US3812229A - Process for forming ceramic sanitary ware having a stone-like appearance - Google Patents
Process for forming ceramic sanitary ware having a stone-like appearance Download PDFInfo
- Publication number
- US3812229A US3812229A US00113712A US11371271A US3812229A US 3812229 A US3812229 A US 3812229A US 00113712 A US00113712 A US 00113712A US 11371271 A US11371271 A US 11371271A US 3812229 A US3812229 A US 3812229A
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- US
- United States
- Prior art keywords
- mold
- slip
- cavity
- ceramic
- lavatory
- 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.)
- Expired - Lifetime
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Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/005—Devices or processes for obtaining articles having a marble appearance
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/26—Producing shaped prefabricated articles from the material by slip-casting, i.e. by casting a suspension or dispersion of the material in a liquid-absorbent or porous mould, the liquid being allowed to soak into or pass through the walls of the mould; Moulds therefor ; specially for manufacturing articles starting from a ceramic slip; Moulds therefor
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/26—Producing shaped prefabricated articles from the material by slip-casting, i.e. by casting a suspension or dispersion of the material in a liquid-absorbent or porous mould, the liquid being allowed to soak into or pass through the walls of the mould; Moulds therefor ; specially for manufacturing articles starting from a ceramic slip; Moulds therefor
- B28B1/261—Moulds therefor
Definitions
- sanitary ware made from ceramic ware china, such as lavatories, toilets, toilet tanks, urinals,
- lbidets and other items of sanitary ware used in residential bathroom and public rest rooms were usually made in white colors, the color derived from a glaze coat applied to the body and the gloss achieved through the firing process.
- An improvement came about when colored sanitary ware was introduced, such as solid blues, greens, tans, pinks, etc., the color being derived from inorganic stains or pigments added to the glaze which' was applied to the ware and gloss achieved through the firing process.
- slip was poured into plaster molds from the top until the mold cavity ⁇ was filled, and after the desired wall thickness has been obtained, the excess liquid slip was drained from the mold.
- An important object of this invention is to provide an improved process lfor making vitrified sanitary ware, wherein the article produced has a natural stone or marble appearance and also the hardness of vitrified china.
- a further object of this invention is to provide for a process and method for making marbleized sanitary ware having the appearance of natural stone or marble.
- Another object of this invention is to provide a method for effective veining of the slip cast clay body of vitrified sanitary ware.
- a further object is to provide :a new and improved method for making ceramic sanitary ware which will permit design configurations to be made different for each product by varying the color ratios and mixture of slip and by manipulating the mold, controlling the amount of colored slip and areas where composite slip is introduced into the mold cavity.
- a further object is toprovide a process for slip casting wherein multi-colored slip is fed into predetermined areas of a water absorbing mold cavity to effect particular styles of veining.
- a further object is to arrange a slip casting process so as to enable a composite multi-color slip to be poured into the mold cavity against a-cavity wall that does not form the marketable surface of the article and allows the marketable surface to gain initial contact with theA multi-color slip as it rises in the mold cavity due to the continued pouring of the slip.
- FIG. 1 shows a pair of water absorbing plaster of paris molds having a cavity therein with the pouring funnels in place and the mold is partially filled with multi-color liquid slip.
- FlG. 2 shows the mold after it has been completely filled with slip of two different colors, but prior to the excess slip being drained therefrom.
- FIG. 3 shows partially dehydrated slip remaining in the mold after the excess liquid slip has been drained therefrom.
- FIG. 4 is a top view showing the natural marble appearance of a ceramic basin formed by the apparatus and process shown in FIGS. l-3 wherein the pouring hole has been off set' to one side of the lavatory.
- FIG. 5 is-a top view showing the: natural marble appearance of the ceramic lavatory formed by the apparatus and process shown in FIGS. l-3 wherein the pouring hole has been centered relative to the sides of' the lavatory.
- FIG. 6 shows an alternative method for pouring two different color slips through the area which will form the waste opening of a lavatory to form a lavatory having a natural stone or marble appearance.
