JP2699262B2 - Manufacturing method of waterproof pan for bathroom unit - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for rationally forming waterproof pans for bathroom units with floor coverings.

[0002]

2. Description of the Related Art As is well known, a bathroom unit is provided for the purpose of simplifying on-site work, improving quality, and stabilizing the quality. Many improvements have been made. Examples of waterproof pans for bathroom units include those in which a bathtub and a washing place are integrated, those in which a bathtub fitting portion and a washing place are integrated, and those in which a bathtub and a washing place are separated.

[0003] When making this kind of waterproof pan, it is widely practiced to integrally form a non-slip irregularity pattern on the floor surface (washing area). It is difficult to obtain the luxury of a dependent bathroom, and the design options are narrowed.

As a countermeasure, a flooring material having a rich design and texture has been stuck to the waterproof pan floor after molding. Such flooring work is generally carried out by the following procedures. Gale coat finish on waterproof pan surface. Grind and wipe the floor of the waterproof pan. Apply adhesive to the floor of the waterproof pan. Stick the floor covering to the floor of the waterproof pan and dry it. The joints (gap) between floor coverings on the waterproof pan floor are filled with joints and cured.

[0005]

When the flooring material is stuck on the floor surface of the waterproof pan, it is necessary to spend a lot of time after molding the waterproof pan, as is apparent from the above description. Cannot rely on manual work to increase the productivity of waterproof pans.

SUMMARY OF THE INVENTION In view of the above technical problems, the present invention incorporates a step of attaching a floor covering to a step of forming a waterproof pan to dramatically improve the productivity of the pan. An object of the present invention is to provide a method of manufacturing a waterproof pan for a bathroom unit.

[0007]

The object of the present invention is to provide a mold for molding a waterproof pan for a bathroom unit, which comprises a boundary between a floor covering material placing portion on a floor molding surface and an adjacent portion thereof. Preparing a raised material for holding the flooring material on the floor, and after preparing the forming die, laying the flooring material on the flooring material mounting portion and then placing the forming material in the forming area of the forming die. Grant,
And, after providing the molding material, the flooring material and the molding material are integrated to form a waterproof pan with the flooring material, and after the waterproof pan is formed, the waterproof pan with the flooring material is removed from the mold. And, after the release of the waterproof pan, filling the recess on the waterproof pan side caused by the protrusion for holding the floor covering with a joint material, and achieving the intended purpose by the problem solving means. I do. As the above-mentioned molding die, it is desirable that the projection for holding the floor covering material forms an endless enclosure on the floor molding surface. As an example, the floor covering material described above is composed of a large number of floor material pieces arranged adjacent to each other and a joint material connecting these floor material pieces to each other.

[0008]

According to the method of the present invention, the flooring material is adhered to the floor surface of the waterproof pan in synchronization with the molding of the waterproof pan, so that the productivity of the waterproof pan with flooring material is enhanced. In the case of the method of the present invention, when forming such a waterproof pan, a molding die having a flooring material placing portion and a projection for holding the flooring material, that is, disposing and holding the flooring material at a predetermined position. Since a molding die that can be used is used, the flooring material does not move to another place, and molding of the waterproof pan with the flooring material is unlikely to occur. Further, in the case of the method of the present invention, after forming the waterproof pan, the recess formed on the waterproof pan side is filled with the joint material, so that the floor finish of the waterproof pan is improved.

[0009]

DESCRIPTION OF THE PREFERRED EMBODIMENTS A method for manufacturing a waterproof pan for a bathroom unit according to the present invention will be described with reference to the illustrated embodiment. 1 and 2, reference numeral 11 denotes a molding die support base with wheels (known), and reference numeral 21 denotes a molding die for molding a waterproof pan by a laminate molding method.

The mold 21 for the waterproof pan is made of synthetic resin (F
RP), metal (eg, aluminum), ceramic, or any material selected from composite materials of two or more of these, and a fitting mold part 22 for forming a bathtub fitting part; It is integrated with a floor mold part 23 for forming a washing area. Mold part 2 for floor
On the floor forming surface of No. 3, a drainage forming section 24 and a floor covering material placing section 25
The drain forming section 24 occupies one corner of the floor forming surface, and the floor covering material placing section 25 occupies most of the floor forming surface. The flooring material placing portion 25 has a projection 26 for holding the flooring material.
, And the frame is formed of an endless polygon (hexagon) based on a square.

