JPH10217338A - Method for forming heat insulating layer and apparatus therefor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To certainly form a heat insulating layer in a bathroom constituting part within a short time and to suppress the cost of a heat insulating layer forming mood low. SOLUTION: The molding space formed by a bathroom component 10 and a mold covering the same is filled with prefoamed beads and these prefoamed beads are fused and re-foamed to form a heat insulating layer T in the bathroom component 10 in a state integrated with the component. Since the bathroom component 10 is also used as a mold, only one mold may do and the fusion and re-foaming of the prefoamed beads are performed within a short time, and the heat insulating layer integrated with the bathroom component 10 can be certainly formed.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a bathtub,
The present invention relates to a method for forming a heat insulating layer provided on a bathroom component such as a waterproof floor pan, a wall panel, and a bathtub with a washing place in order to improve heat insulating properties, and an apparatus for forming the heat insulating layer.

[0002]

2. Description of the Related Art For example, urethane foam is sprayed on the back side of a bathtub to form a heat insulating layer, or a styrofoam molded product is adhered to the backside of the bathtub with an adhesive such as hot melt. Thus, a heat insulating layer is formed.

[0003] However, the urethane foam spraying operation has a problem that the urethane foam is scattered and has a disadvantage that the working environment is poor. Therefore, recently, when a heat insulating layer is formed by sticking a styrofoam molded product. There are many. In this case, the styrofoam molded product is divided in consideration of workability.

[0004]

However, since the styrofoam molded product needs to be formed by foaming a resin in a cavity between a male die and a female die formed of aluminum or the like, the type of the styrofoam molded product is different. However, it is necessary to prepare a male mold and a female mold, and there is a problem that the mold cost is high.

[0005] In addition, when the styrofoam molded product is stuck to the back side of the bathtub, the styrofoam molded product falls out of the bathtub due to poor adhesion unless the bonding conditions such as curing time (compression time, etc.) and crimping force are sufficiently adjusted. There was a problem that it would.

Furthermore, the work of attaching a large number of styrofoam molded products to the back side of the bathtub is complicated, and there has been a problem that the work requires a lot of manpower and time.

SUMMARY OF THE INVENTION In view of the above, the present invention provides a method for forming a heat insulating layer, which can surely form a heat insulating layer in a bathroom component in a short time, and can keep the mold allowance for forming the heat insulating layer low. An object of the present invention is to provide an apparatus for forming a heat insulating layer.

[0008]

According to a first aspect of the present invention, there is provided a method for forming a heat insulating layer, wherein a pre-foaming space is formed in a molding space formed by a bathroom component and a molding die covering the bathroom component. After filling the beads, the pre-foamed beads are welded and re-foamed to form a heat insulating layer integrated with the bathroom components on the bathroom components.

In the present invention, since the bathroom components serve as a mold, only one mold is required to form the heat insulating layer. In addition, the pre-foamed beads are easy to handle, so they are suitable for automating the work.Also, they re-foam in a short time, so that the heat insulating layer is integrated with the bathroom components. It can be formed quickly and reliably. In addition,
The re-foaming of the pre-foamed beads B is performed under a constant temperature and pressure.

According to a second aspect of the present invention, in the case of the first aspect, before filling the pre-expanded beads, steam for welding and re-expanding the pre-expanded beads is used.
This means that the bath layer components are preheated by passing through the molding space.

According to the present invention, since the bathroom components are preheated by the steam for welding and refoaming the pre-expanded beads, the bathroom components can be provided without any special heating means during the welding and re-foaming of the pre-expanded beads. The surrounding temperature can be reliably raised to a predetermined welding refoaming temperature.

According to a third aspect of the present invention, in the case of the first or second aspect, the bathroom component is a resin molded product immediately after demolding having heat during molding.

According to the present invention, since the bathroom components themselves have already reached a certain temperature, it is possible to slightly preheat the bathroom components, or without preheating the bathroom components.
At the time of re-foaming the pre-foamed beads, the temperature around the bathroom components can be reliably raised to a predetermined welding re-foaming temperature.

