JP2009226154A - Method for manufacturing bathtub - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a bathtub formed by decorating a plastic bathtub which requires easy-care and is durable with a fancy wood-grain pattern or the like, and its manufacturing method. <P>SOLUTION: The bathtub 1 has an extremely aesthetic appearance since a sliced veneer 25 is viewed as the lustrous wood-grain pattern through a transparent plastic layer 21 and a glass fiber 23 when being viewed from an internal surface side. Further, since joining parts of the sliced veneers 25 are located on the reverse side of a painted part 17, the joining parts which are slightly misaligned are not be seen from the internal surface side of the bathtub 1. Consequently, the appearance of the entire bathtub 1 is not spoiled. In this way, while the bathtub 1 has the fancy wood-grain pattern, the bathtub requires easy-care and has excellent durability since the bathtub is actually made of plastic. The bathtub 1 is manufactured by laminating each member. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a method of manufacturing a bathtub mainly composed of plastic, and more particularly to a method of manufacturing a bathtub capable of neatly decorating a grain or the like.

Generally, a plastic bathtub is manufactured by various molding methods such as casting, vacuum, pressing, and matched die. Accordingly, the pigment is mixed with the molding material for coloring, or a fine granular decoration material is mixed for decoration. The plastic bathtub has the advantages that it is difficult to get dirt, hardly generates mold, is easy to care for, and has high durability.
By the way, some bathtubs are made of wood typified by firewood, and this kind of wooden bathtub is well established as a representative of luxury products.

However, the wooden bathtub has a problem that it takes a lot of time to clean it, such as mold, unless it is cleaned thoroughly and then dried well.
Therefore, it is desired to decorate a plastic bathtub that is easy to clean, but with the method of mixing pigments and decorative materials into the molding material as described above, a wood pattern decoration was applied. A bathtub cannot be manufactured.
In addition, there are methods such as covering the plastic bathtub around the plastic bathtub at the time of bathroom construction, but it is far from the luxury of a wooden bathtub.
The present invention focuses on the above-mentioned conventional problems, and provides a bathtub that is easy to clean and has a highly durable plastic bathtub decorated with a high-quality wood grain pattern and the like, and a method for manufacturing the same. That is the purpose.

  SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned problems, and the invention of claim 1 is a convex shape in which corners are rounded on the outer surface of the mold corresponding to the bottom and side surfaces of the bathtub. After the transparent plastic layer is formed, tape-like glass fibers are pasted on the corners, and then the corners are flattened to form the edges, and the edges are provided on the corners with the edges. A coating layer is formed, and then a cloth-like glass fiber is disposed on the surface corresponding to the bottom and sides of the transparent plastic layer, and a plurality of decorative sheet materials are further formed thereon. It is a manufacturing method of the bathtub characterized by removing from the above-mentioned type, after arranging so that the joined part of materials may be hidden behind a paint part, and making it a laminated structure.

  The invention of claim 2 is the method for manufacturing a bathtub according to claim 1, wherein the decorative sheet material is made of a veneer, Japanese paper or cloth.

According to the method of the present invention, it is possible to decorate a high-quality wood grain pattern or the like on a plastic bathtub that is easy to clean and highly durable.
Therefore, the bathtub manufactured by the method of the present invention is an FRP bathtub that looks as if it is clear painted on the side plate or bottom plate of thick solid wood.

The bathtub 1 which concerns on embodiment of this invention, and the manufacturing method of this bathtub 1 are demonstrated according to drawing.
First, the configuration of the bathtub 1 will be described with reference to FIGS. 1 to 3.
The bathtub 1 is composed of a main body 3 and a flange 5 which is integrally formed with the main body 3 and protrudes outward. The main body 3 has a substantially rectangular bottom plate 7 and is slightly inclined on each side of the bottom plate 7. The side plates 9, 11, 13, and 15 are integrally provided and expand upward. Adjacent sides of the side plates 9, 11, 13, 15 are integrally connected. The inner surface of the bottom plate 7 and the side plates 9, 11, 13, 15 has a grain pattern, and the boundary between the bottom plate 7 and the side plates 9, 11, 13, 15, the side plates 9, 11, 13, 15 A coating portion 17 is provided at the boundary portion.
In addition, the wood grain pattern is given to the inner surface of the main body 3, and the upper surface and side surface of the flange 5.

  As shown in FIG. 2, the bathtub 1 is mainly made of plastic, and is configured by laminating a transparent plastic layer 21, glass fibers 23, and a projecting plate 25 that is a decorative material from the inner surface. The coating portion 17 described above is located between the protruding plate 25 and the transparent plastic layer 21 as will be described later.