3 to 5, reference numeral 31 denotes an example of a floor covering used in the method of the present invention, and reference numeral 41 denotes a forming die for producing such a floor covering 31.

The floor covering 31 is composed of a large number of flooring pieces 32 arranged in rows and columns, and joints 33 connecting the flooring pieces 32 to each other. Corresponds to the inner shape of the enclosure. The floor material pieces 32 are made of synthetic resin (including FRP), stainless steel, glass, ceramic (including ceramic), or stone (including artificial stone). And a composite material obtained by combining any two or more of them. A typical example of the flooring piece 32 is an FRP tile.
Another typical example of the flooring piece 32 is a ceramic tile or an artificial marble plate. Flooring pieces 32
Are made of a room temperature-curable resin (rubber), a thermosetting resin (rubber), or an ultraviolet-curable resin (rubber), and particularly preferably have a high adhesive effect. A typical example of the joint material 33 is a silicone-based material selected from thermosetting resins (rubbers).

The mold 41 for the floor covering is made of synthetic resin (FR
P), metal (eg, aluminum), ceramic,
Alternatively, a plurality of floor material fitting portions 42, which are made of an arbitrary material selected from these two or more composites and are arranged vertically and horizontally, and are formed between adjacent portions of the floor material fitting portions 42 and in the peripheral portion. And a joint forming part 43. Each floor material fitting portion 42 and each joint forming portion 43 are recessed from the surface (upper surface) of the molding die 41, but the surface (upper surface) of the joint material forming portion 43 is the surface of the floor material fitting portion 42. (Top) is slightly higher.

The floor covering 31 illustrated in FIG. 3 is formed by the following procedure via the forming means shown in FIGS. First, each floor material fitting portion 42 of the molding die 41 is formed by using a release agent.
After releasing the inside, the floor material pieces 32 are fitted into the floor material fitting portions 42, respectively. Next, the interior of the joint forming portion 43 of the molding die 41 is filled with a joint material 33 made of an uncured resin (uncured rubber) and cured. That is, when the joint material 33 is a room-temperature curable resin (rubber), it is cured after a lapse of time, and the joint material 33 is a thermosetting resin (rubber) or an ultraviolet curable resin (rubber). In this case, it is cured in a heating furnace or an ultraviolet irradiation furnace. When the joint material 33 hardens in this way, FIG.
As described above, the floor covering material 31 in which the respective floor material pieces 32 are connected by the joint material 33 is obtained. In the following, the floor covering material 31 is released from the jointing material 33 from the molding die 41, and this is prepared for molding of a waterproof pan described later.

At the time of the molding, in order to prevent the surface (upper surface in FIG. 3) of each floor material piece 32 from being stained or damaged, a curing film or sheet is provided on the surface of each floor material piece 32. May be stuck. Since this curing film (sheet) only adheres to the surface of the flooring piece 32 via a peelable adhesive, it can be peeled off from the flooring piece 32 when the curing becomes unnecessary.

FIGS. 6 and 7 show a specific example of forming a waterproof pan according to the method of the present invention. In this example of forming a waterproof pan, the following steps are taken after preparing the mold 21 described with reference to FIGS.

In the first step, as is apparent with reference to FIG. 6, the above-mentioned floor covering material 31 is laid on the floor covering material placing portion 25 of the molding die 21 and the molding is performed on the surface of the molding die 21. An uncured coating resin (well-known gel-like resin) to be a surface film of the product (waterproof pan) is sprayed uniformly. In this step, the flooring material 31 laid on the flooring material placing portion 25 is held without being shifted from a predetermined position by a protrusion 26 surrounding the periphery thereof.

In the next step, as will be apparent with reference to FIG. 6, the molding area of the molding die 21 (the fitting mold part 22,
A molding material 51 composed of a fiber base material and a resin liquid impregnated in the fibrous base material is laminated on the floor mold 23 and the molding material 5.
1 is pressed by a roller to depressurize the air contained therein. The fiber base material is typically a nonwoven glass fiber layer, but a nonwoven metal fiber layer, a nonwoven synthetic resin fiber layer, a nonwoven plant fiber layer, or the like, or
It may consist of two or more types of mixed fiber layers selected from these. The impregnating resin is typically a thermosetting resin for low-pressure molding such as polyester or epoxy resin, but may be a room-temperature curable resin or an ultraviolet-curable resin. The molding material 51 may include a known filler in some cases.

