JP2008240516A - Manufacturing method for flush toilet stool - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method for a flush toilet stool for sticking divided bodies mutually, tightly, and firmly, preventing the occurrence of water leakage from the toilet stool, and reducing manufacturing cost. <P>SOLUTION: In this manufacturing method for the flush toilet stool provided with a bowl part 1 and a rim part 3 arranged in an upper end part of the bowl part 1, the toilet stool is formed by welding and integrating two divided bodies made of synthetic resin or more. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a method for producing a flush toilet made of synthetic resin.

  A general flush toilet is integrally formed of porcelain by casting, but there is a problem that deformation and cracking are likely to occur during molding, and the product shape cannot be complicated.

  In addition, there is a simple toilet bowl that is integrally formed of synthetic resin as a whole, but since it needs to be molded with a mold, it cannot be formed into a complicated shape with many undercuts, especially the bowl. There is a problem that it is impossible to form a flush toilet in which a washing water flow path through which water for washing the inner surface of the part is formed is formed by a rim part or a bowl part.

Further, in Patent Document 1, as shown in FIG. 25, the ceramic bowl portion 1, the synthetic resin skirt portion 2 that accommodates the bowl portion 1 inside, and the bowl portion 1 and the upper end portion of the skirt portion 2 are arranged. There is disclosed a flush toilet comprising three divided bodies of a synthetic resin rim portion 3, housing and arranging the bowl portion 1 in the skirt portion 2 and mounting the rim portion 3 on the upper edge thereof. However, even in this toilet bowl, the bowl portion 1 is made of ceramic and cannot be made into a complicated shape. Moreover, since the bowl part 1 is made of ceramics with low dimensional accuracy, the bowl part 1 and the other divided bodies 2 and 3 cannot be bonded closely. Further, when a cleaning water flow path is formed in which the water for cleaning the inner surface of the bowl portion flows near the location where the upper end of the bowl portion 1 and the rim portion 3 are connected or the location where the upper end of the skirt portion 2 and the rim portion 3 are connected. May leak from this area.
Japanese Patent Laid-Open No. 10-37279

  The present invention has been invented in view of the above-described conventional problems, and provides a method for manufacturing a flush toilet that can adhere the divided bodies tightly and tightly, can prevent water leakage from the toilet, and can reduce manufacturing costs. The issue is to provide.

  In order to solve the above-described problems, a method for manufacturing a flush toilet according to the present invention is a method for manufacturing a flush toilet comprising a bowl portion 1 and a rim portion 3 disposed at an upper end portion of the bowl portion 1. It is characterized in that a resin divided body is formed by welding and integration. This makes it possible to form a flush toilet made of synthetic resin by bonding and integrating multiple synthetic resin segments with excellent dimensional accuracy, improving the overall dimensional accuracy of the toilet bowl, and fitting the segments together. And can be firmly bonded. This also prevents water leakage from the toilet. Furthermore, it is possible to easily form a flush toilet having a complicated shape as compared with a case where the entire toilet is integrally formed of synthetic resin.

  Moreover, it is also preferable that the bowl part 1 and the rim part 3 are made into independent synthetic resin divided bodies 1 and 3, respectively, and the divided bodies 1 and 3 are welded and integrated.

  The flush toilet is a method for producing a flush toilet comprising a skirt portion 2 that covers the outside of the bowl portion 1, and each of the bowl portion 1, the skirt portion 2, and the rim portion 3 is an independent synthetic resin divided body. It is also preferable to form these three synthetic resin divided bodies 1 to 3 by welding and integration, and in this case, it has a complicated shape including the bowl portion 1, the skirt portion 2, and the rim portion 3. The flush toilet can be easily formed, and the manufacturing cost can be reduced. In addition, the divided bodies 1, 2, and 3 can be easily bonded together with the adhesive material 14 by being compressed in the vertical direction.

  In addition, after heating and melting the welding margin protruding from the surface facing the other divided body of the divided body, both divided bodies were butted through the melted resin obtained by dissolving the welding margin and protruded from the butted portion It is also preferable to fill both the split bodies by filling the space between the relief inclined surface provided in one split body and the other split body with the melted resin.

  Further, the protruding portion 56 is formed on the divided body, and a welding allowance 60 protruding from the tip of the protruding portion 56 is formed, the welding allowance 60 of the divided body is heated and melted, and then the protruding portion 56 of the divided body is formed. It is also preferable to weld the two divided bodies by fitting them into the recessed portions 57 formed in the other divided bodies through the melted resin 62 obtained by dissolving the welding allowance 60. In this case, when a force is applied to the toilet from the outside, it is possible to prevent a positional shift between the divided bodies.

  The divided body is preferably an acrylic resin molded product.

  In the present invention, the divided bodies can be adhered tightly and tightly, water leakage from the toilet can be prevented, and a flush toilet with a complicated shape can be easily formed as compared with the whole molded with synthetic resin. Cost can be reduced.

  Hereinafter, the present invention will be described based on embodiments shown in the accompanying drawings.

