Process for producing a molded part in the sanitary sector using a deep-drawing process

Abstract

Method for producing a molded part in the sanitary sector by means of a deep-drawing process, characterized in that the deep-drawing mold (10) is tilted by 10-80°, advantageously by 20-60°, particularly preferably by 45°, in relation to the position of the finished molded part during the deep-drawing process, the moldable, thermoplastic material is deep-drawn, and after the deep-drawn molded part has hardened, it is removed from the deep-drawing mold.

Description

Field of the invention

[0001] The invention relates to a method for producing a molded part in the sanitary sector by means of a deep-drawing process and to the corresponding molded part. State of the art

[0002] Especially in the senior and nursing care sectors, sit-in bathtubs with a door that facilitates entry are of great advantage. Such a comfortable sit-in bathtub is described by the applicant in DE 10 2004 031 883 B4.

[0003] The production of shell-shaped molded parts, such as bathtubs or washbasins, using deep-drawing processes has long been known. Thermoplastic materials, such as sanitary acrylic (PMMA polymethyl methacrylate, also known as acrylic glass), are typically used. The plastic is heated in sheet form in an oven until it is thermoformable and then drawn over a deep-drawing mold using a vacuum. The plastic is then cooled on the mold to below the deformation limit, so that the plastic retains the shape of the deep-drawing mold.

[0004] US 3,873,659 A and US 3,853,449 A describe the production of multi-chamber liners for refrigerators using a deep-drawing process with a film. Combined tilting and relative pivoting of the individual mold elements relative to one another allows a molded article with a substantially uniform wall thickness to be achieved.

[0005] Patent document JP 2010 240 987 A describes a method and apparatus for manufacturing vehicle interior components in which an outer skin is bonded to a resin core material with a convex surface. The main objective is to ensure a uniform and attractive surface structure, such as a grain pattern, by using a special vacuum bonding process with a tiltable mold. This approach avoids excessive stretching of the outer skin, which can lead to deformation of the decorative pattern with conventional methods.

[0006] The more complex the geometric design of the molded part, the more difficult it is to obtain an intact product in a single process step without having to perform various molding steps. For sit-down bathtubs, in particular, it is also desirable to allow for a high water level. Task

[0007] The object of the invention is to provide a method which enables the production of a shaped part in the sanitary sector, preferably a tub trough of a sit-down bathtub, in a single deep-drawing step, without various forming steps. Solution

[0008] This problem is solved by the subject matter of the independent claim. Advantageous developments of the subject matter of the independent claims are characterized in the subclaim. The wording of all claims is hereby incorporated by reference into this description.

[0009] The use of the singular shall not exclude the plural, and this shall also apply in the reverse sense unless otherwise disclosed.

[0010] Individual method steps are described in more detail below. In a preferred variant of the invention, the steps are performed in the order specified. However, the steps do not necessarily have to be performed in the order specified, and the method to be described may also include additional, unmentioned steps.

[0011] To achieve the object, a method for producing a molded part in the sanitary sector by means of a deep-drawing process is proposed, in which the deep-drawing mold is tilted by 10°-80°, advantageously by 20°-60°, particularly preferably by 45°, in relation to the position of the finished molded part during the deep-drawing process, the moldable, thermoplastic material is deep-drawn, and after the deep-drawn molded part has hardened, it is removed from the deep-drawn mold.

[0012] Using the proposed method, a molded part in the sanitary sector, preferably a tub for a sit-down bathtub, can be produced using a deep-drawing process. However, other sanitary parts with similar shapes are also conceivable.

[0013] The proposed sit-in bathtub consists of a tub with a molded seat that ends in a floor and a skirt. The tub's molded seat is at a level well below the water level of the sit-in bathtub.

[0014] As described by the applicant in DE 10 2004 031 883 B4, the finished sit-in bathtub still has a door and panel walls. However, the subject of this application is the manufacture of a tub tray.

[0015] To achieve a water level in the finished sit-in bathtub that is well above the seat of the tub, the sit-in bathtub should have a height of at least 85 cm, preferably 90 cm - 140 cm, and particularly preferably 100 cm - 130 cm. These values are measured from the end of the skirt to the upper edge of the sit-in bathtub, the support flange.

