CA1084665A - Molding process for a hybrid decorative plumbing fixture - Google Patents
Molding process for a hybrid decorative plumbing fixtureInfo
- Publication number
- CA1084665A CA1084665A CA300,824A CA300824A CA1084665A CA 1084665 A CA1084665 A CA 1084665A CA 300824 A CA300824 A CA 300824A CA 1084665 A CA1084665 A CA 1084665A
- Authority
- CA
- Canada
- Prior art keywords
- ceramic shell
- external surfaces
- toilet
- female mold
- mold member
- 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
Links
Classifications
-
- E—FIXED CONSTRUCTIONS
- E03—WATER SUPPLY; SEWERAGE
- E03D—WATER-CLOSETS OR URINALS WITH FLUSHING DEVICES; FLUSHING VALVES THEREFOR
- E03D11/00—Other component parts of water-closets, e.g. noise-reducing means in the flushing system, flushing pipes mounted in the bowl, seals for the bowl outlet, devices preventing overflow of the bowl contents; devices forming a water seal in the bowl after flushing, devices eliminating obstructions in the bowl outlet or preventing backflow of water and excrements from the waterpipe
- E03D11/02—Water-closet bowls ; Bowls with a double odour seal optionally with provisions for a good siphonic action; siphons as part of the bowl
-
- 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
- B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
- B28B11/04—Apparatus or processes for treating or working the shaped or preshaped articles for coating or applying engobing layers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
Abstract
ABSTRACT OF THE DISCLOSURE
The invention is a molding process adapted fox the production of plumbing fixtures, such as a toilet whose functional surfaces are resistant to erosion by moving water wherein a ceramic shell forms a liner having external surfaces and the functional surfaces of the plumbing fixture.
In the case of the toilet the ceramic shell includes a bowl, siphon trap and a water flush ring. The molding process includes the steps of coating the external surfaces of the ceramic shell with a layer of resilient material and then suspending the ceramic shell upside down within a female mold member having internal surface so that the internal surfaces of the female mold member are slightly spaced from the external surfaces of the ceramic shell thereby leaving a gap between the internal surfaces of the female mold member and the external surfaces of the ceramic shell. The molding process also includes the steps of filling the gap with a catalyzed polyester resin matrix mixed with a filler and pigments and permitting the matrix to bond and to cure to the coated external surfaces of the ceramic shell. The molding process further includes the step of removing the female mold member thereby producing a plumbing fixture, such as a toilet, that has an attractive exterior appearance which matches other plumbing fixtures to be used in the same room in both their color texture and their design.
The invention is a molding process adapted fox the production of plumbing fixtures, such as a toilet whose functional surfaces are resistant to erosion by moving water wherein a ceramic shell forms a liner having external surfaces and the functional surfaces of the plumbing fixture.
In the case of the toilet the ceramic shell includes a bowl, siphon trap and a water flush ring. The molding process includes the steps of coating the external surfaces of the ceramic shell with a layer of resilient material and then suspending the ceramic shell upside down within a female mold member having internal surface so that the internal surfaces of the female mold member are slightly spaced from the external surfaces of the ceramic shell thereby leaving a gap between the internal surfaces of the female mold member and the external surfaces of the ceramic shell. The molding process also includes the steps of filling the gap with a catalyzed polyester resin matrix mixed with a filler and pigments and permitting the matrix to bond and to cure to the coated external surfaces of the ceramic shell. The molding process further includes the step of removing the female mold member thereby producing a plumbing fixture, such as a toilet, that has an attractive exterior appearance which matches other plumbing fixtures to be used in the same room in both their color texture and their design.
Description
. ~ ~6~;s BACKGROUND OF THE INVENTION
Field of the Invention The present invention relates to hybrid decorative plumbing fixtures and more particularly to a toilet which has a ceramic liner which is encased in a polyester casting.
Description of the Prior Art In the past it has been common to construct wash basins and toilets out of a ceramic material, such as vitreous china.
The surfaces of these plumbing Eixtures are glazed in order to form very hard, shiny surfaces which for aIl practical purposes are impervious to stains and are not subject to erosion by moving water. The daily repeated use of a toilet over a period of several years causes a great deal of water to pass over its functional surfaces. However, the toilet shows no signs of wear due to the movement of water across its functional surfaces be-cause the glazed ceramic material resists the effects of water movement.
All of these plumbing fixtures are designed to eliminate the effect of water erosion. They were not designed for their aesthetic part in a coordinated scheme of a decorated bathroom which has other plumbing fixtures including wash basins, bath-tubs and showers which utilize the plastic technology presently available. The decorator of a bathroom until recently was unable to use anything but a glazed ceramic toilet which was basically identical in appearance with other toilets.
Recently there has been a trend toward the redesigning of wash basins, bath-tubs and showers which are now formed out of plastic materials. These plastic materials have sufficient ,~'' ~ '' .; .
': ' ' ' , , ~ ..
~ .
' hardness to withstand wa-ter erosion over a period of several years. These wash basins, bath-tubs and showers are designed in different colors or may even be designed so that they have a simulated marble appearance. The plastic materials enable the decorators of apartments, houses and hotels to replace shiny ceramic plumbing fixtures with decorative plastic plumbing fix-tures which can be baried not only in shape and design, but also in color and texture.