According to a fourth aspect of the present invention, in the case of the first, second or third aspect of the present invention, the supporting means for supporting the bathroom component includes a means for preheating the bathroom component. is there.

According to the present invention, the temperature of the bathroom components can be reliably raised to the required temperature when the pre-expanded beads are welded and re-expanded.

According to a fifth aspect of the present invention, there is provided an apparatus for forming a heat insulating layer, comprising: a support base for positioning and mounting a bathroom component with its back side facing upward; and a bathroom component on the support base. An upper mold having a large number of small holes placed thereon so as to cover the upper part of the bathroom component, and mounted on a support base with the upper mold closed so as to seal the upper mold. A pressurizing unit for pressurizing the upper mold toward the bathroom component;
An outer box having a steam supply unit for welding and refoaming the pre-expanded beads, and an outer box is provided so as to penetrate the outer box and the upper mold, and a preliminary space is formed in the molding space between the upper mold and the bathroom component. And a bead supply means for filling the expanded beads.

According to the present invention, after the upper mold is pressed toward the bathroom component side by the pressurizing portion of the outer box to close the mold, the space formed by the upper mold and the bathroom component is supplied by the pre-expanded bead supply means. Is filled with pre-expanded beads, and then steam for welding and re-expanding the pre-expanded beads is supplied into the outer box.
This steam moves from the small hole of the upper die to the side of the filled pre-expanded beads, and this is fused and re-expanded.

Further, in the present invention, since the upper mold is installed on the bathroom component positioned and mounted on the support base, the male mold and the female mold are formed in the left-right direction (lateral direction). Compared to a general molding device that is closed and opened, large and complicated bathroom components can be easily positioned and supported, and the pressure between the bathroom components and the molding die (mold closing) can be reduced by the upper die. This can be easily performed by the pressurizing unit.

According to a sixth aspect of the present invention, in the case of the fifth aspect, an airtight holding layer having soft rubber elasticity is formed on the upper surface side of the support base. .

According to the present invention, the support base and the outer case can be easily brought into close contact with each other by the airtightness maintaining layer. The airtight layer also has the function of protecting the bathroom components on the support base.

[0021]

Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 shows a waterproof floor pan with a heat insulating layer in which a heat insulating layer is formed on the back side by a heat insulating layer forming apparatus according to one embodiment of the present invention.

As shown in FIG. 1, a waterproof floor pan 1 with a heat insulating layer is made of resin (for example, polystyrene) on the back side of a waterproof floor pan 10 made of, for example, FRP, which is one of the components of a bathroom. A foamed heat insulating layer T having a large heat insulating property is formed to a predetermined thickness.

In the waterproof floor pan 10, a wall mounting portion 12 for mounting a wall panel (not shown) or the like is formed one step higher at an outer peripheral end of a main body portion 11 including a bathtub installation portion and a washing place portion. For example, SMC (Sheet Mo
Lding Compound) is formed by heating and pressing in a molding space (cavity) formed by a male mold and a female mold.

The heat insulating layer T is for preventing heat from escaping from the waterproof floor pan 10 to the outside of the bathroom during bathing or the like, and includes a large number of pre-foamed beads B (see FIG. 2) at a constant temperature and pressure,
They are re-foamed (welded and re-foamed) so as to be welded to each other, and are formed integrally with the waterproof floor pan 10. Note that the pre-expanded beads B are, for example, those obtained by pre-expanding polystyrene particles impregnated with a foaming material such as butane at a constant temperature and pressure, and have a size of several mm (for example, 2 to 2 mm). 6 mm).

FIG. 2 shows a bathroom component (for example, waterproof floor pan 1).
0) shows a heat insulating layer forming apparatus for forming a heat insulating layer T on the back surface side. As shown in FIG. 2, the heat insulating layer forming apparatus 2 includes a support base 20, a support block 21, a female die 22 as an upper die, an outer box 23, a clamper 24, and a bead supply unit. And a feeder 25.

