Sanitary ware body composition

Effective date : A process for producing feldspathic sanitary ware and the end product are disclosed in which a fluxing amount of a glass frit is used in the ceramic slip used to cast the sanitary ware. The frit contains both deflocculent oxides and flocculent alkaline earths which are leachable from the frit when it is placed in the ceramic slip. The deflocculent oxides counterbalance the effect of the flocculent alkaline earths to the extent they are respectively leached from the frit upon dispersal in a ceramic slip and maintain the slip at a workable viscosity.

Upon casting and firing the slip, the present frit precipitates fine crystals of diopside having an average particle size of less than one micron which are particularly useful in lowering the firing temperature of feldspathic bodies by promoting the required degree of vitrification at lower temperatures than heretofore possible. The body is usually formed by the well-known method of slip casting, carefully and slowly dried, glazed and fired to vitrification in a tunnel kiln at a temperature equivalent of Seger pyrometric cone 9 to The body is normally referred to as "feldspathic" indicating that a substantial proportion of the mineral content of the slip is feldspar.

However, nowadays feldspathic sand or nepheline syenite can be optionally used as a partial or complete replacement for the feldspar without changing this generic description. Ideally, and as will be described in more detail hereinafter, the casting slip, as well as the final, fired, vitrified body, must meet certain rigid, rheological and physical property standards.

For example, the viscosity, specific gravity and stability of the casting slip should ideally remain constant over appreciable periods of time as these factors are all critical from the standpoint of casting bodies having desired wall thicknesses, drying shrinkage, etc. The fired body, ideally, will be completely vitrified, have high strength, with minimum, though uniform, shrinkage on firing.

In an effort to either, or both, speed the firing operation and to lower the firing temperature, any number of body additives have been experimented with. For example, many fluxing materials have been tried to speed the body vitrification process, with varying degrees of success.

However, such fluxes have generally created more problems than they have solved. That is, speeding up the vitrification process poses no major problem, in and of itself; but slip instability, excessive shrinkage or warpage on drying or firing, lower strength, short vitrification range, etc.

Therefore, while a vitrification range would be of little or no significance in a small test bar, fired under carefully controlled laboratory conditions, it is vital to successful manufacture of sanitary-ware products on a commercial scale in a continuous production tunnel kiln. Thus, if a sanitary-ware body reaches vitrification at precisely cone 10 down, while at cone 9 it is not vitrified, whereas at cone 11 it has begun to slump, the production problems become readily apparent because there is no practical way to achieve temperature control at precisely cone 10 throughout the cross section of the firing zone of a production kiln.

A related problem in casting sanitary ware from a ceramic slip in which a glass frit serves as a flux is that the frit tends to be somewhat soluble. Components leached from the frit, notably the alkaline earths, act as flocculents and can sufficiently raise the viscosity of the slip to make it unworkable. In fact, some slips may even virtually solidify.

Moreover, this flocculation to an unworkable viscosity can often take place in a relatively short time. Also, sintering of the cast ceramic slip leaves a certain amount of unreacted alkaline earth in the sintered product. This likewise has an undesirable flocculating effect on the slip.In this process, Slip produced by mixing Ball claySilica, China clay and feldspar.

This composition is called Tri-axial body. Consist of Body former, Filler and flux. Body former is plastic material which is required to give strength at the green stage of the sanitary ware. The filler is non-plastic material which is going to give strength after the firing. Flux is a non-plastic material which added to the body to reduce the fusion temperature point of the body during firing. All raw materials are mixed at the proper position and brought to required physical parameters.

Usually following rheological parameters are checked afterslip preparations — Fluidity, Thixotropic of the slip at 1 minute and 5 minutes, Liter weight. These parameters will vary depending upon the composition, climate, casting Bench casting, high-pressure casting, Low pressure casting for sanitaryware and other and required casting rate. This composition also will vary according to the availability of the scrap slip available and required casting rate.

