Integrated environment-friendly toilet for motor home and manufacturing process thereof

Abstract

The application provides a house car integrated environment-friendly toilet and a manufacturing process thereof. The house car integrated environment-friendly toilet comprises an inner wall, an outer wall and a base. The inner wall and the outer wall are both structures penetrating from top to bottom and being closed at the outer periphery. The outer periphery of the base is fixedly connected with the bottom of the inner wall. The inner wall, the outer wall and the base are formed as a whole by pouring foaming material between the inner wall and the outer wall. The integrated toilet has the advantages of light weight, good waterproof and heat preservation performance, convenient standardized and modularized design and manufacturing, environment-friendly manufacturing process and wide market prospect.

Description

Technical Field

[0001] This invention belongs to the field of RV interior facilities technology, and specifically relates to an integrated environmentally friendly toilet for RVs and its manufacturing process. Background Technology

[0002] Nowadays, with the improvement of living standards, RVs have become quite common in people's lives. People can go to the countryside with their families or friends to spend leisure time. A toilet is an essential facility in an RV, and the core requirements for an RV toilet are: waterproof, heat insulation, environmental protection, and lightweight. Existing RV toilets are typically assembled from multiple structural pieces, a complex process that hinders modular design. Furthermore, the method of sealing and waterproofing through adhesive at the joints is prone to aging and deformation over time, leading to leaks. The applicant previously disclosed an integrated RV toilet and its manufacturing process in patent CN 110001500 A. While its base and side walls are integrated and offer good waterproofing, the inner and outer panels of the base and side walls are made of fiberglass, with foam board filling the spaces between them. Fiberglass is known to be heavy and has poor insulation, while foam board offers only average insulation. More importantly, the fiberglass manufacturing process releases large amounts of toxic substances, seriously impacting worker health and contradicting the current trend towards energy conservation and environmental protection.

[0003] In conclusion, there is an urgent need to develop an integrated environmentally friendly toilet for RVs and its manufacturing process to solve the aforementioned technical problems. Summary of the Invention

[0004] In view of this, the present invention provides an integrated environmentally friendly toilet for RVs and its manufacturing process, which can at least partially solve the problems existing in the prior art. To achieve the above objectives, the technical solution adopted by the present invention is as follows: An integrated eco-friendly toilet for RVs includes an inner wall, an outer wall, and a base. The inner wall and the outer wall are both vertically continuous and externally closed. The outer periphery of the base is fixedly connected to the bottom of the inner wall. An insulation layer is formed by pouring foam material between the inner wall and the outer wall. The foam material makes the inner wall, the outer wall, and the base a whole.

[0005] In a preferred embodiment, both the inner and outer walls are made of plastic panels and are formed by bending to create a structure that is vertically continuous and has openings on the sides. The side openings of the inner and outer walls are respectively closed by connectors. The base includes an integrally formed upper part and a lower part. The upper part of the base is formed by plastic vacuum forming, and the lower part of the base is filled with foam material.

[0006] As a further preferred embodiment, the upper surface of the base is configured to be low in the middle and high at the outer perimeter, and a groove is provided at the outer perimeter edge of the base. The groove accommodates the lower end of the inner wall and is fixedly connected to the inner wall by welding.

[0007] As a further preferred embodiment, the outer perimeter of the base is slightly larger than the outer perimeter of the inner wall.

[0008] As a further preferred option, the materials of the inner wall, outer wall and upper part of the base are all high-gloss white plastic, and the inner wall and outer wall are fixed with embedded parts before pouring.

[0009] This invention also discloses a manufacturing process for an integrated environmentally friendly toilet for RVs, characterized by the following steps: (1) Make the base by using vacuum forming process to make the upper part of the base, and use foaming process to fill the lower part of the base and form a whole with the upper part; (2) Make interior and exterior walls by bending plastic panels into interior and exterior walls of a predetermined shape and size. (3) Apply the inner wall to the outer surface of the inner wall and seal the side openings with the connectors; apply the outer wall to the inner surface of the outer wall and seal the side openings with the connectors. (4) The base and the inner wall are welded together. The upper part of the base is placed on the upper end of the inner mold in the preset position, and the base is welded and fixed to the inner wall through the outer periphery of the upper part of the base. (5) Mold assembly and casting: The inner mold and the outer mold are assembled, and the rigid polyurethane foam composite material is poured between the inner wall and the outer wall under the preset parameter conditions to start foaming; (6) Demolding: Remove the foamed whole from the inner and outer molds and turn it over so that the base is facing down and placed normally; (7) Cutting: Cut the bathroom semi-finished product formed in step (6) to reserve space for the assembly of other structures.

