WO2025071536A1

WO2025071536A1 - An improved structure enabling the production of toilet bowls

Info

Publication number: WO2025071536A1
Application number: PCT/TR2024/051102
Authority: WO
Inventors: Mustafa Acar; Yasar Rifat ESENSU; Mustafa ORAKCI
Original assignee: Unimak Makina Sanayi Ve Ticaret AS
Current assignee: Unimak Makina Sanayi Ve Ticaret AS
Priority date: 2023-09-26
Filing date: 2024-09-26
Publication date: 2025-04-03
Anticipated expiration: 2026-03-26
Also published as: CN120513160A; MX2025006184A

Abstract

The invention relates to a casting machine (10) provided with a plurality of molds for casting products such as toilet bowls (70), and in particular to a casting machine (10) which allows at least partial rotation of the mold during this casting process.

Description

AN IMPROVED STRUCTURE ENABLING THE PRODUCTION OF TOILET BOWLS

TECHNICAL FIELD

The invention relates to a casting machine for the production of toilet bowls.

PRIOR ART

Nowadays, for the casting of sanitary ware such as washbasins and shower trays, a sanitary ware casting machine with a multi-mold system that casts a plurality of sanitary ware on one machine can be used. Sanitary ware casting machines enable the production of products with predetermined dimensions and aesthetics, and standardization of production.

However, in these sanitary ware casting machines, the molds are positioned vertically by means of a suspension system. In this case, such a sanitary ware casting machine can only produce sanitary ware that needs to be demolded at 90 degrees. For specific sanitary ware that need to be demolded in a horizontal position, a new sanitary ware casting machine must be provided.

In the state of the art, casting machines provided for sanitary ware that need to be demolded in a horizontal position can cast with a mold. In this case, this leads to inefficiency in terms of labor, time and cost.

There is a patent application with application number US5156855 in the literature. The application referred to relates to an apparatus used in the pressure slip casting of ceramic articles such as plumbing. According to the invention, during molding, the machine is tilted by a hydraulic unit, increasing the efficiency of molding and ensuring that excess raw material is discharged.

In addition, toilet bowl technology has also changed over time. Today, sanitary ware known as smart toilets have more complex indentations and protrusions than conventional toilet bowls. During the production of these indentations and protrusions in the currently used sanitary ware casting machines, the mud/liquid mortar cannot completely settle in the mold, resulting in a hollow structure. In this case, the scrap rate increases, the production cost increases, and time losses occur.

Some other common problems encountered on these machines are described as follows:

- Quality Control Problems: Quality problems may arise in products due to lack of calibration or production errors in casting machines. This can result in defects such as cracks, scratches, or surface roughness of the toilet bowls.

- Casting Errors: Casting errors such as air bubbles or material flow problems can occur during the casting process. This can lead to the formation of defective zones inside or outside the toilet bowls.

Machine Breakdowns: Casting machines can wear out over time or experience technical problems. This can lead to a production line stoppage or irregular production.

Production Efficiency Problems: Efficiency problems can be caused by factors such as the slow running of the machine, frequent breakdowns, or inefficient casting processes.

- Material Problems: The quality of the materials used for the casting process has a great impact on the durability and aesthetics of the toilet bowls. Using low- quality or contaminated materials can cause problems.

Environmental Factors: Environmental factors such as humidity, temperature fluctuations, or dust can affect the performance of casting machines.

Labor Problems: Inadequate labor in the maintenance and operation of casting machines can lead to machine problems.

As a result, all the above-mentioned problems have made it imperative to make an innovation in the relevant technical field. SUMMARY OF THE INVENTION

The present invention relates to a casting machine for eliminating the above-mentioned disadvantages and bringing new advantages to the relevant technical field.

An object of the invention is to introduce a casting machine for molding sanitary ware such as toilet bowls with complex structures.

To achieve all the objects mentioned above and that will emerge from the following detailed description, the present invention relates to a sanitary ware casting machine. The novelty of the invention is that said casting unit is configured to be at least partially rotatable so as to be substantially parallel to the ground, it comprises a carrier body on which said casting unit is positioned, it comprises an upper mold integrally integrable with the casting unit and disconnectably associated with the carrier body, it comprises at least one side mold on opposite sides of the upper mold, said side molds are configured to be moved closer and further apart relative to each other, it comprises a lower mold integrally integrable with the casting unit and disconnectably associated with the carrier body, and it comprises at least one rotating shaft to allow the mold to be rotated around itself by engaging the side mold on one side and a drive source on the other side. Thus, a casting machine with improved toilet bowl production is obtained.

In a possible embodiment of the invention, the upper mold comprises at least one tab and the lower mold comprises at least one tab slot for the connection of the upper mold to the lower mold. Thus, the upper mold and the lower mold are joined and the product is molded.

