JPH0655671A - Bathtub and manufacture thereof - Google Patents

Abstract

PURPOSE:To provide a manufacturing method for a vacuum forming bathtub wherein a bathtub can be manufactured with high productivity in a clean work ing environment. CONSTITUTION:The front surface layer of a bathtub 12 is formed by vacuum forming and the rear surface layer 14 is formed by vacuum forming or press forming, and the layer 12 and the layer 14 are disposed so as to form a predetermined space therebetween so that a liquid resin material is injected into said space and thereafter the injected resin material is expanded and hardened to fill the space with the expanded and hardened resin material, while the layer 12 and layer 14 together with an intermediate layer 16 are fixed integrally to one another.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a bathtub and a manufacturing method thereof.

[0002]

2. Description of the Related Art Conventionally, the problems to be solved by the invention
The resin bath is made by press molding a resin material containing glass fibers such as SMC, BMC, cast molding by pouring and solidifying the resin material in a fluid state into the cavity of a predetermined mold, hand lay-up There are various known types, such as a FRP bath formed by means such as spray-up, and a back side of a vacuum formed surface layer backed up by an FRP layer for reinforcement.

Of these, the vacuum forming bath formed by vacuum forming the surface layer has the advantages that the die cost is low and that a clean surface state is easily obtained, but it requires backup by FRP. However, the following problems have occurred.

In the case of a vacuum forming bath, it is difficult to control the thickness and the wall thickness cannot be increased. Therefore, the strength is weak, and backup by FRP is performed there. The work for forming the layer is almost a manual work, whether it is spray-up or hand-layup, and it takes a lot of time and a long time, and there is a problem that the working environment is bad.

[0005]

The invention of the present application has been made to solve such a problem. Thus, the first invention of the present application relates to a method for manufacturing a bathtub, in which the bathtub surface layer is formed by vacuum forming and the bathtub back surface layer is formed by vacuum forming or press forming, and the surface layer and the back surface are formed. The layer and the layer are arranged so as to form a predetermined space therebetween, and a liquid resin material is injected into the space, and then the injected resin material is foamed or cured to foam or cure the space. At the same time as filling with the resin material, the front surface layer and the back surface layer are fixed and integrated (Claim 1).

Another invention of the present application is characterized in that the legs of the bathtub are simultaneously and integrally formed when the backside layer of the bathtub is formed (claim 2).

Still another invention of the present application relates to a bathtub,
A bath surface layer formed by vacuum forming, a back surface layer formed by vacuum forming or press forming, and an intermediate layer made of a resin foam or a cured body filled in the space between the surface layer and the back surface. It has a laminated structure (Claim 3).

[0008]

As described above, the present invention does not form a back-up layer of FRP on the back side of a vacuum-formed surface layer, but also forms a vacuum-formed or press-formed back surface layer on the back side of such a surface layer. It is arranged such that a predetermined gap (space) is formed between the surface layer and the surface layer, and a liquid resin material is injected therein to foam or cure to fill the space.

According to the present invention, it is not necessary to form the FRP layer which is troublesome and time-consuming when manufacturing the vacuum forming bath, and the back layer and the intermediate layer can be formed easily in a short time. As a result, it becomes easier to manufacture the bathtub as a whole and the productivity is significantly improved. Further, it is possible to work under a good working environment.

In the present invention, the overall thickness of the bath can be easily controlled by appropriately selecting the distance between the front surface layer and the back surface layer.

When a foamable resin material is injected between the front surface layer and the back surface layer to foam, that is, when a resin foam is used as the intermediate layer, the heat insulation of the bath can be effectively improved. it can.

Further, according to the present invention, the legs of the bathtub can be simultaneously formed integrally with the backside layer at the time of forming the backside layer, and in this case, the troublesome secondary process conventionally required for forming the legs of the bathtub. The advantage that processing is unnecessary can be obtained.

Conventionally, leg formation in a vacuum forming bath is
Adhere the legs prepared in advance on the backup layer of the FRP, place a glass mat of a predetermined size on it and impregnate it with liquid resin, and then squeeze with a roller to remove bubbles and reinforce it. However, according to the present invention, such troublesome work can be omitted.

In addition, according to the present invention, since a predetermined strength and rigidity can be secured by the laminated structure of the surface layer, the intermediate layer and the back surface layer, a resin material containing a reinforcing material such as glass fiber or an inorganic filler is used as the resin material. It is not necessary to use it, and in this case, there is an advantage that the disposal of the bathtub is easy.

