Production process of integrated bathroom

Abstract

The invention discloses a production and manufacturing process of an integrated bathroom, and aims to provide the production and manufacturing process of the integrated bathroom which is simple and rapid in bathroom wall installation, capable of realizing rapid installation and small in occupied space. The method comprises the following steps: S1, respectively manufacturing a bathroom unit body a, a bathroom unit body b, a bathroom unit body c, a bathroom unit body d, a bathroom unit body e, a bathroom unit body f and a plurality of U-shaped connecting pieces; s2, the bathroom unit bodies are fixed to the U-shaped connecting pieces correspondingly, S3, all the bathroom unit bodies are sequentially aligned, inserted and folded through the U-shaped connecting pieces, and splicing is completed; s4, the spliced U-shaped connecting pieces are reinforced through screws, and inner cavities of the U-shaped connecting pieces are filled with polyurethane polystyrene foam; and S5, performing surface polishing treatment on gap parts spliced in the step S2, the step S3 and the step S4, and applying glass cement.

Description

Technical Field

[0001] This invention relates to the field of bathroom manufacturing technology, specifically to a manufacturing process for integrated bathroom products. Background Technology

[0002] Currently, bathroom installations on the market, assuming a large external space, typically involve assembling and securing the entire bathroom frame around the outside using screws and glue before hoisting it into the desired location. Traditional bathroom installation methods suffer from several drawbacks: they cannot be installed on-site, or at least not quickly. On-site installation is difficult, especially on large, flat surfaces against walls, and the process is complex and unstable. Furthermore, many small apartments lack the space for large-scale bathroom installations. Therefore, improvements are needed from industry professionals. Summary of the Invention

[0003] The purpose of this invention is to overcome the shortcomings of the existing technology and to propose a production process for integrated bathrooms that is simple and quick to install on the wall, and can achieve rapid installation with small space occupation.

[0004] To solve the above-mentioned technical problems, the present invention provides the following technical solution:

[0005] A manufacturing process for integrated bathroom fixtures, characterized by the following steps:

[0006] S1. Preliminary preparation: Produce bathroom unit a, bathroom unit b, bathroom unit c, bathroom unit d, bathroom unit e, bathroom unit f, and several U-shaped connectors respectively;

[0007] S2. Assembly: Fix both ends of bathroom unit a and bathroom unit b to the U-shaped connectors respectively. One end of the U-shaped connector is parallel to the bathroom unit and the opening faces outward. The other end of the U-shaped connector is perpendicular to the bathroom unit and the opening faces inward. Fix both ends of bathroom unit c and bathroom unit d to the U-shaped connectors respectively. Both ends of the U-shaped connectors are parallel to the bathroom unit and the opening faces outward. Fix one end of bathroom unit e and bathroom unit f to the U-shaped connectors. The U-shaped connectors are perpendicular to the bathroom unit and the opening faces inward.

[0008] S3. Assembly: Align and connect the parallel U-shaped connectors of bathroom unit a and bathroom unit b to complete the assembly of bathroom unit a and bathroom unit b; align and connect the vertically arranged U-shaped connector of bathroom unit a with the U-shaped connector on bathroom unit c to complete the assembly of bathroom unit a and bathroom unit c; align and connect the vertically arranged U-shaped connector of bathroom unit b with the U-shaped connector on bathroom unit d to complete the assembly of bathroom unit b and bathroom unit d; align and connect the vertically arranged U-shaped connector of bathroom unit e with the U-shaped connector at the other end of bathroom unit c to complete the assembly of bathroom unit e and bathroom unit c; align and connect the vertically arranged U-shaped connector of bathroom unit f with the U-shaped connector at the other end of bathroom unit d to complete the assembly of bathroom unit f and bathroom unit d.

[0009] S4. Connection reinforcement: Reinforce the sides of all U-shaped connectors after splicing with self-tapping screws and fill the inner cavity of all U-shaped connectors after splicing with polyurethane foam.

[0010] S5. Aesthetic treatment: Polish the surface of the gaps in the splicing in steps S2, S3 and S4 and apply glass glue.

[0011] Preferably, the manufacturing of the bathroom unit a, bathroom unit b, bathroom unit c, bathroom unit d, bathroom unit e, and bathroom unit f includes the following steps:

[0012] A. Select galvanized steel sheet flat plate, and process the galvanized steel sheet flat plate by shearing machine. The shearing machine cuts out strips of the required size, and then the strips are bent into shape by bending machine to obtain a main keel frame with two long and two short sections that meet the size requirements.