- FIG. 7 shows the stone pattern achieved by pouring slips of two different colors in the manner shown in FIG. 6
- FIG. 8 shows a mold positioned at a tilted angle, so that slip can be poured into the mold without initially contacting the surface of the male mold member which will form the marketable surface of the finished lavatory.
- FIG. 9 shows the natural marble pattern achieved by pouring slips of two or more different colors in the manner shown in FIG. 8.
- FIG. l shows a mold cavity being filled with an incompletely blended multi-colored slip through the drain hole of an inverted mold.
- FIG. 1l shows the pattern resulting from a mold filled in the manner shown in FIG. l0.
- the articles of chinaware I have used to illustrate the invention are lavatories which have a natural stone or marble appearance. Instead of lavatories, the mold could have been shaped to form toilets, bidets, tanks, urinals or other items of ceramic ware which today are made in solid colors.
- FIG. l l have shown a pair of water absorbing matched molds l0 and 112 for forming a lavatory wherein the veining will extend from one corner of the lavatory up on one side and across the basin and up the opposite side of the basin.
- These molds have a cavity formed therein which is of the shape of the product to be formed. Molds of this type are wellknown in the slip casting art and are usually made from plaster of paris.
- the two molds are held together at their peripheral flanges I4 by suitable means such as C clamps 16, or other similar holding means. These C clamps are opened and closed by a suitable clamp screw 17 in a manner well-known in the art.
- a suitable drain hole lll is provided to drain excess slip from the mold cavity.
- a plastic plug l5 is inserted into the hole l1 to plug the same when it is not desired to have slip drained from the hole ll. When the excess slip has been drained out of the mold through hole Il by the removal of plug l5, and the solids remaining in the mold have set, the C clamps are opened.
- the inverted female mold I0 is provided with an opening I8 adjacent the area of the lavatory which is to become the drain hole of the lavatory into which a funnel is inserted.
- One or more vent holes 22 are provided in the upper portion of the mold I0 to allow air to escape as the slip rises in the cavity 24.
- a pouring hole 26, into which a tall funnel 28 is inserted is provided at the base of the inverted mold member l0 which will form the'back edge. All initial pouring is effected through this funnel 28 to accomplish certain appearance affects in the final product as will be more fully explained hereinbelow.
- the pouring hole can be off set to either side of the back ledge of the lavatory or it can be centered.
- slips Two or more slips, either of different colors, or of neutral and colored slip are poured together from different suitable sources of supply. I have shown pouring pails 30 and 32 as being the sources of supply. The poured slip streams join physically together at the bottom mouth ofthe funnel 28 without effecting a uniform blending of the slips with each other.
- the slips employed may be of the usual well-known compositions employed for making ceramic sanitary ware.
- an ordinary slip composition which is neutral in color can be used for this purpose is:
- Inorganic colors are. added in a conventional manner to one or more separate batches of said slips which are poured together in the manner shown in FIG. l so they join in a common stream but do not become uniformly blended with each other.
- Such stains or pigments are obtainable on the open market and are known as body or glaze stains, sold by various companies listed in Trade Directories and Journals for use in a conventional manner for staining or coloring slips.
- the amount of coloring that is added to a batch of slip has to be varied in accordance with the degree of color and contrast that is desired, in a manner similar to the way one adds color to paint.
- i etc. could be used instead for feeding slips of different colors to the funnel 28.
- the important factor is that there should be no uniform blending of the different colored slips taking place as a result of the feeding operation.
- the slip By depositing the slips on the side of the mold which is opposite to the marketable surface, the slip will distribute itself horizontally and as it rises in the cavity the slip then first cornes into contact with the marketable surface of the mold. This results in striations or veining which has depth in the body of the final finished product and will show up in a manner similar to the way veining is formed by nature in sedementary rock so that the ceramic article appears to be made from natural stone or marble.
- the combined slips deposited inside of the cavity 24 rise upwardly in the cavity 24 from the bottom of the cavity. ln this embodiment, the first contact of the slip with the marketable surface I3 of the plaster mold l2 will be as the slip rides upwardly from the bottom and not by pouring the slip directly on the male mold.
