JP5721053B2 - Manufacturing method of heat insulation bathtub - Google Patents

Description

  The present invention relates to a method for manufacturing a heat insulating bathtub.

  Conventionally, in order to improve the heat retaining property of a bathtub, what formed the heat insulation layer in the back side of the bathtub is known. Patent Document 1 discloses a method of post-pasting a heat insulating material formed in accordance with the shape of the back surface of the bathtub on the back surface side of the bathtub. On the other hand, in Patent Document 2, after a bathtub body is molded with a molding die for the bathtub body, a space is formed by opening the mold while keeping the sealed state of the cavity of the bathtub molding die. A manufacturing method in which a resin is injected and foamed is disclosed.

JP-A-8-196458 JP 2010-42518 A

  In general, there are various sizes and shapes of bathtubs. For this reason, preparing a heat insulating material mold for each bathtub as in Patent Document 1 requires a large capital investment, especially in the case of a multi-product, small-volume production bathtub. It was. Moreover, since the reinforcing rib etc. are formed in the bathtub back surface, and it has a complicated shape, shaping | molding the heat insulating material according to the bathtub back surface shape also had the subject that design became complicated. On the other hand, in the method of forming a foam layer following bathtub molding in a bathtub molding die as in Patent Document 2, it is necessary to improve various types of bathtub molding dies, which also requires a large capital investment. There was a problem of becoming.

  This invention is made | formed in view of the subject mentioned above, and it aims at providing the manufacturing method of the heat insulation bathtub which can respond with a very cheap capital investment with respect to various bathtubs.

In order to solve the above-mentioned problems, a method for manufacturing a heat insulating bathtub according to the present invention is a back surface of a bathtub having a tank body part capable of storing water and a rim part extending outward from the upper end edge of the tank body part. Installed so that the side faces upward, forms a frame on the outer side of the tank body part on the back surface of the rim part, and stands up so that the upper part is released, and the back surface of the bathtub and the mold frame A predetermined amount of a non-foamed heat-insulating material is placed in the space between and the heat-insulating material is self-foamed to form a heat-insulating layer on the entire back surface of the tank body, and the tank A hollow masking member that prevents the heat insulating material from flowing into the body before injecting the non-foamed heat insulating material into a part where maintenance-required parts or field-installed parts are connected to the body It is characterized by installing .

According to the present invention, since it is not necessary to prepare an expensive molding die for forming the heat insulating layer, there is an effect that the heat insulating bathtub can be manufactured at a very low cost. In particular, since the mold frame is arranged in a frame shape on the outer side of the back surface of the tank body portion, the heat insulating layer can be formed on the entire back surface of the tank body portion without being affected by the shape of the tank body portion. Moreover, since the upper part of the mold erected in a circumferential shape is open to the atmosphere, no great pressure is applied to the bathtub and the mold when the heat insulating material is self-foamed. For this reason, even if it does not prepare a reinforcement type | mold in the tank body part of a bathtub, a bathtub is not damaged. In addition, since the strength required for the mold is reduced, the cost of the mold can be relatively low. Note that the upper part of the mold is open to the atmosphere, not only when the entire upper part of the frame is fully open, but also when using an upper frame in which a through hole for releasing pressure during self-foaming is used. good.
Moreover, since the heat insulation layer is not formed in the part which connects a maintenance required part and a site installation part, the heat insulation layer cut by post-processing can be decreased very much. The maintenance-required parts and field-installed parts mentioned here include, for example, electric equipment such as a jet bath and underwater lighting, and a drain plug member attached to a bathtub drain.

In order to solve the above-mentioned problems, a method for manufacturing a heat insulating bathtub according to the present invention is a back surface of a bathtub having a tank body part capable of storing water and a rim part extending outward from the upper end edge of the tank body part. Installed so that the side faces upward, forms a frame on the outer side of the tank body part on the back surface of the rim part, and stands up so that the upper part is released, and the back surface of the bathtub and the mold frame A predetermined amount of a non-foamed heat-insulating material in the space between and the heat-insulating material is self-foamed to form a heat-insulating layer on the entire back surface of the tank body, the mold The frame is detachably attached after the heat insulation layer is formed, and after removing the formwork, the heat insulation layer formed in the vicinity of the outer peripheral end of the rim portion is cut to form a bathtub grip portion. It is characterized by that.