The support base 20, together with the support block 21, is a support means for positioning and supporting the waterproof floor pan 10 with the back surface S1 side facing upward, and is formed of soft rubber on the horizontal upper surface side. Airtightness maintenance layer 20 of constant thickness
a is formed.

The support block 21 is a support means which is positioned on the support base 20 and supports the waterproof floor pan 10 at a predetermined interval from the surface S2 side. The upper part 21a which comes into contact with the waterproof floor pan 10 is easily deformed. It is formed of a rubber material. The support block 21 is provided on the surface S of the waterproof floor pan 10.
Depending on the position on the two sides, various heights are provided.

The female mold 22 has a box shape with an open bottom surface, and covers the upper side of the waterproof floor pan 10 on the rear surface S1 side with its lower end abutting against the rear surface of the wall mounting portion 12. ,
The molding space V of the heat insulating layer T is formed between the waterproof floor pan 10 placed on the waterproof floor pan 10 and the male waterproof floor pan 10. The female mold 22 has a certain strength so as to withstand the foaming pressure of the pre-expanded beads B, and is formed of a material having good releasability so that the formed heat retaining layer T can be easily removed from the mold. ing. The female mold 22 is provided at its lower end with an easily deformable elastic portion made of, for example, a rubber material so as to have good adhesion to the waterproof floor pan 10 side. In the female mold 22, small holes 22a slightly smaller in size than the pre-expanded beads B are formed, for example, at a pitch of 50 mm, and a feeder hole 22b into which the tip of the inner end 25a of the feeder 25 is inserted. Is formed.

The outer box 23 covers the upper part of the waterproof floor pan 10 on which the female mold 22 is placed so as to seal it.
It is pressurized and fixed on zero, and is formed to withstand a constant internal pressure (steam pressure). This outer box 23
Is a main body 23a having an open lower surface,
supply nozzle 23b, discharge nozzle 2 attached to a
3c and a pressure projection 23d. An edge P for pressing and fixing the outer box 23 to the support base 20 side by the clamper 24 is formed at the lower end side of the main body 23a.

The supply nozzle 23b is for supplying steam S for welding and refoaming the prefoaming bead B and cooling water C for cooling the formed heat insulating layer T to the inside. The discharge nozzle 23c is used for discharging steam S and cooling water C supplied for preheating. The pressing protrusion 23d is a pressing unit that presses the female mold 22 toward the waterproof floor pan 10 in a state where the outer box 23 is pressurized and fixed to the support base 20 side by the clamper 24. For tight contact with the waterproof floor pan 10 without gaps.
Note that a valve (not shown) that opens and closes the discharge nozzle 23c is attached to the outer end side.

The feeder 25 fills the molding space V between the female mold 22 and the waterproof floor pan 10 with the pre-foamed beads B. When the inner end 25a passes through the outer box 23, It is attached so as to be in close contact with the box 23. The tip of the inner end 25a is fixed in a state where the outer box 23 is pressed and fixed to the support base 20 via the clamper 24,
It is inserted into the feeder hole 22b of the female mold 22.

Next, a procedure for forming the heat insulating layer T on the back surface S1 side of the waterproof floor pan 10 by the heat insulating layer forming apparatus 2 will be described.

First, the waterproof floor pan 10 is placed on the support base 20 and the support block 21 on the support base 20 with the back surface S1 facing upward. Subsequently, after placing the female molds 22 on the waterproof floor pan 10, an outer box 23 is placed on the support base 20 so as to cover them, and the outer box 23 is clamped by the clamper 24 to the support base. Pressurized and fixed to the 20 side. As a result, the edge P of the outer box 23 is in close contact with the airtight holding layer 20 a of the support base 20 without any gap, and the lower end of the female mold 22 is pressed by the pressure projections 23 d of the outer box 23. It presses and adheres to the wall mounting part 12 side. Also, feeder 25
The tip of the inner end portion 25a is a feeder hole 22b of the female mold 22.
Inserted inside.