  The flush toilet according to the present embodiment includes a bowl part 1, a skirt part 2 covering the bowl part 1, and a rim part 3 disposed on the upper end part of the bowl part 1. A washing water channel 16 is formed inside the portion 1a, and a washing water outlet port 23 is formed in the lower part of the washing water channel 16 to communicate the washing water channel 16 and the inside of the bowl portion 1 as shown in FIG. 1 and FIG. Thus, each of the bowl part 1, the skirt part 2 and the rim part 3 is made into independent synthetic resin divided bodies 1 to 3, and these three synthetic resin divided bodies 1 to 3 are bonded and integrated by welding. .

  Each of the divided bodies 1 to 3 is made of a resin molded product having a thickness of 3 to 7 mm formed by injection molding or compression molding. As the molding material, relatively strong acrylic, ABS with reinforcing material, PBT or the like is used. . In addition, since each division body is comparatively large, it is preferable to perform an annealing process. Further, a hard coat material may be coated to improve the surface quality.

  The bowl portion 1 is formed by integrally projecting a drainage cylinder portion 5 toward the rear at a lower portion of the bowl-shaped portion 4 whose vertical direction is a die cutting direction. As shown in FIG. 3, a stepped portion 6 having a stepwise larger diameter on the upper side than the lower side is formed in the circumferential direction at a position slightly below the upper end of the peripheral wall of the bowl-shaped portion 4. Yes.

  The skirt portion 2 has the die cutting direction as the vertical direction, and has a draft that gradually increases in opening diameter as shown in FIGS. 1 and 2. The upper end portion of the front half portion 2a that surrounds the outside of the bowl portion 1 of the skirt portion 2 protrudes upward from the rear half portion 2b positioned rearward of the front half portion 2a. The upper end surface of the front half portion 2a of the skirt portion 2 is an inclined surface that is gradually inclined so as to be positioned lower on the front side, and the upper end surface of the rear half portion 2b is a horizontal plane.

  4-6, the skirt part 2 is provided with a plurality of reinforcing ribs 9 and holding pieces 10 as support parts for supporting the bowl part 1 from below. A plurality of reinforcing ribs 9 are provided on the inner surface of the peripheral wall of the front half 2a of the skirt portion 2 with appropriate intervals in the circumferential direction. In order to prevent sink marks from appearing on the outer surface of the skirt portion 2, the reinforcing rib 9 is provided with a thickness of 2 mm or less and 6 to 10 in the circumferential direction of the skirt portion 2 in a toilet that fits in a projected area with a corner of about 300 to 400 mm. It is preferable. The reinforcing rib 9 may be provided from the lower end to the upper end portion of the skirt portion 2 as shown in FIG. 2, or may be provided partially only at the upper portion of the skirt portion 2 as shown in FIG. .

  Further, as shown in FIGS. 5 and 6, the holding piece 10 is erected on a bottom surface portion 12 projecting inward from the lower end of the peripheral wall of the front half 2 a of the skirt portion 2. A curved receiving surface 10 a for receiving the drain tube portion 5 is formed on the upper surface of the holding piece 10. Note that sink marks may occur on the bottom surface portion 12 which is covered by the peripheral wall of the skirt portion 2 and which is positioned below the bowl portion 1 so as not to be exposed to the outside. Thus, it is not necessary to limit the wall thickness. Therefore, the width may be 2 mm or more under the same conditions as described above.

  The rim portion 3 has a vertical direction as the die cutting direction. As shown in FIGS. 1 and 2, the rear end of the front half 3a is integrally connected to the upper portion of the rising wall portion 13 formed at the front end of the rear half 3b. Is formed.

  The front half 3a of the rim 3 is formed with a substantially U-shaped U-shaped portion 15 which is annular in plan view and opens outward in cross section, and this annular U-shaped portion 15 is formed in the bowl portion. 1 is fitted into the upper end opening edge portion 1a of the bowl portion 1 so that the washing water flow path 16 having a U-shaped cross section surrounded by the U-shaped portion 15 and the upper end opening edge portion 1a of the bowl portion 1 It can be formed on the entire inside of the portion 1a. The space in the U-shaped portion 15 is formed, for example, by sandwiching the rim portion 3 from the left and right sides with two side cores 7 that slide in the direction of the arrow (left and right) as shown in FIG. .

  The washing water channel 16 communicates with a water source (not shown) via a connecting pipe 19 shown in FIG. 9, and the connecting pipe 19 includes a pipe insertion hole 17 and a bowl formed in the rising wall portion 13 shown in FIG. It is provided through a tube-through hole 18 formed in the upper part of the rear side wall part of the hook-like part 4 of the part 1 (specifically, the part positioned higher than the step part 6). Further, as shown in FIG. 3 and the like, the lower horizontal piece portion 22 is provided at the inner end portion of the lower horizontal piece portion 22 that protrudes horizontally from the lower end of the vertical piece portion 20 of the U-shaped portion 15 (that is, the lower portion of the washing water channel 16). A plurality of cleaning water outlets 23 each having a hole formed therein are arranged in the circumferential direction, and the cleaning water flow path 16 communicates with the inside of the bowl portion 1 through the cleaning water outlets 23. Thereby, water can be supplied into the bowl part 1 from the water source through the connecting pipe 19, the washing water flow path 16, and the washing water outlet 23 in order to wash the inner surface of the bowl part 1.

