Patent Publication Number: US-2023146963-A1

Title: Ceramic ball having detergent function and manufacturing method thereof

Description:
BACKGROUND OF THE INVENTION 
     Field of the Invention 
     The present invention relates to a ceramic ball having a detergent function and a method for manufacturing a ceramic ball which is used in a washing machine or a dishwasher, and more particularly, to a ceramic ball having a detergent function and a method for manufacturing a ceramic ball, which can improve washing capacity since the ceramic ball is molded such that the surface area coming into contact with water gets wider, and can improve production efficiency and reduce the manufacturing cost since it is possible to manufacture ceramic balls continuously and automatically. 
     Background Art 
     In general, ceramic balls or washing balls having a detergent function are manufactured by ceramics being molded and burned in the form of a small ball, and are filled in an insertion part  31  of a detergent dispensing device  30  for a dish washer as illustrated in  FIG.  8   , or are filled in a detergent dispensing device  40  for a washing machine as illustrated in  FIG.  9   . 
     The detergent dispensing device  30  for the dish washer or the detergent dispensing device  40  for the washing machine in which the ceramic balls (B) are filled is inserted into the dish washer or the washing machine, so that dishes or laundry are cleaned or washed without using general detergent due to antibacterial effect and purification action caused by far-infrared radiation and anions emitted from the ceramic balls (B). 
     Korean Patent No. 10-1715275 granted to the inventor of the present invention discloses a ceramic ball (B) as a conventional art. 
     The conventional art relates to a ceramic ball having a detergent function and a method for manufacturing a ceramic ball which can improve washing capacity by widening the surface area of the ceramic ball getting in contact with water. That is, the conventional art provides an advantage to improve washing capacity by widening the surface area of the ceramic ball getting in contact with water. 
     Moreover, the conventional art has a groove formed in the ceramic ball in order to widen the surface area of the ceramic ball, and uses a groove making machine in order to form the groove in the ceramic ball. 
     However, because the groove making machine is a device to form a groove in the ceramic ball manually, it takes much time to form the groove in the ceramic ball. So, the groove making machine reduces production efficiency and increases the manufacturing cost. 
     Furthermore, because water flowing into the groove formed in the ceramic ball is not discharged out easily, there is a limitation in contact efficiency that the ceramic ball gets in contact with water. 
     PATENT LITERATURE 
     Patent Documents 
     Patent Document 1: Korean Patent No. 10-1715275 
     Patent Document 2: Korean Patent No. 10-0932949 
     Patent Document 3: Korean Patent Publication No. 10-2011-0006390 
     SUMMARY OF THE INVENTION 
     Accordingly, the present invention has been made to solve the above-mentioned problems occurring in the prior arts, and it is an object of the present invention to provide a ceramic ball having a detergent function and a method for manufacturing a ceramic ball, which can improve washing capacity since the ceramic ball is molded such that the surface area coming into contact with water gets wider, and can improve production efficiency and reduce the manufacturing cost since it is possible to manufacture ceramic balls continuously and automatically. 
     It is another object of the present invention to provide a ceramic ball having a detergent function and a method for manufacturing a ceramic ball, which can improve contact efficiency that the ceramic ball gets in contact with water since water can pass through a through hole formed in the ceramic ball. 
     To accomplish the above object, according to the present invention, there is provided a method for manufacturing a ceramic ball having a detergent function including: a first step of pulverizing and mixing raw materials in a fixed size to form feedstock powder; a second step of putting the feedstock powder formed through the first step into a ball shaping device and spraying water and a bonding agent to shape a ball; a third step of first drying the ball in order to form a through hole in the shaped ball; a fourth step of forming the through hole in the first dried ball by a through hole forming device; a fifth step of second drying the ball in order to perfectly remove moisture when forming the through hole in the ball is completed; and a sixth step of burning the dried ball to manufacture a ceramic ball. 
     The through hole forming device includes a ball aligning part and a through hole forming part which are formed in a row with a fixed slope. The ball aligning part is located at the uppermost part and automatically transferring the balls dried in the third step to the through hole forming part using vibration, and the through hole forming part temporarily fixes the ball transferred by the ball aligning part and forming a predetermined through hole in the ball. 
     Furthermore, the ball aligning part includes: a receiving part for receiving the plurality of balls; a vibration generating part mounted on the bottom surface of the receiving part to generate vibration so as to automatically transfer the balls received in the receiving part to a guide part formed at one side; and the guide part for aligning the balls received in the receiving part in a row and transferring them to the through hole forming part. 