In a possible embodiment of the invention, it comprises at least one lock and at least one lock slot in which said lock is placed. Thus, the molds are tightly locked together and the desired product form is created.

In a possible embodiment of the invention, it comprises at least one hanger for carrying the upper mold. Thus, the upper mold can be moved to facilitate transport or removal of the product from the mold. In a possible embodiment of the invention, the carrier body comprises at least one slide for moving the side molds relative to each other. Thus, the horizontal movement of the side molds is ensured and the creation of the mold structure becomes easier.

BRIEF DESCRIPTION OF THE DRAWING

Fig. 1 shows a representative perspective view of the casting machine of the invention.

Fig. 2 shows a representative exploded view of the casting unit located in the casting machine of the invention.

Fig. 3 shows a representative perspective view of the casting unit located in the casting machine of the invention.

Fig. 4 shows a representative front view of the casting unit located in the casting machine of the invention.

Fig. 5 shows a representative rear view of the casting unit located in the casting machine of the invention.

DETAILED DESCRIPTION OF THE INVENTION

In this detailed description, the subject of the invention is explained by way of example only for a better understanding of the subject, which shall not create any limiting effect.

Fig. 1 shows a representative perspective view of the casting machine (10) of the invention. Accordingly, said casting machine (10) enables particularly the production of sanitary wares by injecting mud/liquid mortar into the mold. In the preferred embodiment of the invention, the sanitary ware is the toilet bowl (70). The casting machine (10) has at least one casting unit (30) and at least one main body (20) for carrying the said casting unit (30). Said casting unit (30) can rotate at least partially around itself parallel to the floor in said main body (20) to enable the molding of particularly complex sanitary wares. The casting unit (30) is rotated by means of at least one rotating shaft (52) positioned thereon being driven by at least one driving element (60) positioned on the main body (20). In the possible embodiment of the invention, there are two rotating shafts (52) and these are supported in bearings on the main body (20) from both opposite sides of the casting unit (30). The rotating shaft (52) is connected to the oppositely positioned side molds (31 ).

Fig. 2 shows a representative exploded view of the casting unit (30) located in the casting machine (10) of the invention. Accordingly, the casting unit (30) comprises at least two side molds (31 ) positioned opposite each other, at least one lower mold (34) and upper mold (35) vertically associated with said side molds (31 ) to form a closed volume for molding the toilet bowl (70). In addition, the casting unit (30) has at least one rear mold (32), and provides mud/liquid mortar introduction into the mold by the said rear mold (32). The molds are configured to be a part of the surface surrounding the form to be produced inside. At least one flow line (33) is located on the rear mold (32) and allows the flow of molding material into the mold.

In the casting unit (30), opposite molds are moved relative to each other for the molding and demolding of the sanitary ware. The side molds (31 ) are positioned to slide on at least one slide (51 ). Said slide (51 ) is connected at each end to at least one carrier body (50) positioned on opposite sides of the casting unit (30). In a possible embodiment of the invention, two side molds (31 ) are hydraulically moved horizontally on a slide (51 ). The lower mold (34) and upper mold (35) are moved vertically by moving elements (not shown in the figures) positioned on the main body (20). The hangers (41 ) positioned on the upper mold (35) ensure that the moving elements carry the upper mold (35). The lower mold (34) and the upper mold (35) are separated from the moving elements to allow the casting unit (30) to rotate around itself. The lower mold (34) and upper mold (35) separated from the moving elements are configured to move together with the casting unit (30).

The lower mold and the upper mold (35) have at least one lock (39) each to ensure that they are positioned in the casting unit (30). Said locks (39) enter at least one lock slot (40) each on the side molds (31 ) and allow the lower mold (34) or upper mold (35) to move vertically together with the casting unit (30). The lock (39) and the lock slot (40) are configured to be connected to each other. In the preferred embodiment of the invention, the lock (39) and the lock slot (40) are at least four each for the lower mold (34) or the upper mold (35) and are pneumatically moved towards the lock slot (40). In another possible embodiment of the invention, the lock (39) is hydraulically driven. In this way, it is difficult to separate the parts that make up the mold from each other under load. In addition, the lower mold (34) and the upper mold (35) have at least one tab (37) each. Said tabs (37) engage with at least one tab slot (38) on the side molds (31 ). To allow this, the tab (37) has an L form. With this L-form, the tabs (37) are fully fitted in the tab slot (38) and locked. In this way, the side molds (31 ) are prevented from moving independently of each other and a rigid structure is obtained. In the preferred embodiment of the invention, at least one airbag (36) is positioned on the molds. Said airbags (36) expand pneumatically to compensate for the mounting gaps that can arise when the molds are joined. The moving elements in the casting machine (10) are connected to at least one control unit (not shown in the figures). By means of said control unit, the approach and withdrawal of the molds and at least partial rotation of the casting unit (30) are programmed and controlled by the user. The controller is preferably an arduino programming platform. In alternative embodiments of the invention, the control unit can be one of MSP430 Raspberry, BeagleBone Black, STM32 Discovery, Parallela Micro ServerBoard, PIC 16F877. In this way, it can be ensured that the casting machine (10) can be commanded in different ways according to the need.