A method for manufacturing the bathtub 1 will be described with reference to FIGS.
The symbol K indicates a mold for molding the bathtub 1, and this mold K has a convex portion K1 having a shape corresponding to the inner surface of the main body 3 of the bathtub 1, and a flange portion K2 formed integrally with the lower end portion of the convex portion K1. Have. A shallow concave portion K3 is formed in the flange portion K2, and the concave portion K3 is continuously formed so as to surround the lower end portion of the convex portion K1. The four corners of the convex portion K1 are rounded.
As shown in FIG. 4, a release agent is applied to the surface of the mold K (the surface on the side visible in FIG. 4).

Next, the process proceeds to the lamination process.
A gel-like transparent plastic constituting the transparent plastic layer 21 is applied by a spray gun G. After the gel-like transparent plastic is solidified and the transparent plastic layer 21 is formed, as shown in FIGS. 5 and 6, the rounded corners of the transparent plastic layer 21 (the bottom plate 7 and the side plates 9 and 11 of the bathtub 1 are provided). , 13, 15 and a portion corresponding to the boundary portion between the side plates 9, 11, 13, 15) are affixed with a glass cloth tape 27 made of glass fiber.
Next, as shown in FIGS. 7 and 8, the laying portion 29 is formed on the glass cloth tape 27 so as to ply the polyester resin. The rounded portion is filled so as to be flat by the arranging portion 29, and the corner portion becomes the edge portion 29a.

  When the arrangement part 29 is solidified, a masking tape 31 is pasted on both sides of the arrangement part 29 as shown in FIG. That is, the masking tape 31 is pasted so that a portion having a predetermined width centered on the corner of the arrangement portion 29 is exposed. Then, the exposed portion of the arrangement portion 29 having a predetermined width is painted to form a painted portion 17 as a mask material. It is assumed that the color of the coating portion 17 approximates that of the protruding plate 25. The masking tape 31 is removed when the paint constituting the coating portion 17 is dry.

Next, as shown in FIG. 10, after applying a polyester resin to the transparent plastic layer 21 and the coating part 17, the glass cloth 33 made of glass fiber is attached. The glass cloth 33 is affixed to the surfaces corresponding to the bottom plate 7 and the side plates 9, 11, 13, 15 of the main body 3 of the bathtub 1.
Then, as shown in FIG. 11, the protruding plate 25 is pasted so as to correspond to the glass cloth 33. This protruding plate 25 is also fixed by a polyester resin.
As shown in FIG. 12, the end portions of the protruding plate 25 are joined to each other on the coating portion 17. Thereby, when it sees from the inner surface side of the bathtub 1 at the time of completion of the bathtub 1, the junction part of the protrusions 25 will be covered with the coating part 17, and will be hidden. Therefore, even if the joint portion is not joined with high accuracy, it is possible to prevent the beauty from being impaired.

As shown in FIG. 13, five plate-like acrylic foam materials 35 are pasted in correspondence with the five glass cloths 33. Similarly to the glass cloth 33, the plate-like acrylic foam 35 is fixed by a polyester resin. When the plate-like acrylic foam 35 is pasted, it is handled using a roller R or the like to push out air bubbles in the polyester resin and to bring the plate-like acrylic foam 35 into close contact with the glass cloth 33.
Next, as shown in FIG. 14, a placing portion 36 is formed so that an FRP putty is placed between the end portions of the acrylic foam material 35 so as to form a round shape.

Then, as shown in FIG. 15, a glass fiber mat 37 is stuck on the plate-like acrylic foam 35, and a glass fiber roving cloth 39 is stuck on the mat 37. The mat 37 and the roving cloth 39 are fixed by a polyester resin.
As shown in FIG. 16, the mat 37 and the roving cloth 39 of the bathtub 1 correspond to the boundary portion between the bottom plate 7 and the side plates 9, 11, 13, 15 of the bathtub 1 and the boundary portion between the side plates 9, 11, 13, 15. The parts are provided so as to overlap each other.
The lamination process is thus completed.

As shown in FIG. 17, when the polyester resin is solidified, the semi-finished product 1a manufactured as described above is removed from the mold K.
The flange 5 of the semi-finished product 1a is cut as shown in FIG. 18B from the one-dot chain line portion shown in FIG. Then, the semi-finished product 1a is set in the state shown in FIG.
Next, as shown in FIG. 20, the semi-finished product 1 a is placed in a posture in which the bottom surface faces downward, and the flange 5 is polished by using the polishing apparatus M to finish the surface smooth.
Then, as shown in FIG. 21, the protruding plate 41 cut into a shape corresponding to the flange 5 is attached to the flange 5 with a heat-welding adhesive. At this time, the iron H is used to work so that the protruding plate 41 is not wrinkled.

Next, as shown in FIG. 22, the glass cloth 43 is affixed on the protruding plate 41 that is affixed to the flange 5.
Then, as shown in FIG. 23, a transparent urethane paint is sprayed using a spray gun G, and the bathtub 1 is completed when the paint is dried.