     Additionally, the through hole forming part includes: a fixing part which is formed in a L-shape on which the received balls are seated, and has a plurality of first holes and a plurality of second holes which are formed in the lateral surface and the bottom surface thereof at regular intervals; a moving part which is mounted adjacent to one side of the fixing part, fixes and supports or transfers the balls seated on the fixing part through a back-and-forth movement, and has third holes formed at positions opposing to the first holes of the fixing part; a first perforating part which is mounted at the other side of the fixing part, a plurality of first perforating pins which are formed at one side thereof and are inserted into the first holes of the fixing part and the third holes of the moving part, and forms a first through hole in the ball seated on the fixing part by the back-and-forth movement; and a second perforating part which is mounted above the fixing part, has a plurality of second perforating pins which are formed at one side thereof and are inserted into the second holes of the fixing part, and forms a second through hole in the ball seated on the fixing part by the back-and-forth movement. 
     Moreover, the stopper part includes: a first stopper mounted in a first space between the guide part of the ball aligning part and the through hole forming part; and a second stopper mounted in a second space between the through hole forming part and the discharge part. 
     Furthermore, in another aspect of the present invention, provided is a ceramic ball having a detergent function including: a first through hole and a second through hole formed in the shape of a cross; and a first area part and a second area part respectively formed by the first through hole and the second through hole so that a cross-sectional area between the ceramic ball and water is increased and water flows through the first through hole and the second through hole. 
     According to an embodiment of the present invention, the ceramic ball having a detergent function and the method for manufacturing the ceramic ball can improve washing capacity since the ceramic ball is molded such that the surface area coming into contact with water gets wider, and can improve production efficiency and reduce the manufacturing cost since it is possible to manufacture ceramic balls continuously and automatically. 
     According to an embodiment of the present invention, the ceramic ball having a detergent function and the method for manufacturing the ceramic ball can improve contact efficiency that the ceramic ball gets in contact with water since water can pass through a through hole formed in the ceramic ball. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
       The above and other objects, features and advantages of the present invention will be apparent from the following detailed description of the preferred embodiments of the invention in conjunction with the accompanying drawings, in which: 
         FIG.  1    is a flow chart illustrating a method for manufacturing a ceramic ball having a detergent function according to a preferred embodiment of the present invention; 
         FIG.  2    is a view illustrating a configuration of a ball molding machine applied to the present invention; 
         FIG.  3    is a schematic side view illustrating a through hole forming device applied to the present invention; 
         FIG.  4    is a perspective view illustrating the through hole forming device applied to the present invention; 
         FIG.  5    is a view illustrating a configuration of the through hole forming device applied to the present invention; 
         FIGS.  6 A to  6 C  are sectional views illustrating the through hole forming device to show a through hole forming process according to the present invention; 
         FIGS.  7 A and  7 B  are respectively a perspective view and a sectional view of a ceramic ball having a detergent function according to the present invention; 
         FIG.  8    is a view illustrating a configuration of a detergent dispensing device for a dish washer to which the ceramic ball of the present invention is applied; and 
         FIG.  9    is a view illustrating a configuration of a detergent dispensing device for a washing machine to which the ceramic ball of the present invention is applied. 
     
    
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings. 
     In the following description, the same components will be designated by the same reference numerals although they are shown in different drawings. Further, in the following description of the present invention, a detailed description of known functions and configurations incorporated herein will be omitted when it may make the subject matter of the present invention rather unclear. 
       FIG.  1    is a flow chart illustrating a method for manufacturing a ceramic ball having a detergent function according to a preferred embodiment of the present invention. 
     As illustrated in the drawing, the method for manufacturing a ceramic ball having a detergent function according to the embodiment of the present invention includes: a first step (S 10 ) of pulverizing and mixing raw materials in a fixed size to form feedstock powder; a second step (S 20 ) of putting the feedstock powder formed through the first step into a ball shaping device and spraying water and a bonding agent to shape a ball; a third step (S 30 ) of first drying the ball in order to form a through hole in the shaped ball; a fourth step (S 40 ) of forming the through hole in the first dried ball by a through hole forming device; a fifth step (S 50 ) of second drying the ball in order to perfectly remove moisture when forming the through hole in the ball is completed; and a sixth step (S 60 ) of burning the dried ball to manufacture a ceramic ball. 
