JP2009189575A - Bathtub or waterproof pan and manufacturing method thereof - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a bathtub or a waterproof pan which enables a mounting component to be mounted by fastening screws and which is excellent in bathing feeling and warm-keeping property. <P>SOLUTION: The bathtub or waterproof pan 1 includes a soft layer 2 formed of a soft surface layer 21 and a foam 22 on the front surface side and an FRP 3 on the rear surface. A through-hole 3a for mounting the mounting component of the bathtub or waterproof pan 1 is formed in an RFP3. In the soft layer 2, a large diameter hole 2a having a diameter larger than the through-hole 3a is formed. Around the through-hole 3a, an area without the soft layer 2 is formed, so that the mounting component can be fixed from front/rear sides by the screws in the through-hole 3a. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a structure of a soft bathtub or waterproof pan provided with a through hole for mounting a mounting component, and a method for manufacturing the same.

Conventionally, as disclosed in Patent Document 1, a recess whose bottom reaches the surface resin layer is formed on the back surface of a molded product in which an intermediate resin layer made of a foamable resin is formed between the surface resin layer and the back surface resin layer. A hard body that is harder than the intermediate resin layer is embedded in the recess and fixed and integrated with the molded product. A through-hole that penetrates the hard body and the surface resin layer is formed in the molded product. There is a hole structure of a soft bathtub in which the peripheral part of the through-hole is inserted between the front and back sides of the molded product by inserting and attaching the mounted component to the molded product.
JP 2007-7273 A

  In the hole structure of the soft bathtub disclosed in Patent Document 1, since the soft surface resin layer remains, the attachment part is inserted into the through hole, and the peripheral part of the through hole is sandwiched from the front and back by the attachment part. At this time, if the mounting part is tightened from the front and back sides, there is a problem that water may leak due to deformation of the surface resin layer.

The present invention provides a bathtub or a waterproof pan that can firmly fix and fix a mounting part with screws from the front and back sides, is not deformed, and has excellent bathing feeling and heat retention, and such a bathtub or waterproof. One of the objectives was to provide a method for producing bread, and in order to achieve at least part of this objective, the following measures were taken.
The present invention is a bathtub or waterproof pan comprising a soft layer on the front surface and an FRP on the back surface, and having a through hole for attaching a mounting part, wherein the soft layer does not exist around the through hole. The gist.

Since there is no soft layer around the through hole, the mounting component can be firmly attached to the hard FRP by tightening a screw from the front and back sides without deformation.
Since such a bathtub or waterproof pan has a soft layer on the surface, it feels soft when touched by the feet of the bather, and the bathing feeling is good, and the heat retaining property is also excellent. .

In the bathtub or waterproof pan of the present invention, the soft layer may have a structure including a soft surface layer and a foam.
If it carries out like this, it will become what was excellent in the feeling of bathing and heat retention with a foam.

In the bathtub or waterproof pan of the present invention, the end face on the through-hole side of the foam may have a water stop structure that prevents water from entering the foam.
In this way, the end face on the through hole side of the foam is not exposed, and water can be prevented from entering the foam from the through hole side, and the foam end face can be prevented from being stained and moldy. .

Moreover, the manufacturing method of the present invention is a method for manufacturing the bathtub or waterproof pan according to claim 1 or 2, wherein a step of opening a large-diameter hole having a diameter larger than the through-hole in the soft layer; The present invention includes a step of attaching a molding jig in the large-diameter hole, molding an FRP on the back surface of the soft layer, and a step of opening the through-hole at a center position of the large-diameter hole in the FRP. .
In the bathtub or waterproof pan manufacturing method of the present invention, the soft layer has a large-diameter hole, and the FRP has a through-hole smaller than the large-diameter hole. It becomes a structure of only the FRP that does not, and it can be securely attached to the FRP by tightening screws from the front and back sides.

