JPH07213445A - Wash basin cabinet - Google Patents

Abstract

PURPOSE: To make a dressing table possible to be economically manufactured, by using a one-piece type seamless molding by vacuum molding and properly reinforcing a sink part, top plate part, etc., using a fiber glass mat, stringer, etc. CONSTITUTION: In manufacturing this dressing table, the top face of the dressing table is vacuum-molded by polymethacrylate at first to form a shell comprising a sink part 2, a horizontal top plate face 3, and a splash stopper 4. Next, a cover film 6 in a protrusion or cup shape is formed around a part to be equipped with a drain port before chips of fiber glass impregnated with polyester resin are sprayed on the lower side of the sink part 2 to form a sink part reinforcing part. A mixture of calcium carbonate and polyester resin is back- filled in the void formed by the cover film and, then, a stringer for reinforcing is inserted in rear of the top plate face 3 and the back-filling mixture material is injected to bury the stringer to reinforce the top plate face 3.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a reinforced toilet vanity formed by thermoplastic molding, and more specifically, a one-piece seamless molded body is used for the upper surface, and the seamless molded body is used as a basin and The present invention relates to a method for manufacturing a vanity including both top surfaces.

[0002]

2. Description of the Related Art For many years, a one-piece vanity having a single or a plurality of basins and a horizontal top surface is first coated with a release material and then a gel coat on the upper surface of the vanity,
Next, it is formed by filling a filler into a molded body. More recently, vanities have been formed by vacuum forming a thermoplastic shell to the top, but this method is currently time consuming and leaves manufacturers with substantial inventory. There is a need.

[0003]

SUMMARY OF THE INVENTION It is an object of the present invention to provide an economical method for manufacturing a one-piece reinforced vanity having a one-piece upper surface formed by vacuum forming. It is an object to provide an alternative vanity manufacturing method to the market.

[0004]

According to the present invention, there is provided a method of manufacturing a one-piece vanity including: a) an upper surface of the vanity including a basin portion made of a thermoplastic material as a one-piece shell. Vacuum forming, b) reinforcing the underside of the shell basin, c) reinforcing at least the underside of the shell top surface, d) at least under the basin, along the outlet, 15
Fixing a millimeter-shaped raised formwork, e) backfilling the space between the raised formwork and the basin with a curable filling material, whereby the curable filling material is a basin A method of making a one-piece vanity is provided that includes ensuring that it will not pass through the outlet of the part and enter the interior of the bowl defining the basin.

[0005]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The method of the present invention will be described below with reference to the drawings. In the manufacturing method according to the present invention of the vanity (shown upside down in the drawings) shown in FIGS. 1 to 7, first, the upper surface of the vanity is vacuum-formed from polymetal methacrylate to form a single or a plurality of basins. A one-piece shell 1 is formed which incorporates 2, a horizontal roof surface 3 and a bounce stop 4. Next, as best shown in FIG. 2, the basin is reinforced by spraying a piece of fiberglass mat containing polyester resin onto the underside of the basin 2 to form a basin reinforced portion 5. .

Prior to reinforcing the basin, a coating, or
It is preferable to form a coating 6 in the form of a ridge or an annular cup around the portion 7 of the basin where the drainage (not shown) is provided. This annular cup-shaped coating is the same as the portion 7
Substantially circular hole 8 slightly larger than the hole that will be
Is. In the drawing, a coating 6 is applied along the perimeter flange portion 9 and this coating is integrated with the fiberglass in the basin around the perimeter flange portion 9 by further application of fiberglass mat and resin. Indicates that otherwise it can be attached.

The fixed annular cup-shaped coating 6 is provided in the space 11
Is defined in FIG. Next, as shown in FIG. 5, this space 11 is backfilled with a mixture 12 of calcium carbonate and polyester resin. Since the diameter of the holes 15 in the coating 6 is slightly larger than the diameter of the outlet, there is an annular opening between the plug 13 and the hole 15 through which backfill material can be injected into the space 11.

The backfill material 12 is also injected into the roof surface 3 after inserting another plug 16 into a hole previously drilled for the faucet. The backfill material flows into the anti-bounce groove 17, but the amount of the backfill material is kept to the minimum necessary to fill the reinforcing stringer 18. Next, a reinforcing stringer 18 is inserted behind the roof surface 3, and a backfilling material is further injected behind the roof surface 3 to embed these reinforcing stringers 18 to finish the roof surface 3 to a desired wall thickness. . After the backfill material 12 has solidified, the peripheral portion 19 of the original shell of polymethylmethacrylate is trimmed from the finished product as shown in FIG. It goes without saying that these peripheral parts 19 serve to house the backfill material 12 therein and to form this backfill material in the desired cross-sectional shape.

The finished product is thus seamless because the shell of polymethacrylate constitutes the entire upper visible surface of the finished product. The shell can be transparent and the unit can be in the color of the backfill material, but again the basin is often coated with a coloring material prior to applying the reinforcing fiberglass to the basin. Before applying the coloring, reinforcing and backfilling material, a floral or other transfer pattern may be placed under the clear shell to give the product a decorative finish.

The reinforcing and backfilling process described above is
It provides strength and stiffness to a polymethacrylate shell that would otherwise not be as stiff as desired. However, although there are many other methods for giving such rigidity to the polymethacrylate shell, those other methods do not always obtain the bulge provided by backfilling the position of the roof surface and the outlet described above. I can't. It has been found important to meet consumer expectations regarding the desired thickness of the vanity unit as a whole. According to the method of the present invention described above, all visible parts of the finished product are considerably thicker, including the surrounding rooftop, outlet and faucet / spout parts.