  According to the present invention, since it is not necessary to prepare an expensive molding die for forming the heat insulating layer, there is an effect that the heat insulating bathtub can be manufactured at a very low cost. In particular, since the mold frame is arranged in a frame shape on the outer side of the back surface of the tank body portion, the heat insulating layer can be formed on the entire back surface of the tank body portion without being affected by the shape of the tank body portion. Moreover, since the upper part of the mold erected in a circumferential shape is open to the atmosphere, no great pressure is applied to the bathtub and the mold when the heat insulating material is self-foamed. For this reason, even if it does not prepare a reinforcement type | mold in the tank body part of a bathtub, a bathtub is not damaged. In addition, since the strength required for the mold is reduced, the cost of the mold can be relatively low. Note that the upper part of the mold is open to the atmosphere, not only when the entire upper part of the frame is fully open, but also when using an upper frame in which a through hole for releasing pressure during self-foaming is used. good.
  Moreover, since the used formwork can be removed and reused, capital investment can be further suppressed.
  Moreover, since there is no heat insulation layer in the outer peripheral edge part of a rim | limb part, a bathtub builder tends to carry a bathtub by grasping a bathtub holding part by hand.

Furthermore, in the present invention, it is preferable that the mold is divided into a plurality of parts in the circumferential direction, and is formed in a circumferential shape by connecting a plurality of divided molds .

  According to this preferable aspect, a formwork can be shared with respect to various size bathtubs by combining and connecting the formwork formed by division. For example, by forming the four sides separately, even if the bathtub has a different size on either the long side or the short side, the molds of the same size side can be shared. Moreover, the separation becomes easy by separating the formwork connecting portion when removing the formwork.

  ADVANTAGE OF THE INVENTION According to this invention, the manufacturing method of the heat insulation bathtub which can respond with a very cheap capital investment with respect to various bathtubs can be provided.

It is an external appearance perspective view of the bathtub which concerns on the 1st process of this invention. It is sectional drawing of the bathtub which concerns on the 1st process of this invention. In the 1st process of this invention, it is sectional drawing of the bathtub which shows the state which attached the formwork. It is sectional drawing of the bathtub which shows the state which inject | poured the heat insulating material in the 2nd process of this invention. It is sectional drawing of the bathtub which shows the state in which the heat insulation layer was formed in the 2nd process of this invention. It is sectional drawing of the bathtub which shows the state after removing a formwork in the 3rd process of this invention. In the 4th process of this invention, it is sectional drawing of the bathtub which shows the state which attached bathtub components. It is an external appearance perspective view of the bathtub which shows another embodiment in the 3rd process of this invention. It is 2nd Example of sectional drawing of the bathtub which shows the state which inject | poured the heat insulating material in the 2nd process of this invention.

  Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings. In order to facilitate understanding of the description, the same constituent elements in the drawings are denoted by the same reference numerals as much as possible, and redundant description will be omitted.

FIG. 1 is an external perspective view of a bathtub according to an embodiment of the present invention. Moreover, FIG. 2 is sectional drawing of the bathtub which concerns on this embodiment.
As shown in FIGS. 1 and 2, the bathtub 10 in the present embodiment includes a tank body 11 capable of storing bathtub water, and a rim extending outward in the horizontal direction from the upper end edge of the tank body 11. A portion 12 and a drooping portion 13 formed downward from the tip of the rim portion 12 are formed. A drain port 14 is formed on the bottom surface of the tank body 11, and support legs 15 for supporting the load of the bathtub 10 are attached to the back surface side thereof.

  First, the bathtub 10 configured as described above is installed so that the back side faces upward. Next, the mold 30 is erected on the rim portion 12 so as not to have a four-side gap. The mold frame 30 is configured in a frame shape so as to surround the outer surface of the tank body portion 11. In an upright state, the upper end of the mold 30 is disposed at a position higher than at least the bottom surface of the bathtub 10 and lower than the tip of the support leg 15. On the other hand, the lower end of the mold 30 is attached to the back surface of the rim portion 12 in a watertight manner through packing or the like. Further, the lower end of the mold 30 is disposed on the inner side with a space from the hanging part 13, and the entire mold 30 is disposed on the outer side of the tank body 11.

