JP2010094932A - Method of manufacturing resin molded product - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method of manufacturing a resin molded product that can accurately adjust the position relationship of main members to carry out welding when a plurality of main members are allowed to abut and vibratingly welded and integrated. <P>SOLUTION: The method of manufacturing the resin molded product by allowing an opening upper edge 21 of a bowl part 2 of an upper face opening and a lower edge 11 of a rim part 1 corresponding to the periphery of the opening upper edge 21, to abut each other and vibratingly welding them, comprises forming an upper positioning rib piece 3 protrusively on the outer surface near the lower edge 11 of the rim part 1, forming a lower positioning rib piece 4 protrusively on the outer surface near the opening upper edge 21 of the bowl part 2, adjusting the position of the rim part 1 and the bowl part 2 by the upper positioning rib piece 3 and the lower positioning rib piece 4, and positioning the rim part 1 and bowl part 2 by a fixing tool to integrally weld the rim part 1 and bowl part 2. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a method of manufacturing a resin molded product, and more particularly to a method of integrally molding and manufacturing a large resin molded product such as a Western-style toilet by vibration welding a plurality of members.

  Conventionally, the toilet bowl body of a Western-style toilet has been used mainly made of earthenware, which is integrally formed by a casting method. In the casting method, for example, slurry is poured into a casting mold and solidified to obtain an integrally molded product. However, it is avoided that the product is deformed or cracked in the manufacturing process such as molding or firing. In other words, the manufacturing cost is high, and it is difficult to obtain a toilet body having a certain quality.

On the other hand, in recent years, the progress of the resin molding method has made it possible to mold a large-sized member, and therefore, a resin-made member and a ceramic-made member are used as main members, and these are combined and joined together for the purpose of a large-sized molded product, For example, a Western-style toilet is manufactured.
In Japanese Patent Laid-Open No. 10-37279, as shown in FIG. 4, the skirt member 7, the flush bowl member 8, and the rim member 9 are provided as independent members, and the flush bowl member 8 is accommodated in the skirt member 7. The conceptual diagram of the structure of the well-known toilet bowl formed by attaching the rim member 9 to the upper end edge of the flush bowl member 8 is shown. Here, the inside of the rim member 9 is hollow, a washing water channel through which washing water flows is provided, and a toilet seat (not shown) is placed on the rim member 9.

In the above publication, the washing bowl member 8 is made of ceramic, the rim member 9 and the skirt member 7 are formed from industrial materials other than ceramics, and the rim member 9 and the skirt member 7 are made of resin. In the case where a molded product is employed, the cost is reduced particularly, and the weight of the toilet bowl is reduced, and the effect is described when it is advantageous for transportation and construction. Furthermore, the degree of freedom is widened in the design of the rim member 9 and the skirt member 7, and the degree of freedom in the arrangement of a hot water sanitary washing device having a local hot water washing function, for example, is increased as well as improvement in design as a Western-style toilet. Such effects are also described.
Japanese Patent Laid-Open No. 10-37279

  However, with the technique described in Patent Document 1, it is difficult to integrally form a large molded product such as a toilet body of a Western-style toilet from the plurality of members according to the design drawing, and in particular, an elliptical curved surface Therefore, there is a problem in that it takes time and effort to adjust the position of each member in order to join and join the toilet body with no gap or gap.

  The present invention has been made in view of the above-mentioned background art, and its purpose is to make a vibration by contacting a plurality of main members made of a thermoplastic resin when manufacturing a molded product having a large curved surface such as a toilet body of a Western-style toilet. It is intended to provide a method of manufacturing a resin molded product with high work efficiency by adjusting the positional relationship of the main members as described in the design drawing to enable welding when welding and integrating.

  In order to solve the above-mentioned problem, a method of manufacturing a resin molded product according to the first aspect of the present invention includes an upper upper edge of a bowl portion of an upper surface opening and a lower edge of a rim portion corresponding to the upper edge circumference of the opening. Is formed by projecting and forming an upper positioning rib piece on the outer surface near the lower edge of the rim, and lower positioning on the outer surface near the upper edge of the opening of the bowl portion. A rib piece is formed in a protruding manner, the rim portion and the bowl portion are adjusted with the upper positioning rib piece and the lower positioning rib piece, and the rim portion and the bowl portion are integrally welded.

  In the vibration welding method described above, the parts to be welded, that is, the upper edge of the bowl portion of the upper surface opening and the lower edge of the rim portion corresponding to the periphery of the upper edge of the opening are brought into contact with each other and pressed against each other. It is made to weld and join by making it vibrate in the direction and melting the welded parts by frictional heat between the welded parts caused by this vibration. At this time, either the bowl part or the rim part is fixed with a fixing jig to be a fixing member, the other member is to be a vibration member, and the parts to be welded are brought into close contact with each other and pressed against each other. Then, vibration is applied from the vibration welding device to the member to be vibrated to cause welding by frictional heat.