In hotels the most popular plumbing fixtures have been those which are ornate and which also have a simulated marble appearance. U.S. Patent No. 3,150,032, entitled Abuse Resistant Articles of Manufacture and Method of Making, issued to David Rubensteln on September 22, 1964, teaches a filled transparent synthetic plastic composition which is used in a plastic structure in which an opague material in visibly embedded in a filled matrix. The synthetic plastic composition is molded into the shape of a shower, a wash basin or a bath-tub.
U.S. Patent No. 3,906,072, entitled Molding Process, issued to Thomas W. Haas, Richard L. Mach, Edward Studley and Robert Hoffman on September 16, 1975, teaches a method of molding sanitary ware from a thermosetting resin such as melamine. The mold is configured to a minimum draft angle for the most steeply sloped wall. The resin is charged into the mold in the form of one or more thickened cakes of agglomerated resin particles.
The mold configuration and method of charging are such that the steeply sloped mold surfaces achieve a relatively high pressure on the plastic so as to minimize surface porosity. During the clQsing movement of the mold the cake of resin is broken and ' ': ' . - . ' . . ~ - ' ~ , , , ., : . .
.. ,-. . - . . .. ~ ~ .
. - . - : : .
... .
, caused to flow upwardly to form an integral deck portion as well as flow downwardly against the steeply sloped surface of the receiving mold. According to the inventors of this mold-ing process, the molding process may be used to mold wash basins, bath-tubs, showers, toilet bowls and toilet tanks.
The present inventors disagree that the above described molding process could be used for toilet bowls because the plastic surfaces of the toilet bowls which are exposed to water movement become eroded and also become stained. The inventors further point out that whereas a shower, a wash basin or a bath-tub is filled with water only it is in use, a toilet bowl is always filled with water with the single exception when it is being flushed. The inventors have found that the plastic mater-ials do not hold up against erosion by the presence of water and by the water movement within a toilet bowl.
The present inventors recognized a need for a toilet bowl whose functional surfaces were formed out of a glazed cer-amic material and whose external surfaces were coated with a synthetic plastic composition such as simulated marble. They first tried using a ceramic shell liner having external surfaces and internal surfaces which were also function and also having a bowl, a siphon trap and a water flush ring. They roughened the external surfaces of the ceramic shell liner by either sand-blasting or chemically etching these surfaces. They left the internal surfaces glazed in order to withstand erosion by water movement. They next placed a synthetic plastic composition about the external surfaces of the ceramic shell liner and allowed the composition to cure and to bond to external surfaces -. . - ~ _ .
'' ' ' ' ' ,~ ' , , ' ' thereby forming a toilet bowl which would match -the other plumb-ing fixtures in a bathroom. The inventors encountered a serious problem in using this molding process because the synthetic plastic composition as it cured itself shrank and cracked the ceramic shell liner.
SUMMARY OF THE INVENTION
The present invention provides a process comprising coating the external surfaces of a ceramic plumbing fixture with a layer of resilient material, molding to the resilient layer a curable poiyester resin matrix that tends to shrink as it cures, and curing said matrix to bond.said matrix to said resilient layer, said resilient layer having sufficient com-pression strength to prevent said fixture from cracking when said matrix is cured. The molding step comprises placing the : resilient material-coated fixture as a male molding member with-.. in a female molding member where the interior surfaces of said female molding member are spaced a predetermined distance from said resilient layer and then filling the space with said cur-able polyester resin matrix.
In another aspect of the invention, there is pro-vided a plumbing fixture comprising a ceramic shell having cer-amic functional surfaces and an external surface at least part-ially coated with a resilient layer and a cured decorative poly-ester resin matrix layer over said resilient layer, said re-silient layer having sufficient compression strength to pre-vent said fixture from cracking when said matrix is cured.
. Thus the present invention provides a toilet fixture which has glazed ceramic functional surfaces and attractively :
. .
': ' ': ' ' : . , . : : . . . :
~ . , ' ` ' ~4$6~;i colored plastic external surfaces. The functional surfaces resist erosion by water movement and are impervious to stains.
In accordance wlth a preferred embodiment of the present invention a molding process adapted for the production of a plumbing fixture, such as a toilet, whose functional sur-faces are resistant to erosion by moving water wherein a cer-amic shell forms a liner having external surfaces and the func-tional surfaces of the plumbing fixture is described. In the ; case of a toilet the ceramic shell includes a bowl, a siphon trap and a water flush ring. The molding process includes the steps of coating the external surfaces of the ceramic shell with a layer of resilient material and then suspending the cer-amic shell upside down within a female mold member having in-ternal surfaces such that the internal surfaces of the female mold member are slightly spaced from the external surfaces of the ceramic shell thereby leaving a gap between the internal surfaces of the female mold member and the external surfaces of the ceramic shell. The molding process also includes the steps of filling the gap with a catalyzed polyester resin matrix mixed with a filler and pigments and permitting the matrix to cure and to bond to the coated external surfaces of the ceramic shell. The molding process further includes the step of re-moving the female mold member thereby producing a plumbing fix-ture, such as a toilet, that has an attractive exterior appear-- ance which matches other plumbing fixtures to be used in the same room in both their color texture and design.
