KR102416744B1 - Method of manufacturing bathtub - Google Patents

Abstract

The present invention relates to a method for manufacturing a bathtub and, more specifically, to a method for manufacturing a bathtub, which manufactures a bathtub in an injection molding method. The method for manufacturing the bathtub according to the present invention comprises: a release agent application step of applying a release agent to a molding surface of each of a cover part mold and a water containing part mold in which cavities having shapes of a bathtub cover part and a bathtub water containing part are provided respectively; a coating layer molding step of molding a coating layer by applying a coating material to the surface of the release agent on the cover part mold and the water containing part mold; a molding step of molding a cover part body and a water containing part body by injecting a molding material into each cavity of the cover part mold and the water containing part mold; a separation step of separating the cover part and the water containing part, manufactured in the molding step, from the cover part mold and the water containing part mold; and an assembling step of assembling the cover part with the water containing part to manufacture the bathtub, wherein the coating material applied to the mold of the cover part or the molding material for molding the cover part body is mixed with a color chip for color matching. The present invention can save manufacturing costs and quality management costs.

Description

{Method of manufacturing bathtub}

The present invention relates to a method for manufacturing a bathtub, and more particularly, to a method for manufacturing a bathtub for manufacturing a bathtub by an injection molding method.

In general, bathtubs are installed on one side of a bathroom and used for bathing and the like, and are usually made of synthetic resin that is easy to mold and harmless to the human body as a raw material.

Such a bathtub is a method of manufacturing a bathtub of a desired shape by injection molding a heated synthetic resin into the cavity of a mold manufactured in advance to reflect a predetermined shape, such as the bathtub and its manufacturing method disclosed in Korean Patent Registration No. 10-0803387 is made with At this time, the bathtub must be precisely manufactured according to the standard of the installation space. In addition, the bathtub is designed to have a number of curved surfaces as furniture that the user directly contacts with. However, it is very difficult to manufacture a bathtub of precise specifications by injection molding while considering external conditions between manufacturing processes including molding shrinkage. Therefore, the manufacturing method of a bathtub suitable for a bathroom while having a user-friendly curved surface has the disadvantages of low productivity and high quality control costs.

In addition, such a bathtub is limited to a single shape and a single color through a mass production line and uniformly supplied. Therefore, there is a problem in that a conventional bathtub cannot satisfy the needs of consumers who require more various shapes and colors.

Republic of Korea Patent No. 10-0803387: Bathtub and its manufacturing method Republic of Korea Patent No. 10-1834296: Safety bathtub manufacturing method and safety bathtub manufactured by the manufacturing method

An object of the present invention is to improve the above problems, and to provide a bathtub manufacturing method capable of manufacturing a bathtub with improved productivity for mass production.

In addition, an object of the present invention is to provide a method for manufacturing a bathtub that can produce various colors and shapes.

In order to solve the above technical problem, in the bathtub manufacturing method according to the present invention, a release agent is applied to each molding surface of the mold for the cover part and the mold for the tub part each having cavities having the shapes of the lid part of the bathtub and the tub part of the bathtub. application step; a coating layer forming step of forming a coating layer by applying a coating material to the surface of the mold release agent of the cover mold and the tub mold; a molding step of injecting a molding material into the respective cavities of the cover mold and the tub mold to mold the lid body and the tub body; a separation step of separating the cover part and the tub part manufactured in the forming step from the cover part mold and the tub part mold; and an assembly step of manufacturing the bathtub by assembling the cover part and the tub part, wherein the coating material or the molding material is mixed with color chips for toning.

In addition, the molding material is mixed with at least one of a resin, stone powder, calcium carbonate, and glass fiber for forming a pattern.

In addition, the coating material includes at least one of a polyurethane compound, an acrylic gel compound, and an epoxy gel compound.

In addition, the molding step is to cure the molding material at 60 to 100 ℃.

In addition, in the assembling step, an adhesive is applied to a contact surface of either side of the cover part and the tub part in contact with each other, and the cover part and the tub part are adhered to each other.