[0013] B. Select galvanized steel pipes and cut them into three connecting skeletons that meet the size requirements using a sawing machine.

[0014] C. Select galvanized steel sheet flat plate, and use a shearing machine to cut the galvanized steel sheet flat plate into ten connecting pieces that meet the size requirements;

[0015] D. First, weld the two long and two short main keel frames with a welding machine to form a cuboid main keel frame. Then, weld the connecting frame to the short main keel frame with a welding machine, and weld the connecting piece to the long main keel frame with a welding machine. This will result in a bathroom unit frame that meets the requirements.

[0016] E. Fill the bathroom unit frame with polyurethane filler and polish and shape the inner and outer sides of the bathroom unit frame.

[0017] F. Finally, marble or ceramic tiles are attached to the inside of the bathroom unit frame to obtain bathroom unit a, bathroom unit b, bathroom unit c, bathroom unit d, bathroom unit e, and bathroom unit f that meet the requirements.

[0018] Preferably, the bathroom unit a and bathroom unit b are the same size, the bathroom unit c and bathroom unit d are the same size, and the bathroom unit e and bathroom unit f are the same size.

[0019] Preferably, the dimensions of bathroom unit c and bathroom unit d are larger than those of bathroom unit a and bathroom unit b, and larger than those of bathroom unit e and bathroom unit f.

[0020] Preferably, the manufacturing process of the U-shaped connector includes the following steps: A. First, select a galvanized steel plate and shear the galvanized steel plate using a shearing machine to obtain strips of the required size; B. Next, punch holes in the strips using a punch press; C. Then, bend both sides of the strips using a bending machine; D. Finally, grind and polish to obtain a U-shaped connector that meets the requirements.

[0021] Preferably, the U-shaped connector includes a U-shaped female connector and a U-shaped female connector, wherein the size of the U-shaped female connector is larger than the size of the U-shaped female connector.

[0022] Preferably, both ends of the bathroom unit a are fixed with connecting female parts, the bathroom unit b is fixed with a connecting female part at one end parallel to it and a connecting female part at the other end vertically, both ends of the bathroom unit c and bathroom unit d are fixed with connecting female parts, and one end of the bathroom unit e and bathroom unit f is fixed with a connecting female part.

[0023] Preferably, the length, width and height of the galvanized steel plate are 2200mm, 1250mm and 1mm respectively, the shearing machine is a high-precision CNC shearing machine and the bending machine is a high-precision CNC bending machine.

[0024] Preferably, the welding machine is a carbon dioxide shielded welding machine.

[0025] Preferably, in process B, the U-shaped connector is punched with several sets of equally spaced punch holes by a punch press, and each set of punch holes includes a waist-shaped hole and a round hole.

[0026] Compared with the prior art, the beneficial effects of the present invention are:

[0027] The integrated bathroom manufacturing process of this invention reduces the bending process of bathroom walls, minimizes new damage or deformation caused by handling or logistics, allows for rapid on-site assembly or installation, and enables independent adjustment of wall gaps and inner wall height on-site; it also does not affect handling or logistics transportation, effectively reducing processing difficulty, reducing processes, improving product quality, reducing costs, facilitating rapid installation, and improving installation quality.

[0028] The integrated bathroom manufacturing process of this invention allows for rapid on-site assembly or installation in enclosed spaces or low-rise rooms. Even when the large flat surface is against a wall, the installation and assembly are not affected, and the overall stability and quality are excellent. The U-shaped connector can accommodate more glue for fixing, further improving the quality and stability. Even when installed on one side of a large flat wall, the installation speed and quality are not affected. Attached Figure Description

[0029] Figure 1 This is a process flow diagram of the present invention;

[0030] Figure 2 This is an exploded schematic diagram illustrating the manufacturing process of an integrated bathroom fixture according to the present invention.

[0031] Figure 3 This is an assembly diagram illustrating the manufacturing process of an integrated bathroom fixture according to the present invention.

