SANITARY ARTICLE

Abstract

A sanitary article, which has a support body and an outer coating which is applied to the support body at least in certain portions and forms the outer side of the sanitary article, the support body being of a first composite material of a filled polymeric binder matrix containing at least one filler in the form of hollow glass beads and the outer coating being of a second composite material of a polymeric binder matrix, which is filled with at least one filler and does not contain any hollow glass beads.

Claims

1. A sanitary article, which has a support body and an outer coating which is applied to said support body at least in certain portions and forms the outer side of the sanitary article, the support body consisting of a first composite material of a filled polymeric binder matrix containing at least one filler in the form of hollow glass beads and the outer coating consisting of a second composite material of a polymeric binder matrix, which is filled with at least one filler and does not contain any hollow glass beads.

2. The sanitary article according to claim 1, wherein the constituent parts of the first composite material and the constituent parts of the second composite material are the same except for the hollow glass beads, or in that the constituent parts of the first composite material and the constituent parts of the second composite material differ at least to some extent besides the hollow glass beads.

3. The sanitary article according to claim 1, wherein the second composite material contains at least one flame retardant, in particular aluminum trihydrate, as filler.

4. The sanitary article according to claim 1, wherein the second composite material contains at least one color additive, in particular an organic pigment or an inorganic pigment.

5. The sanitary article according to claim 4, wherein the inorganic pigment is titanium dioxide.

6. The sanitary article according to claim 1, wherein the second composite material contains (in % by weight of the hardened composite material): Polymeric binder: 44.0-65.0 Flame retardant: 35.0-55.0 Color additive: 1.0-5.0

7. The sanitary article according to claim 1, wherein the first composite material contains (in % by weight of the hardened composite material): Polymeric binder: 34.0-49.0 Flame retardant+poss. quartz: 47.0-62.0 Hollow glass beads: 1.0-5.1 Color additive: 2.4-2.8

8. The sanitary article according to claim 1, wherein the first composite material also contains a metal carbonate, in particular calcium carbonate, as filler.

9. The sanitary article according to claim 1, wherein the first composite material contains (in % by weight of the hardened composite material): Polymeric binder: 19.0-50.0 Metal carbonate: 45.0-70.0 Hollow glass beads: 0.5-9.5

10. The sanitary article according to claim 8, wherein the first composite material contains as filler at least one flame retardant, in particular aluminum trihydrate, to a maximum of 21% by weight.

11. The sanitary article according to claim 8, wherein the first composite material contains at least one color additive, in particular an organic pigment or an inorganic pigment, to a maximum of 5.0% by weight.

12. The sanitary article according to claim 11, wherein the inorganic pigment is titanium dioxide.

13. The sanitary article according to claim 1, wherein the first and/or second composite material also contains quartz as filler, the first composite material containing quartz to a maximum of 10.1% by weight and the second composite material containing quartz to a maximum of 5.7% by weight.

14. The sanitary article according to claim 1, wherein the first and/or the second composite material also contains dolomite as filler, the first and the second composite material each containing dolomite to a maximum of 7.3% by weight.

15. The sanitary article according to claim 1, wherein the first and/or the second composite material also contains one or more fillers selected from zircon, muscovite, garnet, melanite and feldspar, each to a maximum of 3.8% by weight.

16. The sanitary article according to claim 1, wherein the thickness of the outer coating is between 0.1-2.0 mm, in particular between 0.2-1.5 mm.

17. The sanitary article according to claim 1, wherein the overall thickness of the support body and outer coating is between 8.0-26.0 mm.

18. The sanitary article according to claim 1, wherein the article is a bathtub, a shower base, a shower tray, a wash basin, a washstand or a WC.

19. A method for producing a sanitary article according to claim 1, wherein a fluid outer coating of a polymeric binder, which is filled with at least one filler but does not contain any hollow glass beads, is applied at least in certain portions to a support body of a first composite material of a filled polymeric binder matrix containing at least one filler in the form of hollow glass beads, said polymeric binder then hardening to form a second composite material.