Next, with the discharge nozzle 23c opened, steam S for welding and re-foaming is blown into the outer box 23 from the supply nozzle 23b, and the steam S is discharged from the small hole 22a of the female die 22 into the molding space V. To preheat the waterproof floor pan 10 and the like to a predetermined temperature. Subsequently, after the supply of the steam S is stopped, the prefoamed beads B are filled into the molding space V from the feeder 25 by air pressure or the like. in this case,
The air in the outer box 23 is discharged to the outside by the discharge nozzle 23c.

Next, after closing the discharge nozzle 23c, the supply nozzle 2 is kept until the inside of the outer box 23 reaches a certain temperature and pressure.
The steam S for welding and re-foaming is blown into the outer box 23 from 3b. As a result, the steam S is formed in the small holes 2 of the female mold 22.
2a, flows into the pre-expanded beads B side, and the area around the pre-expanded beads B is constant (for example, when the pressure is 1.5 to 2).
When the pressure and temperature reach 80 to 100 ° C.), the pre-expanded beads B are re-foamed while being welded to each other within a short time (for example, 10 to 20 seconds). The heat insulation layer T having the same shape as the female mold 22 is formed integrally with the waterproof floor pan 10. Subsequently, the supply nozzle 23b and the discharge nozzle 23c are opened, and the outer box 23 is opened.
Cooling water C is passed through the inside, and this heat insulating layer T is
(1 to 2 minutes) After cooling, the outer box 23 and the like are removed, and the heat retaining layer T is removed from the female mold 22, whereby the waterproof floor pan 1 with the heat retaining layer can be obtained.

As described above, in the heat insulating layer forming apparatus 2, the pre-foamed beads B are filled between the back surface S1 of the waterproof floor pan 10 and the female mold 22 covering the back surface S1. By simply fusing and foaming the beads B, the heat insulating layer T integrated with the waterproof floor pan 10 can be formed on the back surface S1 of the waterproof floor pan 10 in a short time in a good shape. In this case, since the waterproof floor pan 10 functions as a male mold, only the female mold 22 needs to be formed, and the mold cost can be reduced.
In this case, since the pre-expanded beads B are granular and easy to handle, automation of the heat insulating layer forming device 2 is also easy.

Further, in the heat insulating layer forming apparatus 2, before filling the pre-expanded beads B, the steam S for welding and re-foaming is passed through the molding space V, and the waterproof floor pan 10 is sufficiently pre-heated. Therefore, heat can be sufficiently transmitted to the pre-foamed beads B near the waterproof floor pan 10 where heat is not easily transmitted. Therefore, the pre-foamed beads B near the waterproof floor pan 10
Can be sufficiently welded and refoamed to form a sufficiently welded heat insulating layer T on the back surface S1 side of the waterproof floor pan 10.

Further, in the heat insulating layer forming apparatus 2, the male and female molds are not closed and opened in the left-right direction (lateral direction) as in the conventional molding apparatus, but the male waterproof floor is formed. Since the female mold 22 is arranged above the pan 10 and the female mold 22 and the waterproof floor pan 10 are closed and opened in the vertical direction, the male waterproof floor pan 10 is large and complicated. Even if it has a simple shape, it can be easily positioned and supported on the support base 20, and the female mold 22 can be easily pressed against the waterproof floor pan 10 side.

In the thermal insulation layer forming apparatus 2, the outer box 2
3 is simply fixed on the support base 20 by pressing.
3, the female mold 22 is connected to the waterproof floor pan 10 by the pressure projection 23d.
Since it can be pressed to the side, a special device is not required for pressurizing the female mold 22, and the size and cost of the device can be reduced.