[0010] As a further preferred option, an inspection process is provided between steps (6) and (7), requiring that the surface of the bathroom semi-finished product formed in step (6) must not have bulges or deformations, the visible surface must not have pits or scratches, and the dimensions must meet the predetermined requirements.

[0011] As a further preferred option, step (7) is followed by the following steps: (8) Baking: Place the cut whole piece into the baking room and bake it according to the preset parameters; (9) Assembly: Assemble the necessary parts for use in the bathroom; (10) Cleaning: Clean the assembled finished product; (11) Final inspection: to conduct a final inspection of the product's conformity.

[0012] As a further preferred option, the rigid polyurethane foam composite material used in the molding and casting process in step (5) is divided into material A and material B, and the preset parameters are: ambient temperature is 16°-35°, the temperature of material A and material B before mixing is 20°-40° respectively, the circulating pressure of material A is 0.6-1.2Mpa, the casting pressure is 1.0-1.5Mpa, the circulating pressure of material B is 1.0-1.5Mpa, the casting pressure is 1.5-2.0Mpa, the ratio of material A and material B during casting is between 1:1.5 and 1:1, the casting time is 40-60s, and the pressure holding time after casting is 30-50min.

[0013] As a further preferred option, the preset parameters for the baking process in step (8) are: baking temperature 65°-75°, baking time 3-5h, and the product must not bulge or crack after baking.

[0014] Compared with the prior art, the present invention has the following significant advantages: 1. The interior and exterior walls and the upper part of the floor are all made of plastic, which is lightweight and the manufacturing process is more environmentally friendly; 2. The bathroom structure is integrally formed by pouring foam material between the inner and outer walls, resulting in high strength and excellent waterproof and thermal insulation performance; 3. Facilitates standardized and modular design and manufacturing. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the overall structure of the present invention; Figure 2 for Figure 1 Top view; Figure 3 for Figure 2 Sectional view along line AA; Figure 4 for Figure 3 A magnified view of a section at point I; Figure 5 This is a schematic diagram of the structure of the base of the present invention; Figure 6 This is a schematic diagram of the structure of the inner mold of the present invention; Figure 7 This is a schematic diagram of the structure of the base and inner wall welded together in the manufacturing process of this invention; Figure 8 This is a schematic diagram of the structure after mold closing in the manufacturing process of this invention; Figure 9 This is a flowchart of the manufacturing process of the present invention.

[0016] Attached reference numerals: 100 Integrated eco-friendly toilet, 110 Inner wall, 120 Outer wall, 130 Base, 131 Upper part of base, 1311 Groove, 132 Lower part of base, 140 Foaming material, 200 Inner mold, 300 Outer mold. Detailed Implementation

[0017] Embodiments of the present invention are described in detail below. Examples of these embodiments are illustrated in the accompanying drawings, wherein the same or similar reference numerals denote the same or similar elements or elements having the same or similar functions throughout. The embodiments described below with reference to the accompanying drawings are exemplary and intended to explain the present invention, and should not be construed as limiting the present invention.

[0018] The present invention will be described in detail below with reference to the accompanying drawings and specific embodiments. For the sake of simplicity, doors and other internal components are omitted from the drawings.

[0019] like Figures 1 to 8 As shown, an integrated eco-friendly toilet 100 for RVs includes an inner wall 110, an outer wall 120, and a base 130. The inner wall 110 and the outer wall 120 are both vertically continuous and externally closed. The outer periphery of the base 130 is fixedly connected to the bottom of the inner wall 110. A thermal insulation layer is formed by pouring foam material 140 between the inner wall 110 and the outer wall 120, and the inner wall 110, the outer wall 120, and the base 130 are formed into a whole by the foam material 140.

[0020] In a preferred embodiment, both the inner wall 110 and the outer wall 120 are made of plastic panels and are formed by bending to create a structure that is vertically continuous and has openings on the sides. The side openings of the inner wall 110 and the outer wall 120 are closed by connectors, which can be sealed by plastic welding. This manufacturing method is low-cost, efficient, and meets the usage requirements. The base 130 includes an integrally formed upper part 131 and a lower part 132. The upper part 131 of the base is formed by plastic vacuum forming, and the lower part 132 of the base is filled with foam material. Alternatively, the inner wall 110 and the outer wall 120 can also be integrally injection molded. This manufacturing method has high strength, good sealing, and is more aesthetically pleasing, but it is difficult and costly to manufacture due to limitations in structural dimensions and process requirements.