20. The method according to claim 19, having the following steps: casting a polymeric casting composition of a filled polymeric binder containing at least one filler in the form of hollow glass beads into a mold and hardening the casting composition to form the support body, thermally and/or mechanically aftertreating the support body which has been removed from the mold, applying a further polymeric, fluid mass of a polymeric binder, which is filled with at least one filler but does not contain any hollow glass beads, in order to form the outer coating, performing thermal aftertreatment in order to harden the outer coating and possibly mechanically aftertreating the outer coating.

21. The method according to claim 19, wherein the fluid mass is sprayed out or applied by dipping.

22. The method according to claim 19, wherein a fluid mass of a polymeric binder, which is filled with at least one filler but does not contain any hollow glass beads, is introduced into a mold for the purpose of coating the mold surfaces, which mass at least sets to form an outer coating, after which a further polymeric casting composition, which contains a filler in the form of hollow glass beads, is introduced into the mold such that the outer coating is backfilled, after which the mass and the casting composition harden to form two composite materials.

23. The method according to claim 22, having the following steps: spraying the fluid mass of a polymeric binder, which is filled with at least one filler but does not contain any hollow glass beads, onto the mold surfaces, thermally treating the coating in such a way that the coating sets to form an outer coating, casting the further polymeric casting composition, which contains a filler in the form of hollow glass beads, into the mold such that the outer coating is backfilled, hardening the mass and the casting composition, thermally aftertreating the sanitary article and possibly mechanically aftertreating the outer coating.

Description

BRIEF DESCRIPTION OF THE DRAWING

[0070] In the drawing:

[0071] FIG. 1 shows a basic illustration of a sanitary article according to the invention in a partial view according to a first embodiment,

[0072] FIG. 2 shows a basic illustration of a sanitary article according to the invention of a second embodiment in a partial view,

[0073] FIG. 3 shows a flow diagram for elucidating the method according to the invention of a first embodiment, and

[0074] FIG. 4 shows a flow diagram for elucidating the method according to the invention of a second embodiment.

DETAILED DESCRIPTION OF THE INVENTION

[0075] FIG. 1 shows a basic illustration of a sanitary article 1 according to the invention, which is for example a bathtub, only a detail being shown here. Shown in the basic illustration is a support body 2 which is provided on both sides with an outer coating 3. The support body 2 consists of a first composite material 4, while the two outer coatings consist of a second composite material 5.

[0076] The first composite material 4 consists of a filled polymer binder matrix 6, preferably a polyester resin. Said first composite material contains hollow glass beads 7, which serve to reduce the weight, as filler. Depending on the quantity of hollow glass beads 7 added, the weight can be reduced by up to approx. 15%.

[0077] A flame retardant 8, here in the form of aluminum trihydrate (ATH), can also be included as further filler. In addition, in the example shown, provision can be made albeit optionally for a color pigment 9, here for example TiO.sub.2, to be included, that is to say that this is used to color the support body 2.

[0078] It is also the case that the outer coatings 5 consist of a polymeric binder matrix 10, which is in turn a polyester resin. The binder matrix 10 also contains a flame retardant 11 here, in turn aluminum trihydrate. Furthermore also included here are color pigments 12, also here in turn TiO.sub.2.

[0079] It is clearly the case here that the first composite material 4 and the second composite material 5 as far as possible contain identical constituent parts, but in a different quantity. In the example shown, the composite materials 4, 5 differ merely in that the first composite material 4 contains the hollow glass beads 7, while the second composite material 5 does not contain said hollow glass beads.

[0080] The layer thickness of the respective outer coating 5 is in the range of from 0.1-2.0 mm, preferably from 0.2-1.5 mm, while the thickness of the support body 2 is a multiple of that. The overall thickness of the carrier layer 2 and outer layer(s) 5 should be between 8.0-26.0 mm.

[0081] As described, there is the possibility of dispensing with color pigments 9 in the first composite material 4, thus not to color it throughout. This is possible and leads to a further reduction in costs, after which the outer coating 5 contains corresponding color pigments 12, as explained.

[0082] Furthermore, there is additionally the possibility of adding further fillers, which may replace the flame retardant 8, i.e. the aluminum trihydrate, which is relatively cost-intensive, such as for example quartz, dolomite or the like.