This invention will be more readily appreciated as the same becomes better understood by reference to the following ~ . .
- : - . ' .. . .
~ ' . '. :
.
6~
detailed description and considered in connection wi-th the accompanying drawing in which like reference symbols designate like parts throughout the figures.
DESCRIPTION OF THE DRAWING
FIG. 1 is a side cross-sectional view of a ceramic toilet shell that has external surfaces and functional surfaces which are glazed and fired.
FIG. 2 is a side cross-sectional view of the ceramic toilet shell of FIG. 1 which has its external surfaces coated with a layer of resilient material in accordance with the prin-ciples of the present invention.
; FIG. 3 is a cross-sectional view of the ceramic toilet shell of FIG. 1 disposed upside down and suspended within a fe-male mold member which is also shown in a cross-sectional view.
FIG. 4 is a cross-sectional view of the ceramic toilet shell of FIG. 1 which is suspended upside down in the female mold member of FIG. 3 after a synthetic polyester resin compos-ition has beèn injected between the internal surfaces oE the fe-male mold member and the external surfaces of the external sur-faces of the ceramic toilet shell.
.. .
FIG. 5 is a side elevational view of a simulated marbleor plastic plumbing fixture which is constructed in accordance with the principles of the present invention.
DESCRIPTION OF TE~E PREFERRED EMBODIMENT
The present invention can best be unders-tood by re-ference to a description of its preferred embodiment in conjun-ction with the figures of the drawing. The preferred embodiment of the present invention is a toilet fixture which has its .
~,: ' ' , ' ' . ' :
, . ~ . .. . . .
external surfaces coated with simulated onyx.
Referring to FIG. 1 a side cross-sectional view of a ceramic shell liner 11 of a toilet fixture is shown. The ceramic shell liner 11 has unfinished external surfaces 12 and functional surfaces 13. The ceramic shell liner ll includes a bowl 14, a siphon trap 15 and a water ring 16. The howl 14 has an opening 17 around which the water flush ring 18 is dis-posed. The bottom portion of the bowl 14 has an opening 16 which connects with the siphon trap 15. The visable portions of the functional surfaces of the bowl 14, the siphon trap 15 and the water flush ring 16 are glazed and fired in kiln there-by producing a hard shiny layex 19. The formation of this layer ~ 19 is accomplished by conventional methods. In a conventional - process for manufacturing a ceramic toilet, the external sur-faces would also be glazed and fired. The external surfaces 12 of the ceramic liner 11 are unglazed. Generally the ceramic shell liner is of even thickness throughout and is approximately three-eights of an inch.
Referring now to FIG. 2 the external surface 12 of ceramic shell liner 11 is coated with a layer 20 of resilient material which bonds thereto.
Referring now to FIG. 3 the ceramic shell is placed in an upside down manner within a mold cavity formed by the female mold assembly 30. The female mold assembly 30 includes a first side mold member 31 a second side mold member 32 and a bottom mold member 33. The ceramic shell 11 is placed within the female mold cavity so that there is an even gap located all about the external surfaces 12 of the ceramic shell liner 11. It is to be , - :
,~
noted that the gap 34 extends about the water flush ring 16 wi-th a protuberance of the female mold assembly 30 being located with-in a water inlet opening which supplies water from a tank (not shown) into the bowl of the toilet fixtures to seal off during casting the water ring 12. The positioning of the ceramic shell within the mold cavity to produce an even gap 34 is facilitated due to the placement of the protuberance within the opening which is essentially a self aligning feature.
Within the gap 34 is to be poured the plastic matrix.
This plastic matrix will entirely fill the gap 34. This plastic material upon curing will be bonded directly to layer 20 of resilient material 24 of the ceramic shell liner 11. There will be a slight amount of shrinkage, usually two to three percent, during the curing of the plastic material. This shrinkage is absorbed by the layer 20 of resilient material and serves to insure a strong mechanical bond to the ceramic shell liner 11.
With the addition of the layer 20 the shrinkage is not suffi-cient to cause any undue strain or stress upon the ceramic shell liner 11 which will break it.
Generally it is desirable to obtain a smooth, glossy external layer of plastic that is also hard. This layer is ob-tained by coating the interior cavity of the female mold assembly 30 with a gel coat. The use of the gel coat i.s very comrnon in the plastic industry where there are several different types of gel coat materials. For use in the present invention a gel coat in the form of a thin liquid plastic material which can be easily sprayed upon the interior surfaces of the cavity has been found acceptable by the inventors.
. .
, . . . . .
- . . .. . . :
,' ,: ' . ' , , ' , ' ,' ' ' "' ' :
. ~ :
-~846~
The molding process includes the step of pouring a matrix 35 of a particular color into the gap 34. The matrix may be colored to include striations such that it resembles marble texture. The matrix 35 generally includes a polyester resin that has been catalyzed by a methyl-ethyl ketone peroxide or a methyl methacrylate monomer catalyzed appropriately. The matrix 35 further includes fillers such as CaCO3 and hydrated alumina in addition to other organic and inorganic ma-terials.