  Further, the vertical piece 20 is inclined so as to be positioned outward as it extends upward in order to give a draft angle. Further, the outer end portion of the upper horizontal piece portion 24 protruding horizontally from the upper end of the vertical piece portion 20 protrudes further outward than the lower horizontal piece portion 22 to form a lower butted portion 25.

  In addition, at both sides of the rear portion of the annular U-shaped portion 15 in plan view, the vertical piece 20 extends further upward than the upper horizontal piece 24 as shown in FIG. The extending portion 27 is formed, and the upper surface constituting horizontal piece portion 28 protrudes outward from the upper end of the extending portion 27. As shown in FIG. 10 and FIG. 17, the upper surface configuration horizontal piece portion 28 has substantially the same thickness as the upper horizontal piece portion 24, and gradually increases in the rearward direction so as to correspond to the upper end surface of the front half portion 2a of the skirt portion 2 described above. It inclines so that it may be located upward, and the front end is continuing to the rear end of the upper horizontal piece part 24a provided in the front side edge part of the U-shaped part 15. FIG. That is, the upper horizontal piece portion 24a has a shape bifurcated into a horizontal upper horizontal piece portion 24b located rearward at the rear end and an inclined upper surface constituting horizontal piece portion 28. The upper surface of the front half portion 3a of the rim portion 3 is formed by the portion 24a and the upper surface configuration horizontal piece portion 28. Further, as shown in FIG. 3B, the outer end portion of the upper surface constituting horizontal piece portion 28 protrudes further outward than the upper horizontal piece portion 24 to form an upper butted portion 29. In addition, the rear end of the upper surface configuration horizontal piece portion 28 and the rear end of the upper horizontal piece portion 24 provided at the center of the rear side edge portion of the U-shaped portion 15 are connected to the upright wall portion 13. The rear ends of the upper horizontal piece portions 24 provided on the left and right sides of the rear edge of the shape portion 15 are connected to the rear end portions of the upper surface constituting horizontal piece portions 28.

  In order to bond and integrate the three divided bodies 1 to 3, welding locations A1, A2, and B1 to B3 shown in FIGS. 2 and 3 are welded.

  That is, in the bowl portion 1 and the rim portion 3, the upper surface of the upper end opening edge portion 1 a of the bowl portion 1, the lower surface of the lower butted portion 25 of the upper lateral piece portion 24 of the rim portion 3 (welding location A 1), the bowl The upper surface of the stepped portion 6 of the portion 1 and the lower surface (welding location A2) of the outer end portion of the lower lateral piece portion 22 of the rim portion 3 are welded. Here, the welding locations A1 and A2 are welded over the entire circumference of the annular U-shaped portion 15, whereby the annular cleaning water channel 16 is water-tight over the entire circumference at the welding locations A1 and A2. .

  Further, in the skirt portion 2 and the rim portion 3, the upper end surface of the rear half portion 2 b of the skirt portion 2, the lower end surface of the rear half portion 3 b of the rim portion 3 (see welding position B 1, FIG. 2), and the front side wall of the skirt portion 2. The upper end surface of the rim portion and the lower side of the upper side piece 24a of the rim 3 (the upper side piece 24 provided at the front side edge of the U-shaped part) (the welding location B2, FIG. 3 (c) )), The upper end surface of the peripheral wall of the front half portion 2a of the skirt portion 2 (excluding the front side wall portion) and the lower surface of the upper butted portion 29 of the upper surface configuration lateral piece portion 28 of the rim portion 3 (welding location B3, FIG. 3). (See (b)).

  Thus, in this embodiment, compared with the toilet bowl containing the conventional ceramic-made division body, the synthetic resin division bodies 1-3 excellent in dimensional accuracy are bonded and integrated, and the synthetic resin 1-3 division bodies are combined. In this case, the rim part 3 and the bowl part 1 that form the washing water flow path 16 are particularly welded. Since the locations A1 and A2 and the skirt portion 2 and the rim portion 3 in the vicinity of the washing water flow channel 16 can be welded together B2 and B3, water leakage from the toilet can be prevented. Furthermore, by forming the toilet bowl by bonding and integrating a plurality of divided bodies 1 to 3, the undercut portion can be reduced, thereby forming a unitary toilet bowl made of synthetic resin such as a conventional simple toilet bowl. It is possible to form an annular or U-shaped washing water channel 16 (annular in the present embodiment) in plan view that could not be performed.

  Here, the welding location A1 (that is, the upper surface of the upper end opening edge 1a of the bowl portion 1 and the lower surface of the lower butted portion 25 of the upper lateral piece 24 of the rim 3) is, for example, as shown in FIGS. Welded.