     The first step (S 10 ) is a step of pulverizing and mixing raw materials into a fixed size to form feedstock powder. The feedstock powder mainly includes silicon oxide (SiO 2 ), aluminum oxide (Al 2 O 3 ), and zirconium oxide (ZrO 2 ). 
     The second step (S 20 ) is a step of putting the feedstock powder formed through the first step into a ball shaping device and spraying water and a bonding agent to shape a ball. The ball is shaped by a ball shaping device  10  illustrated in  FIG.  2   . 
     The ball shaping device  10  is known-technology, for instance, disclosed in Korean Patent Publication No. 10-2015-0051777 invented by the inventor of the present invention. Now, the configuration of the ball shaping device  10  and the step of shaping the ball will be described. 
     The ball shaping device  10  includes: a rotary drum  12  rotatably mounted above a base  11  with a constant slope through a rotary support part  13 ; a driving part  14  for rotating the rotary drum  13 ; a polygonal part  16  formed on the inner face of an insertion hole  15  formed at one side of the rotary drum  13 ; and a spray part  17  for spraying water and a bonding agent to the insertion hole  15  of the rotary drum  13  by a nozzle  18  at a fixed rate. 
     Now, a process of shaping a ball will be described. The feedstock powder is inserted into the insertion hole  15  of the rotary drum  13 , and then, the rotary drum  13  is rotated. 
     After that, water and the bonding agent is sprayed into the insertion hole  15  by the nozzle  18  of the spray part  17  at the fixed rate. 
     The water and the bonding agent sprayed into the insertion hole  15  are bonded with the feedstock powder in the form of waterdrops, and at the same time, and roll inside the rotary drum  13  of which the inner surface is coated with cement so as to be naturally shaped into a plurality of balls. 
     Moreover, strength of the balls increases since the balls are formed while being bumped against the polygonal part  16 . 
     The third step (S 30 ) is a step of first drying the ball in order to form a through hole in the shaped ball, namely, is a step of properly drying moisture in order to form a through hole in the ball without the burning step. 
     Preferably, it takes two to three hours to dry moisture. In this instance, the surface of the ball is soft and flexible since moisture is removed. 
     The fourth step (S 40 ) is a step of forming the through hole in the first dried ball by a through hole forming device. A through hole forming device illustrated in  FIGS.  3  and  4    is provided in order to form a through hole in the ball. 
     The through hole forming device forms a through hole in the ball so as to increase the surface area of the ceramic ball  20  getting in contact with water. 
     The through hole forming device includes a ball aligning part  100 , a through hole forming part  200 , and a discharge part  300  which are connected in a row with a fixed slope. 
     The ball aligning part  100  is located at the uppermost part, and is a part to automatically transfer the balls dried in the third step (S 30 ) to the through hole forming part  200 . The ball aligning part  100  includes: a receiving part  110  for receiving the plurality of balls  20 ; a vibration generating part  120  mounted on the bottom surface of the receiving part  110  to generate vibration so as to automatically transfer the balls  20  received in the receiving part  110  to a guide part  130  formed at one side; and the guide part  130  for aligning the balls  20  received in the receiving part  110  in a row and transferring them to the through hole forming part  200 . 
     As illustrated in  FIG.  5   , the through hole forming part  200  is to form a through hole after temporarily fixing the balls transferred through the ball aligning part  100 , and includes a fixing part  210 , a moving part  220 , a first perforating part  230 , a second perforating part  240 , and a stopper part. 
     The fixing part  210  is formed in a L-shape, on which the received balls  20  are seated, and has a plurality of first holes  211  and a plurality of second holes  212  which are formed in the lateral surface and the bottom surface thereof at regular intervals. 
     The first holes  211  and the second holes  212  are holes into which perforating pins are inserted, and are designed to face the centers of the balls  20  seated on the fixing part  210 . 
     The moving part  220  is mounted adjacent to one side of the fixing part  210 , and fixes and supports or transfers the balls  20  seated on the fixing part  210  through a back-and-forth movement. 
     The moving part  220  has third holes  221  formed at positions opposing to the first holes  211  of the fixing part  210 , and performs the back-and-forth movement through a first cylinder  222 . 
     The first perforating part  230  is mounted at the other side of the fixing part  210 , and forms a first through hole  21  in the ball  20  seated on the fixing part  210  by the back-and-forth movement as illustrated in  FIGS.  7 A and  7 B . 