The catalysts and fillers are mixed together and the resulting mixture has pigments added thereto in order to form the matrix - 35 which is Poured into the qa~ 34.
- The inventors have noted that the greater the amount of fillers added to the polyester resin, the less likely the composition will pour. Since it is desirable that the matrix 35 be pourable, the preferrable range of filler to ov~rall com-position is from the thirty per cent to sixty per cent by weight.
Reference -to FIG. 4 shows the female mold assembly 30 after the matrix 35 has been poured into the gap 34.
When the matrix hardens sufficiently, the mold mem-bers 31, 32 and 33 are removed and the resulting finished pro-- duct is shown in FIG. 5. The toilet fixture has a smooth, glossy external surface 40 and is mechanically coupled to a water tank 41. The toilet fixture has all of the features of a conventional toilet fixture plus the addition of an ornamental and attractive external surface 40. The construction of the water tank 41 may be totally done by a method of molding or casting a com-position that is similar to the external surface 40 of the toilet fixture.
., .
' :: .....
~ 34665 The inventors have also discovered that if they use a composition of polyester resins that is relatively low-shrink-ing they can elimate the layer 20 of resilient material. Pre-sently these resins are more expensive than the resins in commercial use.
The inventors believe that their basic invention is a ceramic shell liner 11 which is used as the male mold member in conjunction with a female mold assembly to produce an orna-mental plumbing fixture. The use of the ceramic shell liner 11 is unique in and of itself. The inventors have discovered two aIternative methods of eliminating the breaking that occurs when the resins cure. The first method is to add a layer of re-silient material`to the-external surfaces of the ceramic shell liner in order to absorb the shrinkage of the resins. The second method is use a low-shrinking resin.
From the foregoing it can be seen that a toilet fix-ture with an attractive and ornamental external surface has been described. Furthermore the functional surfaces of this toilet fixture are formed from a ceramic material with those functional surfaces that are visable being glazed and fired to provide a hard and shiny surface that is impervious to stains and water erosion.
It should be noted that the schematics of the molding process are not drawn to scale and that distances of and between the figures are not to be considered signiflcant.
' Accordingly, it is intended that the foregoing dis-closure and showing made in the drawing shallbe considered only - as an illustration of the principle of the present invention.
....
. . ~: :. .
.
, . . . ~ . .
. .. . . . . . .
.: . , : .
'' : ;.
. ' ', , , ' , :
Field of the Invention The present invention relates to hybrid decorative plumbing fixtures and more particularly to a toilet which has a ceramic liner which is encased in a polyester casting.
Description of the Prior Art In the past it has been common to construct wash basins and toilets out of a ceramic material, such as vitreous china.
The surfaces of these plumbing Eixtures are glazed in order to form very hard, shiny surfaces which for aIl practical purposes are impervious to stains and are not subject to erosion by moving water. The daily repeated use of a toilet over a period of several years causes a great deal of water to pass over its functional surfaces. However, the toilet shows no signs of wear due to the movement of water across its functional surfaces be-cause the glazed ceramic material resists the effects of water movement.
All of these plumbing fixtures are designed to eliminate the effect of water erosion. They were not designed for their aesthetic part in a coordinated scheme of a decorated bathroom which has other plumbing fixtures including wash basins, bath-tubs and showers which utilize the plastic technology presently available. The decorator of a bathroom until recently was unable to use anything but a glazed ceramic toilet which was basically identical in appearance with other toilets.
Recently there has been a trend toward the redesigning of wash basins, bath-tubs and showers which are now formed out of plastic materials. These plastic materials have sufficient ,~'' ~ '' .; .
': ' ' ' , , ~ ..
~ .
' hardness to withstand wa-ter erosion over a period of several years. These wash basins, bath-tubs and showers are designed in different colors or may even be designed so that they have a simulated marble appearance. The plastic materials enable the decorators of apartments, houses and hotels to replace shiny ceramic plumbing fixtures with decorative plastic plumbing fix-tures which can be baried not only in shape and design, but also in color and texture.
In hotels the most popular plumbing fixtures have been those which are ornate and which also have a simulated marble appearance. U.S. Patent No. 3,150,032, entitled Abuse Resistant Articles of Manufacture and Method of Making, issued to David Rubensteln on September 22, 1964, teaches a filled transparent synthetic plastic composition which is used in a plastic structure in which an opague material in visibly embedded in a filled matrix. The synthetic plastic composition is molded into the shape of a shower, a wash basin or a bath-tub.
U.S. Patent No. 3,906,072, entitled Molding Process, issued to Thomas W. Haas, Richard L. Mach, Edward Studley and Robert Hoffman on September 16, 1975, teaches a method of molding sanitary ware from a thermosetting resin such as melamine. The mold is configured to a minimum draft angle for the most steeply sloped wall. The resin is charged into the mold in the form of one or more thickened cakes of agglomerated resin particles.
The mold configuration and method of charging are such that the steeply sloped mold surfaces achieve a relatively high pressure on the plastic so as to minimize surface porosity. During the clQsing movement of the mold the cake of resin is broken and ' ': ' . - . ' . . ~ - ' ~ , , , ., : . .