Next, as shown in FIG. 3, a hollow masking member 20 is attached to a portion of the tank body 11 of the bathtub 10 to which the jet bath is attached. In addition, although not illustrated, the same hollow masking member 20 is attached also when an underwater lighting fixture is attached. One side surface of the hollow masking member 20 is in watertight contact with the outer surface of the tank body 11. Moreover, the opening for attaching a maintenance required part or a field installation part only to the one side is formed.
In addition, a cylindrical hollow masking member 21 having openings formed vertically is attached to the drain port 14. The lower end of the masking member 21 is in watertight contact with the outer surface of the tank body 11. On the other hand, the upper end of the masking member 21 is disposed above the upper end of the mold.

  FIG. 4 shows a cross section of the bathtub 10 in which the unfoamed heat insulating material 40 is injected into the mold 30 after the hollow masking members 20 and 21 are attached. As described above, in this embodiment, the unfoamed heat insulating material 40 is injected while the upper portion of the space formed between the back surface of the bathtub 10 and the inner surface of the mold 30 is open to the atmosphere. The unfoamed heat insulating material 40 thus injected self-foams to the vicinity of the upper end of the support leg.

  FIG. 5 shows a cross section of the bathtub 10 after foaming. Thus, the foam does not enter the portion where the hollow masking members 20 and 21 are attached.

FIG. 6 shows a section of the bathtub 10 with the mold 30 removed. Thus, after self-foaming is completed, the mold 30 is removed. The removed mold 30 can be used repeatedly after washing.
Further, in order to pass the electric cable 51 for operating the jet bath to the outside, the heat insulating layer 41 and the masking member 20 are drilled with a drilling tool. Similarly, when an underwater lighting fixture is attached, through-hole processing is performed on the heat insulating layer 41 and the masking member 20 with a drilling tool.

  FIG. 7 shows a cross section in which a jet bath pump and a drain fitting are attached to the tank body. In this manner, the electric cable 51 is passed through the heat insulating layer 41 and the through hole of the middle masking member and connected to the external power source. Similarly, when an underwater lighting fixture is attached, an electric cable is passed through the heat insulating layer 41 and the through hole of the masking member and connected to an external power source. Although not shown, a drain plug member is attached to the drain port.

  FIG. 8 is a perspective view showing the structure of the mold 30. The four sides are divided and formed, and the mold 30 on each side can be removed independently by separating a mold connecting portion (not shown). In order to separate the mold 30 from the heat insulating layer, the mold 30 is subjected to a mold release process.

  According to the manufacturing method of the heat insulation bathtub comprised as mentioned above, there exist the following effects.

  According to the present embodiment, since it is not necessary to prepare an expensive molding die for forming the heat insulating layer 41, there is an effect that the heat insulating bathtub can be manufactured at a very low cost. In particular, since the mold frame 30 is arranged in a frame shape on the outer side of the back surface of the tank body portion 11, the heat insulating layer 41 is formed on the entire back surface of the tank body portion 11 without being affected by the shape of the tank body portion 11. can do. Moreover, since the upper part of the mold 30 erected in a frame shape is open to the atmosphere, no large pressure is applied to the bathtub 10 and the mold 30 when the heat insulating material 40 is self-foamed. Yes. For this reason, even if it does not prepare a reinforcement type | mold in the tank body part 11 of the bathtub 10, the bathtub 10 is not damaged. In addition, since the strength required for the mold 30 is reduced, the cost of the mold can be relatively low.

  In addition, according to the present embodiment, the hollow masking member 20 that prevents the heat insulating material from flowing into the inside is attached to the tank body portion 11 before the non-foamed heat insulating material 40 is injected. In addition, it is possible to extremely reduce the heat insulating layer 41 to be cut in order to connect maintenance-required parts and field-mounted parts.

  Moreover, according to the present Example, since the used formwork 30 can be removed and used again, capital investment can be suppressed further.

  Moreover, according to the present Example, since the divided | segmented formwork 30 is combined and connected, the formwork 30 can be shared with respect to the bathtub 10 of various sizes. For example, by forming the four sides separately, even if the bathtub 10 is different in size of either the long side or the short side, the molds 30 having the same size can be shared. Further, by separating the formwork connecting portion when the formwork 30 is removed, the removal becomes easy.