- FIG. l shows the slip rising inthe mold cavity 24 and at this time the cavity is partially filled with slip.
- the male portion ll2 of the mold forms the finished marketable surface 13; that is, the surface of the finished product that will be permanently visible to the consumer.
- the first contact of combined neutral and colored slip with the male mold member l2 will be as the slip arises upwardly incavty 24 and not as it runs down the side of lthe mold surface.
- the colored slip as it rises and as it moves horizontally in its initial Contact with the marketable surface of the mold leaves streaks or striations, due to the stretching out of the colored slip as it moves in the mold cavity, thereby leaving striations of color along the mold surface.
- the filling funnel 28 fits tightly in the hole 26 in which the funnel is positioned, so very little, if any, slip leaks out at this junction.
- the cavity 24 has been completely filled with slip, as shown in FIG. 3, all cavity portions thereof will be filled and excess air will have escaped throughthe vent openings 22, and through the waste opening I8.
- the slip is allowed to remain in the mold cavity 24 a length of time sufficient to permit the desired amount of water to be absorbed from the slip which results in the walls of the article building up to the thickness desired.
- the pin l is then removed from hole l1 and the excess slip still remaining in a liquid form the runs out through the hole 1l.
- an overflow passageway 25 is formed, as shown in FIG. 4 which connects with the drain outlet 18.
- a hole 27 is cut in the upper edge ofthe basin with a knife or cookie cutter, when the clay is firm enough to work, to form an overflow entrance from the basin into the overflow passageway, in a manner wellknown inthe art.
- the formed green ware shown in FIGS. 4 & 5 made from a composite slip of two different colorings, poured in the manner and with the apparatus shown in FIGS. 1-3 has marble or stone like appearance such as shown in FIGS. 4 or 5 depending on the location of the pouring hole.
- var iations can be obtained by varying the factors just mentioned, namely, the mold shape, its pouring position, the color combinations, and rate of pouring.
- the composite slip instead of introducing the composite slip at the bottom of the mold cavity, it can be introduced at some other point in the mold cavity, thus obtaining a different aesthetic appearance in the final product.
- a mixed slip 70 from two separate colored slip sources of supply 72 can be poured with the mold right side up, directly through the funnel 77 into the drain opening 76 formed in the male mold member 78 made from plaster of paris.
- Conventional vent openings 80 and 82 areV formed in the male mold member 78 to allow air in the mold cavity to escape as the poured slip rises in the cavity fills the same with multi-colored slip.
- FIG. 7 shows generally how the symmetrical striations and veining will appear when slip is poured in the manner just described.
- slip is poured through the top edge of the mold while the male and female mold members are supported at an angle in a manner shown.
- the simultaneous pouring of the several colored slips from pails S0 and 52 is effected through an opening 54 formed in the male mold mem? ber 56.
- the male member 56 and female member 58 are held together by suitable C clamps 60 and 62 in the same manner as shown in FIG. l.
- Vent holes 64 and 66 are provided to allow excess air to escape from the mold cavity 68 when the pouring is being effected.
- the embodiment shown in FIG. 8 shows how slip can be poured without depositing any of the poured slip mixed with the color slipdirectly on to the marketing surface of the mold member.
- the mold is then righted so that excess slip still remaining liquid can be drained off through the hole 59 by the removal of plug 6I.
- the overflow hole connects with the hollow cavity and this serves the usual purpose of providing an overflow passageway to carry any overflow water from the top of the lavatory down into the drain outlet.
- FIG. 9 shows the pattern of the final product after it has been removed from the mold shown in FIG. 8.
- FIG. l shows how partially blended different colored slips 90 and 92 can be poured from suitable sources of supply into the inverted mold through the drain opening 94. Suitable vent holes 96 and 98 are provided to enable the mold cavity 100 to be cornpletely filled with partially blended multicolored slip.