.. ,-. . - . . .. ~ ~ .
. - . - : : .
... .
, caused to flow upwardly to form an integral deck portion as well as flow downwardly against the steeply sloped surface of the receiving mold. According to the inventors of this mold-ing process, the molding process may be used to mold wash basins, bath-tubs, showers, toilet bowls and toilet tanks.
The present inventors disagree that the above described molding process could be used for toilet bowls because the plastic surfaces of the toilet bowls which are exposed to water movement become eroded and also become stained. The inventors further point out that whereas a shower, a wash basin or a bath-tub is filled with water only it is in use, a toilet bowl is always filled with water with the single exception when it is being flushed. The inventors have found that the plastic mater-ials do not hold up against erosion by the presence of water and by the water movement within a toilet bowl.
The present inventors recognized a need for a toilet bowl whose functional surfaces were formed out of a glazed cer-amic material and whose external surfaces were coated with a synthetic plastic composition such as simulated marble. They first tried using a ceramic shell liner having external surfaces and internal surfaces which were also function and also having a bowl, a siphon trap and a water flush ring. They roughened the external surfaces of the ceramic shell liner by either sand-blasting or chemically etching these surfaces. They left the internal surfaces glazed in order to withstand erosion by water movement. They next placed a synthetic plastic composition about the external surfaces of the ceramic shell liner and allowed the composition to cure and to bond to external surfaces -. . - ~ _ .
'' ' ' ' ' ,~ ' , , ' ' thereby forming a toilet bowl which would match -the other plumb-ing fixtures in a bathroom. The inventors encountered a serious problem in using this molding process because the synthetic plastic composition as it cured itself shrank and cracked the ceramic shell liner.
SUMMARY OF THE INVENTION
The present invention provides a process comprising coating the external surfaces of a ceramic plumbing fixture with a layer of resilient material, molding to the resilient layer a curable poiyester resin matrix that tends to shrink as it cures, and curing said matrix to bond.said matrix to said resilient layer, said resilient layer having sufficient com-pression strength to prevent said fixture from cracking when said matrix is cured. The molding step comprises placing the : resilient material-coated fixture as a male molding member with-.. in a female molding member where the interior surfaces of said female molding member are spaced a predetermined distance from said resilient layer and then filling the space with said cur-able polyester resin matrix.
In another aspect of the invention, there is pro-vided a plumbing fixture comprising a ceramic shell having cer-amic functional surfaces and an external surface at least part-ially coated with a resilient layer and a cured decorative poly-ester resin matrix layer over said resilient layer, said re-silient layer having sufficient compression strength to pre-vent said fixture from cracking when said matrix is cured.
. Thus the present invention provides a toilet fixture which has glazed ceramic functional surfaces and attractively :
. .
': ' ': ' ' : . , . : : . . . :
~ . , ' ` ' ~4$6~;i colored plastic external surfaces. The functional surfaces resist erosion by water movement and are impervious to stains.
In accordance wlth a preferred embodiment of the present invention a molding process adapted for the production of a plumbing fixture, such as a toilet, whose functional sur-faces are resistant to erosion by moving water wherein a cer-amic shell forms a liner having external surfaces and the func-tional surfaces of the plumbing fixture is described. In the ; case of a toilet the ceramic shell includes a bowl, a siphon trap and a water flush ring. The molding process includes the steps of coating the external surfaces of the ceramic shell with a layer of resilient material and then suspending the cer-amic shell upside down within a female mold member having in-ternal surfaces such that the internal surfaces of the female mold member are slightly spaced from the external surfaces of the ceramic shell thereby leaving a gap between the internal surfaces of the female mold member and the external surfaces of the ceramic shell. The molding process also includes the steps of filling the gap with a catalyzed polyester resin matrix mixed with a filler and pigments and permitting the matrix to cure and to bond to the coated external surfaces of the ceramic shell. The molding process further includes the step of re-moving the female mold member thereby producing a plumbing fix-ture, such as a toilet, that has an attractive exterior appear-- ance which matches other plumbing fixtures to be used in the same room in both their color texture and design.
This invention will be more readily appreciated as the same becomes better understood by reference to the following ~ . .
- : - . ' .. . .
~ ' . '. :
.
6~
detailed description and considered in connection wi-th the accompanying drawing in which like reference symbols designate like parts throughout the figures.
DESCRIPTION OF THE DRAWING
FIG. 1 is a side cross-sectional view of a ceramic toilet shell that has external surfaces and functional surfaces which are glazed and fired.
FIG. 2 is a side cross-sectional view of the ceramic toilet shell of FIG. 1 which has its external surfaces coated with a layer of resilient material in accordance with the prin-ciples of the present invention.
; FIG. 3 is a cross-sectional view of the ceramic toilet shell of FIG. 1 disposed upside down and suspended within a fe-male mold member which is also shown in a cross-sectional view.
FIG. 4 is a cross-sectional view of the ceramic toilet shell of FIG. 1 which is suspended upside down in the female mold member of FIG. 3 after a synthetic polyester resin compos-ition has beèn injected between the internal surfaces oE the fe-male mold member and the external surfaces of the external sur-faces of the ceramic toilet shell.