[0015]

Embodiments of the present invention will now be described in detail with reference to the drawings. In FIG. 1, reference numeral 10 denotes a vacuum forming bath, which has a laminated structure of a front surface layer 12, a back surface layer 14, and an intermediate layer 16, that is, a sandwich structure.

The front surface layer 12 is formed by vacuum forming a resin sheet and has a thickness of 1 to 5 mm. The back surface layer 14 is formed by vacuum forming or press forming a resin sheet and has a thickness of 0.5 to 0.5 mm. It has 4 mm. The legs 18 of the bathtub are integrally formed on the back surface layer 14.

The intermediate layer 16 is formed by injecting a liquid resin material into the space between the front surface layer 12 and the back surface layer 14 and foaming the resin material to fill the same space or fill the same space. It is formed by injecting a thermosetting resin and curing it.

The intermediate layer 16 is not partially formed at the drainage port portion and the chain stopper portion for drainage taps, and the front surface layer 12 and the back surface layer 14 are in direct contact with each other at the same portion.

The material of the surface layer 12 is preferably a material having a high texture as a bath surface material, good hot water resistance, excellent chemical resistance, and easy to vacuum form. In this sense, acrylic resin, polypropylene resin, polycarbonate It is preferable to use a resin or the like.

On the other hand, as the back surface layer 14, ABS resin, HI
A product obtained by vacuum-molding a PS (high-impact polystyrene) resin, a polypropylene resin, a polyvinyl chloride resin, an ultraviolet-curable unsaturated polyester resin, or the like, or an SMC-molded unsaturated polyester / glass can be preferably used.

On the other hand, the intermediate layer 16 is a foam such as polyurethane foam, polyethylene foam, polystyrene foam, cast molding, urethane resin capable of RIM molding, epoxy resin, dicyclopentadiene resin,
A thermosetting resin such as an unsaturated polyester resin can be used.

FIG. 2 shows a specific manufacturing procedure of the bath 10 of this embodiment. As shown, in this method, the surface layer 12
The back surface layer 14 and the back surface layer 14 are prepared in advance by vacuum molding or press molding, and the front surface layer 12 and the back surface layer 14 are superposed on each other so that a predetermined gap is formed therebetween.

Then, a liquid foamable resin material or a thermosetting resin material is injected into the space between them, and in that state, this is put into a furnace to cause the injected liquid resin material to undergo a foaming reaction or a curing reaction.

When a foamable material is used as the resin material, it is necessary to inject the resin material so as to fill the space between the front surface layer 12 and the rear surface layer 14 after foaming, but it is thermosetting. When a resin composition is used, it is necessary to inject the liquid resin material until the space between the front surface layer 12 and the back surface layer is filled.

A transparent resin is used as the surface layer 12,
By applying a desired color or pattern to the intermediate layer 16 with a pigment or the like, a bath having a deep color or pattern can be obtained.

As is clear from the above, according to this example, the vacuum forming bath 10 can be easily manufactured, and moreover, sufficient strength can be provided. Further, according to this method, a bathtub can be manufactured from a resin material containing neither glass fiber nor inorganic filler, which can contribute to solving a problem in waste treatment of the bathtub.

The embodiment of the present invention has been described in detail above, but this is merely an example, and the present invention is embodied in various modes and modes with various modifications made based on the knowledge of those skilled in the art without departing from the spirit of the invention. -Configurable.

[Brief description of drawings]

FIG. 1 is a cross-sectional view of a vacuum forming bath which is an embodiment of the present invention.

FIG. 2 is a process explanatory view of a bathtub manufacturing method which is an embodiment of the present invention.

[Explanation of symbols]

 10 Bathtub 12 Surface layer 14 Backside layer 16 Middle layer 18 Legs

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁵ Identification code Office reference number FI technical display location B29L 22:00 4F 31:44 4F

Claims (3)

[Claims] 1. A state in which a bath surface layer is formed by vacuum forming and a bath back surface is formed by vacuum forming or press forming to form a predetermined space between the front surface layer and the back surface layer. Liquid resin material is injected into the space, and then the injected resin material is foamed or hardened to fill the space with the foamed or hardened resin material and at the same time the front surface layer and the back surface layer are fixed. A method for manufacturing a bathtub, characterized by being integrated. 2. The method for manufacturing a bathtub according to claim 1, wherein the legs of the bathtub are simultaneously and integrally formed when the backside layer of the bathtub is formed. 3. A bath surface layer formed by vacuum forming, a bath back surface layer formed by vacuum forming or press forming, and a resin foam or a cured body filled in a space between the front surface layer and the back surface layer. A bath having a laminated structure with the intermediate layer.