  In FIG. 11A, a convex welding allowance 31 is integrally projected upward from the center of the upper surface of the upper end opening edge portion 1a of the bowl portion 1 and directed downward from the lower surface of the lower butted portion 25 of the rim portion 3. The convex welding allowance 32 protrudes integrally. Further, a corner portion formed by the inner surface and the upper surface of the upper end opening edge portion 1 a of the bowl portion 1 and a corner portion formed by the outer surface and the upper surface are both chamfered to form a relief inclined surface 33. Then, the welding margins 31 and 32 are heated and melted, and thereafter, the upper surface of the upper end opening edge portion 1a is passed through a melting resin 35 (adhesive material 14) in which the welding margins 31 and 32 are melted as shown in FIG. This portion is welded by being brought into contact with the lower surface of the lower butted portion 25 and being compressed in the direction of the arrow. In addition, the dimension and angle (theta) 1 of d1-d3 of Fig.11 (a) are respectively d1 = 1-2 mm, d2 = 0.5 mm, (theta) 1 = 5-45 degrees, d3 = 1-2 mm.

  In FIG. 12 (a), a convex welding allowance 31 is integrally projected upward from the center of the upper surface of the upper end opening edge 1a of the bowl portion 1, and the corners formed by the inner surface and the upper surface of the upper opening edge 1a are chamfered. Thus, a relief inclined surface 33 is formed. In addition, the lower surface of the outermost portion of the lower butted portion 25 of the rim portion 3 is positioned one step higher than the lower surface of the inner portion of the rim portion 3 to form the step portion 39, and the side surface of the step portion 39 The relief slope 33 is inclined so as to be located on the outer side as it goes upward. Then, the welding allowance 31 is heated and melted, and thereafter, the upper surface of the upper end opening edge 1a is brought into lower contact via the dissolving resin 35 (adhesive material 14) in which the welding allowance 31 is dissolved as shown in FIG. It is welded by being brought into contact with the lower surface of the portion 25 and compressed in the direction of the arrow. The dimension d4 and the angle θ2 in FIG. 12A are d4 = 1 to 2 mm and θ2 = 5 to 45 °, respectively.

  In any of the examples in FIGS. 11 and 12, when welded, between the lower butted portion 25 and the portion to be abutted with the lower butted portion 25 on the upper surface of the upper end opening edge 1 a. The melted resin 35 is filled in. Further, in this case, the melted resin 35 protrudes and fills the void 42 formed between each relief inclined surface 33 and the lower surface of the upper horizontal piece portion 24. Therefore, after the melted resin 35 is cured, the upper end opening edge portion that is close to and faces the lower surface of the lower butted portion 25 between the lower surface of the upper horizontal piece portion 24 and the upper surface of the upper end opening edge portion 1a. A melted resin 35 composed of a thin portion 43 interposed between the upper surface of la and a thick portion 44 on both sides continuous with the thin portion 43 and thicker than the thin portion 43, Thus, the upper surface of the upper end opening edge 1a and the lower surface of the lower abutting portion 25 are welded in a state where the upper surface is securely sealed. Further, on the outer side of the thin portion 43 and the thick portion 44 of the melted resin 35, the upper end portion of the peripheral wall of the skirt portion 2 (see FIGS. 3B and 3C) and the rising wall portion 13 (see FIG. 3) are covered. (Refer to (a)), and the thin portion 43 and the thick portion 44 of the dissolved resin 35 are covered from the outside by these covering portions. Therefore, the thin portion 43 and the thick portion 44 of the dissolved resin 35 are not exposed to the outside, and the appearance of the toilet bowl is not impaired by the dissolved resin 35. In particular, since the convex welding allowance 32 of FIG. 11 serving as an undercut portion is not provided on the lower surface of the upper horizontal piece portion 24 of the U-shaped portion 15 shown in FIG. 12, the rim portion 3 can be easily formed. .

  Further, the welding location A2 (that is, the upper surface of the stepped portion 6 of the bowl portion 1 and the lower surface of the outer end portion of the lower horizontal piece portion 22 of the rim portion 3) is welded as shown in FIG.

  In FIG. 13A, a convex welding allowance 49 is integrally projected downward from the lower surface of the mounting portion 48 formed of the outer end portion of the lower horizontal piece portion 22 of the rim portion 3, and the upper surface of the step portion 6 is A concave relief recess 50 is formed at a location slightly inward from the welding allowance 49. Further, the inner edge corner portion of the step portion 6 is chamfered to form a relief inclined surface 51. Then, the welding allowance 49 is heated and melted, and then, as shown in FIG. 13B, the mounting portion 48 is placed on the stepped portion 6 via the dissolving resin 52 as the adhesive material 14 obtained by dissolving the welding allowance 49. By placing and compressing in the direction of the arrow, the upper surface of the stepped portion 6 and the lower surface of the lower horizontal piece portion 22 are welded. When welding is performed in this manner, the dissolved resin 52 is filled between the placement portion 48 and the portion where the placement portion 48 of the stepped portion 6 is placed. Further, in this case, the melted resin 52 protrudes and fills the space 53 formed between the escape recess 50 and the bottom surface of the escape slope 51 and the lower horizontal piece 22. Therefore, after the molten resin 52 is cured, the molten resin 52 between the upper surface of the stepped portion 6 and the lower surface of the mounting portion 48 becomes a step in the bowl portion 1 that is close to and opposite to the lower surface of the mounting portion 48. A thin-walled portion 54 interposed between the upper surface of the portion 6 and a thick-walled portion 55 that is filled in the escape recess 50 or the void 53 and continues to the thin-walled portion 54 and is thicker than the thin-walled portion 54. Thus, the upper surface of the stepped portion 6 and the lower surface of the mounting portion 48 are welded in a state of being reliably watertight. In addition, the dimension of d5-8 of Fig.13 (a) is d5 = 1-2 mm, d6 = 0.5 mm-2 mm, d7 = 1-2 mm, d8 = 0-2 mm, respectively.