- the plaster of paris molds 102 and 104 are aligned with each other by means of dowel balls 106 and 108 and are held together by suitable clamps 110 and 112.
- the poured material comes into contact initially with the marketable surface of the mold and runs down the sides of the male mold.
- the pattern configuration shown in FIG. l1 will be obtained in this arrangement.
- an additional head is also poured into the funnel 110 to provide for shrinkage due to water absorption. This keeps the mold cavity completely filled with slip, despite the shrinkage and permits the slip to remain in the mold for the amount of time required to allow the product walls to build up to the thickness desired.
- the excess liquid slip is then drained from the mold by removing pin 101 from drain hole 103, thus leaving a hollow cavity in the finished article which can be used for the overflow.
- the molded product which is then in a form known as green ware ⁇ is then sent through a kiln for heat treatment of about 2,300 in a manner well known in the art to vitrify the same.
- a kiln for heat treatment of about 2,300 in a manner well known in the art to vitrify the same.
- a glaze which is translucent or transparent and forms a glossy surface after it has passed through the kiln.
- the process of making ceramic ware resembling natural stone which comprises providing a water absorbing mold having a cavity therein for forming an article of ceramic sanitary ware of a particular shape, filling said space with slip from at least two sources of supply, one of which has a contrasting color, said filling being effected so that the separate streams of slip join before they enter the mold, but do not completely blend with each other to thereby show contrasting colors in the formed ceramic ware.
Abstract
Description
Claims (7)
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US00113712A US3812229A (en) | 1969-07-30 | 1971-02-08 | Process for forming ceramic sanitary ware having a stone-like appearance |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US84614269A | 1969-07-30 | 1969-07-30 | |
US00113712A US3812229A (en) | 1969-07-30 | 1971-02-08 | Process for forming ceramic sanitary ware having a stone-like appearance |
Publications (1)
Publication Number | Publication Date |
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US3812229A true US3812229A (en) | 1974-05-21 |
Family
ID=26811384
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
US00113712A Expired - Lifetime US3812229A (en) | 1969-07-30 | 1971-02-08 | Process for forming ceramic sanitary ware having a stone-like appearance |
Country Status (1)
Country | Link |
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US (1) | US3812229A (en) |
Cited By (15)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO1980001715A1 (en) * | 1979-02-07 | 1980-08-21 | C Sadler | Solar heater |
US4316864A (en) * | 1978-03-10 | 1982-02-23 | American Standard Inc. | Method and apparatus for slip casting toilet bowls |
US4428895A (en) | 1979-03-02 | 1984-01-31 | Blasch Precision Ceramics, Inc. | Composite inorganic structures and process of producing same |
US4521355A (en) * | 1981-07-29 | 1985-06-04 | Toppan Printing Company, Ltd. | Method of producing ceramic ware |
US4528152A (en) * | 1982-05-27 | 1985-07-09 | Inax Corporation | Method for obtaining drain-cast hollow articles for ceramic ware |
US4626454A (en) * | 1985-08-05 | 1986-12-02 | Kohler Co. | Decorative fitting |
US5229050A (en) * | 1992-02-04 | 1993-07-20 | Herron Rodney M | Method of making marble-like porcelain figurines |
US5268047A (en) * | 1992-04-09 | 1993-12-07 | Chuang M J | Method of producing a toilet assembly |
WO1997024209A1 (en) * | 1995-12-28 | 1997-07-10 | The Spectrastone Company International, Inc. | Method and apparatus for creating patterns in cast materials |