  At this time, for example, a bowl as a fixing member using the upper positioning rib piece formed on the outer surface in the vicinity of the lower edge of the rim portion and the lower positioning rib piece formed on the outer surface in the vicinity of the upper edge of the bowl portion. After precisely adjusting the positional relationship between the rim portion and the rim portion as the member to be vibrated and positioning with a fixing jig, the rim portion is vibrated from a vibration welding device, and the rim portion and the bowl portion are friction-welded. Let

  The invention according to claim 2 of the present application is the method of manufacturing a resin molded product according to claim 1, wherein the upper positioning rib piece and the lower positioning rib piece are integrally welded to the bowl portion and the rim portion. And have a resectable structure. For example, the cutting groove is provided in the immediate vicinity of the portion where the upper positioning rib piece protrudes from the main body of the rim portion, and the cutting groove portion is provided in the immediate vicinity of the lower positioning rib piece protruding from the main body of the bowl portion, and after vibration welding, The rib pieces can be excised.

  In the method of manufacturing a resin molded product according to the first aspect of the present invention, the upper positioning rib piece protrudes from the outer surface near the lower edge of the rim portion, and the lower positioning rib piece protrudes from the outer surface near the upper edge of the bowl portion. Since the upper positioning rib piece and the lower positioning rib piece can be formed and positioned for vibration welding, the optimum portion for vibration welding between the rim portion and the bowl portion can be selected and friction welded. .

  In addition, by vibration welding the entire surface of the lower edge of the rim part and the entire upper edge of the opening of the bowl part, the two are melted and integrated with each other. Can be manufactured. A resin molded product such as a toilet body of a Western-style toilet can be manufactured at a low cost while maintaining a certain quality.

  In the method of manufacturing a resin molded product according to the second aspect of the present invention, the upper positioning rib piece and the lower positioning rib piece have a resectable structure after the bowl portion and the rim portion are integrally welded. Therefore, the upper positioning rib piece and the lower positioning rib piece, which are no longer necessary after vibration welding, can be easily separated from the rim and bowl, respectively, and only the main body is integrally welded to obtain a resin molded product. Can do.

  Hereinafter, an embodiment of a method for producing a resin molded product according to the present invention will be described in detail with reference to the drawings. FIG. 1 shows an embodiment of the present invention, which is made of a thermoplastic resin such as ABS, polypropylene, etc., and a bowl portion 2 opened on the upper surface and a rim portion 1 is vibration welded to the bowl portion 2 to manufacture a toilet body of a western toilet. It is decomposition | disassembly explanatory drawing which shows a process.

  As shown in FIG. 1, a lower positioning rib piece 4 is formed on the outer surface in the vicinity of the upper edge 21 of the bowl portion 2 that opens to the upper surface, and a rim portion corresponding to the circumference of the upper edge 21 of the opening. On the outer surface in the vicinity of the lower edge 11, an upper positioning rib piece 3 is formed so as to protrude. Further, a right-angle notch 31 is provided at the outer lower end of the upper positioning rib piece 3, and a right-angle notch 41 is provided at the outer upper end of the lower positioning rib piece 4.

  Further, a cutting groove 33 described later is provided in the immediate vicinity of the portion where the upper positioning rib piece 3 protrudes from the main body of the rim portion 1. Similarly, a cutting groove 43 is also provided in the immediate vicinity of the portion where the lower positioning rib piece 4 protrudes from the main body of the bowl portion 2.

  FIG. 2 shows a state in which the bowl portion 2 is fixed by a non-illustrated fixing jig used for vibration welding, and vibration welding is performed by applying vibration as shown by an arrow V to the rim portion 1 from a vibration welding apparatus (not shown). It is explanatory drawing which shows. FIG. 3 is an explanatory cross-sectional view taken along line XX in FIG. As shown in FIG. 3, the inside of the rim portion 1 is hollow, and a washing water channel 5 through which washing water flows is formed. A plurality of discharge holes 6 through which washing water is ejected are arranged in the bottom of the washing water channel 5.

  The vibration welding is performed after the upper positioning rib piece 3 and the lower positioning rib piece 4 adjust the positions of the opening upper edge 21 of the bowl portion 2 and the lower edge 11 of the rim portion 1. First, the upper edge 21 and the lower edge 11 are overlapped and brought into contact with each other, and the positional relationship between the upper positioning rib piece 3 and the lower positioning rib piece 4 and the outer lower end portion of the upper positioning rib piece 3 are provided. The positional relationship is adjusted by observing the clearance, width, etc. of the space formed by the right-angle notch 31 and the right-angle notch 41 provided at the outer upper end of the lower positioning rib piece 4.