Moreover, the manufacturing method of the present invention is a method for manufacturing the bathtub or waterproof pan according to claim 1 or 2, wherein a step of opening a large-diameter hole having a diameter larger than the through-hole in the soft layer; The gist of the present invention includes a step of bonding and integrating a soft layer having a large-diameter hole and a separate FRP, and a step of opening the through-hole at the center position of the large-diameter hole in the FRP.
In this way, a large-diameter hole is made in the soft layer, a separate FRP is bonded and integrated, and then a through-hole is made in the FRP, which makes it easy to manufacture, and there is a soft layer around the through-hole. Since it is configured only by the FRP that does not, the mounting part can be inserted through the through hole and the screw can be tightened to ensure the mounting.

Further, in the method for manufacturing a bathtub or waterproof pan according to the present invention, the step of forming a large-diameter hole in the soft layer composed of the soft surface layer and the foam is formed by forming a recess having a diameter larger than the through-hole in the soft layer. Thus, the step of forming the large-diameter hole by cutting the bottom side of the concave portion in parallel with the soft layer can be employed.
By so doing, a soft layer composed of a soft surface layer and a foam is formed with a recess having a diameter larger than that of the through hole, and the bottom side of the recess is cut so that the large diameter hole is formed in the portion where the recess is cut. Appears, and a large-diameter hole can be easily formed in the soft layer, which facilitates manufacture. Moreover, the inner periphery of the large-diameter hole is covered with a soft surface layer.

Next, the best mode for carrying out the present invention will be described using examples.
FIG. 1 is an enlarged configuration view of a main part of a waterproof pan 1 that forms a washing place in a bathroom.
The waterproof pan 1 is composed of a soft layer 2 on the front surface side and a hard FRP reinforcing layer 3 on the back surface side.
Moreover, the soft layer 2 has a double structure of the soft surface layer 21 on the front side and the foam 22 on the back side. The soft surface layer 21 may be formed of a thermosetting resin such as polyurethane or may be formed of a thermoplastic elastomer. The foam 22 is formed by foaming polyolefin, polystyrene, polyurethane or the like. The FRP reinforcing layer 3 is made of FRP such as glass fiber reinforced polyester.

In order to attach the drain outlet metal fitting to such a waterproof pan 1, a through hole 3 a penetrating vertically is formed in the FRP reinforcing layer 3. The soft layer 2 above the through-hole 3a is formed with a large-diameter hole 2a having a diameter larger than that of the through-hole 3a, and the periphery of the through-hole 3a is configured only by the FRP reinforcing layer 3 in which the soft layer 2 does not exist. ing.
Further, the inner periphery of the large-diameter hole 2a is applied with a water-stopping agent such as a caulking agent such as silicon or an adhesive, or is water-stopped using water-stopping parts.

In such a structure, for example, when fixing the mounting parts constituting the drain fitting from the front and back sides with screws, the mounting parts are passed through the through holes 3a and tightened with the screws from the front and back sides. Only the front and back sides are clamped, and the soft layer 2 is not clamped, so that it is not deformed, and a mounting part such as a drain fitting can be securely fixed to the hard FRP reinforcing layer 3.
Since the inner periphery of the large-diameter hole 2a is water-stopped by the water-stopper 4 or the like, water does not enter the foam 22 from the large-diameter hole 2a side, and the large-diameter hole 2a of the foam 22 It is possible to prevent the end face on the side from becoming dirty and the foam 22 from being moldy.

Next, the waterproof pan 1 shown in the enlarged sectional view of FIG. 2 is a modification.
In FIG. 2, the inner periphery of the large-diameter hole 2a formed in the soft layer 2 is covered with the soft surface layer 21, and the soft surface layer 21 is bent downward on the large-diameter hole 2a side. Then, a cover portion 21a whose lower end is in contact with the FRP reinforcing layer 3 is continuously formed, and the inner periphery of the large-diameter hole 2a is stopped by the cover portion 21a, so that water enters the foam 22 side. It has a prevented structure.
The hard FRP reinforcing layer 3 is formed with through holes 3a having a diameter smaller than that of the large diameter hole 2a. The outer periphery of the upper surface of the through hole 3a is a region where the soft layer 2 does not exist. .