[0021] As a further preferred option, the surface of the upper part 131 of the base is set to be low in the middle and high on the outer perimeter, so that water can flow out from the drain in the middle. A groove 1311 is provided on the outer perimeter edge of the base. The groove 1311 accommodates the lower end of the inner wall 110 and is fixed to the inner wall 110 by welding.

[0022] As a further preferred option, the outer periphery of the base 130 is slightly larger than the outer periphery of the inner wall 110, which facilitates the insertion of the groove 1311 of the base into the outer periphery of the inner wall 110, and also facilitates subsequent casting between the inner wall 110 and the outer wall 120.

[0023] As a further preferred option, the materials of the inner wall 110, the outer wall 120 and the upper part of the base 131 are all high-gloss white plastic. High-gloss white plastic has a good smoothness, excellent waterproof performance and beautiful appearance. In addition, the inner wall 110 and the outer wall 120 are fixed with embedded parts before pouring. The purpose of the embedded parts is to facilitate the subsequent installation of the required components such as washbasins and shower heads.

[0024] like Figure 9 As shown, the present invention further discloses a manufacturing process for an integrated environmentally friendly toilet for RVs, specifically including the following steps: (1) Making the base. The upper part 131 of the base is made of plastic using vacuum forming process, and the lower part 132 of the base is filled using foaming process and formed into a whole with the upper part 131.

[0025] (2) Making the inner and outer walls. The plastic sheet is made into an inner wall 110 and an outer wall 120 of a preset shape and size by bending process. The inner wall 110 and the outer wall 120 are connected vertically and open on the side. Since the bathroom in this embodiment has 5 sides, the inner and outer walls need to be bent multiple times.

[0026] (3) Sealing the inner and outer walls. The inner wall 110 is attached to the outer surface of the inner mold 200 and its side opening is closed by the connector. The outer wall 120 is attached to the inner surface of the outer mold 300 and its side opening is closed by the connector. Since the bending process is used, there will inevitably be openings on the sides of the inner and outer walls after bending. After attaching the inner wall 110 and the outer wall 120 to the corresponding molds respectively, the openings are closed by the connector, that is, sealing the edges. Sealing the edges can prevent the material from flowing out from the opening when the foaming material 140 is poured later. Attaching the inner and outer walls to the molds first and then sealing the edges can ensure the required dimensional accuracy of the inner and outer walls and prevent dimensional deformation after sealing the edges.

[0027] (4) Welding the base and the inner wall. Place the upper part 131 of the base downwards at the preset position on the upper end of the inner mold 200, and weld it to the inner wall 110 through the outer periphery of the upper part 131 of the base. The plastic welding process is used to ensure that there is sufficient connection strength between the base 130 and the inner wall 110.

[0028] (5) Mold assembly and casting. The inner mold 200 and the outer mold 300 are assembled, and the rigid polyurethane foam composite material is poured into the space between the inner wall 110 and the outer wall 120 under the preset parameter conditions to start foaming. During the entire foaming process, the foaming material 140 will gradually fill the space between the inner wall 110 and the outer wall 120.

[0029] (6) Demolding. Remove the foamed whole from the inner and outer molds and turn it over so that the base 130 is facing down and placed normally to facilitate subsequent processes.

[0030] (7) Inspection. The bathroom semi-finished products placed in step (6) shall be inspected. There shall be no bulges or deformations, no pits or scratches on the visible surfaces, and a small number of pits and scratches are allowed on the non-visible surfaces. The dimensions shall meet the predetermined requirements.

[0031] (8) Cutting. Cut the bathroom semi-finished product that has passed the inspection in step (7) to make room for the assembly of other structures, such as bathroom doors.

[0032] (9) Baking. Place the cut whole piece into the baking room and bake it according to the preset parameters.

[0033] (10) Assembly. Assemble the necessary parts for the bathroom, including the door, shower head, and sink.

[0034] (11) Cleaning. Clean the assembled finished product.

[0035] (12) Final inspection. Conduct a final inspection to verify the conformity of the products. Products that pass the inspection are sent to the warehouse for storage or shipped directly.

[0036] It is worth noting that there is no necessary order between steps (1) and (2) above. Either step can be completed first or both can be performed simultaneously.