Further, in the heat insulating layer forming apparatus 2, the airtight holding layer 20a which is easily elastically deformed is provided on the upper surface of the support base 20.
Is provided, the outer box 23 and the support base 20 are closely adhered to each other without any gap just by pressing and fixing the outer box 23 to the support base 20 side. Easy sealing.

The heat insulating layer T may not be formed on the entire back surface S1 side of the waterproof floor pan 10, but may be formed only on the washing area side of the main body 11 of the waterproof floor pan 10, for example. . In this case, it is necessary to partially change the shape of the lower end of the female mold 22.

In addition, the outer box 23 is not provided with the discharge nozzle 23c, and before the outer box 23 is pressurized and fixed to the support base 20 side, the steam S and the pre-expanded beads B are filled. Is also good. This is because steam or air containing drain can be discharged to the outside from the gap between the outer box 23 and the support base 20.

Furthermore, if the waterproof floor pan 10 that has just been removed and still has molding heat can be used, the amount of air in the preheating steam S can be reduced or eliminated. Further, instead of using the preheating steam S, a preheating means such as an electric heater may be provided in the support block 21 to preheat the waterproof floor pan 10. of course,
In this case, the steam S for preheating may be used together with this preheating means, or the waterproof floor pan 10 immediately after demolding may be heated by this preheating means if necessary.

Further, the feeder 25 is not fixed to the outer box 23, but the inner end 25a can be moved in the outer box 23 so that the feeder 25 can cope with various outer boxes 23 and the female mold 22. You may. In this case, feeder 2
5 is inserted into the feeder hole 22 of the female mold 22 at the tip of the inner end 25a.
After insertion into b, the periphery of the feeder 25 through the outer box 23 is sealed.

Further, a push rod may be provided on the female mold 22 side, and the heat retaining layer T may be quickly removed from the female mold 22 by the push rod.

Further, the support base 20 and the outer box 23 of the thermal insulation layer forming apparatus 2 can be used also when the thermal insulation layer T is formed on other bathroom components (bath tub, wall panel, bath tub with washing place, etc.). Alternatively, it may be formed slightly larger. In this case, the support projections 23d and the like of the outer box 23 are replaced depending on the size and shape of the female mold 22.

FIG. 3 shows a state in which the heat insulating layer T is formed on the back side of the bathtub 30 by the heat insulating layer forming apparatus 2. In this case, the bathtub 30 is not a resin molded product, but may be, for example, a casting.

FIG. 4 shows a state in which a heat insulating layer T is formed on the back side of the wall panel 40 by the heat insulating layer forming apparatus 2. In this case, since the wall panel 40 can be positioned and supported only by the support base 20, the support block 21 is unnecessary. In this case, a heating means may be provided on the support base 20 to preheat the wall panel 40.

[0049]

The present invention has the following effects.

According to the invention of the method for forming a heat insulating layer according to claim 1 of the present invention, the pre-expanded beads are filled in a molding space formed by a bathroom component and a molding die covering the bathroom component. The pre-foamed beads are welded and re-foamed to form a heat insulating layer integrated with the bathroom component on the bathroom component, so that the heat insulating layer is reliably formed on the bathroom component in a short time. In addition to this, the mold allowance for forming the heat insulating layer can be suppressed low.

According to the second aspect of the present invention,
In the case of the first aspect of the present invention, before the pre-expanded beads are filled, steam for welding and re-expanding the pre-expanded beads is passed through the molding space to pre-heat the bath layer components. Pre-expanded beads near bathroom components that are difficult to transmit can be easily welded and re-expanded.

According to the third aspect of the present invention,
In the case of the invention as set forth in claim 1 or 2, since the bathroom component is a resin molded product immediately after demolding having heat during molding, for example, only a slight preheating of the bathroom component will transfer heat. Pre-expanded beads near the difficult bathroom components can be sufficiently welded and re-expanded.