[0083] FIG. 2 shows a further basic illustration of a sanitary article 1 according to the invention, for example in turn a detail of a bathtub. The basic structure corresponds to that as described in relation to FIG. 1, that is to say it is also the case here that a support body 2 and also outer coatings 3 on both sides are provided, the support body 2 consisting of a first composite material 4 and the outer coatings 3 consisting of a second composite material 5. As in the example according to FIG. 1, the second composite material 5 consists of a polymeric binder matrix 10, in turn a polyester-resin matrix, a filler in the form of a flame retardant 11, in turn aluminum trihydrate, and also pigments 12, in turn for example TiO.sub.2, being introduced in the binder matrix 10. The outer coating 5 thus corresponds to that of FIG. 1.

[0084] However, the structure or the composition of the first composite material 4 is different. This consists in turn of a polymeric binder matrix 6, in which in turn hollow glass beads 7 are introduced in a corresponding fraction. Likewise optionally included are color pigments 9, also here in turn TiO.sub.2.

[0085] In the first composite material 4, which is shown here, however, the relatively expensive flame retardant ATH is replaced by a metal carbonate 13 in the form of calcium carbonate, in the present case a complete replacement being assumed. It would also be conceivable to replace ATH only partially. That is to say that, in the simplest configuration, the first composite material only consists of the binder matrix 6 and the hollow glass beads 7 and also the metal carbonate 13, but contains neither color pigments 9 nor further additives, in particular in the form of the flame retardant 8.

[0086] As can be seen in both FIGS. 1 and 2, by virtue of a mechanical surface treatment of the two outer surfaces of the support body 2, hollow glass beads 7 which are close to the surface have been opened, that is to say ground open. This leads to a microporosity on the support body 2, which could lead in turn to the carrier body 2 tending to be easier to contaminate if it is not sealed by way of the outer coatings 5 provided according to the invention, since very fine dirt particles can penetrate into the micropores, i.e. the open hollow glass bodies 7.

[0087] As a consequence of the outer coatings 5 on the processed surfaces that are applied according to the invention, however, a complete sealing takes place with an outer coating which is comparable to the fundamental haptics, since said outer coating also consists of a binder matrix which contains fillers, etc.

[0088] FIGS. 1 and 2 are merely examples of a possible composition of the first and second composite materials 4, 5. It is fundamentally possible that the composite materials 4, 5 shown contain additional fillers such as, for example, quartz, dolomite, zircon, muscovite, garnet, melanite or feldspar. In particular, the first composite material 4 contains these fillers, since said first composite material ultimately does not necessarily need to have the corresponding visual and haptic properties as required by the outer coating 5, because said first composite material is sealed by the outer coating 5 which in turn forms the exterior visible surface. It is therefore readily possible, for example, to replace the color pigments 5 with another, cheap filler such as quartz or dolomite, since the support body 2 does not have to be colored throughout, since the outer coating 5 is colored. It may also be the case that the flame retardant is also replaced to a corresponding extent, or else, as described, completely, by adding one or more of the abovementioned additional fillers.

[0089] In the form of a flow diagram, FIG. 3 shows a first method variant according to the invention for producing a sanitary article according to the invention.

[0090] The casting composition, which forms the first composite material, is prepared in step S1. For this purpose, the binder B, i.e. the polyester resin, the additives A, such as for example the hardening agent (MEKP) and also color pigments, and the filler F, in the present case calcium carbonate since by way of example the configuration according to FIG. 2 is described, are mixed with one another in order to form the corresponding, sufficiently castable mass. Hollow glass beads are used as filler F.

[0091] The mass is cast into the mold in step S2, where it gelates and hardens in step S3. 2 0 This takes place at approx. 35°-40° Celsius for a duration of 15-40 minutes. After the hardening, the then-cast, finished support body is removed from the mold in step S4. It consists of the first composite material, which contains hollow glass beads.

