JPH0418329A - Bathtub manufacturing method and mold - Google Patents

Abstract

PURPOSE:To mold even a bathtub having an overhanging section to the outside on a sidewall without using a split mold particularly by forming a section for molding the overhanging section of a molding die on the inner surface of the bathtub by a flexible material and deflecting said section to the inside on mold release. CONSTITUTION:A molding die 22 is composed of a continuous surface layer 24 consisting of an elastic body such as a rubber and a backup layer 26 backing up the surface layer 24 on the rear side of the surface layer 24 and made up of a curing material such as wood. The molding die 22 has an expanding section 27 for molding an overhanging section 18 in a bathtub 10. A bathtub forming material such as a resin is laminated and molded on the surface of the molding die 22 by using such a molding die 22, thus molding said overhanging section 18, an armrest section 20, on the sidewall 14a of the bathtub 10 at the same time as molding of the bathtub 10. When the molding material is cured and a molded form is mold-released, backup molds 28 are removed, and the expanding section 27 is deflected in the inward direction, thus easily mold- releasing the molded form from the molding die 22.

Description

[Detailed Description of the Invention] (!!1 Field of Industrial Application) The present invention relates to a method for manufacturing a bathtub and a mold, and more specifically, a method for manufacturing a bathtub in which a part of the side wall extends outward. and regarding molds.

(Prior Art) One type of bathtub has an armrest on a side wall. Figures 6 and 7 show an example.
As shown in the figure, in the case of this type of conventional bathtub with an armrest, a portion of the side wall 100 from the intermediate height position to the upper edge protrudes outward, and an armrest portion 1 is formed on the inner surface of the side wall 100.
02 was set up.

The reason why the armrest portion 102 is conventionally provided in this form is to solve the problem of demoldability when removing a molded bathtub from a mold. That is, for example, if a part of the side wall below the upper edge of the side wall is partially extended outward by a predetermined distance and an armrest part is formed on the inner surface of the part, the molded product (bathtub) is The mold cannot be removed from the inner mold, so in consideration of removability, the entire part from the middle part of the side wall to the upper edge, that is, the part on the opening side of the bathtub, is removed. It protrudes outward to form an armrest.

(Problem to be solved by the invention!!) However, when the armrest portion is provided in this manner, the width of the flange portion 104 at the upper edge of the bathtub becomes narrower, making the bathtub look flimsy. Otherwise, the width of the bottom 106 of the bathtub becomes narrow, making it feel cramped.

Of course, if the mold is a split mold, demolding is possible even when an armrest portion is provided by partially projecting outward only the intermediate portion that does not reach the upper end edge of the side wall. However, if the molds are split molds, the molding material will get into the gaps between the molds, causing debris to form there, making the inner surface of the bathtub dirty, or requiring a lot of effort to finish it. It takes.

(Means for Solving the Problems) The present invention has been made to solve the above problems, and the gist thereof is to use a flexible material as a part for molding the overhang of a mold for molding the inner surface of a bathtub. The molded product is removed from the mold by bending the portion for molding the overhang inward after molding the bathtub.

(Operations and Effects of the Invention) As described above, in the present invention, the part for molding the protruding part of the mold on the inner surface of the bathtub is formed of a flexible material, and the part is bent inward when demolding. .

In this way, even if an outwardly projecting portion is formed on the side wall, and even if the shape of the projecting portion does not reach the opening at the upper edge of the bathtub, the bathtub molded product can be moved into the molding die. It can be easily demolded from the mold. In other words, according to the present invention, it becomes possible to mold a bathtub having this type of outwardly projecting portion on the side wall without using a split mold.

When the overhang part is formed in this manner, the width of the flange part and the width of the bottom part are not narrowed in any way. Therefore, when the armrest part is formed on the inner surface side by forming the overhang part in this form, the bathtub is It can be luxurious, spacious and relaxing.

The part for forming the overhang is made of flexible material.

It is necessary to maintain a predetermined shape during bathtub molding. Various means can be used as the shape-retaining means. For example, gas, liquid,
The shape can be maintained by applying pressure using powder (including sand, etc.) as a medium, or alternatively, the shape can be maintained by applying a backup mold to the inside of the part for forming the overhang. You can also do it.

As described above, according to the present invention, it is possible to mold a bathtub having an outwardly projecting portion at the middle portion of the side wall without using a split mold. In this case, since no cracks are generated along the mW(7) parting line on the inner surface of the bathtub, the inner surface of the bathtub can be finished with a beautiful surface without any special finishing process.

