. It is best to bond the two immediately afterwards. Also, if you leave the raw material alone,
It shrinks rapidly and stops when the moisture content reaches 17-18%. However, the moisture content of the green material immediately after demolding is 24 to 25.
%, it easily deforms plastically, deforms when lifted by hand or given a shock, and cracks occur after drying.

When bonding a torso material with such properties and a rim material, the conventional manual bonding method requires that the moisture content of the rim material reach a level (approximately 21%) that can be lifted by hand. On the other hand, in order to improve adhesion, it was necessary to cover the body material with a cloth or the like to prevent the moisture content from decreasing and keep it in a soft state. As a result, there is a difference in shrinkage between the body and the rim, making it impossible to match the body and rim completely, and if you try to force them to match, the material may deform or crack. did.

Furthermore, the body material and the rim material are susceptible to deformation even during demolding. In addition, it is difficult to control the temperature and humidity in the molding room, and after demolding, the green material has a moisture content that can be lifted by hand (approximately 21
%) and tend to become hard.
For this reason, the adhesive surface cannot always maintain the same shape, resulting in unreasonable adhesion. Also, although the raw rim material has hardened to the extent that it can be lifted by hand, it is still in a fragile state, and since the gluing work cannot be done by one person but requires two people, it is difficult to rotate it 180 degrees. It was difficult and required skill to match the timing of the two people and the timing to match the joint surface of the rim material to the joint surface of the body material, which was inefficient and caused variations, resulting in deformation and cracks. .

Additionally, since the rim part is pressed by hand while supporting the body part during adhesion, it is not possible to apply pressure evenly to the entire joint surface, resulting in deformation or incomplete adhesion. There were some shortcomings.

SUMMARY OF THE INVENTION It is therefore an object of the present invention to provide a method for gluing green substrates, which allows the bonding of green substrates to be carried out mechanically and which eliminates the above-mentioned disadvantages.

The first feature of the method of the present invention is that the adhesive work is performed while the green substrate is held in the mold,
In this way, since the pressing of the adhesive surface is performed with the mold, the pressing force can be applied uniformly over a wide range to the adhesive surface, and therefore reliable adhesion can be achieved without deforming the green substrate.

The second feature of the method of the present invention is that the mold matching portions (female and male shaped so-called "dowels") of the mold pieces provided in the respective molds for the body and rim are
By using it for positioning the body and rim during bonding work, it is possible to accurately position the body and rim in a simple manner without deformation and always in the same shape.

Another feature of the method of the present invention is that because the body material and the rim material are held with molds rather than by hand, they can be bonded immediately even when the material has poor shape retention, that is, immediately after soil compaction is completed. It is possible to start the work easily, thus shortening the work time, saving labor compared to the conventional two-person work, and eliminating the need for the rim material to be hard enough to retain its shape. Therefore, it is possible to join the body part raw material and the rim part raw material in a state of the same moisture content, and therefore there is no shrinkage of the rim part raw material and body part raw material of the joined product, so there is no cracking after drying. This is the case.

Further, since there is no deformation or shrinkage, the time required for preparing and finishing the green material after bonding the rim portion green material and the body material material and releasing the rim upper mold and the body side mold can be shortened.

Embodiments of the method of the present invention will be described below with reference to the accompanying drawings.

FIG. 1 shows a rim green material 12 held in a rim upper mold 10 of a mold for molding a rim material of sanitary ware. The rim molding die consists of an upper rim die 10 and a lower rim die that cooperates with each other, but FIG. 1 shows only the lower rim die removed from the mold, so the lower rim die is not shown. Not yet.
When molding slurry into a mold to form a rim raw material, the rim upper mold 10 and the rim lower mold are accurately positioned by mold matching portions (so-called "dowels") 14. ing. In the case of this embodiment, the mold matching part 14 provided on the lower surface of the rim upper mold 10 is a concave female mold matching part, and is in contact with the male mold matching part of the corresponding convex part of the rim lower mold. engage. The female mold matching part 14 of the rim upper mold 10 not only engages with the male mold matching part of the rim lower mold, but also is provided on the upper surface of the trunk side mold 16 of the trunk mold shown in FIG. It also engages with the male mold mating portion 18.
Therefore, when the mold matching part 14 of the rim upper mold 10 and the mold matching part 18 of the body side mold 16 are engaged, the rim part raw material 12 and the trunk part raw material 20 (second
(Fig.) must be located so that they are accurately positioned relative to each other. The female/male relationship between the mold matching part 14 provided on the rim upper mold 10 and the mold matching part 18 provided on the body side mold 16 is reversed from the female/male relationship shown in FIGS. 1 and 2. Then, the mold matching part 14
Of course, it is also possible to make the molding part 18 male-shaped and the mold matching part 18 female-shaped.

Figure 2 shows a body material 20 inside the body side mold 16 (left and right two-part mold) of a mold for forming the body of sanitary ware.
Shows where is held. The body mold is composed of a body side mold 16 and a middle body mold placed on the body side mold 16. FIG. is not shown. When the slurry is cast into the mold to form the body material, the mold matching part 18 of the body side mold 16 is engaged with the mold matching part of the middle body mold, so that both molds are accurately positioned. ing.