     The first perforating part  230  includes a plurality of first perforating pins  231  which are formed at one side thereof and are inserted into the first holes  211  of the fixing part  210  and the third holes  221  of the moving part  220 , and moves in the back-and-forth direction through a second cylinder  232 . 
     The second perforating part  240  is mounted above the fixing part  210  and perforates a second through hole  22  in the ball  20  seated on the fixing part  210  by the back-and-forth movement as illustrated in  FIGS.  7 A and  7 B . 
     The second perforating part  240  includes a plurality of second perforating pins  241  which are formed at one side thereof and are inserted into the second holes  212  of the fixing part  210 , and moves in the back-and-forth direction through a third cylinder  242 . 
     The stopper part is mounted at both ends of the fixing part  210 , and includes: a first stopper  251  mounted in a first space S 1  between the guide part  130  of the ball aligning part  100  and the through hole forming part  200 ; and a second stopper  252  mounted in a second space S 2  between the through hole forming part  200  and the discharge part  300 . 
     Now, operations of the first stopper  251  and the second stopper  252  will be described. First, the first stopper  251  moves upwards to open the first space S 1 , and the second stopper  252  moves downwards to close the second space S 2 . 
     Therefore, the balls  20  transferred through the guide part  130  of the ball aligning part  100  are aligned on the fixing part  210  of the through hole forming part  200  in a row, but are blocked from being transferred to the discharge part  300  by the second stoper  252 . 
     In the above state, the first stopper  251  moves downwards to close the first space S 1  so that the balls  20  of a predetermined amount are seated on the fixing part  210 . 
     When the balls  20  are seated on the fixing part  210 , the through hole forming part  200  performs the step of forming the through hole in the ball  20 . When the step of forming the through hole is finished, the second stopper  252  opens the second space S 2  so that the balls  20  seated on the fixing part  210  are automatically transferred to the discharge part  300 . 
     Next, the operation that the second stopper  252  closes the second space S 2  and the first stopper  251  opens the first space S 1  is repeated. 
     Meanwhile, referring to  FIGS.  6 A to  6 C , the step of forming the through hole in the ball  20  by the through hole forming part  200  is described. 
     First, when the ball  20  is aligned and seated on the fixing part  210 , as illustrated in  FIG.  6 A , the first cylinder  222  of the moving part  220  is operated to fix and support the ball  20  seated on the fixing part not to be moved. 
     Next, as illustrated in  FIG.  6 B , when the first perforating part  230  moves forwards by operation of the second cylinder  232 , the first perforating pin  231  passes through the first hole  211  of the fixing part  210 , the ball  20 , and the third hole  221  of the moving part  220  in order, so that the first through hole  21  is formed in the ball  20  as illustrated in  FIGS.  7 A and  7 B . 
     When the first through hole  21  is formed in the ball  20 , the first perforating part  230  moves backwards to its original position. After that, as illustrated in  FIG.  6 C , when the second perforating part  240  moves forwards by operation of the third cylinder  242 , the second perforating pin  241  passes through the ball  20  and the second hole  212  of the fixing part  210  in order, so that the second through hole  22  is formed in the ball  20  as illustrated in  FIGS.  7 A and  7 B . 
     When the second through hole  22  is formed in the ball  20 , the second perforating part  240  moves backwards to its original position. 
     The first through hole  21  and the second through hole  22  formed in the ball  20  are in the shape of a cross, a first area part  21   a  and a second area part  22   a  respectively formed by the first through hole  21  and the second through hole  22  increase a cross-sectional area that the ceramic ball  20  gets in contact with water, and water flows through the first through hole  21  and the second through hole  22 , so that contact efficiency between the ceramic ball and water is increased so as to increase washing efficiency. 
     The fifth step (S 50 ) is a step of second drying the ball in order to perfectly remove moisture when forming the through hole in the ball is completed, and is a preconditioning process for burning. 
     The sixth step (S 60 ) is a step of burning the dried ball at a constant temperature for predetermined time to finally manufacture a ceramic ball. 
     Therefore, the manufactured ceramic balls  20  are filled in a detergent dispensing device  30  for a dish washer as illustrated in  FIG.  8   , or are filled in a detergent dispensing device  40  for a washing machine as illustrated in  FIG.  9   . 
     While the present invention has been described by the limited embodiments and the drawings as described above, the present invention is not limited by the above and various modifications and variations are possible to those skilled in the art from the above description.