EP1459860A2 (en) * | 2003-03-21 | 2004-09-22 | Inteco Ceramic Supplies S.R.L. | Method for forming variegated ceramic cladding articles, particularly tiles, plates or the like, and associated apparatus |
US20050158400A1 (en) * | 2004-01-21 | 2005-07-21 | Microban Products Company | Antimicrobial ceramic glaze |
US20050196430A1 (en) * | 2004-01-21 | 2005-09-08 | Microban Products Company | Antimicrobial enamel glaze |
EP2532500A1 (en) * | 2011-06-07 | 2012-12-12 | Geberit International AG | Method for manufacturing ceramic items |
ITMO20130147A1 (en) * | 2013-05-27 | 2014-11-28 | Sir Soc Italiana Resine Spa | SUPPORT FRAME FOR MOLDS |
US11421413B2 (en) * | 2019-04-19 | 2022-08-23 | Kohler Co. | Plumbing fixture with drain-casted jet orifice |
-
1971
- 1971-02-08 US US00113712A patent/US3812229A/en not_active Expired - Lifetime
Cited By (23)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US4316864A (en) * | 1978-03-10 | 1982-02-23 | American Standard Inc. | Method and apparatus for slip casting toilet bowls |
WO1980001715A1 (en) * | 1979-02-07 | 1980-08-21 | C Sadler | Solar heater |
US4428895A (en) | 1979-03-02 | 1984-01-31 | Blasch Precision Ceramics, Inc. | Composite inorganic structures and process of producing same |
US4521355A (en) * | 1981-07-29 | 1985-06-04 | Toppan Printing Company, Ltd. | Method of producing ceramic ware |
US4528152A (en) * | 1982-05-27 | 1985-07-09 | Inax Corporation | Method for obtaining drain-cast hollow articles for ceramic ware |
US4664610A (en) * | 1982-05-27 | 1987-05-12 | Inax Corporation | Apparatus for obtaining drain-cast hollow articles for ceramic ware |
US4626454A (en) * | 1985-08-05 | 1986-12-02 | Kohler Co. | Decorative fitting |
US5229050A (en) * | 1992-02-04 | 1993-07-20 | Herron Rodney M | Method of making marble-like porcelain figurines |
US5268047A (en) * | 1992-04-09 | 1993-12-07 | Chuang M J | Method of producing a toilet assembly |
US5795513A (en) * | 1995-12-28 | 1998-08-18 | Mark Austin | Method for creating patterns in cast materials |
EA000269B1 (en) * | 1995-12-28 | 1999-02-25 | Спектрастон Компани Интернэшнл Инк. | Method and apparatus for creating patterns in cast materials |
WO1997024209A1 (en) * | 1995-12-28 | 1997-07-10 | The Spectrastone Company International, Inc. | Method and apparatus for creating patterns in cast materials |
EP1459860A3 (en) * | 2003-03-21 | 2005-10-05 | Inteco Ceramic Supplies S.R.L. | Method for forming variegated ceramic cladding articles, particularly tiles, plates or the like, and associated apparatus |
EP1459860A2 (en) * | 2003-03-21 | 2004-09-22 | Inteco Ceramic Supplies S.R.L. | Method for forming variegated ceramic cladding articles, particularly tiles, plates or the like, and associated apparatus |
US7250178B2 (en) | 2004-01-21 | 2007-07-31 | Microban Products Company | Antimicrobial ceramic glaze |
US20050196430A1 (en) * | 2004-01-21 | 2005-09-08 | Microban Products Company | Antimicrobial enamel glaze |
US20050158400A1 (en) * | 2004-01-21 | 2005-07-21 | Microban Products Company | Antimicrobial ceramic glaze |
EP2532500A1 (en) * | 2011-06-07 | 2012-12-12 | Geberit International AG | Method for manufacturing ceramic items |
US8920701B2 (en) | 2011-06-07 | 2014-12-30 | Geberit International Ag | Method for producing ceramic articles |
ITMO20130147A1 (en) * | 2013-05-27 | 2014-11-28 | Sir Soc Italiana Resine Spa | SUPPORT FRAME FOR MOLDS |
EP2808141A1 (en) * | 2013-05-27 | 2014-12-03 | Sir S.P.A. | Support framework for molds |
US11421413B2 (en) * | 2019-04-19 | 2022-08-23 | Kohler Co. | Plumbing fixture with drain-casted jet orifice |
US11761189B2 (en) | 2019-04-19 | 2023-09-19 | Kohler Co. | Plumbing fixture with drain-casted jet orifice |
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