Also in the structure of FIG. 2, since the soft layer 2 does not exist around the through hole 3a and only the FRP reinforcing layer 3 is formed, the mounting parts are fastened to the hard FRP reinforcing layer 3 from the front and back sides with screws. The mounting component can be firmly attached without being deformed.
Further, since the inner periphery of the large-diameter hole 2a is covered with the cover portion 21a of the soft surface layer 21, it is possible to prevent the end face of the foam 22 from being contaminated and the foam 22 from being moldy. Is.

Next, FIG. 3 shows a further modification of the waterproof pan 1.
Also in the waterproof pan 1 shown in FIG. 3, the front side is composed of the soft layer 2, and the back side is composed of the FRP reinforcing layer 3, and the through hole 3 a is formed in the FRP reinforcing layer 3. A large-diameter hole 2a having a diameter larger than that of the through-hole 3a is formed.
Male and female screws 5a and 6a are formed on the front surface side component 5 and the rear surface side component 6 of the mounting component P constituting the drain fitting, and the screws 5a and 6a of the front surface side component 5 and the rear surface side component 6 are formed. The part can be inserted into the through hole 3a, the screws 5a and 6a can be screwed together from the front and back sides, and the front side part 5 and the back side part 6 can be fastened with screws, and the screws 5a and 6a can be fastened. In this state, the pressing portion 5b of the front surface side component 5 is in contact with the upper surface of the FRP reinforcing layer 3, and the flange portion 6b of the back surface side component 6 is in contact with the back surface of the FRP reinforcing layer 3, so that the FRP reinforcing layer 3 is It is sandwiched between the pressing part 5 b of the side part 5 and the flange part 6 b of the back side part 6, and the attachment part P is firmly attached to the FRP reinforcing layer 3.

In FIG. 3, a rib 5c that extends horizontally and has a tip protruding downward is integrally formed on the outer periphery of the surface side component 5 in a ring shape. When the surface side component 5 is tightened, the rib 5c is soft. The layer 2 is pressed against the FRP reinforcing layer 3 side, whereby the end of the large-diameter hole 2a side of the foam 22 is compressed in the vertical direction so that water does not enter the foam 22 from the large-diameter hole 2a side. It is comprised as follows.
That is, when the front-side component 5 and the rear-side component 6 are fastened and fixed without using the water-stopping agent 4 such as silicon, the end portion of the foam 22 on the large-diameter hole 2a side is simultaneously crushed by the rib 5c. It has a structure that can do.

Next, the manufacturing method of the part of the through-hole in the bathtub 11 which consists of the soft layer 2 and the FRP reinforcement layer 3 is demonstrated in FIGS.
The soft layer 2 has a double structure of the soft surface layer 21 and the foam 22 on the surface side, and the soft surface layer 21 and the foam 22 are integrated by vacuum forming or adhesion, and the soft layer 2 is integrated. Is formed in the shape of the bathtub 11.

From the state of FIG. 4, the large-diameter hole 2a is formed in the soft layer 2 as shown in FIG. 5, and the forming jig 7 is fitted into the formed large-diameter hole 2a as shown in FIG.
In this state, the FRP reinforcing layer 3 is integrally formed on the back side of the forming jig 7 and the soft layer 2 by, for example, a method of manually stacking glass fibers and resin (hand layup method).
Thereafter, the forming jig 7 is removed from the large-diameter hole 2a, and as shown in FIG. 7, a through-hole 3a that penetrates the FRP reinforcing layer 3 is formed at the center position of the large-diameter hole 2a using a tool such as a drill or a hole saw. Let