  In addition, at the welding locations B1 to B3 of the skirt portion 2 and the rim portion 3, a protruding portion 56 is formed on one divided body of the skirt portion 2 and the rim portion 3 that are bonded and integrated as shown in FIGS. In addition, a recessed portion 57 is formed in the other divided body, the protruding portion 56 is fitted into the recessed portion 57, and the opposing surfaces of the protruding portion 56 and the recessed portion 57 are welded.

  In FIG. 14A, the welded portion 59 (the upper end surface of the rear half 2b, the upper end surface of the front side wall, or the upper end surface of the peripheral wall of the front half 2a) of the skirt portion 2, which is one of the divided bodies, is directed upward. And a convex welding allowance 60 is formed at the center of the upper surface of the protruding portion 56, and the welded portion 61 (the rear half 3b) of the rim 3 which is the other divided body. A concave recessed portion 57 is formed on the lower end surface, the lower surface of the lower butted portion 25 of the upper horizontal piece portion 24a, and the lower surface of the upper butted portion 29 of the upper surface constituting horizontal piece portion 28). Then, the welding allowance 60 is heated and melted, and thereafter, as shown in FIG. 14 (b), the protrusion 56 is formed in the recessed and recessed portion 57 via the dissolving resin 62 as the adhesive material 14 obtained by dissolving the welding allowance 60. By fitting, the protruding portion 56 and the recessed portion 57 are welded with the molten resin 62 interposed therebetween. In addition, the dimension of d9-12 of Fig.14 (a) is respectively d9 = d10 = 1.5-3mm, d11 = 0.5-1mm, d12 = 2-3mm.

  Further, in FIG. 15A, a plurality of convex protrusions 56 are formed upward on the welded portion 59 of the skirt portion 2 which is one divided body, and the welded portion of the rim portion 3 which is the other divided body. A V-groove-shaped recessed portion 57 is formed in 61, and in this example, the surface portion of the protruding portion 56 serves as a welding allowance. And in this example, the surface part of the protrusion part 56 is heated and melted, and then protrudes through a dissolving resin 64 as an adhesive material 14 obtained by dissolving the surface part of the protrusion part 56 as shown in FIG. By fitting the portion 56 into the recessed portion 57, the portion excluding the surface portion of the protruding portion 56 and the recessed portion 57 are welded with the molten resin 64 interposed therebetween. In addition, the dimension of d13-17 of Fig.15 (a) is d13 = 1mm, d14 = 1mm, d15 = 0-0.3mm, d16 = d17 = 0.5-2mm.

  In the welding examples shown in FIGS. 14 and 15, the projecting portion 56 is fitted into the recessed portion 57 and the opposing surfaces of the projecting portion 56 and the recessed portion 57 are welded to form the two divided bodies 2 and 3. Since they are bonded and integrated, it is possible to prevent positional displacement between the divided bodies 2 and 3 when a force is applied to the toilet.

  14 and 15, when the protruding portion 56 is formed by partially protruding the welded portion 59, for example, the welded portion B2 (that is, the upper end surface of the front side wall portion of the skirt portion 2 and the rim portion). 3, the upper butted portion of the upper side piece 24 a of the lower half of the upper side piece 24 a, the upper end face of the peripheral wall of the front half 2 a of the skirt portion 2, and the upper side piece 28 of the rim portion 3. 29), there is a problem that the recessed portion 57 becomes an undercut portion. Therefore, for example, the welding locations B2 and B3 are preferably welded as shown in FIG.