Finished products must be visually judged by consumers and users, and must be structurally sound and tolerant to their "knack". I won't. This slap-type test audibly tells the finish product whether it is "hollow" or "sturdy" when struck inside the basin or other parts of the product. It has been found that the manufacturing method described above is reassuring to the consumer not only in the appropriate mechanical properties, but also in this "tapping" test and apparent wall thickness.

An embodiment of the present invention is shown in FIG. 8 in which an annular cup-shaped coating or flange portion 6 includes an overflow outlet 20, an overflow outlet 21, and an overflow inlet 22. According to the manufacturing method of the present invention, it is easy to provide such an overflow outlet. The overflow system additionally includes a cup-shaped coating shaped to receive a preformed tube for the overflow drain. These coatings may be applied to the shell basin by fiberglass and then covered with a thin coating of backfill material. The overflow inlet, which is a relatively thin portion of the shell's basin, may be hidden by visibly incorporating baffles 23 in shell 1 or later adding them. Although the present invention has been described above with reference to specific examples, it should be understood that many modifications can be made within the present invention.

[0013]

The present invention provides an economical method for manufacturing a one-piece reinforced vanity that uses a vacuum formed one-piece top surface, and at least provides an alternative to the conventional method. Manufacturing methods are provided to the market.

[Brief description of drawings]

FIG. 1 is a cross-sectional view of a shell used in connection with the present invention taken from the front to the rear.

2 is a cross-sectional view of the shell of FIG. 1 after reinforcing the basin.

FIG. 3 is a cross-sectional view of the shell of FIG. 2 after depositing the coating.

4 is a cross-sectional view of the shell of FIG. 3 after opening the outlet.

5 is a cross-sectional view of the shell of FIG. 4 after backfilling the coating.

FIG. 6 FIG. 5 after reinforcing and backfilling the horizontal part
3 is a sectional view of the shell of FIG.

7 is a cross-sectional view of the shell of FIG. 6 after completion of the manufacturing process.

FIG. 8 is a cross-sectional view of the shell of FIG. 1 including an overflow outlet in the basin after completion of the manufacturing process.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 shell 2 water plate part 3 top surface 4 bounce stop 6 annular cup-shaped coating 8 circular hole 9 peripheral flange part 11 space 12 mixture 12 backfill material 15 hole 16 plug 18 stringer 19 peripheral part 20 overflow drain 21 overflow overflow Road 22 Overflow inlet 23 Baffle

Claims (10)

[Claims] 1. A method for manufacturing a one-piece vanity, which comprises: a) vacuum forming the upper surface of the vanity including the basin into a one-piece shell shape from a thermoplastic material; and b) a shell. Reinforcing the underside of the basin of c, c) Reinforcing at least the underside of the shell top surface, d) Raised underside of the basin, at least 15 mm thick, along the outlet location. E) Backfilling the space between the raised formwork and the basin with a curable filler so that the curable filler will position the outlet of the basin. A method of making a one-piece vanity including through ensuring that it does not enter the inside of the bowl defining this basin. 2. The raised mold is a cup-shaped coating,
The cup-shaped coating has a contour shape so as to form a space between the bottom of the basin and the coating adjacent to the portion forming the discharge port, and the cup-shaped coating is for facilitating backfilling. The method for manufacturing a one-piece vanity according to claim 1, which is provided with holes. 3. Curing through the outlet position of the basin portion by ensuring that the amount of curable filler does not enter inside the bowl portion defining the basin portion through the outlet position of the basin portion. Ensuring that the amount of permeable filler does not get inside the bowl defining the basin is a) drainage acting to receive drainage on a vacuum formed one-piece shell for a vanity. Providing an outlet, b) An opening is provided in the cup-shaped coating, and the opening is positioned so as to be directly above the outlet of the basin when the vanity is turned upside down, and has a diameter slightly larger than the outlet. C) inserting a removable plug into the discharge port of the basin, and placing the plug at least at the height of the opening in the cup-shaped coating when the vanity is turned upside down. Distracting, d) Backfilling the space between the cup-shaped coating and the basin with an amount of curable filler through the opening between the cup-shaped coating and the plug; e) curing of the curable filler The method for manufacturing a one-piece vanity according to claim 2, further comprising removing the plug after the step. 4. The method of manufacturing a one-piece vanity according to claim 1, wherein the one-piece shell is made of polymethylmethacrylate. 5. "c) Inserting a removable plug into the discharge port of the basin, and extending the plug to at least the height of the opening in the cup-shaped coating when the vanity is turned upside down. 2. The method for manufacturing a one-piece vanity according to claim 1, wherein the "doing" is carried out while maintaining the shell in an inverted state, and the reinforcing is carried out only by the amount of the filler or by the amount of the filler and the reinforcing member. . 6. An overflow discharge channel is fixed to the back side of the basin section, and the overflow discharge channel connects an overflow inlet port communicating with the basin section at a position adjacent to the upper end of the basin section and a raised mold. The method for manufacturing a one-piece vanity according to any one of the preceding claims, comprising an overflow drainage port communicating with the drainage port of the extension basin. 7. The method of manufacturing a one-piece vanity according to claim 3, wherein the overflow inlet is hidden by a visible baffle. 8. A vanity manufactured by the method according to claim 1. 9. A vanity manufactured by the method according to claim 3. 10. A vanity manufactured by the method according to claim 4.