[0032] Figure 4 This is a schematic diagram of the bathroom unit of the present invention;

[0033] Figure 5 This is a schematic diagram of the unfolded U-shaped connector of the present invention. Detailed Implementation

[0034] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0035] Please see Figures 1-5 A manufacturing process for integrated bathroom fixtures includes the following steps:

[0036] S1. Preliminary preparation: Produce bathroom unit a1, bathroom unit b2, bathroom unit c3, bathroom unit d4, bathroom unit e5, bathroom unit f6, and several U-shaped connectors 7.

[0037] S2. Assembly: Fix both ends of bathroom unit a1 and bathroom unit b2 to U-shaped connectors 7 respectively. One end of the U-shaped connector 7 is parallel to the bathroom unit and the opening faces outward. The other end of the U-shaped connector 7 is perpendicular to the bathroom unit and the opening faces inward. Fix both ends of bathroom unit c3 and bathroom unit d4 to U-shaped connectors 7 respectively. Both ends of the U-shaped connectors 7 are parallel to the bathroom unit and the opening faces outward. Fix one end of bathroom unit e5 and bathroom unit f6 to U-shaped connectors 7. The U-shaped connector 7 is perpendicular to the bathroom unit and the opening faces inward.

[0038] S3. Assembly: Align and insert the parallel U-shaped connectors 7 of bathroom unit a1 and bathroom unit b2 to complete the assembly of bathroom unit a1 and bathroom unit b2; align and insert the vertically arranged U-shaped connector 7 of bathroom unit a1 with the U-shaped connector 7 on bathroom unit c3 to complete the assembly of bathroom unit a1 and bathroom unit c3; align and insert the vertically arranged U-shaped connector 7 of bathroom unit b2 with the U-shaped connector 7 on bathroom unit d4. Align and connect the U-shaped connectors 7 and d4 to complete the splicing of bathroom unit b2 and bathroom unit d4; align and connect the U-shaped connector 7 vertically set on bathroom unit e5 with the U-shaped connector 7 at the other end on bathroom unit c3 to complete the splicing of bathroom unit e5 and bathroom unit c3; align and connect the U-shaped connector 7 vertically set on bathroom unit f6 with the U-shaped connector 7 at the other end on bathroom unit d4 to complete the splicing of bathroom unit f6 and bathroom unit d4.

[0039] S4. Connection and reinforcement: The sides of all U-shaped connectors 7 after splicing are reinforced with self-tapping screws and the inner cavity of all U-shaped connectors 7 after splicing is filled with polyurethane foam.

[0040] S5. Aesthetic treatment: Polish the surface of the gaps in the splicing in steps S2, S3 and S4 and apply glass glue.

[0041] The integrated bathroom manufacturing process of this invention involves the independent assembly of individual bathroom units to form a complete integrated bathroom unit. During on-site installation, each bathroom unit is assembled and installed sequentially. Even in difficult conditions such as walls on the back or sides, narrow spaces where personnel and tools cannot enter, or extremely small gaps, production or assembly can still be carried out normally. This is mainly achieved by adding positioning holes on both sides and the front and back of the main frame of the bathroom unit beforehand, and then fitting the U-shaped connectors of different sizes onto the pre-drilled waist-shaped or round screw holes. On-site, the U-shaped connectors of different sizes are fixed to the corresponding left and right frames of the bathroom unit, and the fit is flat to ensure the inner gaps are closed. Finally, self-tapping flat-head screws are used for reinforcement on the top, upper, and sides. This sequentially completes the fixed connection assembly or installation between the integrated bathroom units.

[0042] The fabrication of bathroom unit a1, bathroom unit b2, bathroom unit c3, bathroom unit d4, bathroom unit e5, and bathroom unit f6 includes the following steps:

[0043] A. Select galvanized steel plate flat sheet, and process the galvanized steel plate flat sheet by shearing machine. The shearing machine cuts out strips of the required size, and then the strips are bent into shape by bending machine to obtain a main keel frame 11 with two long and two short sections that meet the size requirements.

[0044] B. Select galvanized steel pipes and cut them into three connecting skeletons 12 that meet the size requirements using a sawing machine.

[0045] C. Select galvanized steel sheet flat plate, and use a shearing machine to cut the galvanized steel sheet flat plate into ten connecting pieces 13 that meet the size requirements;

[0046] D. First, weld the two long and two short main keel frames 11 with a welding machine to form a cuboid main keel frame 11. Then, weld the connecting frame 12 to the short main keel frame 11 with a welding machine, and weld the connecting piece 13 to the long main keel frame 11 with a welding machine to obtain a bathroom unit frame that meets the requirements.