In the subsequent steps, as apparent from FIG. 7, the molding materials 52 and 53 are further laminated on the molding material 51 on the side of the floor mold portion 23. Molding material 5 in this case
Reference numeral 2 denotes a wooden board, hard cardboard, a synthetic resin board, a metal board, or any other material selected from these, and the molding material 53 is the same as the molding material 51. Even when the molding materials 52 and 53 are overlapped in this way, the molding material 53 is pressed and degassed by the above-described pressurizing means.

In the subsequent steps, in order to integrate the floor covering material 31 and the molding materials 51 to 53, the molding die 21 holding them is put into a curing furnace (for example, a heating furnace) (not shown). , 53 are cured. Thus, both molding materials 5
When 1 and 53 are cured, waterproof pan 5 with floor covering 31
4 is obtained, and is removed from the mold 21. As shown in FIGS. 8 and 9, a recess 55 due to the protrusion 26 is formed on the floor surface of the waterproof pan 54 removed from the molding die 21.

After molding the waterproof pan, the recess 5 of the waterproof pan 54
Required secondary processing steps, such as a step of filling 5 with a joint material, a step of processing a hole for drainage and a hole for fitting in a bathtub, are performed before or after each other or simultaneously.

At the time of the joint filling step, as shown in FIGS. 8 and 9, the joint material 56 is filled in the recess 55 and hardened.
As the joint material 56, a thermosetting resin, a room temperature curable resin,
Either an ultraviolet curable resin or a thermoplastic resin is used.
As a specific example, when the joint material 56 is made of a silicone resin, the uncured joint material 56 filling the recess 55 is cured in a curing furnace as described above.

When processing the holes required for the waterproof pan 54, the processing is basically the same as the processing of wood or metal, for example,
Appropriate means such as cutting, shearing, punching, piercing, crease folding, and fusing are adopted, and through such processing means, the drainage hole 57 and the bathtub fitting hole 5 shown in FIG.
8 is formed.

Other examples, embodiments and design modifications of the method of the present invention will be described below.

In the floor covering 31, each of the floor covering pieces 32 connected to each other via the joint material 33 is a triangle or a pentagon or more polygon arranged in a row or column, a strip shaped in a row or column. , Circular ones arranged vertically and horizontally (including an elliptical shape), one having any of these shapes but not forming a row, one having an irregular shape and randomly arranged, and the like may be used. . When the shape of the flooring piece 32 is like this, a molding die 41 for the flooring material corresponding to this is used. In addition to these, the floor covering 31 may be composed of only one piece of floor covering 32 having a large area, and in this case, the joint material 33 is omitted. In addition, the outer shape of the floor covering 31 may be a circle or an irregular shape instead of a polygon. When the outer shape of the flooring material 31 is like this, the projection 26 for holding the flooring material formed on the floor mold portion 23 of the molding die 21 also corresponds to this.

The projection 26 for holding the floor covering formed on the floor mold portion 23 of the molding die 21 does not need to be an endless frame. For example, a plurality or a large number of protrusions 26 projecting partially and / or intermittently on the floor surface of the floor mold portion 23.
Also, the floor covering material 31 can be held by the floor covering material placing section 25. Examples of the shape of the plurality of protrusions 26 projecting in this manner include a linear shape, a point shape, an angle shape, a bracket shape, a curved shape, and the like.
1 may be adopted according to the outer shape.

As the joint material 56 for filling the recess 55 of the waterproof pan 54, a soft or hard member made of rubber, synthetic resin, or the like may be used. This joint material 56 is
As an example, it has a shape like an elongated string, and as another example, it has an endless shape like a ring. When the joint material 56 is fitted and fixed in the recess 55, press-fitting (fixing using relative friction between the recess 55 and the joint material 56), adhesive fixing (using an adhesive), or Adopt both.

Waterproof pan 5 in which bathtub and washing area are integrated
When forming the mold 4, a mold in which the fitting mold part 22 is replaced with a bathtub mold part is used as the mold 21, and when forming the waterproof pan 54 only in the washing place without the bathtub fitting part, the mold is used. The one without the fitting mold part 22 is used as 21.

The waterproof pan 5 without using the molding materials 52 and 53
When forming step 4, after the step of FIG. 6 is completed, the step of FIG. 7 is omitted and the molding material 51 is cured. Other steps in this embodiment conform to the contents described above.