Once slip prepared according to the required parameter, it will be sent to slip storage silos. Whenever slip is required, then it will be supplied to the casting department for casting. In this process, the glaze prepared for spraying department. Body preparation and glaze preparation are a parallel process.

sanitary ware body composition

Different colours of glaze will be made according to the requirement. The raw material used for glaze preparations is zircon, feldspar, quartz, calcite, china clay and zinc oxide. Raw materials ground in a ball mill and particle size tested before unloaded from ball mill. Alumina ball used in ball mils because of its strength. The glaze will be passed through sieves to remove coarse particles and magnets to remove iron particles. Sample spraying will be done and fired to check the final colour of the glaze.

Before supply to the spraying, the glaze will be mixed with a binder to give the required properties. Density, drying time, fluidity and viscosity are maintained to get the proper spray. In this process required shape and size mould will be produced for casting. Case moulds are received form case making section to Moulding section. Case moulds used cast plaster moulds. Mould is prepared using mixing water with Plaster of Paris in a proper ratio.

Plaster of Paris chemical formula is CaSO 4.Eat healthy, drink some green smoothies and go to the gym — you know the drill. Girls live in a world where being healthy is cool and well, expensive. But then again, we tend to overlook the other important factors that are considered unhealthy and unsafe. So how well do you know your favorite sanitary pads?

Check out my post about the " Advantages and Disadvantages of Menstrual Cups ". They would accumulate inside our bodies and threaten our reproductive health. Just the thought of having these cancerous chemicals on our vagina is sickening and scary. We all know pads are made of cotton. Like other crops, cotton crops are being sprayed with pesticides and herbicides that can definitely cause harm when they reach your bloodstream. Imagine having this chemical contaminant inside your body.

Furan is even linked to cancer in some experimental animals. Herbicides and pesticides are linked to thyroid malfunction, infertility and other health problems. Cotton is not naturally ultra — white. Unconsciously, we are paying a very high price for being neat freaks. Such companies may argue that the pads contain very low levels of dioxin. Based on research, a short-term exposure to dioxin can cause skin darkening and altered liver function. A woman might be using 6, sanitary napkins in her lifetime and when dioxin accumulates in the body it can cause serious health risks and diseases such as immune system damage, diabetes, hormone dysfunction, pelvic inflammatory disease, ovarian cancer and others.

Your pads contain odor neutralizers or deodorants because every woman hates the smell of blood. Also, it is not recommended to use scented feminine hygiene products because they can cause irritation.

Some symptoms of toxic shock syndrome are dizziness, fever and diarrhea. Your pads are made of synthetic materials which can cause blockage of wetness, which encourage bacterial growth.

Paradise Sanitaryware India - Manufacturing Process Video

Being a woman is not just about having your monthly period, being beautiful with your makeup on or having a vagina.Imerys Ceramics, the world leader in industrial mineral solutions, is your trusted partner for efficient sanitaryware production. Our strategy is to deliver improved performance and greater productivity with the ultimate aim of helping our customers achieve ever higher yields and design possibilities.

From your first installation to the optimization of existing lines, Imerys Ceramics is your partner of choice to meet your technical and business challenges. Our worldwide technical support team is at your service and is dedicated to help you reach your Challenges.

Productivity of your kiln: an optimized design, adapted to your product mix, is essential to have a high loading rate of your firing line. Find Imerys Ceramics nearest facilities in the interactive map! Leader in supplying sanitaryware industry with kiln furniture solutions From your first installation to the optimization of existing lines, Imerys Ceramics is your partner of choice to meet your technical and business challenges.

Prepared bodies can therefore be tailor made to meet an individual manufacturer's particular needs. Consistency of production Our worldwide technical support team is at your service and is dedicated to help you reach your Challenges.

Physical and Chemical Reaction during Firing of Sanitaryware

Phone number.All Glossary. A type of porcelain zircon-glazed ceramic that includes bathtubs, sinks, toilets, etc. Details This is a very large industry world wide, second only to ceramic tile in clay and energy use. The knowledge of how to make sanitary ware can be found on every industrial continent. Although alot of it is made in China e. Chaozhou is a small city in Southern China that has hundreds of sanitary ware factories many other countries have very highly developed processes and innovative products we are impressed by many in the middle east.

