Introduction
In the modern sanitary ceramics industry, the traditional gypsum mold grouting molding is accelerating the evolution to high-pressure molding technology. However, from the point of view of manufacturing economics and process mechanics, not all product forms cut into the marginal benefits of high pressure forming are exactly the same. For wall-mounted toilets, integrated washbasins and column basins, which have extreme "high consistency" requirements for geometric accuracy, water absorption and micro-defect rates,High pressure molding shows irreplaceable technical dominance. Based on long-term equipment development and production practice, Sunland deeply analyzes the underlying application logic of high-pressure molding in such products.
1. Wall-mounted toilet: Solving the stress problem of complex suspended structures
Wall-mounted toilet due to its suspended installation of load-bearing characteristics,The mechanical strength and the compactness of the internal structure are the key to determine the safe life of the product.
Due to the lack of direct support on the ground, the flatness error of the back installation area must be controlled at the millimeter level. Due to the low solid content (about 55-60wt%) and large drying shrinkage of traditional grouting, it is easy to produce warpage on the amorphous surface.
Under the high pressure of 1.0 - 1.2 MPa, the free water between the microscopic particles is forced to be squeezed out by the high pressure multi-grouting system, so that the initial density of the green body is greatly increased. The high pressure forming reduces the internal porosity of the green body by more than 35%. The overall size deformation rate of the wall-hanging toilet seat after burning is reduced by 75%,It perfectly fits the strict indicators of installation consistency of global B2B engineering projects.
2. Washbasin and integrated basin: eliminate large plane bending and glaze pinhole defects
Washbasins, especially desktop integrated basins with large stretching planes, are recognized as the hardest hit areas of "edge cracking and pinholes" in ceramic manufacturing.
Edge effect and stress concentration: In traditional molding, mud passively absorbs water by the capillary force of the mold, and the dehydration speed of the center and edge of the large plane is uneven, resulting in a gradient difference in the internal density of the unfired body. The core of high pressure grouting is to achieve omni-directional, isotropic synchronous dehydration through porous resin mold. Because the pressure is evenly distributed on the surface of the basin,The shear stress generated by thickness is effectively avoided.
3. Column Basin: Gravity droop of long longitudinal component
The column Basin is a typical large length to diameter ratio, long longitudinal Hollow Member. In traditional manufacturing,This kind of structure is prone to "sagging" or "instability and distortion" due to its own weight in the high temperature sintering stage ".
High temperature creep resistance: to resist the sagging of gravity in the firing stage, the green body must have a very high packing density of skeleton particles before sintering. Sunland's technical path is under micron-level pressure holding control of the high-pressure multi-Cascade grouting machine before high-pressure grouting,The fine particles are precisely embedded in the gaps of the coarse particles, forming a dense interlocking skeleton in the mold. This structure imparts extremely high "green strength" to the basins, effectively counteracting non-uniform volume shrinkage during subsequent sintering.
To sum up, the core scenario of high-pressure molding technology (HPC) is the high-end, complex configuration or mass delivery of bathroom products that are difficult to overcome "physical deformation", "internal stress defects" and "poor wall thickness consistency" by traditional manual work and conventional gypsum grouting.