After forming the small-diameter through hole 3a in the FRP reinforcing layer 3 in this way, as shown in FIG. 8, the front side part 5 of the attachment part P is inserted into the through hole 3a from the front side, and from the back side. Inserts the back side part 6 and fastens the front side part 5 and the back side part 6 with the screws 5a, 6a from the front and back sides, and the FRP reinforcing layer 3 is sandwiched between the front side part 5 and the back side part 6. The attachment part P is firmly attached to the FRP reinforcing layer 3.
In addition, as shown in FIG. 8, when attaching the attachment part P, the water stop part 8 which consists of a ring-shaped hard resin is inserted in the inner periphery of the large diameter hole 2a, and this water stop part 8 is large diameter. The inner peripheral surface of the hole 2a can be water-stopped like a cover.
Even by using such a separate water-stopping part 8, the end surface of the foam 22 on the large-diameter hole 2a side is water-stopped in a cover-like manner to reliably prevent water from entering the foam 22; Generation of mold and the like can be prevented.

Next, another example of the manufacturing method is shown in FIGS.
In FIG. 9, the cross section of the soft layer 2 formed in the shape of the waterproof pan 1 by vacuum forming or the like is enlarged, and the soft layer 2 is composed of a soft surface layer 21 on the front side and a foam 22 on the back side. A concave portion R is formed at the position where the attachment part of the soft layer 2 is configured, for example, during vacuum forming. The horizontal diameter dimension of the recess R is larger than that of the through hole 3a.
When the soft layer 2 in which the concave portion R is integrally formed in this way is cut along the soft layer 2 horizontally at the bottom side of the concave portion R and the bottom side of the concave portion R is removed, a shape as shown in FIG. 10 is obtained. The large-diameter hole 2a appears in the portion where the recess R is cut. The cover portion 21a of the soft surface layer 21 is continuously suspended from the inner periphery of the large diameter hole 2a, and the inner periphery of the large diameter hole 2a is covered with the cover portion 21a of the soft surface layer 21. .

A molding jig 7 is fitted into the large-diameter hole 2a as shown in FIG. 11, and glass fiber and resin are manually stacked on the back side of the molding jig 7 and the soft layer 2 (hand lay-up method). The FRP reinforcing layer 3 can be formed.
After forming the FRP reinforcing layer 3 integrally, the forming jig 7 is removed, and as shown in FIG. 12, the FRP reinforcing layer 3 is moved downward from the top to the center position of the large-diameter hole 2a using a drill D or the like. The through-hole 3a is formed in As a result, a through hole 3a for attaching and fixing the attachment part is formed, and the soft layer 2 does not exist near the outer periphery on the upper surface side of the through hole 3a. Therefore, the attachment part is firmly attached to the FRP reinforcing layer 3 from the front and back sides. It can be attached by tightening.
Further, since the inner peripheral surface of the large-diameter hole 2a is stopped by the cover portion 21a of the soft surface layer 21, water can be prevented from entering the foam 22 from the large-diameter hole 2a side. The occurrence of dirt and mold on the end face of 22 is prevented.

Next, FIGS. 14-16 shows the further modification of a manufacturing method.
As shown in FIG. 14, the soft layer 2 and the FRP reinforcing layer 3 are separately manufactured in the shape of the bathtub 11, the large diameter hole 2 a is formed in the soft layer 2, and then the back surface of the soft layer 2. The FRP reinforcing layer 3 formed as a separate body is attached by adhesion and integrated as shown in FIG. 15, and then, as shown in FIG. 16, a tool such as a drill is inserted from the surface side to the center of the large-diameter hole 2a. The through hole 3 a is formed in the FRP reinforcing layer 3 by being inserted.
Further, a water-stopping agent 4 such as silicon is applied to the inner periphery of the large-diameter hole 2a, or a hard-resin water-stopping part 8 as shown in FIG. It can be water-stopped.

When the front surface side component 5 and the back surface side component 6 of the attachment component P are tightened from the front and back sides to the through hole 3a formed in this way, the FRP reinforcing layer 3 is sandwiched between the front surface side component 5 and the back surface side component 6. The mounting part P is firmly attached to the FRP reinforcing layer 3.
In the case of the bathtub 11, examples of the mounting part P include a jetting metal fitting, a reheating metal fitting, a handrail, and the like, and the mounting part P can be firmly attached without being deformed. 22 can be prevented from being stained and moldy.
In the bathtub 11 and the waterproof pan 1 having such a structure, since the soft layer 2 provided with the foam 22 exists on the surface side, a soft contact feeling is obtained during bathing, and the bathing feeling is extremely improved. This soft layer 2 significantly improves the heat retention.