When the bathtub 1 is viewed from the inner surface side, the protruding plate 25 can be visually recognized as a glossy wood grain pattern through the transparent plastic layer 21 and the glass cloth 33, and an extremely high aesthetic appearance is exhibited.
Moreover, since the junction part of the protrusions 25 is located in the back side of the coating part 17, even if a junction part has shifted | deviated somewhat, it cannot be seen from the inner surface side of the bathtub 1. FIG. Therefore, the beauty of the entire bathtub 1 is not impaired.
As described above, the bathtub 1 has a high-quality wood grain pattern, but since it is substantially made of plastic, it is easy to care for and has high durability.

The embodiment of the present invention has been described in detail above. However, the specific configuration is not limited to this embodiment, and the present invention can be changed even if there is a design change without departing from the gist of the present invention. included.
For example, in the above-described embodiment, the veneer plate 25 is used as the decoration material. However, the decoration material is not limited to this, and any sheet-like material having a pattern or the like that can exhibit aesthetics may be used. be able to.

  The present invention can be used in the manufacturing industry of bathtubs.

It is a perspective view of the bathtub which concerns on embodiment of this invention. It is AA sectional drawing of FIG. 1, and its partial enlarged view. It is the top view of the bathtub of FIG. 1, and its partial enlarged view. It is a perspective view which shows the process of apply | coating transparent plastic to the type | mold used for manufacture of the bathtub of FIG. It is a perspective view which shows the process of sticking a glass cloth tape on the corner | angular part of a transparent plastic layer after completion | finish of the process shown in FIG. It is BB sectional drawing of FIG. 5, and its partial expansion part. It is a perspective view which shows the process of forming a mounting part on a glass cloth tape after completion | finish of the process shown in FIG. FIG. 8 is a cross-sectional view taken along line BB in FIG. 7 and a partially enlarged portion thereof. It is sectional drawing of the part corresponding to FIG. 7 which shows the process of forming a coating part in the arrangement | positioning part after the process shown in FIG. 7, and its partial enlarged view. It is a perspective view which shows the process of sticking a glass cloth on a transparent plastic layer after completion | finish of the process shown in FIG. It is a perspective view which shows the process of sticking a protruding board on a glass cloth after completion | finish of the process shown in FIG. It is sectional drawing after completion | finish of the process shown in FIG. It is a perspective view which shows the process of sticking a plate-shaped acrylic foam material on a glass cloth after completion | finish of the process shown in FIG. It is sectional drawing which shows the process of forming a mounting part between acrylic foam materials after completion | finish of the process shown in FIG. It is a figure which shows the process of sticking the glass fiber mat and the glass fiber roving cloth on the acrylic foam after completion of the process shown in FIG. FIG. 16 is a cross-sectional view of the vicinity of a corner after the process illustrated in FIG. It is a perspective view which shows the process of removing the semi-finished product of a bathtub from a type | mold. It is a figure which shows the process of cutting and removing a part of flange of the semi-finished product of a bathtub after completion | finish of the process shown in FIG. It is a perspective view of the semi-finished product of the bathtub after completion | finish of the process of FIG. It is a perspective view which shows the process of grind | polishing the flange of the semi-finished product of the bathtub shown in FIG. It is a perspective view which shows the process of sticking a projecting board to the flange of the semi-finished product of a bathtub after completion | finish of the process shown in FIG. It is a perspective view which shows the process of sticking a glass cloth on the veneer stuck on the flange of the semi-finished product of a bathtub after completion | finish of the process shown in FIG. It is a perspective view which shows the process of giving urethane coating to the semi-finished product of a bathtub after completion | finish of the process shown in FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Bathtub 3 ... Main body 5 ... Flange 7 ... Bottom plate 9, 11, 13, 15 ... Side plate 17 ... Paint part 21 ... Transparent plastic layer 23 ... Glass fiber 25 ... Projection board 27 ... Glass cloth tape 29 ... Placing part 29a ... Edge part DESCRIPTION OF SYMBOLS 31 ... Masking tape 33 ... Glass cloth 35 ... Plate-shaped acrylic foam material 36 ... Placing part 37 ... Glass fiber mat 39 ... Glass fiber roving cloth 41 ... Projection board K ... Mold K1 ... Mold convex part K2 ... Mold flange Part K3 ... concave part of mold flange G ... spray gun R ... roller

Claims (2)

After forming a convex transparent plastic layer with rounded corners corresponding to the inner surface of the bottom and side of the bathtub on the outer surface of the mold,
After pasting tape-like glass fiber at the corner, fill the roundness of the corner flat to form an edge, and form a coating layer on the corner with the edge,
Next, cloth-like glass fibers are arranged on the surfaces corresponding to the bottom and sides of the transparent plastic layer, and a plurality of decorative sheet materials are further coated on the joints between the sheet materials. A method for manufacturing a bathtub, wherein the method is arranged so as to be hidden by the layered structure and then removed from the mold.   The method for manufacturing a bathtub according to claim 1, wherein the decorative sheet material is made of a veneer, Japanese paper or cloth.

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