[0047] E. Fill the bathroom unit frame with polyurethane filler and polish and shape the inner and outer sides of the bathroom unit frame.

[0048] F. Finally, marble or ceramic tile 14 is attached to the inside of the bathroom unit frame to obtain bathroom unit a1, bathroom unit b2, bathroom unit c3, bathroom unit d4, bathroom unit e5, and bathroom unit f6 that meet the requirements.

[0049] The various bathroom units differ only in size; in other words, one set of production equipment can process all types of bathroom units, reducing production difficulty and simplifying the production process. In particular, it reduces bending, welding, and assembly processes, and also saves on raw material costs to some extent.

[0050] Bathroom unit a1 and bathroom unit b2 are the same size, bathroom unit c3 and bathroom unit d4 are the same size, and bathroom unit e5 and bathroom unit f6 are the same size.

[0051] The dimensions of bathroom unit c3 and bathroom unit d4 are larger than the dimensions of bathroom unit a1 and bathroom unit b2, which are larger than the dimensions of bathroom unit e5 and bathroom unit f6. The dimensions of bathroom unit e5 and bathroom unit f6 are the smallest, leaving space for the installation of the bathroom door.

[0052] The manufacturing process of U-shaped connector 7 includes the following steps: A. First, select a galvanized steel plate and shear the galvanized steel plate using a shearing machine to obtain strips of the required size; B. Next, punch holes in the strips using a punch press; C. Then, bend both sides of the strips using a bending machine; D. Finally, grind and polish to obtain U-shaped connector 7 that meets the requirements.

[0053] The U-shaped connector 7 includes a U-shaped female connector 71 and a U-shaped female connector 72. The size of the U-shaped female connector 71 is larger than the size of the U-shaped female connector 72. The arrangement of the female and male connectors of the U-shaped connector 7 ensures the alignment and mating of the bathroom units.

[0054] Both ends of bathroom unit a1 are fixed with connecting female parts 71. Bathroom unit b2 is parallel to one end and fixed with connecting female parts 72, and vertically to one end and fixed with connecting female parts 71. Both ends of bathroom unit c3 and bathroom unit d4 are fixed with connecting female parts 72. One end of bathroom unit e5 and bathroom unit f6 is fixed with connecting female parts 71.

[0055] The length, width and height of the galvanized steel plate are 2200mm, 1250mm and 1mm respectively. The shearing machine is a high-precision CNC shearing machine and the bending machine is a high-precision CNC bending machine.

[0056] The welding machine is a carbon dioxide shielded welding machine.

[0057] In process B, the U-shaped connector 7 is punched with several sets of equally spaced punch holes 8. Each set of punch holes 8 includes a waist-shaped hole 81 and a round hole 82. The waist-shaped hole 81 is used for adjustment and the round hole 82 is used for locking. This ensures that the adjustment compensates for the errors or deviations generated during the previous production processes. It allows for on-site adjustment of the gaps between bathroom walls and the height difference between large surfaces.

[0058] Although embodiments of the invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A manufacturing process for integrated bathroom fixtures, characterized in that: Includes the following steps: S1. Preliminary preparation: Produce bathroom unit a, bathroom unit b, bathroom unit c, bathroom unit d, bathroom unit e, bathroom unit f, and several U-shaped connectors respectively; S2. Assembly: Fix both ends of bathroom unit a and bathroom unit b to the U-shaped connectors respectively. One end of the U-shaped connector is parallel to the bathroom unit and the opening faces outward. The other end of the U-shaped connector is perpendicular to the bathroom unit and the opening faces inward. Fix both ends of bathroom unit c and bathroom unit d to the U-shaped connectors respectively. Both ends of the U-shaped connectors are parallel to the bathroom unit and the opening faces outward. Fix one end of bathroom unit e and bathroom unit f to the U-shaped connectors. The U-shaped connectors are perpendicular to the bathroom unit and the opening faces inward. S3. Assembly: Align and connect the parallel U-shaped connectors of bathroom unit a and bathroom unit b to complete the assembly of bathroom unit a and bathroom unit b; align and connect the vertically arranged U-shaped connector of bathroom unit a with the U-shaped connector on bathroom unit c to complete the assembly of bathroom unit a and bathroom unit c; align and connect the vertically arranged U-shaped connector of bathroom unit b with the U-shaped connector on bathroom unit d to complete the assembly of bathroom unit b and bathroom unit d; align and connect the vertically arranged U-shaped connector of bathroom unit e with the U-shaped connector at the other end of bathroom unit c to complete the assembly of bathroom unit e and bathroom unit c; align and connect the vertically arranged U-shaped connector of bathroom unit f with the U-shaped connector at the other end of bathroom unit d to complete the assembly of bathroom unit f and bathroom unit d. S4. Connection and reinforcement: Reinforcement is achieved by using self-tapping screws on the sides of all U-shaped connectors after splicing and by filling the inner cavity of all U-shaped connectors with polyurethane foam after splicing. S5. Aesthetic treatment: Polish the surface of the gaps in the splicing in steps S2, S3 and S4 and apply glass glue.