.. .
FIG. 5 is a side elevational view of a simulated marbleor plastic plumbing fixture which is constructed in accordance with the principles of the present invention.
DESCRIPTION OF TE~E PREFERRED EMBODIMENT
The present invention can best be unders-tood by re-ference to a description of its preferred embodiment in conjun-ction with the figures of the drawing. The preferred embodiment of the present invention is a toilet fixture which has its .
~,: ' ' , ' ' . ' :
, . ~ . .. . . .
external surfaces coated with simulated onyx.
Referring to FIG. 1 a side cross-sectional view of a ceramic shell liner 11 of a toilet fixture is shown. The ceramic shell liner 11 has unfinished external surfaces 12 and functional surfaces 13. The ceramic shell liner ll includes a bowl 14, a siphon trap 15 and a water ring 16. The howl 14 has an opening 17 around which the water flush ring 18 is dis-posed. The bottom portion of the bowl 14 has an opening 16 which connects with the siphon trap 15. The visable portions of the functional surfaces of the bowl 14, the siphon trap 15 and the water flush ring 16 are glazed and fired in kiln there-by producing a hard shiny layex 19. The formation of this layer ~ 19 is accomplished by conventional methods. In a conventional - process for manufacturing a ceramic toilet, the external sur-faces would also be glazed and fired. The external surfaces 12 of the ceramic liner 11 are unglazed. Generally the ceramic shell liner is of even thickness throughout and is approximately three-eights of an inch.
Referring now to FIG. 2 the external surface 12 of ceramic shell liner 11 is coated with a layer 20 of resilient material which bonds thereto.
Referring now to FIG. 3 the ceramic shell is placed in an upside down manner within a mold cavity formed by the female mold assembly 30. The female mold assembly 30 includes a first side mold member 31 a second side mold member 32 and a bottom mold member 33. The ceramic shell 11 is placed within the female mold cavity so that there is an even gap located all about the external surfaces 12 of the ceramic shell liner 11. It is to be , - :
,~
noted that the gap 34 extends about the water flush ring 16 wi-th a protuberance of the female mold assembly 30 being located with-in a water inlet opening which supplies water from a tank (not shown) into the bowl of the toilet fixtures to seal off during casting the water ring 12. The positioning of the ceramic shell within the mold cavity to produce an even gap 34 is facilitated due to the placement of the protuberance within the opening which is essentially a self aligning feature.
Within the gap 34 is to be poured the plastic matrix.
This plastic matrix will entirely fill the gap 34. This plastic material upon curing will be bonded directly to layer 20 of resilient material 24 of the ceramic shell liner 11. There will be a slight amount of shrinkage, usually two to three percent, during the curing of the plastic material. This shrinkage is absorbed by the layer 20 of resilient material and serves to insure a strong mechanical bond to the ceramic shell liner 11.
With the addition of the layer 20 the shrinkage is not suffi-cient to cause any undue strain or stress upon the ceramic shell liner 11 which will break it.
Generally it is desirable to obtain a smooth, glossy external layer of plastic that is also hard. This layer is ob-tained by coating the interior cavity of the female mold assembly 30 with a gel coat. The use of the gel coat i.s very comrnon in the plastic industry where there are several different types of gel coat materials. For use in the present invention a gel coat in the form of a thin liquid plastic material which can be easily sprayed upon the interior surfaces of the cavity has been found acceptable by the inventors.
. .
, . . . . .
- . . .. . . :
,' ,: ' . ' , , ' , ' ,' ' ' "' ' :
. ~ :
-~846~
The molding process includes the step of pouring a matrix 35 of a particular color into the gap 34. The matrix may be colored to include striations such that it resembles marble texture. The matrix 35 generally includes a polyester resin that has been catalyzed by a methyl-ethyl ketone peroxide or a methyl methacrylate monomer catalyzed appropriately. The matrix 35 further includes fillers such as CaCO3 and hydrated alumina in addition to other organic and inorganic ma-terials.
The catalysts and fillers are mixed together and the resulting mixture has pigments added thereto in order to form the matrix - 35 which is Poured into the qa~ 34.
- The inventors have noted that the greater the amount of fillers added to the polyester resin, the less likely the composition will pour. Since it is desirable that the matrix 35 be pourable, the preferrable range of filler to ov~rall com-position is from the thirty per cent to sixty per cent by weight.
Reference -to FIG. 4 shows the female mold assembly 30 after the matrix 35 has been poured into the gap 34.
When the matrix hardens sufficiently, the mold mem-bers 31, 32 and 33 are removed and the resulting finished pro-- duct is shown in FIG. 5. The toilet fixture has a smooth, glossy external surface 40 and is mechanically coupled to a water tank 41. The toilet fixture has all of the features of a conventional toilet fixture plus the addition of an ornamental and attractive external surface 40. The construction of the water tank 41 may be totally done by a method of molding or casting a com-position that is similar to the external surface 40 of the toilet fixture.
., .
' :: .....