In addition, between the step of applying the release agent and the step of forming the coating layer for forming the coating layer of the cover part, the transfer paper on which a specific pattern is printed between the release agent and the coating layer is disposed so that the transfer surface of the transfer paper faces the coating layer. The method further includes a printing step for transferring the specific pattern to the surface of the coating layer.

In addition, the molding material for molding the cover part includes the calcium carbonate mixed with the resin, and the molding material for molding the tub part is made of the resin, or the resin is mixed with the glass fiber. include

As described above, the bathtub manufacturing method according to the present invention has an advantage in that the manufacturing cost and quality control cost for manufacturing the bathtub are reduced by separately manufacturing the bathtub part and the cover part exposed to the user's field of view.

In addition, there is an advantage in that aesthetics are improved by manufacturing the cover part to have various colors or patterns.

1 is a block diagram showing the procedure of a bathtub manufacturing method according to a preferred embodiment of the present invention;
2 is a perspective view of a bathtub manufactured by the method for manufacturing a bathtub according to a first embodiment of the present invention;
3 is an exploded perspective view for explaining the assembly steps of the cover part and the tub part manufactured by the bathtub manufacturing method according to the first embodiment of the present invention;
Figure 4 is a cross-sectional view showing the structure of the cover portion of Figure 2;
5 is a cross-sectional view showing the structure of the tub part of FIG. 2;
Figure 6 is a cross-sectional view for explaining a state in which the bathtub manufactured by the bathtub manufacturing method of the present invention is installed;
7 is a perspective view for explaining a bathtub manufacturing method according to a second embodiment of the present invention;
Figure 8 is a cross-sectional view of the cover for explaining the bathtub manufacturing method according to the third embodiment of the present invention.
9 is an exploded perspective view showing another embodiment of the cover part and the tub part of FIG. 3;

Hereinafter, with reference to the accompanying drawings, a method for manufacturing a bathtub according to a first embodiment of the present invention will be described in detail with reference to the accompanying drawings.

1 to 6 show a bathtub manufactured by the method for manufacturing a bathtub according to the first embodiment of the present invention. Referring to the drawings, in the bathtub manufacturing method according to the present invention, the cavities having the shapes of the cover part 10 of the bathtub 1 and the tub part 20 of the bathtub 1 are respectively provided. A release agent application step (S1) of applying a release agent to each molding surface, a coating layer forming step (S3) of forming a coating layer 30 by applying a coating material to the surface of the release agent of the cover part mold and the tub part mold (S3), and covering the molding material The molding step (S4) of molding the cover body and the bath body by injecting into each cavity of the secondary mold and the tub part mold, and the cover part 10 and the tub part 20 manufactured in the molding step (S3) are covered It includes a separation step (S5) of separating the secondary mold and the tub part from the mold, and an assembling step (S7) of assembling the cover part 10 and the tub part 20 to manufacture the bathtub 1 .

At this time, the tub portion 20 of the bathtub 1 has a lower plate 22 having a drain hole 23 that can be opened and closed by a stopper, and extends upward from the edge of the lower plate 22 so that water can be stored. The water storage space 25 is provided with a side wall 24 forming a formation, and a flange 26 extending from an upper portion of the side wall 24 to a predetermined width in the horizontal direction.

The cover part 10 of the bathtub 1 includes a plate-shaped upper plate 12 formed in a predetermined size so as to be in contact with the upper surface of the flange 26 of the bathtub part 20 , and a flange 26 from the edge of the upper plate 12 . ) is provided with a side plate 13 extending downward so as to cover the outer part. At this time, the upper plate 12 has a through hole 14 formed therein so that the water storage space 25 is opened in the assembled state with the tub unit 20 .

The shape of the bathtub 1 having the flange 26 as described above in this embodiment is an example in consideration of the assembly of the cover part 10 and the tub part 20 in the assembling step (S7). Any other shape capable of assembling the tub part 20 and the cover part 10 by another method may be used.

Of course, the mold for the cover part and the tub part mold for manufacturing the bathtub 1 may be a mold commonly used for molding a general bathtub.

In addition, the lid part 10 and the tub part 20 are respectively formed to cover the lid part body 11 and the tub part body 21 formed from a molding material, and the lid part body 11 and the tub part body 21, respectively. The formed coating layer 30 is provided.

