Introduction
With the consumer's pursuit of integrated luxury bathroom experience, the ultra-long smart toilet with 720mm or even 750mm or more has become the core growth point of the high-end market. However, in the field of sanitary ceramics manufacturing, the difficulty of process control increases geometrically for every 10mm increase in product length.As a pioneer focusing on bathroom technology and equipment integration, Senlant Technology has conducted in-depth mechanical quantitative research on the "long-span deformation" pain points of ultra-long body intelligent toilets in the molding and high-temperature sintering stages in the process of long-term service industry head enterprises (such as Jiumu, Huida, etc.).
1.Multiplier effect of physical scale
In the mechanics of materials, when the length of the toilet body increases, the bending deflection and moment change greatly in the unsintered stage and the high temperature softening stage. When the toilet is sintered at high temperature (1200 ° C +), it is essentially a continuous beam structure supported by two ends or more points.This means that when the standard 650mm toilet is expanded to 720mm or even longer, even if the material is exactly the same, the physical trend of collapse, forward tilt or bottom swing deformation due to its own weight will surge by more than 40%.
Intelligent toilet in order to hide the internal complex electronic waterway, usually using all-inclusive skirt design.The ultra-long all-inclusive body means that the area of the side wall is greatly increased, resulting in a serious imbalance of the mass center of gravity before and after the toilet. Before being sintered in the kiln, the wet billet has already produced microscopic asymmetric creep under the gravity field.
2. It is difficult to control the deformation of forming and firing section
The extra-long toilet means a substantial increase in cavity volume,The requirements for high-pressure grouting equipment and slurry rheology are almost stringent.
The longer the product, the longer the flow path and drainage distance of the distal mud. This results in a significant "compaction gradient" between the region near the main inlet and the distal region of the elongated body ". When the high-pressure forming is finished and the slurry is discharged (returned slurry),If the residual mud in the super-long internal pipeline cannot be emptied synchronously in the whole cavity, it will form a small uneven wall thickness inside the toilet, which is the culprit of deformation in subsequent drying and burning.
The long axis direction of the super-long smart toilet is usually consistent with the running direction of the kiln. In a continuous tunnel kiln or shuttle kiln, due to the small vibration or airflow disturbance when the kiln car is propelled,In the high temperature liquid region of the long body, the front and rear will produce a slight speed difference, which will cause the product to tilt forward or overall distortion.
Burning frame resistance and bottom pendulum deformation: between the bottom of the toilet and the burning load-bearing plate at high temperature shrinkage will produce violent friction. Long toilet in the process of contraction (the overall shrinkage rate is usually 10% - 12%),The contraction of the bottom points is not synchronized due to the large span. If the rigidity of the bearing plate is insufficient or the flatness deviation exceeds 0.5mm, the "bottom pendulum warping" visible to the naked eye will occur at the bottom of the toilet, which will directly lead to the failure to fit the ground when the finished product is installed.