  In FIG. 16 (a), the upper surface of the outermost portion of the welded portion 59 of the skirt portion 2 which is one of the divided bodies is positioned one step higher than the lower surface on the inner side of this, and the stepped protrusion 56 is formed. A convex welding allowance 67 is formed on the upper surface of the protrusion 56 so as to protrude upward. Further, a stepped recessed portion 57 is formed by positioning the outermost portion of the welded portion 61 of the rim portion 3 which is the other divided body one step above the lower surface of the inner portion, and The outer corner of the recessed portion 57 is chamfered to form a relief inclined surface 68. In this example, the welding allowance 67 is heated and melted, and thereafter, the stepped protrusion 56 is formed via the dissolving resin 69 as the adhesive material 14 obtained by dissolving the welding allowance 67 as shown in FIG. By fitting into the stepped depressions 57, the stepped protrusions 56 and the stepped depressions 57 are welded with the melted resin 69 interposed therebetween. Further, the melted resin 69 protrudes and fills the void 66 formed between the escape inclined surface 68 and the welded portion 61 of the rim portion 3. In other words, in this case, the welding portion 59 of the skirt portion 2 and the welding portion 61 of the rim portion 3 are interposed between the welding portion 59 of the skirt portion 2 and the welding portion 61 of the rim portion 3 that is in close proximity to and opposite to the welding portion 59 of the skirt portion 2. The melted resin 69 composed of the thin-walled portion 63 and the thick-walled portion 65 that is continuous with the thin-walled portion 63 and is thicker than the thin-walled portion 63 is interposed. Note that the dimensions d18 to d23 and the angle θ3 in FIG. 16A are d18 = d23 = 1.5 to 3 mm, d19 = 0.5 to 2 mm, d20 = 1 to 3 mm, d21> d20, d22 = 0. 5 to 1 mm and θ3 = 10 to 45 °. Further, the welding example may be used in combination with the welding example shown in FIG. The welding examples shown in FIGS. 14 to 16 may be applied to the welding locations A1 and A2.

  Next, for welding the three divided bodies composed of the bowl part 1, the skirt part 2, and the rim part 3, for example, a welding device 70 shown in FIG. 18 is used.

  The welding apparatus 70 includes upper and lower compression plates 71a and 71b that are relatively movable in the vertical direction, and a heating plate 73 that heats the welding locations A1, A2, and B1 to B3. A rim support portion 76 is provided on the lower surface of the upper compression plate 71a. The lower compression plate 71b is provided with a shaft 74 that is movable in the vertical direction. A bowl support 75 is provided at the upper end of the shaft 74 that protrudes upward from the lower compression plate 71b.

  In order to weld and integrate the three divided bodies 1 to 3 using the welding device 70, the skirt portion 2 is placed on the lower compression plate 71b as shown in FIG. The drain tube portion 5 of the bowl portion 1 is supported from below by the bowl support portion 75 of the shaft 74, and at the same time the rim portion 3 is supported by the rim support portion 76 of the upper compression plate 71a. A2, B1 to B3 are heated (for example, heating temperature 300 to 700 ° C., heating time 5 to 10 seconds). Thereafter, as shown in FIG. 18 (b), the upper and lower compression plates 71a and 71b are brought closer to each other, and the shaft 74 is moved upward with respect to the lower compression plate 71b, whereby the upper half 2a of the skirt portion 2 is moved upward. The bowl portion 1 is housed from above, and the U-shaped portion 15 of the rim portion 3 is fitted into the upper end opening edge portion 1a of the bowl portion 1 from above to compress the divided bodies 1 to 3 in the vertical direction. Cool for at least 30 seconds.

  Here, as shown in FIGS. 4 to 6 and the like, the skirt portion 2 is provided with reinforcing ribs 9 and holding pieces 10 for supporting the bowl portion 1 from below, so that the rim portion 3 and the bowl portion 1 are welded (that is, the rim portion). When the part 3 and the bowl part 1 are compressed in the vertical direction), the bowl-like part 4 of the bowl part 1 is placed on the upper surface of the plurality of reinforcing ribs 9 of the skirt part 2 and the curved receiving surface of the holding piece 10 The drain cylinder part 5 of the bowl part 1 is placed on 10a, and the bowl part 1 can be stably supported by the skirt part 2, whereby the bowl part 1 and the rim part 3 can be reliably welded. Further, the plurality of reinforcing ribs 9 and the holding pieces 10 can stably support a seating load when using the toilet bowl after welding, and can suppress deformation of the toilet bowl when sitting. It is sufficient that the reinforcing rib 9 and the holding piece 10 be disposed at a position that can support the load when a downward load is applied to the bowl portion 1 during the welding or use of the toilet bowl. The upper surface may be in contact with the lower surface of the bowl portion 1 as shown in FIG. 9, or a slight gap is formed between the upper surface and the lower surface of the bowl portion 1 as shown in FIG. Alternatively, the upper surface may contact the lower surface of the bowl portion 1 only when a downward load is applied to the bowl portion 1 when using the toilet bowl.

  In this example, as shown in FIGS. 10 and 17, the upper horizontal piece portion 24a provided at the front edge of the U-shaped portion 15 is inclined with the horizontal upper horizontal piece portion 24b positioned behind the upper horizontal piece portion 24b. Since it is branched to the upper surface configuration horizontal piece portion 28, the upper horizontal piece portion 24 can be made horizontal so that the divided pieces 1 to 3 are compressed and welded in the vertical direction as described above. In addition, while the upper horizontal piece 24b and the upper surface configuration horizontal piece 28 are made to be substantially uniform thick without causing sink marks, the upper surface of the front half 2a of the rim 3 is designed to be other than a horizontal surface such as the inclined surface. The surface can be excellent.