Hereinafter, the bonding method of the present invention will be explained in order of steps.

First, the surfaces 24 and 22 to be joined of the body green body 20 and the rim body green 12, which have been molded by casting slurry into the body mold and the rim mold, respectively, are exposed. To do this, the middle body mold is removed from the body mold, and the lower rim mold is removed from the rim mold. As a result, the mold matching part 14 of the rim upper mold 10 is exposed together with the downward facing surface 22 of the rim part green material 12 to be joined, and the body part raw material 20 is exposed.
The mold matching portion 18 of the body side mold 16 is exposed together with the upward facing surface 24 to be joined.

Next, as shown in FIG. 1, the rim green material 12 is moved above the slurry adhesion device 30 shown in FIG. 3 while being held within the rim upper mold 10. Although this moving device is not shown, any known method may be used. The slurry adhesion device 30 includes a storage tank 34 for storing a slurry bath 32 and a slurry adhesion frame 36.
and has. The slurry adhesion frame 36 is supported by a support 38, and by further supporting the support 38 with a hydraulic (or pneumatic) cylinder 40, the position where the slurry adhesion frame 36 is immersed in the slurry bath 32 (indicated by a solid line) is determined. position) and the position where it abuts the downward facing surface 22 of the rim portion raw material 12 to be joined (the position shown by the broken line)
It is now possible to move up and down between the two. The slurry adhesion frame 36 is made of a porous body such as a sponge made of a material such as woven fabric, rubber, or plastic, which is impregnated with an appropriate amount of slurry when immersed in the slurry bath 32, and a rim portion material. It is configured to have the same outline as the downward facing surface 22 of No. 12 to be joined. Therefore, by pressing the slurry adhesion frame 36 against the downward facing surface 22 of the rim portion green material 12 to be joined for a certain period of time, an appropriate amount of slurry can be adhered to the surface 22. Incidentally, the number 42 indicates a stirring device for maintaining the consistency of the slurry bath 32 at all times. Note that the adhesive slurry may be applied by any known method, and the present invention does not limit the present invention.

Next, while holding the rim part raw material 12 to which the slurry has been adhered in the rim upper mold 10, as shown by the broken line in FIG. 4, and then lowered the rim upper mold 10 as shown by the solid line in FIG.
The mold matching part 14 of the body side mold 16 and the mold matching part 18 of the body side mold 16
For a certain period of time until the slurry has sufficient adhesion, the two are kept in close contact with each other.

The series of steps for bonding green substrates by the green substrate bonding method of the present invention has been completed above, but in order to return to the next step of forming a new green substrate, the mold is operated as follows. After maintaining the state shown by the solid line in FIG. 4 for a certain period of time, the moisture contained in the rim upper mold is passed through the air supply hose 44 to the rim upper mold having grooves formed inside the open-pore porous body, so that the moisture contained in the rim upper mold is connected to the rim material. The porous body is moved back to the boundary surface of the rim upper mold, and a water film is formed on the surface of the rim raw material, and the mold is released. Next, as shown in FIG. 5, when the rim upper mold 10 is lifted upward, the portion of the rim material 12 bonded to the body material 20 is completely exposed. The lifted rim upper mold 10 is returned to the molding line for molding a new rim green material.
The body material 20 is released from the mold by supplying air into the body mold 16 through the air supply hose 46, but before the air is supplied, the body material 20 is released from the mold. Place Uketochi 48 underneath. The body side mold 16, which is separated from the body raw material 20 by supplying air and divided into two parts, is returned to the mold assembly line to be combined with the body middle mold in order to mold the next new body raw material. As shown in FIG. 6, the completely integrated sanitary ware blank is transported to a treatment line, where correction work such as flash removal is performed before entering the next firing process.

[Brief explanation of the drawing]

FIG. 1 is a sectional view showing the rim green material held within the rim upper mold. FIG. 2 is a cross-sectional view showing the torso fabric held within the torso mold. FIG. 3 is a schematic cross-sectional view showing a slurry application device and a method of applying the slurry to the surfaces of the rim green material to be joined using the device. FIG. 4 is a schematic cross-sectional view showing a method of adhering the rim material to which the slurry has been adhered to the body material. FIGS. 5 and 6 are schematic sectional views showing a method of releasing the rim upper mold and the body side mold after completion of the bonding work. 10... Rim upper mold, 12... Rim raw material, 1
4, 18...Mold matching part, 20...Body material,
30...Sludge adhesion device.

Claims (1)

[Claims] 1. Body raw material 20 and rim raw material 1 of sanitary ware
2, the rim lower mold is removed from the rim mold, and the middle trunk mold is removed from the body mold. Surface to be joined 2
2 and 24, the rim upper mold 10 holding the rim part raw material 12 in the mold and the trunk side mold 16 holding the body part raw material 20 in the mold are combined to expose the exposed parts. A step of bonding the bonding surface 22 of the rim portion fabric 12 and the bonding surface 24 of the body portion fabric 20 with adhesive slurry, the bonded rim portion fabric 12 and the body portion fabric 2
1. A method for bonding green sanitary ware to a green body, characterized by sequentially performing the steps from the above steps, including the step of releasing 0 from the rim upper mold 10 and the body side mold 16.