In order to manufacture the bathtub 1, a heat medium circulation device is connected to each of the cover mold and the tub mold, and the temperature sensor detects the circulation temperature of the heat medium so that the temperature of the cover mold and the tub mold is constant. to keep It is preferable that the temperature of the mold for the cover part and the mold for the tank part is controlled and maintained at a temperature that meets the working standards of the mold release material or coating material or molding material applied in each step.

In addition, each of the cover mold and the tub mold is connected to an injection part through which the molding material can be injected, and the molding material can be injected into each cavity while the cover mold and the tub mold are combined. A material injection means is provided.

Before performing the release agent application step (S1), each molding surface of the mold for the cover part and the mold for the tub part for applying the release agent is preferably cleaned so as to be kept clean without foreign matter in order to improve processing quality. In addition, it is preferable that there are no scratches on the molding surfaces of the cover mold and the tub mold.

Before performing the release agent application step (S1), each of the cover part mold and the tub part mold is prepared in a separate state so that the operator can easily apply the release agent and the coating material to the molding surface.

The release agent used in the release agent application step (S1) may be a release agent used for molding a conventional bathtub, such as wax or a matte agent. In addition, it goes without saying that by applying an additive such as a polyvinyl alcohol (PVA) aqueous solution before applying the release agent, and then applying the release agent, the cover part or the tub part can be easily released from the molding surface. As an example of the PVA aqueous solution, a PVA concentration of 5 to 50 wt% may be used.

As an example of the operation of applying the release agent to the cover mold and the tub mold, the mold is washed with alcohol to completely remove foreign substances, then the PVA solution is applied 2 to 4 times at 40 to 50 ° C., and the release agent is applied 3 to 7 times. After drying, the effect of the release agent can be effectively exhibited by drying at a temperature of 55 to 90° C. for about 30 minutes to 7 hours.

In the release agent application step (S1), a spray-up method in which the release agent is applied to the molding surface by spraying or a hand lay-up method in which an operator directly applies and applies the release agent using a brush may be applied.

In this release agent application step (S1), when the operator separates the molded cover part 10 or the tub part 20 from the molded surface, the coating layer 30 adheres to the molded surface and the lid part body 11 or hot water The effect of preventing peeling from the rough part main body 21 is exhibited.

In a state in which the release agent application step (S1) is completed as described above, the operator may perform the coating layer forming step (S3) for forming the coating layer 30 .

As the coating material applied to the surface of the release agent in the coating layer forming step (S3), one containing at least one of a polyurethane compound, an acrylic gel compound, and an epoxy gel compound may be used. Preferably, it is preferable to use a coating material that becomes transparent when applied and cured.

At this time, the coating layer forming step (S3) for forming the coating layer of the cover part 10 includes a toning step (S2) of mixing the color chip with the coating material.

In the toning step (S2), the coating material is dyed with a specific color by mixing the color chip with the coating material. The coating layer 30 formed by applying a coating material dyed in a specific color causes the manufactured cover part 10 to have a specific color. In this case, a color chip to which a pigment of a predetermined color is added may be used in the form of a urethane-based, acrylic-based, or epoxy-based resin fillet. In addition, any color chip that can be mixed with the coating material to form the coating layer 30 toned to a predetermined color may be used. The color chip 32 may have a single color and may be mixed with a coating material. In addition, various colors may be produced by mixing the color chips 32 made of a plurality of colors with the coating material. In addition, additives such as a brightening agent or a matting agent may be mixed together. This toning step (S2) is a step for dyeing the coating layer 30 in a specific color, and may be omitted when mixing a color chip with a molding material for molding the cover part 10 .

As described above, the preparation for the coating layer forming step (S3) is completed by preparing a coating material for forming the coating layer 30 toned to a specific color through the toning step (S2).

It is good for the operator to apply the coating material so that the coating layer 30 having a thickness of 1 to 4 mm is formed and dried. If the coating layer is less than 1 mm, there is a fear that the cushioning feeling felt by the user may be insufficient due to insufficient elasticity of the manufactured cover or tub portion. there may be Preferably, it is good to dry after application so that the coating layer is formed to a thickness of 1.8 to 2.5 mm. The toning step ( S2 ) is for imparting aesthetics to the cover part 20 or the tub part 20 and may be omitted or replaced with other means for imparting aesthetics.