[0092] In step S5, said first composite material is thermally treated, i.e. tempered, at a temperature of 60°-120° for 2-6 hours in order to reduce any stresses. Subsequent to this, in step S6, a mechanical reworking by grinding the surface takes place, it being possible for the hollow glass beads close to the surface to be ground open, i.e. opened, in the process, as described.

[0093] Then, in step S7, the finished support body is prepared for the subsequent coating with the outer coating.

[0094] This is prepared in step S8. In turn, for this purpose, the binder B, the polyester resin, the additives A such as the hardening agent and here imperatively the color pigments, and the filler F, in the present case the flame retardant aluminum trihydrate, are mixed in order to form a fluid, sprayable mass. Compared with the mass produced in step S1, the binder fraction of the mass produced in step S8 is considerably higher, in order to adjust the sprayability. This mass does not contain any hollow glass beads.

[0095] In step S9, the fluid mass produced in step S8 is sprayed onto the ground surfaces of the support body, the layer thickness being between 0.1-2 mm in relation to the finished, hardened state.

[0096] After the spraying-on, in step S10, for the purpose of hardening it is also the case here that a temperature-controlling step takes place at 60°-110° Celsius for 2-3 hours, that is to say that it is also the case here that any layer stresses are reduced by tempering. This forms the second composite material, which does not contain any hollow glass beads.

[0097] In step S11, which is however optional, the sprayed-on coating surface is reworked in order to provide it with a matt finish. This matt finish is provided by a very fine grinding means, there being no problems in this respect in terms of grinding open the hollow glass beads as there are when the support body is being mechanically ground, since the outer coating 5 does not contain any hollow glass beads.

[0098] In the method variant according to FIG. 3, the support body is thus produced as a separate component in a corresponding casting mold, which is subsequently covered with the outer coating. FIG. 4 describes an alternative method variant, in which the two layers or parts are applied or created in a common mold.

[0099] According to FIG. 4, in step S12, first the fluid mass which serves for forming the outer coating 5 is produced. For this purpose, in turn, the binder B, polyester resin, and the additives A, such as hardening agents and color pigments, and also the filler F in the form of the flame retardant are correspondingly mixed in order to form a sprayable mass.

[0100] In step S13, said sprayable mass is then sprayed onto the mold surfaces of the casting mold in which the actual support body is subsequently cast, specifically with a corresponding low layer thickness, in order to form the thin outer coating 5 on the end product.

[0101] In step S14, the sprayed-out mass is tempered at 60-110° for 0.5-3 hours such that it at least sets; a complete through-hardening is not absolutely necessary.

[0102] In step S15, the casting mold is prepared for the subsequent step in that, as described below, the outer coating is backfilled with the first composite material, which forms the support body.

[0103] The fluid mass, which forms the first composite material, is produced in step S16. For this purpose, in turn, the binder B, polyester resin, the additives A, such as hardening agents and color pigments, and also here again the metal carbonate, specifically calcium carbonate, as filler F are mixed in order to form a castable mass, which is then cast into the casting mold in step S17. In this respect, a complete backfilling of the set outer coating of the second composite material occurs.

[0104] The casting is followed, in step S18, by the gelating or hardening operation, which takes place at 35°-40° Celsius for 15-40 minutes. In that case, after both masses are hardened, i.e. both the support body 2 and the outer coating 5, the then almost-finished sanitary article is removed from the mold in step S19 and tempered at 60°-110° Celsius for 2-6 hours in step S20 in order to reduce any stresses in the sanitary article. The sanitary article is thus ultimately finished; this is followed merely still by an optional mechanical surface treatment in step S21 when the intention is to provide the surface with a matt finish.

[0105] Whereas in the example described above it is always the case that only calcium carbonate was used as filler for forming the first composite material composition of the support body, there is instead also the possibility of using ATH, i.e. the flame retardant, that is to say that ultimately the structure of the first and second composite materials are relatively similar in terms of the constituent parts. In addition, there is however of course also the possibility that also in this case further fillers, such as quartz, dolomite and the like, are added.

[0106] While specific embodiments of the invention have been shown and described in detail to illustrate the inventive principles, it will be understood that the invention may be embodied otherwise without departing from such principles.