(Example) Next, embodiments of the present invention will be described in detail based on the drawings.

In FIGS. 2 and 3, 10 is an FRP bathtub, which has a bottom 12, sides 1q14a, 14b, and a flange 16 at the upper edge of the side wall.

The pair of side walls 14a are provided with projecting portions 18 that partially project outward at a certain distance below their upper edges, and an armrest portion for resting the arms on the inner surface of the projecting portions 18. 20 is formed.

FIG. 1 shows the configuration of a mold for molding the inner surface of this bathtub 10. As shown in the figure, this mold 22 has a continuous surface layer 24 made of an elastic material such as rubber, and a back surface layer 24. It consists of a back-up layer 26 made of hard material such as wood to back up this.

This mold 22 has an overhanging portion 18 in the bath [10].
It has a bulge 27 for molding. In this bulging portion 27, the backup layer 26 is not provided and 1
Instead, a backup mold 28 made of a hard material is removably attached, and the convex surface of the backup mold 28 is attached to the surface layer 2 through a flexible reinforcement M30 made of cloth, wire, etc.
It is placed on the back of number 6.

By laminating and molding a bathtub forming material such as a resin on the surface of the mold 22 using such a mold 22, as shown in FIG.
The overhanging portion 18, that is, the armrest portion 20 can be formed on the portion a. When demolding the molded product after the molding material has hardened, the backup mold 28 is removed as shown in the same figure, and the bulging portion 27 is moved to the arrow P in the figure.
By bending inward as shown by , the molded product can be easily removed from the mold 22 . The bathtub lO formed in this way has a flange portion 16. despite the presence of the armrest portion 20. The width of the bottom portion 12 is not narrowed in any way.

In addition, when the outer surface of the bathtub 10 is molded using the outer surface molding die 32 as shown in FIG. ), its outer mold 3
Regarding 2, a split mold consisting of the split molds 32a, 32a can be used, and in this case, even if flakes occur on the outer surface of the bathtub 10, there is no particular problem because the outer surface of the bathtub 10 is not exposed to the outside in the installed state.

Alternatively, as shown in FIG. 5, pressure is applied from inside the bulge 18 using gas, liquid, or powder as a medium without using the backup mold 28 as described above, thereby forming a flexible bulge. It is also possible to maintain the shape of the portion 18.

In addition, in the method using the backup mold 28 shown in FIG. 1, since the shape of the surface layer 24 is maintained by the backup mold 28, reinforcement made of cloth or the like is not required. ! i! It is also possible to omit 30.

In addition, the present invention can be configured and implemented in various forms based on the knowledge of those skilled in the art without departing from the spirit thereof, such as being applicable to the molding of bathtubs having overhanging portions other than those described above. It is.

[Brief explanation of drawings]

Figure 1 is a cross-sectional view of a mold that is an embodiment of the present invention;
3 are a perspective view and a sectional view, respectively, of a bathtub formed by the mold shown in FIG. 1. Figures 4 (A) and (B) are explanatory diagrams of a manufacturing method using the mold shown in Figure 1, and Figure 5 is a diagram showing a manufacturing method using the mold shown in Figure 1. 6 and 7 are a perspective view and a sectional view of a conventionally known bathtub with an armrest. 10: Bathtub 14a, 14b: Side wall 18: Overhanging part 20 Near-mrest part 22: Molding mold
24. Surface layer 26: Hack-up layer 27. Bulging portion 282 Backup type 30: Reinforcement layer Fig. 1 Patent applicant Inax Co., Ltd. Fig. CB) Fig. (A) Fig.

Claims (4)

[Claims] (1) A method for manufacturing a bathtub in which a part of the side wall partially protrudes outward, wherein at least a portion of a mold for forming the inner surface of the bathtub is flexible. 1. A method of manufacturing a bathtub, the method comprising: molding the bathtub, and removing the molded product by bending inward a portion for molding the overhang after the bathtub is molded. (2) The bathtub manufacturing method according to claim (1), wherein the bathtub is an FRP bathtub. (3) A mold for molding the inner surface of a bathtub in which a part of the side wall partially protrudes outward, at least a portion for forming the protrusion part is made of a flexible material, and 1. A mold for a bathtub, characterized in that the portion for molding the overhang portion is bent inward during molding. (4) The mold for a bathtub according to claim (3), wherein the bathtub is an FRP bathtub.