2. The manufacturing process of an integrated bathroom according to claim 1, characterized in that: The manufacturing of the bathroom unit a, bathroom unit b, bathroom unit c, bathroom unit d, bathroom unit e, and bathroom unit f includes the following steps: A. Select galvanized steel sheet flat plate, and process the galvanized steel sheet flat plate by shearing machine. The shearing machine cuts out strips of the required size, and then the strips are bent into shape by bending machine to obtain a main keel frame with two long and two short sections that meet the size requirements. B. Select galvanized steel pipes and cut them into three connecting skeletons that meet the size requirements using a sawing machine. C. Select galvanized steel sheet flat plate, and use a shearing machine to cut the galvanized steel sheet flat plate into ten connecting pieces that meet the size requirements; D. First, weld the two long and two short main keel frames with a welding machine to form a cuboid main keel frame. Then, weld the connecting frame to the short main keel frame with a welding machine, and weld the connecting piece to the long main keel frame with a welding machine. This will result in a bathroom unit frame that meets the requirements. E. Fill the bathroom unit frame with polyurethane filler and polish and shape the inner and outer sides of the bathroom unit frame. F. Finally, marble or ceramic tiles are attached to the inside of the bathroom unit frame to obtain bathroom unit a, bathroom unit b, bathroom unit c, bathroom unit d, bathroom unit e, and bathroom unit f that meet the requirements.

3. The manufacturing process of an integrated bathroom according to claim 1, characterized in that: Bathroom unit a and bathroom unit b are the same size, bathroom unit c and bathroom unit d are the same size, and bathroom unit e and bathroom unit f are the same size.

4. The manufacturing process of an integrated bathroom according to claim 3, characterized in that: The dimensions of bathroom unit c and bathroom unit d are larger than those of bathroom unit a and bathroom unit b, and larger than those of bathroom unit e and bathroom unit f.

5. The manufacturing process of an integrated bathroom according to claim 1, characterized in that: The manufacturing process of the U-shaped connector includes the following steps: A. First, select a galvanized steel plate and shear it using a shearing machine to obtain strips of the required size; B. Next, punch holes in the strips using a punch press; C. Then, bend both sides of the strips using a bending machine; D. Finally, grind and polish to obtain a U-shaped connector that meets the requirements.

6. The manufacturing process of an integrated bathroom according to claim 1, characterized in that: The U-shaped connector includes a U-shaped female connector and a U-shaped female connector, wherein the size of the U-shaped female connector is larger than the size of the U-shaped female connector.

7. The manufacturing process of an integrated bathroom according to claim 6, characterized in that: Both ends of the bathroom unit a are fixed with female connectors. The bathroom unit b is parallel to one end and fixed with a female connector at the other end. Both ends of the bathroom unit c and d are fixed with female connectors. One end of the bathroom unit e and f is fixed with a female connector.

8. The manufacturing process of an integrated bathroom according to claim 2 or 5, characterized in that: The galvanized steel plate has a length, width, and height of 2200mm, 1250mm, and 1mm, respectively. The shearing machine is a high-precision CNC shearing machine, and the bending machine is a high-precision CNC bending machine.

9. The manufacturing process of an integrated bathroom according to claim 2, characterized in that: The welding machine is a carbon dioxide shielded welding machine.

10. The manufacturing process of an integrated bathroom according to claim 2, characterized in that: In process B, the U-shaped connector is punched with several sets of equally spaced punch holes by a punch press, and each set of punch holes includes a waist-shaped hole and a round hole.

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