In a possible embodiment of the invention, when a toilet bowl (70) is desired to be cast in the casting machine (10), the side molds (31 ) and the rear mold (32) move horizontally and rest against each other. After the horizontal engagement, the lower mold (34) and the upper mold (35) rest on the side molds (31 ) with vertical movement. With the lower mold (34) and the upper mold (35) resting on the side molds (31 ), the tabs (37) enter the tab slots (38) and the lock (39) engages the lock slot (40). The lower mold (34) and the upper mold (35) are separated from the movement elements after joining with the side molds (31 ). In this case, the casting unit (30) is connected with the casting machine (10) only with the rotating shaft (52). The rotating shaft (52) can be rotated by the drive element (60) in a predetermined amount. In order to mold the toilet bowl (70), the molding material is injected from the flow line (33) and the production of the product is achieved. During the casting of the toilet bowl (70), the casting unit (30) is rotated by the drive element (60) by a predetermined amount in order for the mud/liquid mortar that will form the toilet bowl (70) to settle in the mold without any gaps. After casting, the tabs (37) and locks (39) on the lower mold (34) and upper mold (35) are separated from the side mold (31 ) and removed from the side mold (31 ) vertically in order to remove the toilet bowl (70) from the mold. The toilet bowl (70) can then be removed by a robotic arm (not shown in the figures) by being held from its base (71 ). Or, if a separate gluing process is required on the rim (72) of the toilet bowl (70), the toilet bowl (70) can be rotated so that the weight of the toilet bowl (70) is on top, and glued.

With this structure, the casting angle, washing angle, discharge angle during casting can be easily achieved owing to the rotation feature of the casting unit (30). In addition, vertical casting and rim (72) casting methods are performed by a single casting machine (10) to prevent an extra product cost as a result. In addition, with the rotation feature, it is ensured that the heavy part is on top in glued toilet seat (70) production processes that cannot be produced in one go. In this way, the scrap rate is reduced, the production cost is reduced, and a high production amount is obtained in a short time.

The scope of protection of the invention is specified in the appended claims and cannot be limited to what is described for illustrative purposes in this detailed description. It is clear that a person skilled in the art can produce similar embodiments in the light of what is explained above, without deviating from the main theme of the invention.

REFERENCE NUMERALS GIVEN IN DRAWING

10 Casting Machine

20 Main Body

30 Casting Unit

31 Side Mold

32 Rear Mold

33 Flow line

34 Lower Mold

35 Upper Mold

36 Airbag

37 Tab

38 Tab Slot

39 Lock

40 Lock slot

41 Hanger

50 Carrier Body

51 Slide

52 Rotating Shaft Drive Element Toilet Bowl

71 Base

Claims

1 . A casting machine (10) comprising a casting unit (30) with at least two side molds (31 ), characterized in that said casting unit (30) is configured to be at least partially rotatable so as to be substantially parallel to the ground, it comprises a carrier body (50) on which said casting unit (30) is positioned, it comprises an upper mold (35) integrally integrable with the casting unit (30) and disconnectably associated with the carrier body (50), it comprises at least one side mold (31 ) on opposite sides of the upper mold (35), said side molds (31 ) are configured to be moved closer and further apart relative to each other, it comprises a lower mold (34) integrally integrable with the casting unit (30) and disconnectably associated with the carrier body (50), and it comprises at least one rotating shaft (52) to allow the mold to be rotated around itself by engaging the side mold (31 ) on one side and a drive source on the other side.

2. A casting machine (10) according to claim 1 , characterized in that the upper mold (35) comprises at least one tab (37) and the lower mold (31 ) comprises at least one tab slot (38) for the connection of the upper mold (35) to the lower mold (31 ).

3. A casting machine (10) according to claim 1 , characterized in that it comprises at least one lock (39) and at least one lock slot (40) in which said lock (39) is placed.

4. A casting machine (10) according to claim 1 , characterized in that it comprises at least one hanger (41 ) for carrying the upper mold (35).

5. A casting machine (10) according to claim 1 , characterized in that the carrier body (50) comprises at least one slide (51 ) for moving the side molds (31 ) relative to each other.