According to the invention described in claim 4 of the present invention,
In the case of the first, second or third aspect of the present invention, since the supporting means for supporting the bathroom component includes the means for preheating the bathroom component, the pre-expanded beads near the bathroom component, which is difficult to conduct heat, can be reliably formed. And can be re-foamed.

According to the heat insulating layer forming apparatus according to the fifth aspect of the present invention, a support base for positioning and mounting the bathroom components with the back side facing upward, and the bathroom configuration on the support base An upper mold having a number of small holes placed on the product so as to cover the upper part of the bathroom component, and mounted on a support base with the upper mold closed so as to seal the upper part. And an outer box having a pressurizing unit for pressing the upper mold toward the bathroom component side, a steam supply unit for welding and refoaming the pre-expanded beads, and a penetrating outer box and upper mold. Provided in the molding space between the upper mold and bathroom components,
Since a bead supply means for filling the pre-expanded beads is provided, the same effect as the first aspect can be obtained. Further, according to the present invention, the positioning and support of the bathroom components can be easily performed, and the female mold can be easily pressed (closed).

According to the sixth aspect of the present invention,
In the case of the invention according to claim 5, since the airtight holding layer having soft rubber elasticity is formed on the upper surface side of the support base, the periphery of the female mold can be easily sealed by the outer box, and the bathroom configuration Products can be protected.

[Brief description of the drawings]

FIG. 1 is a sectional view of a waterproof floor pan on which a heat insulating layer is formed by a heat insulating layer forming apparatus according to one embodiment of the present invention.

FIG. 2 is a sectional view of a heat insulating layer forming apparatus.

FIG. 3 is a view showing a state in which a heat insulating layer is formed on the back surface side of a bathtub by a heat insulating layer forming apparatus according to a modified embodiment.

FIG. 4 is a diagram showing a state in which a heat insulating layer is formed on the back surface side of a wall panel by a heat insulating layer forming apparatus according to another modified embodiment.

[Explanation of symbols]

 2 Insulation layer forming apparatus 10 Waterproof floor pan (bathroom component) 20 Support base (support means) 20a Airtight holding layer 21 Support block (support means) 22 Female type (upper type) 22a Small hole 23 Outer box 23b Supply nozzle ( Steam supply part) 23d Pressure projection (pressure part) 25 Feeder (bead supply means) 30 Bathtub (bathroom component) 40 Wall panel (bathroom component) B Pre-expanded beads T Heat insulation layer V Molding space

Claims (6)

[Claims] 1. A preform beads are filled in a molding space formed by a bathroom component and a molding die covering the bathroom component, and then the prefoam beads are welded and refoamed to form the bathroom component. A method for forming a heat insulating layer, comprising forming a heat insulating layer integrated with the bathroom component. 2. A method for preheating the bath layer component by passing steam for welding and refoaming of the pre-foamed beads into the molding space before filling the pre-foamed beads. The method for forming a heat retaining layer according to claim 1. 3. The method for forming a heat retaining layer according to claim 1, wherein said bathroom component is a resin molded product immediately after demolding having heat during molding. 4. The method for forming a heat insulating layer according to claim 1, wherein said supporting means for supporting said bathroom component comprises means for preheating the bathroom component. 5. A support base for positioning and placing a bathroom component with its back side facing upward, and a bathroom component on the support base so as to cover above the bathroom component. And an upper die having a number of small holes, and mounted on the support base in a state of covering the upper die so as to hermetically seal the upper die, and placing the upper die on the bathroom component side. An outer box having a pressurizing unit for applying pressure, and a steam supply unit for welding and refoaming the pre-expanded beads, provided so as to penetrate the outer box and the upper mold, and the upper mold and the bathroom configuration. An apparatus for forming a heat retaining layer, comprising: a bead supply means for filling a pre-expanded bead in a molding space between the articles. 6. An apparatus for forming a heat insulating layer according to claim 5, wherein an airtight holding layer having soft rubber elasticity is formed on the upper surface side of said support base.