JP7236688B2 - METHOD OF MANUFACTURING SHEET COVER - Google Patents

Description

TECHNICAL FIELD The present invention relates to a method for producing a sheet covering in which the surface of a substrate is covered with a sheet material.

As this type of sheet covering, there is one in which an insert is laminated on a base material that constitutes the main member of the product, and the entire surface of the insert is covered with a sheet material. As such a sheet covering, for example, a floor pan for a bathroom is obtained by laminating an insert made of a functional member such as a heat insulating material, a cushioning material, a planar heater, etc. on a plate-like base material, and covering it with a sheet material. and washroom counters are known (see, for example, Patent Document 1).

The method disclosed in Patent Document 1 employs a method in which a functional member is arranged on a base material, and the entire surface of the functional member is adhered and covered with a sheet material (surface material). In other words, the sheet covering is configured such that the functional member is sandwiched between the molded product and the sheet material to protect the functional member from permeation of water.

JP 2015-190286 A

However, when the functional member is arranged on the inner bottom surface of the rectangular bread-shaped base material as in Patent Document 1, a gap is formed between the inner wall surface of the rectangular bread-shaped body and the functional member, and the sheet is formed only on the surface of the functional member. There is a possibility that the side end face of the functional member may be exposed only by disposing the material. In other words, simply covering the surface of the functional member with the sheet material is insufficient to protect the functional member. It is sufficient to cover the sheet material so as to cover the side end faces of the functional members so as not to form gaps, but this work is extremely difficult.

As a method of protecting the functional member, it is conceivable to place it on the back side of the base material, but if the functional member is a planar heater, the thickness of the base material may hinder the function of the planar heater. It may not be fully demonstrated. Therefore, this method cannot be said to be a good measure either.

SUMMARY OF THE INVENTION The present invention has been proposed in consideration of such circumstances, and its object is to provide a method of manufacturing a sheet covering that can reliably and simply protect an insert such as a functional member with a sheet material. to do.

In order to achieve the above object, the method for producing a sheet covering of the present invention includes placing an insert on the inner bottom surface of a substrate having an upwardly protruding peripheral edge so that substantially the entire inner bottom surface is hidden. and pressing the heated sheet material from above the base material so as to cover the exposed portion of the insert, thereby bonding the sheet material to the upper end surface and the inner wall surface of the peripheral edge portion. a step of adhering to the base material so as to be formed.

Since the method for producing a sheet covering according to the present invention has the structure described above, it is possible to reliably and simply protect an insert such as a functional member with the sheet material.

1 is a diagram showing a schematic procedure of a method of manufacturing a sheet covering according to one embodiment of the present invention; FIG. (a) is a perspective view showing an example of a substrate, (b) is a perspective view of a substrate on which an insert is placed, and (c) is an enlarged partial longitudinal sectional view of part of (b). (a) is a perspective view of the sheet covering (before trimming) formed by the sheet covering manufacturing method, (b) is a perspective view of the sheet covering (after trimming) formed by the sheet covering manufacturing method, (c) is a partially enlarged perspective view schematically showing the X portion of (b).

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described below with reference to the accompanying drawings. First, the general basic procedure of the method for producing a sheet covering (hereinafter abbreviated as the present production method) will be described.

This manufacturing method includes the steps of placing the insert 20 on the base material 10, and pressing the heated sheet material 25 from above the base material 10 so as to cover the exposed portion of the insert 20. and a step of adhering to the substrate 10 (see FIG. 1).

Here, various materials can be assumed for the base material 10, but since the sheet material 25 is adhered to the base material 10 by heating as described later, it should not be deformed by heating. desirable. On the other hand, the sheet material 25 is desirably made of a material that softens when heated, as will be described later. For example, a thermoplastic resin sheet can be preferably used.

Next, the details of this manufacturing method will be described. In the following description, the base material 10 used in this manufacturing method is a rectangular bread-shaped body 10 having a peripheral portion 11 protruding upward, as an example. As the sheet covering 1 using the rectangular bread-shaped body 10 as the base material 10, for example, a bathroom floor pan 1 can be mentioned (see FIGS. 2 and 3). That is, the bathroom floor pan 1 has a configuration in which the insert 20 is laminated on the inner bottom surface 14 of the rectangular pan-shaped body 10 as the base material 10 (see FIG. 2) and covered with the sheet material 25 (see FIG. 3). be done. The insert 20 for the bathroom floor pan 1 includes a functional member 20 such as a planar heater 20 .

As shown in FIG. 2( a ), a drain port 18 is formed at the edge of the inner bottom surface 14 of the rectangular bread-shaped body 10 , and the bottom (inner bottom surface 14 ) directs water toward the drain port 18 . It is formed with a water gradient so that the water flows. This inner bottom surface 14 consists of three planes separated by two folding lines 15 .