~ 34665 The inventors have also discovered that if they use a composition of polyester resins that is relatively low-shrink-ing they can elimate the layer 20 of resilient material. Pre-sently these resins are more expensive than the resins in commercial use.
The inventors believe that their basic invention is a ceramic shell liner 11 which is used as the male mold member in conjunction with a female mold assembly to produce an orna-mental plumbing fixture. The use of the ceramic shell liner 11 is unique in and of itself. The inventors have discovered two aIternative methods of eliminating the breaking that occurs when the resins cure. The first method is to add a layer of re-silient material`to the-external surfaces of the ceramic shell liner in order to absorb the shrinkage of the resins. The second method is use a low-shrinking resin.
From the foregoing it can be seen that a toilet fix-ture with an attractive and ornamental external surface has been described. Furthermore the functional surfaces of this toilet fixture are formed from a ceramic material with those functional surfaces that are visable being glazed and fired to provide a hard and shiny surface that is impervious to stains and water erosion.
It should be noted that the schematics of the molding process are not drawn to scale and that distances of and between the figures are not to be considered signiflcant.
' Accordingly, it is intended that the foregoing dis-closure and showing made in the drawing shallbe considered only - as an illustration of the principle of the present invention.
....
. . ~: :. .
.
, . . . ~ . .
. .. . . . . . .
.: . , : .
'' : ;.
. ' ', , , ' , :
Claims (7)
IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A process comprising coating the external surfaces of a ceramic plumbing fixture with a layer of resilient material, molding -to the resilient layer a curable polyester resin matrix that tends to shrink as it cures, and curing said matrix to bond said matrix to said resilient layer, said resilient layer having sufficient compression strength to prevent said fixture from cracking when said matrix is cured; said molding step comprising placing the resilient material-coated fixture as a male molding member within a female molding member where the interior surfaces of said female molding member are spaced a predetermined distance from said resilient layer and then filling the space with said curable polyester resin matrix.
2. The process of claim 1 wherein said polyester resin matrix comprises at least one filler.
3. The process of claim 2 wherein said at least one filler is selected from the group consisting of calcium carbonate and hydrated alumina.
4. The process of claim 1, 2 or 3 wherein said polyester resin matrix comprises at least one pigment.
5. The process of claim 1, 2 or 3 wherein the plumbing fixture is a toilet.
6. A molding process adapted for the production of a plumbing fixture whose functional surfaces are resistent to erosion caused by moving water where-in a ceramic shell forms a liner having external surfaces and the functional surfaces of said plumbing fixture, said molding process comprising the steps of:
a. coating the external surfaces of said ceramic shell with a layer of resilient material;
b. suspending said ceramic shell upside down within a female mold member having internal surfaces so that the internal surfaces of said female mold member are slightly spaced from the external surfaces of said ceramic shell thereby leaving a gap between the internal surfaces of said female mold member and the external surfaces of said ceramic shell;
c. filling said gap with a catalyzed polyester resin matrix mixed with a filler and pigments;
d. permitting said matrix to bond and to cure to the coated external surfaces of said ceramic shell; and e. removing said female mold member thereby producing a plumbing fixture having an attractive exterior appearance which matches the color texture and the design of other plumbing fixtures to be used in the same room.
a. coating the external surfaces of said ceramic shell with a layer of resilient material;
b. suspending said ceramic shell upside down within a female mold member having internal surfaces so that the internal surfaces of said female mold member are slightly spaced from the external surfaces of said ceramic shell thereby leaving a gap between the internal surfaces of said female mold member and the external surfaces of said ceramic shell;
c. filling said gap with a catalyzed polyester resin matrix mixed with a filler and pigments;
d. permitting said matrix to bond and to cure to the coated external surfaces of said ceramic shell; and e. removing said female mold member thereby producing a plumbing fixture having an attractive exterior appearance which matches the color texture and the design of other plumbing fixtures to be used in the same room.