  By the way, in the welding apparatus 70 shown in the said FIG. 18, the division bodies 1-3 before welding are hold | maintained horizontally with the same inclination attitude | position as after welding, and the upper surface and rim | limb of the upper end opening edge part 1a of the bowl part 1 are shown. The lower surface of the lower horizontal piece portion 22 of the U-shaped portion 15 of the portion 3 is made horizontal, and the welded portions A1, A2, B1 to 3 of the divided bodies 1 to 3 that are horizontal in the same manner as after the welding are heated by the heating plate 73. After heating, the divided bodies 1 to 3 are welded by being compressed in the vertical direction by the upper and lower compression plates 71a and 71b and the shaft 74. This is because the welding position A1, A2, B1, B2 where the welding surface is horizontal is surely welded by welding the bowl part 1 and the rim part 3 in the horizontal posture in the same manner as after the welding. . However, as shown in FIG. 18A, the welding apparatus 70 includes a horizontal upper surface of the upper end opening edge portion 1a of the bowl portion 1 and an inclined upper end surface of the front half portion 2a of the skirt portion 2 when heated by the heating plate 73. The bowl portion 1 and the skirt portion 2 are not held so as to be flush with each other. For this reason, the upper surface of the upper end opening edge portion 1a of the bowl portion 1 and the upper end surface of the front half portion 2a of the skirt portion 2 are In order to heat, it is necessary to make the shape of the heating plate 73 into a complicated shape as shown in FIG.

  Therefore, as shown in FIG. 19, a bowl support portion 75 is provided on the welding device 70 so as to be rotatable about the left and right axes with respect to the shaft 74, and when heated by the heating plate 73, the bowl portion 1 is placed with the front side lowered. When the upper surface of the upper end opening edge portion 1a of the bowl portion 1 and the upper end surface of the front half portion 2a of the skirt portion 2 are positioned on the same plane, and thereafter, the divided bodies 1 to 3 are compressed and welded up and down. As shown in FIG. 18, it is preferable to rotate and hold the bowl portion 1 so as to be in a horizontal posture like the rim portion 3. In this case, the shape of the heating plate 73 can be simplified as shown in FIG.

  Further, as shown in FIG. 2 and the like, if the lower horizontal piece 22 of the U-shaped portion 15 constituting the lower surface portion of the cleaning water flow path 16 is made horizontal, there arises a problem that dirt or the like accumulates in the cleaning water flow path 16. Therefore, for example, as shown in FIGS. 20 and 21, the lower horizontal piece portion 22 of the U-shaped portion 15 is inclined to form a water gradient on the lower surface portion of the washing water channel 16, and the bowl portion is formed at the lower end portion of the washing water channel 16. A drain opening 77 that communicates with the inside 1 may be formed. Thus, after the bowl portion 1 is washed with water, the water in the washing water channel 16 can be smoothly drained from the draining opening 77 as shown by the arrows in FIGS. Here, in FIG. 20, the lower horizontal piece 22 of the U-shaped portion 15 is inclined by an angle θ4 with respect to the horizontal plane so as to be positioned lower on the front side, thereby creating a water gradient on the lower surface portion of the cleaning water channel 16 and A drainage opening 77 is formed at the front end portion of the lower horizontal piece portion 22 provided at the front edge of the character-shaped portion 15, and in FIG. Inclined by an angle θ5 with respect to the horizontal plane so as to be positioned below, a water gradient is given to the lower surface portion of the washing water flow path 16, and the lower horizontal piece portion 22 provided at the rear edge of the U-shaped portion 15 is rearward. A drainage opening 77 is formed at the end.

  Further, in order to smoothly drain the washing water channel 16, as shown in FIG. 22, the lower horizontal piece portion 22 of the U-shaped portion 15 is inclined so as to be positioned downward as it goes outward, and the U-shaped A drain opening 77 may be provided at the outer end of the lower horizontal piece 22 of the portion 15, and in this case, the inclination of the lower horizontal piece 22 can be used as the draft of the side core 7 described above.

  20 to 22 may be provided at a position different from the above-described cleaning water outlet 23 in the inner and outer directions of the lower horizontal piece portion 22, or the cleaning water outlet 23 and the draining opening 77 May be provided at the same position in the inner and outer directions of the lower horizontal piece 22. Further, the drainage opening 77 may be formed by a through-hole penetrating the lower horizontal piece portion 22 vertically, or a gap formed between the outer end surface of the lower horizontal piece portion 22 and the inner peripheral wall surface of the bowl portion 1. You may comprise.