Most sanitary ware is fired at high temperatures from porcelain bodies resembling the standard 4x25 recipe feldspar, kaolin, silica, ball clay and is glazed using zircon opacified feldspar based recipes.

EP0090094A1 - Sanitary ware and process of production - Google Patents

The manufacture pushes many ceramic processes to their limit thick casting, high mass drying and firing, thick glaze layers, highly deflocculated slips, etc. Many of the factories in the third world that make sanitary ware are less automated but still very dependent on supplier technical support they do not have technical people on staff.

Most of the requests we get for technical assistance come from these types of companies. Example of the oversize particles from a gram wet sieve analysis test of a powdered sample of a porcelain body made from North American refined materials. Although these materials are sold as mesh, that designation does not mean that there are no particles coarser than mesh.

Here there are significant numbers of particles on the and even 70 mesh screens. These contain some darker particles that could produce fired specks if they are iron and not lignite ; that goodness in this case they do not.

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Oversize particle is a fact of life in bodies made from refined materials and used by potters and hobbyists. Industrial manufacturers e. The original recipe had a very low clay content, sourcing almost all of its Al 2 O 3 from feldspar instead. Although the glaze slurry was maintained at 1. Lack of clay content in the glaze. The fix was to source much more of the Al 2 O 3 from kaolin instead of feldspar.

The reduction in feldspar shorted the glaze on KNaO and SiO 2 so these were sourced from a frit and pure silica instead the calculations to do this were done in Insight-live.

This reduced the thermal expansion and reduced crazing issues. Sanitary ware factories optimize their slips to have the lowest possible specific gravity for production volume reasons. Potters would be happy with 1. They often teeter on the edge of issues like this sections softening causing localize warping and inexperienced technicians can be unaware of the critical balances needed to prevent loss in production. This sanitary ware tank lid was made in China.

Notice how thick the white glaze is being applied to cover the iron containing body below.

sanitary ware body composition

This is a testament to how opaque a zircon opacified glaze can be. Of course, high percentages create a stiffer glaze melt and conditions can more often combine to produce crawling like this.Table past technology with sanitary ware of.

The sanitary ware according to claim 1, wherein the bulk density Db was blank 1.

sanitary ware body composition

The sanitary ware according to claim 1, wherein the transparency of the glaze layer is made of glaze. The sanitary ware according to claim 1, wherein the glaze layer is composed of more than two different glaze layer.

The sanitary ware according to claim 1, wherein the glaze layer is composed of two or more selected from the glaze engobe, coloring glaze constituting the glaze transparency. The sanitary ware according to claim 13, wherein, in the sanitary ware portion or the whole portion is provided is not formed in the engobes. The sanitary ware according to claim 1, wherein the sanitary ware to wash hands, a face, a urinal, toilet, a toilet tank, the filter toilet, laundry pool, children tub, a shower tub arbitrary species.

CN CNC en. USB2 en. EPA4 en. JPA en. CNC en. AUA en.

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WOA1 en. Composition for sanitary ware body, method for producing the same, and method for producing sanitary ware using the composition. Method of manufacturing ceramic capable of adsorbing fragrance and releasing fragrant aroma. DEB4 en. Glaze composition with glass plates of various sizes, process for their preparation, process for the production of glazed sanitary ware and use of the glaze composition.

Process for production of glazed, high density engineered surface products and products thereof. JPB2 en.

sanitary ware body composition

JPHA en. TWB en. USA en. Method for preparing high strength and high thermal shock-resistant china for ceramic whiteware.

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DEA1 en. Ceramic whiteware, ceramic body, processes for producing these, sanitary ware, and process for producing these, sanitary ware, and process for producing the sanitary ware.

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USA1 en.The present invention relates to a composition for a sanitary ware body for use in slip casting, a process for producing the same, and a process for producing a sanitary ware using said composition. In the production of sanitary wares, slip casting is generally adopted for the production of green bodies. This is because sanitary wares are relatively large and have a complicated shape. Slip casting is, for example, carried out as follows.