In this manufacturing method, a vacuum/pressure forming machine 30 (hereinafter referred to as forming machine 30) having upper and lower chamber boxes 31 and 35 that can be individually evacuated is used as a manufacturing apparatus for the bathroom floor pan 1 (FIG. 1). (a)). This molding machine 30 is a device for adhering sheets and films to the surfaces of various substrates.

The upper chamber box 31 and the lower chamber box 35 are configured such that their openings face each other and can be opened and closed (separated/approached between the openings), and when closed, a closed space is formed inside. ing. In this example, opening and closing is performed by moving the upper chamber box 31 up and down.

The upper chamber box 31 has a heater 32 that heats the internal space. The upper chamber box 31 is provided with an upper driving device 33 , and the upper driving device 33 performs opening/closing operation of the upper chamber box 31 and ON/OFF operation of the heater 32 .

The lower chamber box 35 has therein a vertically movable installation table 36 for installing the substrate 10 . The lower chamber box 35 is provided with a lower driving device 37, and the lower driving device 37 moves the installation table 36 up and down.

The molding machine 30 also includes a sheet holder 39 that holds the sheet material 25 in a stretched state between the openings of the upper and lower chamber boxes 31 and 35 . When the openings of the upper and lower chamber boxes 31 and 35 are closed, the sheet material 25 placed in a stretched state is sandwiched between the openings as shown in FIG. 1(a). The molding machine 30 further has a vacuum tank for decompressing the internal space and a compressed air tank for pressurizing the internal space, but illustration of these is omitted.

A specific example of this manufacturing method will be described with reference to FIGS. 1(a) to (e), FIGS. 2(a) to (c) and FIGS.

First, the functional member 20 (planar heater 20) is placed in the concave portion of the rectangular bread-shaped body 10 (preparatory step, see FIGS. 1(a), 2(a), 2(b) and 2(c)). The planar heater 20 has such a shape and dimensions that it can be placed on the inner bottom surface 14 of the concave portion of the rectangular pan-shaped body 10 . As shown in FIG. 2(b), the planar heater 20 preferably has such a shape and dimensions that the inner bottom surface 14 of the concave portion of the rectangular bread-shaped body 10 is almost hidden.

A lead wire 21 for receiving electric power is connected to the planar heater 20. In order to expose the lead wire 21 to the outside, a hole 16 communicating with an outer bottom surface 17 is formed in the inner bottom surface 14 of the rectangular pan-shaped body 10. is opened (see FIG. 2(c)). It should be noted that the planar heater 20 may be placed on the inner bottom surface 14 after the lead wires 21 are drawn out from the holes 16 .

In order to adhere and cover the sheet material 25, the sheet material 25 is adhered in advance to one surface of the sheet material 25, or to the upper end surface 11a of the peripheral edge portion 11 of the rectangular bread-shaped body 10, the inner wall surface 12, the upper surface of the planar heater 20, and the like. You can apply the agent. Alternatively, the back surface of the planar heater 20 may be adhered and fixed to the inner bottom surface 14 with an adhesive.

Next, the substrate 10 (rectangular bread-like body 10) with the planar heater 20 arranged in the recess is placed on the installation table 36 in the lower chamber box 35 so that the upper surface of the planar heater 20 is exposed ( Substrate installation step, see Fig. 1(a)). That is, the rectangular bread-shaped body 10 is installed on the installation table 36 with the concave portion facing upward.

When the rectangular bread-shaped body 10 is installed, the outer bottom surface 13 is in contact with the installation table 36, and most of the inner bottom surface 14 is hidden by the insert 20, so that the other parts are covered with the lower chamber box. It is exposed to the internal space within 35 . Specifically, the upper end surface 11a of the peripheral portion 11 of the rectangular bread-shaped body 10, the inner wall surface 12, the outer wall surface 13, and the upper surface of the planar heater 20 are exposed. Note that the preparation process may be performed with the substrate 10 placed on the installation table 36 .

Before and after this base material setting step, the sheet material 25 is held by the sheet holder 39 so as to be in a stretched state, and the sheet material 25 is placed between the openings of the upper and lower chamber boxes 31 and 35 ( Sheet material installation step, see Fig. 1 (a)). Then, the upper and lower chamber boxes 31 and 35 are closed, thereby dividing the internal space into two upper and lower spaces by the sheet material 25 (see FIG . 1 (a)).

Next, the interiors of the upper and lower chamber boxes 31 and 35 are simultaneously evacuated to a vacuum, and the interior of the upper chamber box 31 is heated by the heater 32 (heating step, see FIG. 1 (b)). The sheet material 25 is gradually softened by being heated. As indicated by the two-dot chain line in FIG. 1B , the sheet material 25 is softened and becomes slack. The decompression and air introduction of the upper and lower chamber boxes 31 and 35 are indicated by two-dot chain lines extending horizontally with respect to the upper and lower chamber boxes 31 and 35 in each figure.