  In the flush toilet described above, when the two divided bodies are bonded and integrated, a welding resin is formed on the facing surfaces of the divided bodies in A1, A2, and B1 to B3, and a molten resin formed by heating and melting the welding allowance is formed. The opposing surfaces of the divided bodies were welded to each other. Here, as a reference example, it is possible to apply a separate adhesive to the opposing surfaces of the divided bodies without providing a welding allowance, and to bond the opposing surfaces of the divided bodies with the adhesive. The adhesive material 14 to be bonded becomes an adhesive. Further, the flush toilet is formed by bonding and integrating three synthetic resin divided bodies composed of the bowl portion 1, the skirt portion 2, and the rim portion 3. As shown in FIGS. 23 and 24, the toilet bowl is composed of two synthetic resins. The divided parts 83 and 84 may be formed by bonding and integration. Here, the toilet shown in FIGS. 23 and 24 includes the bowl portion 1, the bowl covering portion 85 that covers a part of the bowl portion 1, and the rim portion 3 that includes the U-shaped portion 15. The washing water flow path 16 is formed with the bowl part 1 and the rim | limb part 3 similarly to a form. Then, a synthetic resin divided body 83 constituted by the bowl portion 1 and the front half portion of the bowl cover portion 85 formed integrally with the bowl portion 1, and the bowl cover formed integrally with the rim portion 3 and the rim portion 3. A flush toilet is formed by bonding and integrating a synthetic resin divided body 84 constituted by the latter half of the portion 85. In addition, although not shown, four or more synthetic resin segments may be bonded and integrated, that is, two or more synthetic resin segments that are independent of each other may be bonded and integrated to form a toilet. It will be good.

It is a disassembled perspective view of the toilet bowl of an example of embodiment of this invention. It is a sectional side view of a toilet bowl same as the above. (A) is the A section enlarged view of FIG. 2, (b) is BB sectional drawing of FIG. 2, (c) is the C section enlarged view of FIG. It is a top view of a skirt part. It is front sectional drawing of the holding piece part of FIG. FIG. 5 is a side sectional view of FIG. 4. It is a principal part expanded sectional view which shows the other example of a reinforcement rib. It is plane explanatory drawing which shows operation | movement of the side core used when shape | molding a rim | limb part. It is a perspective view of the front half part of a toilet bowl. It is side sectional drawing which shows the upper part of the front half part of a toilet bowl. The example of welding in welding location A1 is shown, (a) is sectional drawing before welding, (b) is sectional drawing after welding. The other welding example in welding location A1 is shown, (a) is sectional drawing before welding, (b) is sectional drawing after welding. The example of welding in welding location A2 is shown, (a) is sectional drawing before welding, (b) is sectional drawing after welding. The welding example of the welding location which welds a division body is shown, (a) is sectional drawing before welding, (b) is sectional drawing after welding. The other welding example of the welding location which welds a division body is shown, (a) is sectional drawing before welding, (b) is sectional drawing after welding. The other welding example of the welding location which welds a division body is shown, (a) is sectional drawing before welding, (b) is sectional drawing after welding. It is a perspective view of the front half part of a rim | limb part. The welding apparatus is shown, (a) is a cross-sectional view at the time of heating the welding location, (b) is a cross-sectional view at the time of welding. It is sectional drawing at the time of the welding location heating which shows another welding apparatus. The example which inclined so that a washing water flow path may be located below the front side is shown, (a) is a sectional view of a toilet bowl, (b) is the D section enlarged view of (a). The example which inclined so that a washing | cleaning water flow path may be located below the back side is shown, (a) is sectional drawing of a toilet bowl, (b) is the E section enlarged view of (a). It is a principal part expanded sectional view which shows the draining shape of another example. The toilet bowl of another example is shown, (a) is a side view, (b) is a front view, (c) is a sectional side view. It is an exploded side view same as the above. It is a disassembled perspective view of the conventional toilet bowl.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Bowl part 2 Skirt part 3 Rim part 14 Adhesive material 15 U-shaped part 16 Washing water flow path 24 Upper horizontal piece part 43 Thin part 44 Thick part 56 Projection part 57 Concave part

Claims (6)

  A method for manufacturing a flush toilet comprising a bowl portion and a rim portion disposed at an upper end of the bowl portion, wherein two or more synthetic resin divided bodies are integrally formed by welding and manufacturing Method.   The method for manufacturing a flush toilet according to claim 1, wherein each of the bowl portion and the rim portion is made of an independent synthetic resin divided body, and the two divided bodies are integrated by welding.   A method for manufacturing a flush toilet equipped with a skirt covering the outside of the bowl, wherein the bowl, skirt and rim are each made of independent synthetic resin segments, and the three synthetic resin segments are divided. The method for manufacturing a flush toilet according to claim 1, wherein the body is formed by welding and integration.   After the welding allowance protruding from the surface facing the other divided body of the divided body is heated and melted, both divided bodies are butted through a melted resin obtained by dissolving the welding allowance, and the melted resin protruding from the butted portion 3 or 2 is filled in a space between a relief slope provided on one of the two divided bodies and the other divided body, and the two divided bodies are welded. A method for producing a flush toilet according to claim 1.   Forming a protruding portion on the divided body and forming a welding allowance protruding from the tip of the protruding portion, heating and dissolving the welding allowance of the divided body, and then dissolving the protruding portion of the divided body in the welding allowance The method for manufacturing a flush toilet according to claim 1 or 2, wherein both divided bodies are welded by fitting into a recessed portion formed in another divided body via a dissolved resin. .   The method for manufacturing a flush toilet according to any one of claims 1 to 5, wherein the divided body is an acrylic resin molded product.

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