Abstract: This paper introduces the development of a high-efficiency water-saving toilet, and lists the problems and corresponding solutions in the development and production of this product in detail, providing reference for ceramic enterprises to further develop energy-saving products.
Key words: toilet; water saving
1.At present, the domestic sanitary ceramics market is oversupplied and the market competition is becoming increasingly fierce; raw materials, fuels, water, electricity, and labor prices continue to rise, which increases production costs. Fourth, my country’s sanitary wares are mainly exported to the US and Canada markets. Stricter and more demanding requirements are put forward for the import of toilets, not only requiring less and less water consumption, but also requiring thicker pipe diameters; at the same time, there are more and more supervision and testing items and stricter standards, so rough High-efficiency water-saving toilets with pipe diameters are very popular with customers and become a market selling point and the focus of enterprise development. Under this market situation, enterprises can win users and occupy the market only by following the trend of the times, meeting the needs of users and the market, and developing high-quality, efficient, water-saving, and high value-added products. This is also an important way for sanitary ceramics companies to get out of the predicament and improve economic efficiency.
According to market research, after nearly a year of research, we have successfully developed a large-diameter, luxurious (super-long, super-high, solemn and generous) toilet that is formed at one time. The discharge is thorough, far higher than the requirements of the American high-efficiency water-saving toilet (HET) standard. At present, it has been put into mass production and accepts a large number of orders from customers. The development, development and production process of the toilet is briefly introduced.
2.Development Goals and Requirements
The products we develop are developed and processed according to the outline drawings provided by customers.
The basic requirements are:
(1) The product is a split type, with a total of 2 toilets and water tanks;
(2) The combined dimensions are: length X width x height = 700mmx395mmx750mm;
(3) The sewage discharge form of the toilet is the bottom drainage, and the distance between the sewage discharge scale (wall distance) is 305mm (12inch);
(4) The structural form of the product is jet siphon type;
(5) The water seal area is required to be above 200mmx100mm;
(6) The water consumption requirement is <6L, 19mm small balls, place 100 and discharge >90; bean paste simulated notes pass >7 (≤350g);
(7) Thick pipes should pass through a 48mm detection sphere;
(8) Others are based on the provisions of GB6952-2005.
3. Design ideas
Through market research, it is found that there are products with similar appearance on the market, but their production process is complicated, the output is low, and the quality is not easy to guarantee. When we develop this product, we must first ensure that the product has a beautiful appearance, conform to the popular trend of the market, and make it easy for users to accept; various sizes meet the requirements of customers, so that the product looks luxurious and dignified; toilet and water tank, water tank and water tank The cover should be consistent with each other to reflect the streamlined unity of the whole set of products; secondly, adopt the current sanitary ceramics industry.The mature combined vertical pouring forming process, one-time forming, ensures quality, and can be mass-produced, which is conducive to production arrangement. Third, through careful research on the structure of product pipelines, and fully drawing on our company’s experience in developing jet siphon toilets, we designed toilet pipelines with excellent sewage discharge functions; fourth, in the design of pipeline waterway structures, we carefully studied The direction of the waterway is cleverly designed and manufactured to shorten the water flow process and reduce frictional resistance as much as possible to increase the momentum of sewage discharge; fifth, the standard pipe is thickened to ensure that the effective inner diameter of the finished product is increased from 42mm to 53mm, and the diameter of the smooth passage is 48mm solid sphere; at the same time, double water seals are added to enhance the effect of odor isolation and increase the momentum of sewage discharge.
4. Molding operation
(1) Process operation procedure
Model cleaning-mold clamping-micro-pressure grouting-slurry suction-slurry release-micro-pressure consolidation-mold opening-wet billet-Eye-catching crack detection->Turn the mold, take out the blank, wet the blank, trim it, dry it, and brush the blank.
(2) Product forming characteristics
Toilets, water tanks, and water tank covers are all produced vertically. Compared with other ordinary toilets in our company, this toilet is long, tall and bulky, which brings great difficulty to the forming production operation. During the storage and handling of the blank body, it should be handled with care, and protective measures should be taken to reduce damage; since the pipeline has double water seals, all pulping channels must be blocked after the pulping is completed to prevent air leakage, otherwise it will be damaged. Affect the sewage discharge function of the toilet.
5. Production process parameters
5.1 Glaze
Using our company’s ready-made glaze, using pressure glazing, the thickness of the glaze layer is 0.8~1.0mm
5.2 Model
Mixed gypsum powder was used to make the mold, the ratio of water to plaster was 1:1.4, and the mixing time was 2~3inin.
Use after drying at about 50°C.
5.3 Forming process parameters
Forming room temperature: 28~30℃ during the day, 32~36℃ at night;
Relative humidity: 50%~60%;
Micro pressure consolidation pressure: 0.015~0.02MPa;
Micro pressure consolidation time:20~40min;
Drying cycle: 7d;
Moisture when semi-finished products are brushed: less than 2%
6. Enhance water-saving function and increase the power of sewage discharge
For the jet siphon toilet, in order to reduce the sewage water consumption, it is necessary to make the flow from water release to siphon generation.The suction time should be as short as possible, so that the jet hole has a strong momentum and the instantaneous siphon suction force is strong. And this is related to factors such as the thickness, length, water seal height, jet port size, ring eye position, size, quantity, slope and other factors of the toilet sewage pipe. We use our factory’s rich design experience in sewage pipelines, and on the basis of similar products at home and abroad, carefully study the pipeline structure, water flow direction and other issues, and design the pipeline waterway structure ingeniously, reducing the water flow process as much as possible and increasing the size of the pipeline. Jet momentum; at the same time, the size and quantity of the ring holes and the size of the jet port are repeatedly tested and tested to determine the best solution, and finally the toilet has the properties of high efficiency, water saving, high momentum, and thorough discharge of dirt, reaching the predetermined goal Require. The siphon effect and sewage water consumption of this product are significantly improved compared with similar products. The product produces siphon early, short siphon action time, less water replenishment, less water consumption, complete discharge of dirt, and strong pumping force. In particular, its thick pipeline can eliminate the clogging of the toilet from the root, and the simulated note test meets the requirements of the American Standard HET (High Efficiency Water Saving) standard, and only 3.5L of water is used when urinating, and the water saving effect is remarkable. All the demanding ordering requirements put forward by customers have been met, and some indicators are better than the standard requirements.
7. Conclusion
The toilet breaks through the shackles of the traditional production process, and is produced by one-time forming combined casting.The appearance of the product is luxurious and solemn, integrating “thick pipe diameter”, “super long and super high”, “high efficiency and water saving”, “one time Forming” and integrated into one body, it has realized the perfect integration of product shape, internal structure and production technology. The toilet is favored by users because of its novel shape and excellent sewage discharge function. Its successful development has promoted the technological progress of the industry. It plays a great role in upgrading the toilet products and alleviating the pressure on the current sanitary ceramics enterprises.