In the toning step (S2), the cover body 11 and the hot tub body 21 may be colored with different colors by mixing the color chips 32 of different colors. In addition, the cover body 11 and the bath body 21 may be selectively colored or the entire body 21 may be colored. As an example, FIG. 3 shows a state in which only the cover body 11 is toned. As another example, referring to FIG. 9 , a state in which only the bath body 11 is toned is shown.

The coating layer 30 as described above formed in the coating layer forming step (S3) provides cushioning properties to the surface of the cover part or the tub part, and at the same time prevents the cover part or the tub part from being cracked or damaged by an external impact, It exerts the effect of providing chemical resistance and waterproofness to the bathtub (1).

As described above, from the state where the coating layer forming step (S3) is completed, the cover part mold or the hot water tank part mold in the separated state for the release agent application step (S1) and the coating layer forming step (S3) up to before is combined to cover the inside Preparation for the forming step (S4) is completed by forming a cavity so that the part or the tub part can be molded.

As a molding material for forming the cover body 11 and the hot tub body 21 in the molding step (S4), a mixture containing at least one of a curing agent, glass fiber, calcium carbonate, and stone powder in a resin may be used. have.

In this case, the resin may be an unsaturated polyester resin. Unsaturated polyester resin is a thermosetting resin obtained by mixing polymerization of polyester and vinyl units. ) is reacted at 100 to 200° C. to make polyester having an unsaturated group, and a solution obtained by mixing units such as diallyl styrene phthalate and methyl methacrylate with this may be used. At this time, as a resin serving as a base of a molding material for molding the tub body 21, an acrylic resin for weight reduction may be applied.

Calcium carbonate chemically bonds between the composition mixed with the unsaturated polyester resin to prevent deformation or pores, and to improve aesthetics by forming a rock-like wave pattern on the cover body 11 and the bath body 21 used as an additive for

Glass fiber reinforces the strength of unsaturated polyester resin and is applied as a reinforcing material to improve aesthetics by forming multiple hairlines for scratch texture patterns on the surface.

Stone powder is made of any one or more powders of feldspar, monolith, limestone, gypsum, acid clay, alumina, iron oxide, silica sand, wollastonite, clay, pyrophyllite, kaolin, barite, leaf feldspar, porcelain, talc, and graphite. It can be applied selectively. Stone powder increases the specific gravity of the composition, thereby exhibiting the effect of effectively filling the mold with the resin. In addition, stone powder exhibits the effect of improving the moldability by preventing the resin from sticking to the hand or the mold during molding.

Calcium carbonate, glass fiber, and stone powder may be applied to either one or both in consideration of the pattern and formability to be produced. Alternatively, it may be manufactured in a manner using only resin.

When the colorless coating material is applied in the above-described coating layer forming step (S3), the forming step (S4) is performed by further mixing a color chip with the molding material for manufacturing the cover body 11 and the hot tub body 21 to form the cover It may further include a main body toning step of toning the main body 11 and the hot water tank main body 21 . In the body toning step, as in the toning step (S2), the cover body 11 and the bath body 21 may be colored in different colors or the same color. In addition, in the main body toning step, either one of the main body of the cover part or the main body of the tub body may be toned or all of them may be toned.

In addition, the cover body 11 and the bath body 21 may be made of different molding materials. Preferably, the molding material for molding the cover body 11 is a resin in which the calcium carbonate is mixed, As a molding material for molding the tub main body 21, a resin in which glass fibers are mixed may be applied. The cover body 11 exposed to the user's gaze is formed in an Onyx pattern in which calcium carbonate is mixed with resin and multicolored lines are lined up layer by layer. In addition, the tub main body 21 can improve workability by reducing the weight while having sufficient durability.

In the forming step (S4), the molding material as described above is injected at a high pressure to fill each cavity of the mold for the cover part or the mold for the tank part in a sufficiently mixed state.