A suitable amount of water is added to the raw material for a sanitary ware body to render the raw material fluid. Next, the raw material, to which water has been added, is mixed and ground in a ball mill or the like to prepare a slurry.

The slurry thus obtained as such is poured into a slip casting mold. In this way, the raw material for a sanitary ware body for use in slip casting is slurried and, in this state without being solidified, is then used in the step of slip casting. On the other hand, in the production of pottery or ceramic whiteware, such as tiles, in which a green body is prepared by plastic pressing, the raw material for a pottery or ceramic whiteware body is subjected to the step of plastic pressing in the form of a plastic pressing body prepared by dehydrating a slurry of the raw material, that is, in the form of a solid.

Japanese Patent Laid-Open No. Accordingly, an object of the present invention is to provide a composition for a sanitary ware body for use in slip casting, possessing excellent long-term storage stability, transportability and slurry regeneration, a production process of the same, and a production process of a sanitary ware using the composition for a sanitary ware body.

According to another aspect of the present invention, there is provided a process for producing a composition for a sanitary ware body for use in slip casting, said process comprising the steps of:.

According to a further aspect of the present invention, there is provided a process for producing a sanitary ware, comprising the steps of:.

Sanitary ware Manufacturing/Production Process

In the present invention, the particle diameter distribution on a weight basis may be measured with a dry sieving apparatus according to JIS Z Specifically, a sieving apparatus equipped with test sieves specified in JIS Z is provided, and a single test sieve or a plurality of test sieves put on top of each other is vibrated for sieving.

The sieving time is the time which has elapsed between the start of the sieving and the time when the mass of a group of particles which has passed through the sieve per minute reaches not more than 0. Particles which clog meshes are removed by turning the sieve upside down so that the backside of the sieving net faces upward, and removing the particles by a clogging eliminating brush.

The particles which cause clogging of the meshes are regarded as the oversize. The composition for a sanitary ware body according to the present invention is a composition which can form into a raw material slurry for a sanitary ware body by adding water to the composition and stirring the mixture.

The composition for a sanitary ware body according to the present invention is usable in slip casting.

Sanitary ware

This composition for a sanitary ware body according to the present invention enables a raw material for a sanitary ware body for slip casting to be stably stored for a long period of time. Further, a burden on raw material transfer and storage can be significantly reduced. Furthermore, a slurry for a sanitary ware body can be immediately regenerated from the composition for - a sanitary ware body by a very simple method and can be used for slip casting. Therefore, a burden on raw material transfer and storage can be significantly reduced, and the efficiency of the transfer and storage can be increased.

The composition for a sanitary ware body according to the present invention is not a slurry and, thus, is free from a problem, which is likely to occur in the slurry, that is, a change in slurry properties during storage for a long period of time, for example, precipitation of solid matter.

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That is, the raw material for a sanitary ware body can be stably stored for a long period of time. The water content of powder provided after drying may somewhat fluctuate during storage and keeping.

The fluctuation in water content of the powder, however, poses no problem because, in reslurrying, water is added to the powder to regulate the amount of water in the regenerated slurry.

This particle diameter distribution corresponds to the particle diameter distribution which is commonly possessed by a slurry for a sanitary ware body for use in slip casting. By virtue of this, before use in slip casting, a slurry for a sanitary ware body can be immediately regenerated from the composition according to the present invention by a very simple method in which water is added and the mixture is stirred.

Therefore, unlike the case where raw materials for a sanitary ware body such as pottery stone, feldspar, and clay are stored as they are, the composition according to the present invention can rapidly cope with a sudden increase in a demand.

The raw material for a sanitary ware body according to the present invention is not particularly limited so far as the material is a body material commonly used in the production of sanitary wares, and examples thereof include pottery stone, silica rock, feldspar, kaolin, and clay. The mixing ratio of ingredients in the raw material for a sanitary ware body is not particularly limited.

A preferred example thereof is as follows.


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