7. A molding process according to claim 6 wherein said plumbing fixture is a toilet and said ceramic shell includes a bowl, a siphon trap and a water flush ring.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US05/788,547 US4086318A (en) | 1977-04-18 | 1977-04-18 | Molding process for a plastic-coated ceramic decorative plumbing fixture |
| US788,547 | 1977-04-18 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1084665A true CA1084665A (en) | 1980-09-02 |
Family
ID=25144832
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA300,824A Expired CA1084665A (en) | 1977-04-18 | 1978-04-10 | Molding process for a hybrid decorative plumbing fixture |
Country Status (3)
| Country | Link |
|---|---|
| US (1) | US4086318A (en) |
| CA (1) | CA1084665A (en) |
| DE (1) | DE2816848A1 (en) |
Families Citing this family (11)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4328179A (en) * | 1980-04-07 | 1982-05-04 | Gruber Systems, Inc. | Method for making a cast toilet base of plastics material |
| FR2676957B1 (en) * | 1991-05-27 | 1993-09-24 | Oreal | METHOD FOR MANUFACTURING A PART HAVING THE APPEARANCE OF A NATURAL STONE BY MOLDING A COMPOSITION CONTAINING A THERMOSETTING RESIN AND PART OBTAINED BY THIS PROCESS. |
| EP0753401B1 (en) * | 1995-06-29 | 1999-05-06 | Louise Dr. Schlaaff | Multilayered composite body and method for its manufacture |
| WO1998020473A1 (en) * | 1996-11-07 | 1998-05-14 | United Surgical Services Limited | Method of manufacturing a surgical model |
| US6000673A (en) * | 1997-09-12 | 1999-12-14 | Talon Surfaces Llc | Mold assembly for producing a countertop exhibiting an integrally formed sink bowl and built-up edge and method for producing the same |
| US5948333A (en) * | 1998-05-21 | 1999-09-07 | Replica Plastics | Method for creating imitation marble facade for objects |
| US20080318071A1 (en) * | 2007-06-21 | 2008-12-25 | Moen Incorporated | Metallic coating on substrate |
| CN106638870B (en) * | 2015-11-02 | 2019-10-15 | 佛山市恒洁卫浴有限公司 | Hydrosphere inner wall surface layer seals sanitary ware |
| US10711442B2 (en) | 2016-04-26 | 2020-07-14 | Kohler Co. | Composite faucet body and internal waterway |
| US11047122B2 (en) | 2017-05-22 | 2021-06-29 | Kohler Co. | Toilet with vitreous china flush engine and polymeric outer structure |
| US11118338B2 (en) | 2017-05-22 | 2021-09-14 | Kohler Co. | Plumbing fixtures with insert-molded components |
Family Cites Families (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3172775A (en) * | 1965-03-09 | Method of coating resin on ceramic | ||
| US2657153A (en) * | 1948-06-04 | 1953-10-27 | Burns & Russell Co | Coating ceramic and masonry products |
| US3060608A (en) * | 1956-01-16 | 1962-10-30 | Gladding Mcbean & Co | Three-dimensional carrier sheet for decorating hollow ware |
| US3212106A (en) * | 1963-07-18 | 1965-10-19 | American Radiator & Standard | Coatings |
| US3607606A (en) * | 1967-05-16 | 1971-09-21 | Coors Porcelain Co | Ceramic-rubber composites |
| US3575916A (en) * | 1967-12-08 | 1971-04-20 | Corning Glass Works | Impregnating and coating composition for porous ceramic insulation |
| US3660214A (en) * | 1969-04-21 | 1972-05-02 | Merry Co Inc | Concrete block or the like with multiple brick facing and method of making the same |
| US3664799A (en) * | 1969-11-04 | 1972-05-23 | American Standard Inc | Powder compacting press |
-
1977
- 1977-04-18 US US05/788,547 patent/US4086318A/en not_active Expired - Lifetime
-
1978
- 1978-04-10 CA CA300,824A patent/CA1084665A/en not_active Expired
- 1978-04-18 DE DE19782816848 patent/DE2816848A1/en not_active Withdrawn
Also Published As
| Publication number | Publication date |
|---|---|
| DE2816848A1 (en) | 1978-10-19 |
| US4086318A (en) | 1978-04-25 |
Similar Documents
| Publication | Publication Date | Title |
|---|---|---|
| CA1084665A (en) | Molding process for a hybrid decorative plumbing fixture | |
| US6491852B1 (en) | Method of making monolithic terrazzo floors having seamlessly integrated inlays | |
| CN111844569B (en) | Method for forming pattern, bathroom product and shielding film | |
| CN110788961B (en) | Mold for manufacturing siphon type pedestal pan and preparation method of siphon type pedestal pan | |
| CN213774208U (en) | Waterproof building material | |
| CN206737067U (en) | A kind of integral type artificial stone shell adds the console mode toilet structure of ceramic liner | |
| KR200342431Y1 (en) | Grooved pebble stone bonding structure | |
| KR102416744B1 (en) | Method of manufacturing bathtub | |
| JP4403718B2 (en) | Method for manufacturing plate-shaped building materials for protruding corners | |
| CN219095429U (en) | Complex detachable box type mould for exposed aggregate floor tile | |
| JP2024016675A (en) | sanitary ware | |
| FR2676020A1 (en) | Method of manufacturing a cladding material based on mortar reinforced with glass fibres | |
| JPH0339810B2 (en) | ||
| JP2644033B2 (en) | Casting method for ceramics with pattern | |
| IT9085015A1 (en) | PROCEDURE FOR THE PRODUCTION OF MONOLITHIC WASHBASINS AND SINKS IN MARBLE AGGLOMERATE AND WASHBASINS AND SINKS SO OBTAINED | |
| JPH0728226Y2 (en) | Western style toilet | |
| CN206737072U (en) | A kind of integral type artificial stone shell adds the wall-hung type toilet structure of ceramic liner | |
| KR200325217Y1 (en) | Pebble stone bonding structure | |
| CN2687198Y (en) | Composite board (ABS) water closet | |
| KR960007950Y1 (en) | Assembling panel | |
| KR200419411Y1 (en) | Pebble stone bonding structure | |
| CN201011280Y (en) | One-shot forming artificial stone doorsill | |
| JPS59192525A (en) | Manufacture of sink for lavatory | |
| JPH0360650B2 (en) | ||
| JPS5941539A (en) | Production of washing ball |
Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| MKEX | Expiry |