And, the molding material injected into each cavity of the cover mold or the tub mold is cured at 60 to 100° C. for about 1 hour, and is adhered to the coating layer 30, and the cover body 11 and the tub body 21 ) are formed respectively.

When the curing process is completed, the operator opens the cover part mold and the tub part mold, respectively, and separates the molded lid part 10 and the tub part 20, respectively, and assembles the lid part 10 and the tub part 20. The preparation for the assembling step (S7) of manufacturing the bathtub is completed.

In the assembling step (S7), the adhesive 40 is first applied to the contact surface of either side where the cover part 10 and the tub part 20 are in contact with each other. In this embodiment, it is applied to the upper surface of the flange 26 of the tub part 20 in contact with the lower surface of the upper plate 12 of the cover part 10 . Unlike this embodiment, any other method capable of exhibiting a predetermined adhesive force by contacting each other may be used.

As the adhesive 40, it is preferable to use a solvent-type adhesive resin capable of hot-melt bonding of a polyurethane compound, an acrylic gel compound, an epoxy gel compound, and the like. Alternatively, the adhesive 40 made of any other material that is cured on the adhesive surface and exhibits a predetermined adhesive force may also be used.

When the application of the adhesive 40 is completed, the upper surface of the flange 26 and the lower surface of the upper plate 12 are brought into contact with each other and the adhesive 40 is cured. When the adhesive 40 is cured, a predetermined adhesive force is exerted so that the lid part 10 and the tub part 20 do not separate from each other, thereby completing the manufacture of the bathtub 1 .

The bathtub 1 manufactured as described above may be installed as shown in FIG. 6 . At this time, on the side of the bathtub part 20 that is not covered by the wall of the bathroom, a wall 2 having a design suitable for the interior or the cover part 10 of the bathroom may be installed and constructed to improve aesthetics.

The bathtub manufacturing method as described above does not strictly require precision or quality standards for the part not exposed to the user's view in manufacturing the complex-shaped tub part 20, so mass production is possible and quality control costs are reduced. can do.

In addition, since the cover part 10 exposed to the user's view is separately manufactured and then assembled, it can be manufactured in various colors according to the user's request, and the bathtub is not completely demolished to install a bathtub of a different color, such as remodeling. There is an advantage that the user can be satisfied by reconstructing only the cover portion 10 without the need to do so.

Hereinafter, a method for manufacturing a bathtub according to a second embodiment of the present invention will be described. Except for the coating layer forming step (S3) and the separating step (S5), it is the same as the first embodiment, and thus a detailed description thereof will be omitted.

7, between the release agent application step (S1) and the coating layer forming step (S3) for forming the coating layer 30 of the cover part 10, a specific pattern is printed between the release agent and the coating layer 30. and a printing step for transferring a specific pattern to the surface of the coating layer 30 by arranging the transfer paper so that the transfer surface of the transfer paper faces the coating layer 30 .

In the printing step, the operator attaches the transfer paper 35 on which a specific pattern is printed to the molding surface of the mold for the cover part to which the release agent is applied. At this time, it is attached so that the transfer surface on which a specific pattern is printed is exposed to the cavity.

Thereafter, the coating layer forming step (S3) may be performed by applying a coating material to the surface of the transfer surface 35 exposed to the cavity.

The separation step (S5) may include a transfer paper removal step of removing the transfer paper from the cover part 10 separated from the cover part mold. By performing a transfer paper removal step of removing the transfer paper 35 from the cover portion 10, the cover portion 10 in a state in which a specific pattern is transferred is completed. In addition, in the transfer paper removal step, a specific pattern of more precise print quality can be printed by removing the transfer paper after heat-treating the surface at 180° C. or higher while the transfer paper 35 is attached to the upper plate 10 .

On the other hand, when the transfer paper is made of the same material as the coating material, it is possible to omit the removal step by not removing the transfer paper, as well as to print a clearer specific pattern and to form a smoother surface of the cover part 10 . can

As described above, the decoration step (S3) using the transfer paper 35 has an advantage in that it is possible to manufacture the bathtub 1 of more various designs by printing complex shapes, photos, patterns, etc. on the surface of the cover part.

Hereinafter, a method for manufacturing a bathtub according to a third embodiment of the present invention will be described.