Next, the installation table 36 of the lower chamber box 35 is moved upward to press the base material 10 against the back surface of the sheet material 25 . At the same time, air is introduced into the upper chamber box 31, and the air pressurizes the sheet material 25 from above to adhere the sheet material 25 to the exposed portions of the base material 10 and the inserts 20 (primary molding step). , FIG. 1 (c) and (d)).

Furthermore, compressed air may be introduced into the upper chamber box 31 to further pressurize the sheet material 25 (additional molding step, see FIG . 1 (d)).

Next, air is introduced into the lower chamber box 35, the upper chamber box 31 is moved upward, and the substrate 10 covered with the sheet material 25 is taken out (take-out step, see FIG. 1 (e)).

FIG. 3(a) is a perspective view of the substrate 10 (the sheet covering 1 before trimming) with the removed sheet material 25. FIG. Since the planar heater 20 is pressed downward together with the sheet material 25 during the primary forming process, the sheet covering 1 is formed so that the folding line 15 of the inner bottom surface 14 of the rectangular bread-shaped body 10 is aligned with the planar heater 20 . , through the sheet material 25 . Similarly, the shape of the surface of the drain port 18 appears on the surface through the sheet material 25 .

After that, the surplus sheet material is removed to obtain a product (sheet covering 1 after trimming) (trimming step, see FIGS. 3(a) and 3(b)). In this step, the outer wall surface 13, which is not exposed when the bathroom floor pan 1 is installed in the bathroom, and the surplus sheet material adhering to the opening of the drain port 18 may be removed. Thus, the bathroom floor pan 1 as a product is obtained.

By using the molding machine 30 as described above, the sheet material 25 is formed on the inner wall surface 12 of the rectangular bread-shaped body 10 corresponding to the three-dimensional surface such as the rectangular bread-shaped body 10 and the exposed portion of the planar heater 20. are also glued without any gaps in the middle. Therefore, even if a clearance space 19 is formed at the inner corner as shown in FIG. The material 25 enters, the gap space 19 is filled, and the planar heater 20 is covered without being exposed (see FIG. 3(c)).

As described above, according to this manufacturing method, the insert 20 such as the functional member 20 is covered with the sheet material 25 without gaps, so that the insert 20 can be reliably and simply protected. Further, by carrying out this manufacturing method, even when the base material 10 is the rectangular bread-shaped body 10 as described above, the sheet material 25 is formed so as to cover the entire inner wall surface 12 of the peripheral portion 11 together with the insert 20. Since it can be glued, the insert 20 is protected without being exposed. In particular, it is effective when the sheet covering 1 to be molded is a floor pan 1 for a bathroom, and the surface thereof is wet with water.

In addition, if the base material 10 has holes 16 for lead wires 21, for example, the functional member 20 may be mounted so that the lead wires 21 lead out from the holes 16. Therefore, the electrical wiring is formed in the preparation process. can be done with certainty. Moreover, since the hole 16 and the lead wire 21 on the surface on which the insert 20 is placed are covered with the sheet material 25, watertightness can be ensured. Even if the lead wire 21 is exposed from the hole 16 on the surface opposite to the surface on which the insert 20 is placed, the entire exposed portion of the insert 20 on the surface on which the insert 20 is placed is a sheet. Since it is covered with the material 25, the watertightness of the opposite side can be ensured.

The sheet covering 1 whose surface is wetted with water is not limited to the bathroom floor pan 1, but includes a washbasin counter. The sheet covering 1 may be one that does not get wet with water, and may be any one in which the insert 20 is laminated on the base material 10 and covered with the sheet material 25 . Also, the insert 20 may be a heat insulating material, a cushioning material, or the like.

1 sheet covering (bathroom floor pan)
10 base material (rectangular bread-shaped body)
REFERENCE SIGNS LIST 11 peripheral portion 11a upper end surface 12 inner wall surface 16 hole 20 insert (functional member, planar heater)
25 sheet material

Claims (3)

a step of placing the insert on the inner bottom surface of the substrate having the peripheral edge portion protruding upward so that substantially the entire inner bottom surface is hidden;
A heated sheet material is pressed from above the base material so as to cover the exposed portion of the insert, and the sheet material is bonded to the upper end surface and the inner wall surface of the peripheral edge portion. and adhering to a substrate. In claim 1,
A sheet covering characterized in that a hole is formed in the base material, and a part of the insert is exposed from the surface of the base material opposite to the surface on which the insert is placed in the hole. manufacturing method. In claim 1 or 2,
A method for producing a sheet covering, wherein the surface of the sheet material is used as a water receiving surface.

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