  Further, according to the present embodiment, the lower end portion of the mold frame 30 is arranged on the inner side of the outer peripheral end of the rim portion 12, so that the outer peripheral end (the hanging portion 13) of the rim portion 12 and the mold frame are arranged. The bathtub holding part 50 in which the heat insulation layer 41 does not exist can be formed between the lower end part of 30, and the bathtub 10 becomes easy to carry.

  Further, by forming the bathtub grip 50 having no heat insulating layer 41 between the outer peripheral end of the rim 12 and the lower end of the mold 30, it does not interfere with the hanging part 13 when the mold 30 is removed. Therefore, detachability can also be improved.

  In the above embodiment, the bathtub grip 50 is formed by disposing the lower end of the mold 30 on the inner side of the outer periphery of the rim 12, but after removing the mold 30, the rim 12 You may make it form the bathtub holding | grip part 50 by cutting the heat insulation layer 41 formed in the outer peripheral end vicinity.

  As shown in FIG. 9, the upper frame 32 may be installed on the upper part of the mold 30 after injecting an unfoamed heat insulating material. A plurality of through holes 33 are formed in the upper frame 32, and pressure during self-foaming can be released from the through holes 33. By doing so, it is possible to reduce the trouble of cutting the heat insulating material overflowing from the upper part after foaming, and the appearance of the skin layer on the upper surface improves the aesthetics, and the heat insulating layer into which the liquid cannot easily enter Can be formed. The timing for installing the upper frame 32 is not before the thermal insulation material is injected, but before the self-foaming is completed after the thermal insulation material is injected and the large pressure generated in the initial stage of self-foaming is released. It is preferable to do.

  Further, the supporting legs 15 of the bathtub may be arranged in the through holes 33 provided in the upper frame 32. In this case, the through hole 33 may be formed in advance with a diameter larger than that of the support leg 15, and the pressure may be released from the gap between the through hole 33 and the support leg 15.

Moreover, although the position of the support leg 15 may change a little with the model of a bathtub, you may design the size of the through-hole 33 so that it can respond to the support leg position of various bathtubs.

  DESCRIPTION OF SYMBOLS 10 ... Bathtub, 11 ... Tank part, 12 ... Rim part, 13 ... Hanging part, 14 ... Drainage port, 15 ... Supporting leg, 20, 21 ... Masking member, 30 ... Formwork, 32 ... Upper frame, 33 ... Through Hole, 40 ... heat insulating material, 41 ... heat insulating tank, 50 ... bathtub gripping part, 51 ... electric cable

Claims (3)

A bathtub having a tank body portion capable of storing water and a rim portion extending outward from the upper end edge of the tank body portion is installed so that the back side faces upward,
A frame is erected so that the frame shape on the outer side of the tank body portion on the rear surface of the rim portion, and the upper part is released,
A predetermined amount of an unfoamed heat insulating material is placed in the space between the back surface of the bathtub and the mold,
The heat insulating material is configured to form a heat insulating layer on the entire back surface of the tank body by self-foaming ,
In the portion where maintenance-required parts or field-installed parts are connected to the tank body part, before injecting the unfoamed heat-insulating material, a hollow shape is formed so that the heat-insulating material does not flow inside. A method for manufacturing a heat insulating bathtub, wherein a masking member is attached . A bathtub having a tank body portion capable of storing water and a rim portion extending outward from the upper end edge of the tank body portion is installed so that the back side faces upward,
A frame is erected so that the frame shape on the outer side of the tank body portion on the rear surface of the rim portion, and the upper part is released,
A predetermined amount of an unfoamed heat insulating material is placed in the space between the back surface of the bathtub and the mold,
The heat insulating material is configured to form a heat insulating layer on the entire back surface of the tank body by self-foaming,
The mold is removably attached after the heat insulation layer is formed,
After removal of the formwork, a manufacturing method of adiabatic tub you and forming a bath gripper by cutting the insulation layer formed around the outer peripheral edge of said rim portion. The mold is divided into a plurality in the circumferential direction,
The method for manufacturing a heat insulating bathtub according to claim 2 , wherein the heat insulating bathtub is formed in a circumferential shape by connecting a plurality of divided molds .

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