A detailed description will be omitted since it is the same as the first embodiment except for the coating layer forming step (S3).

Referring to Figure 8, the coating layer forming step (S3) for forming the cover portion in the bathtub manufacturing method according to the third embodiment of the present invention is a first coating layer 36 that provides a cushioning feeling to the user, and improving aesthetics in use. The second coating layer 37 is sequentially applied.

The first coating layer 36 is formed by the operator applying the coating material to the molding surface of the mold for the cover part to which the release agent is applied when the release agent application step (S1) is completed. At this time, the coating material for forming the first coating layer 36 is the same as the coating material described in the first embodiment, but has a transparent color.

The second coating layer 37 is formed by applying a coating material for forming the second coating layer 37 on the surface of the first coating layer 36 when the formation of the first coating layer 36 is completed. At this time, the coating material for forming the second coating layer 37 is toned to a specific color by adding the color chip 32 as described in the first embodiment, and at the same time, a reflector 38 is added to reflect light from the outside. It makes the production possible.

At this time, the reflector 38 may be any glass beads, silver foil paper, metal fiber material, etc. may be used.

As described above, in the bathtub manufactured by the method for manufacturing a bathtub according to the third embodiment of the present invention, the cover part 10 has a sparkling effect by transmitting the reflected light from the reflector 38 to the outside through the first coating layer 36 . It has the advantage of being able to produce

Although the method for manufacturing a bathtub according to the present invention described above has been described with reference to an example shown in the drawings, this is merely an example, and those of ordinary skill in the art may make various modifications and equivalent other embodiments therefrom. You will understand that it is possible. Accordingly, the scope of true technical protection of the present invention should be defined by the technical spirit of the appended claims.

1: bathtub 10: cover part
20: tank part 30: coating layer
40: adhesive

Claims (7)

A release agent application step of applying a release agent to each molding surface of the mold for the cover part and the mold for the tub part each provided with cavities having the shapes of the cover part of the bathtub and the tub part of the bathtub;
a coating layer forming step of forming a coating layer by applying a coating material to the surface of the mold release agent of the cover mold and the tub mold;
a molding step of injecting a molding material into the respective cavities of the cover mold and the tub mold to mold the lid body and the tub body;
a separation step of separating the cover part and the tub part manufactured in the forming step from the cover part mold and the tub part mold;
An assembling step of assembling the cover part and the tub part to manufacture a bathtub; including,
The coating material or the molding material is mixed with a color chip for toning,
In the coating layer forming step for molding the cover part, when the release agent application step is completed, a first coating layer providing a cushioning feeling to the user is applied to the molding surface to which the release agent is applied, and a second coating layer is applied to the surface of the first coating layer. and
The coating material for forming the first coating layer is a transparent color,
The coating material for forming the second coating layer is a bathtub manufacturing method, characterized in that the light-reflecting reflector is added. The method of claim 1,
The molding material is a bathtub manufacturing method, characterized in that the resin and at least one or more of stone powder, calcium carbonate, and glass fiber for forming a pattern are mixed. The method of claim 1,
The coating material is a bathtub manufacturing method, characterized in that it contains at least one of a polyurethane compound, an acrylic gel compound, and an epoxy gel compound. The method of claim 1,
The molding step is a bathtub manufacturing method, characterized in that curing the molding material at 60 to 100 ℃. The method of claim 1,
In the assembling step, an adhesive is applied to a contact surface on either side of the cover and the tub part in contact with each other, and the cover part and the tub part are adhered to each other. The method of claim 1,
Between the release agent application step and the coating layer forming step for forming the coating layer of the cover part, a transfer paper on which a specific pattern is printed between the release agent and the coating layer is disposed so that the transfer surface of the transfer paper faces the coating layer, and the coating layer Bath manufacturing method, characterized in that it further comprises a printing step for transferring the specific pattern on the surface of the. 3. The method of claim 2,
The molding material for molding the cover part comprises that the calcium carbonate is mixed with the resin,
A molding material for molding the tub part is made of the resin, or a method for manufacturing a bathtub, characterized in that it comprises a mixture of the glass fiber with the resin.

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