[0037] In a preferred embodiment, the rigid polyurethane foam composite material used in the molding and casting process of step (5) is divided into component A and component B. Both component A and component B contain multiple components and are liquids. This material is a mature existing technology in the foaming field and will not be described in detail here. The ambient temperature is 16°-35°. The temperatures of component A and component B before mixing are 20°-40°. The circulating pressure of component A is 0.6-1.2 MPa and the casting pressure is 1.0-1.5 MPa. The circulating pressure of component B is 1.0-1.5 MPa and the casting pressure is 1.5-2.0 MPa. The ratio of component A to component B during casting is between 1:1.5 and 1:1. The casting time is 40-60 seconds, and the holding time after casting is 30-50 minutes.

[0038] As a preferred embodiment, the preset parameters for the baking process in step (9) are: baking temperature 65°-75°, baking time 3-5h, and the baked product must not bulge or crack and deform.

[0039] In the description of this invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings, and are only for the convenience of describing this invention, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation, and therefore should not be construed as a limitation of this invention. Furthermore, the terms "first" and "second" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0040] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," and "linking" should be interpreted broadly. For example, they can refer to fixed connections or detachable connections; mechanical connections or electrical connections; direct connections or indirect connections through an intermediate medium; and internal connections between two components. Those skilled in the art can understand the specific meaning of these terms in this invention based on the specific circumstances.

[0041] The above embodiments merely illustrate the basic principles and characteristics of the present invention. The present invention is not limited to the above embodiments. Various changes and modifications can be made to the present invention without departing from its spirit and scope, and all such changes and modifications fall within the scope of the present invention as claimed. The scope of protection of the present invention is defined by the appended claims and their equivalents.

Claims

1. The manufacturing process of an integrated eco-friendly toilet for RVs, characterized in that, Includes the following steps: (1) Make the base by using vacuum forming process to make the upper part of the base, and use foaming process to fill the lower part of the base and form a whole with the upper part; (2) Make interior and exterior walls by bending plastic panels into interior and exterior walls of a predetermined shape and size. (3) Apply the inner wall to the outer surface of the inner wall and seal the side openings with the connectors; apply the outer wall to the inner surface of the outer wall and seal the side openings with the connectors. (4) The base and the inner wall are welded together. The outer periphery of the base is provided with a groove. The upper part of the base is placed on the upper end of the inner mold in the preset position. The groove accommodates the lower end of the inner wall and is welded to the inner wall through the upper periphery of the base. (5) Mold assembly and casting: The inner mold and the outer mold are assembled, and the rigid polyurethane foam composite material is poured between the inner wall and the outer wall under the preset parameter conditions to start foaming; (6) Demolding: Remove the foamed whole from the inner and outer molds and turn it over so that the base is facing down and placed normally; (7) Cutting: Cut the bathroom semi-finished product formed in step (6) to reserve space for the assembly of other structures.

2. The manufacturing process of the integrated environmentally friendly toilet for RVs according to claim 1, characterized in that: There is also an inspection process between steps (6) and (7), which requires that the surface of the bathroom semi-finished product formed in step (6) must not have bulges or deformations, the visible surface must not have pits or scratches, and the dimensions must meet the predetermined requirements.

3. The manufacturing process of the integrated environmentally friendly toilet for RVs according to claim 1, characterized in that, Step (7) is followed by the following steps: (8) Baking: Place the cut whole piece into the baking room and bake it according to the preset parameters; (9) Assembly: Assemble the necessary parts for use in the bathroom; (10) Cleaning: Clean the assembled finished product; (11) Final inspection: to conduct a final inspection of the product's conformity.

4. The manufacturing process of the integrated environmentally friendly toilet for RVs according to claim 1, characterized in that, In step (5), the rigid polyurethane foam composite material used in the mold-closing and casting process is divided into material A and material B, and the preset parameters are: ambient temperature is 16°-35°, the temperature of material A and material B before mixing is 20°-40° respectively, the circulating pressure of material A is 0.6-1.2Mpa, the casting pressure is 1.0-1.5Mpa, the circulating pressure of material B is 1.0-1.5Mpa, the casting pressure is 1.5-2.0Mpa, the ratio of material A and material B during casting is between 1:1.5 and 1:1, the casting time is 40-60s, and the pressure holding time after casting is 30-50min.

5. The manufacturing process of the integrated environmentally friendly toilet for RVs according to claim 3, characterized in that, The preset parameters for the baking process in step (8) are: baking temperature 65°-75°, baking time 3-5h, and the product must not bulge or crack after baking.

Images