It is an expanded sectional block diagram of the part of the through-hole of the waterproof pan which consists of a soft layer and a FRP reinforcement layer. It is a principal part cross-section enlarged view of the waterproof pan which shows the example of a change of FIG. It is a principal part expanded sectional block diagram of the part of the through-hole of the waterproof pan which shows the further modification and shows the attachment state of attachment components. It is a principal part block diagram of the soft layer formed in the shape of a bathtub. FIG. 5 is a cross-sectional configuration diagram of a main part in which large diameter holes are formed in the soft layer of FIG. 4. Furthermore, it is a cross-sectional block diagram in which a molding jig is fitted into the large-diameter hole and an FRP reinforcing layer is formed on the back side. Furthermore, it is the cross-sectional block diagram which made the through-hole penetrate the FRP reinforcement layer. It is a section lineblock diagram of the state where it tightened and attached attachment parts from the front and back sides in a penetration hole. It is a section expanded lineblock diagram of a crevice in a soft layer formed in a waterproof bread shape. It is a section lineblock diagram of the state where the bottom side of a crevice was cut horizontally. Furthermore, it is a cross-sectional block diagram in which a molding jig is fitted into the large-diameter hole and an FRP reinforcing layer is formed on the back side. It is a cross-sectional block diagram at the time of forming a through-hole with a drill etc. with respect to a FRP reinforcement layer. It is a section lineblock diagram of the state where a through hole was formed. It is a sectional exploded view in the state where the soft layer and the FRP reinforcement layer were separately formed in the shape of a bathtub. It is the cross-section block diagram which made the soft layer and FRP reinforcement layer which were formed separately adhere and integrate. FIG. 3 is a cross-sectional configuration diagram of a state in which through holes are formed in an integrated state and a water-stopping agent is applied to the inner periphery of a large diameter hole.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Waterproof pan 2 Soft layer 2a Large diameter hole 3 FRP reinforcement layer (FRP)
3a Through-hole 4 Water-stopping agent 5 Surface side part 5a Screw 5b Pressing part 5c Rib 6 Back side part 6a Screw 6b Knee part 7 Molding jig 8 Water-stop part 21 Soft surface layer 21a Covering part 22 Foam R Recessed part D Drill

Claims (6)

In a bathtub or waterproof pan comprising a soft layer on the front surface and FRP on the back surface, and having a through hole for mounting a mounting part,
A bathtub or waterproof pan, wherein the soft layer is formed around the through-hole.   The bathtub or waterproof pan according to claim 1, wherein the soft layer is composed of a soft surface layer and a foam.   3. The bathtub or waterproof pan according to claim 2, wherein an end face of the foam on the side of the through-hole has a water stop structure that prevents water from entering the foam. It is a manufacturing method of the bathtub or waterproofing bread according to claim 1 or 2,
Opening a large-diameter hole larger in diameter than the through-hole in the soft layer;
Attaching a molding jig in the large-diameter hole, and molding FRP on the back surface of the soft layer;
And a step of opening the through hole at the center position of the large diameter hole in the FRP. It is a manufacturing method of the bathtub or waterproofing bread according to claim 1 or 2,
Opening a large-diameter hole larger in diameter than the through-hole in the soft layer;
A step of bonding and integrating a soft layer having a large-diameter hole and a separate FRP;
And a step of opening the through hole at the center position of the large diameter hole in the FRP. The step of opening a large diameter hole in the soft layer composed of a soft surface layer and a foam,
The step of forming the large-diameter hole by forming a concave portion having a larger diameter than the through-hole in the soft layer and cutting the bottom side of the concave portion in parallel to the soft layer. Of manufacturing bathtubs or waterproof pans.

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