  For example, in FIG. 3, by measuring the clearance d of the space, it is possible to confirm whether or not the lower edge 11 of the rim part 1 and the upper opening edge 21 of the bowl part 2 have a predetermined contact distance. Yes, if it is not the predetermined contact distance, it is adjusted and fixed so that the optimum distance can be obtained by operating the non-illustrated fixing jig.

  Similarly, when the upper positioning rib piece 3 and the lower positioning rib piece 4 are viewed from the front, any one of the rim portion 1 and the bowl portion 2 does not swing left and right as long as it has a linear shape. It can be determined that it is in the position. In FIG. 3, if the side end edge 32 of the upper positioning rib piece 3 and the side end edge 42 of the lower positioning rib piece 4 maintain linearity as shown by the dotted line in FIG. It can be determined that the outer surface of the portion 2 is flush with the predetermined vibration welding position. In this way, it is possible to determine whether or not the rim portion 1 and the bowl portion 2 are in a predetermined positional relationship by the upper positioning rib piece 3 and the lower positioning rib piece 4. If not, the non-illustrated fixing jig is operated to adjust to the optimum position.

  After adjusting the position with the upper positioning rib piece 3 and the lower positioning rib piece 4, the position is fixed with an unillustrated fixing jig, and the opening upper edge 21 is fixed to the opening upper edge 21 of the fixed bowl portion 2. The lower edge 11 of the rim portion 1 corresponding to the circumference of the rim portion 1 is brought into contact with the rim portion 1, and vibrations from a vibration welding device (not shown) are applied to the rim portion 1. For example, vibration is applied as shown by an arrow V in FIG. 3, and the lower edge 11 of the rim portion 1 and the upper opening edge 21 of the bowl portion 2 are welded by frictional heat. In this case, how to apply the vibration, the magnitude, etc. may be selected as appropriate.

  The vibration welding area between the entire upper edge 21 of the bowl portion 2 and the entire lower edge 11 of the rim portion 1 is considerably wide, and both are melted and firmly fixed. Thus, after the said rim | limb part 1 and the bowl part 2 are welded integrally, the upper positioning rib piece 3 and the lower positioning rib piece 4 are previously provided in the vicinity of the main body of each protrusion part. It is cut off from the cutting grooves 33 and 43 which are the resectable structure.

  After excision of the upper positioning rib piece 3 and the lower positioning rib piece 4, the rim portion 1 and the bowl portion 2 which are integrally welded constitute a toilet bowl body of a Western-style toilet, and a toilet seat outside the figure is further placed on the product. It is said. In addition, you may provide the skirt part which covers the said bowl part 2, and may improve an external appearance property.

  In the above embodiment, the case where the resin molded product is a toilet body of a Western-style toilet comprising the rim portion 1 and the bowl portion 2 is described. However, the present invention is not limited to the above, and the manufacturing method of other resin molded products is also described. In any case, the present invention falls within the technical scope of the present invention as long as it is applicable and does not depart from the scope of the claims.

Explanatory explanatory drawing which shows the process of manufacturing the toilet body of a western-style toilet by vibrating and welding a rim | limb part to a bowl part. Explanatory drawing which shows the state which fixes a bowl part and a rim part by giving a vibration to a rim part from a vibration welding apparatus, fixing a bowl part. Cross-sectional explanatory drawing which follows the XX line in FIG. The conceptual diagram which shows the structure of a well-known toilet bowl.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Rim part 11 Lower edge 2 Bowl part 21 Opening upper edge 3 Upper positioning rib piece 31 Right angle notch part 32 Side edge 33 Cutting groove part 4 Lower positioning rib piece 41 Right angle notch part 42 Side edge 43 Cutting groove part 5 Wash water channel 6 Discharge hole 7 Skirt member 8 constituting a known toilet bowl Flush bowl member 9 constituting a known toilet bowl Rim member d constituting a known toilet bowl formed between an upper positioning piece and a lower positioning piece Clearance of space

Claims (2)

  A method for manufacturing a resin molded product by contacting an upper edge of an opening of a bowl portion of an upper surface opening and a lower edge of a rim portion corresponding to the periphery of the upper edge of the opening and vibration welding, the lower edge of the rim portion An upper positioning rib piece protrudes from the outer surface in the vicinity, a lower positioning rib piece protrudes from the outer surface near the upper edge of the opening of the bowl portion, and the position of the rim portion and the bowl portion is determined by the upper positioning rib piece and the lower positioning rib piece. A method for producing a resin molded product, characterized in that adjustment is performed and the rim portion and the bowl portion are integrally welded.   The method for producing a resin molded product according to claim 1, wherein the upper positioning rib piece and the lower positioning rib piece have a resectable structure after the bowl portion and the rim portion are integrally welded.

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