The technical contents of the present invention can also be applied to a low-pressure resin injection method. When this molding means is used, a pair of molding dies (convex and concave) described below are used. One of the molds (convex mold) of the pair of molds is substantially the same as the mold 21 described above, and includes a flooring material placing portion, a protrusion for holding the flooring material, and the like. And the other mold (concave mold)
Has a shape corresponding to one mold (convex mold).

When the waterproof pan is molded by the low-pressure resin injection method, first, the floor covering 31 is placed on the floor covering section of the floor molding section on the molding die (convex mold), and The fiber base material is applied over the molding region of the molding die (convex mold) so as to cover the mold, and then both molds (convex mold and concave mold) are clamped. The interior of the molding space is evacuated while injecting the above-described resin, and then the resin in the molding space is cured to form the floor covering material 3.
1. Integrate fiber base material and resin. In curing the resin in this case, the mold may be heated as necessary. Thus, after the waterproof pan with flooring material is formed, both molds (convex and concave) are opened and the waterproof pan is taken out.
Filling of the waterproof pan after demolding, secondary processing, etc.
Same as above.

[0032]

When the waterproof pan for a bathroom unit is manufactured by the method of the present invention, the following effects can be obtained.

[Effect 1] When molding a waterproof pan with flooring material, it is only necessary to install a flooring material manufactured in a separate process in a predetermined portion of a molding die and carry out an existing process. The performance is dramatically improved, and the cost of waterproof pans with floor coverings can be reduced.

[Effect 2] When molding a waterproof pan with flooring material, the flooring material is arranged and held at a predetermined position depending on the flooring material placing portion of the forming die and the projection for holding the flooring material. Therefore, the floor covering does not shift to other places, and therefore, molding errors are unlikely to occur.

[Effect 3] Since the work required for attaching the floor covering and filling the joint is mechanized in synchronization with the molding of the waterproof pan, the molded article (waterproof pan with floor covering) is homogenized and stabilized. .

[Effect 4] After forming the waterproof pan with floor covering,
Since the recess formed on the waterproof pan side is filled with the joint material, the floor finish of the waterproof pan is good.

[Brief description of the drawings]

FIG. 1 is a perspective view schematically showing an example of a waterproof bread mold in the method of the present invention.

FIG. 2 is an enlarged sectional view taken along the line AA of FIG.

FIG. 3 is a plan view schematically showing an example of a floor covering in the method of the present invention.

FIG. 4 is a plan view schematically showing an example of a flooring material forming die in the method of the present invention.

FIG. 5 is an enlarged sectional view taken along line BB of FIG. 4;

FIG. 6 is a front view schematically showing some steps in the method of the present invention.

FIG. 7 is a front view schematically showing other partial steps in the method of the present invention.

FIG. 8 is a cross-sectional view of a waterproof pan with floor covering produced by the method of the present invention.

FIG. 9 is an enlarged sectional view of a portion surrounded by line CC in FIG. 8;

[Explanation of symbols]

 Reference Signs List 21 molding die 23 floor mold part 25 flooring material placing part 26 protrusion 31 flooring material 32 floor material piece 33 joint material 51 molding material 52 molding material 53 molding material 54 waterproof pan 55 recess 56 joint material

Claims (3)

(57) [Claims] 1. A molding die for molding a waterproof pan for a bathroom unit, wherein a protrusion for holding a flooring material is formed at a boundary between a flooring material placing portion on a floor forming surface and an adjacent portion thereof. After preparing the mold, and after preparing the molding die, providing the molding material to the molding region of the molding die after laying the flooring material on the flooring material mounting portion, and, after the provision of the molding material, Molding the waterproof pan with the floor covering by integrating the floor covering and the molding material, and removing the waterproof pan with the floor covering from the mold after forming the waterproof pan, and A method for manufacturing a waterproof pan for a bathroom knit, comprising: after removing the mold, filling a recess on the waterproof pan side generated by the protrusion for holding the floor covering with a joint material. 2. The method for manufacturing a waterproof pan for a bathroom unit according to claim 1, wherein the protrusion for holding the floor covering material forms an endless frame enclosure on the floor forming surface of the forming die. 3. The waterproof pan for a bathroom unit according to claim 1, wherein the floor covering is composed of a number of flooring pieces arranged adjacent to each other and joints connecting the flooring pieces to each other. Production method.