[0016] It has now been discovered that if the deep-drawing mold for the tub is tilted by 20-60°, preferably by 45°, relative to the upright position in which the finished tub will later be used, with the base parallel to the room floor, the moldable, thermoplastic material, particularly a plastic, has less depth to cover. More surface area is available, and the plastic does not become too thin during deep-drawing and does not burst. Using the specified process, it is therefore possible to produce a molded part in the sanitary sector, preferably a tub for a tub, in a single deep-drawing step. No preforming or even the production of multiple tub sections that would then have to be thermally molded together is necessary.

[0017] It is also advantageous if the height of the deep-drawing mold is the same length as the distance from the rear wall of the deep-drawing mold to the door insert, or is 0.1%-30% shorter than this.

[0018] If the deep-drawing mold for the tub were used vertically in these dimensions, i.e. upright in the position in which the finished sit-in tub would later be used, with the base parallel to the room floor, and the moldable, thermoplastic material, particularly a plastic, were deep-drawn over the upright tub mold, the plastic would not be able to expand completely (all the way down to the floor) due to the side walls of the tub mold, so that the entire mold would be covered in plastic, and the plastic could burst. With the deep-drawing mold for the tub mold in this position, it would only be possible to produce a sit-in bathtub up to around 85 cm deep.

[0019] The process according to the invention further provides that the moldable, thermoplastic material is a plastic, preferably polymethyl methacrylate (PMMA), particularly preferably polymethyl methacrylate / acrylonitrile butadiene styrene (PMMA / ABS). The moldable, thermoplastic material is preferably used in the form of sheets in the deep-drawing process. Coextruded ABS / PMMA composite sheets are particularly suitable. The sheets can have dimensions of 2.60m - 2.00m x 2.20m - 1.70m and a thickness of up to 8mm-10mm, preferably 4mm-5mm.

[0020] The object is further achieved by a molded part, in particular a tub of a sit-down bathtub, obtainable by means of the described deep-drawing process.

[0021] The term "tub height" refers to the height of the tub from the bottom of the apron to the top of the tub, which is formed by a flange area, the support flange. The water inlet fittings and parts for the door closure can be mounted in this flange area. The term "tub depth" refers to the height from the bottom of the tub to the support flange.

[0022] In one embodiment, the height of the tub is the same length as the distance from the back wall of the tub to the door insert, or is 0.1%-30% shorter than this.

[0023] Furthermore, the tub trough advantageously has a height of at least 85 cm, preferably 90 cm - 150 cm, particularly preferably 100 cm - 130 cm. According to a further aspect of the present invention, the tub trough has a depth of at least 85 cm, preferably 86 cm - 140 cm, particularly preferably 90 cm - 120 cm. The upper end of the tub trough is formed, as described above, by a support flange. Not included in these ranges are any attachments or superstructures at the upper end of the tub trough, the support flange, or the lower apron that are attached after the tub trough has been manufactured and increase its height.

[0024] As mentioned at the beginning, the finished sit-in bathtub also features a door and paneling. The preferred height of the bathtub, preferably 90cm - 150cm, and particularly 100cm - 130cm, allows for a water level well above the seat of the tub.

[0025] The tub preferably has at least one seat. The at least one seat typically has a height of approximately 40 cm. This allows people with mobility difficulties to enjoy a pleasant bathing experience, especially in a full-body sitz bath with a high water level. Furthermore, the high water level allows for water movement therapies, such as light aqua aerobics, in the sitz bath. This way, joint problems and tension can be alleviated and prevented through gentle movement in the water without physical exertion.

[0026] Using the described process, tub trays for sit-in bathtubs of various basic shapes can be manufactured. The sit-in bathtub can be designed as a mobile or stationary type. It can be wall-mounted, corner, or even round. Multiple seating areas are also possible, on each inner wall of the tub tray. This allows several people to take a sit-in bath at the same time. A whirlpool system can also be integrated into the tub tray of the sit-in bathtub. For this purpose, it is advantageous for the tub tray to have air injection openings in the floor and / or on a seating area. Air ducts, preferably acrylic ducts, are firmly connected to the tub tray along the air injection openings on the back of the tub tray and laminated into a single unit. Air can be injected into the sit-in bathtub via the air injection openings, which are preferably arranged in a U-shape in the floor and / or on a seating area.

[0027] The firmly connected systems of tub and air duct have the advantage that no water can escape from the air duct. There is no seal that can leak, as is the case with air jets in a whirlpool, for example. Furthermore, the numerous small air injection openings allow for gentle and even air distribution, so the bather's body is not hit by a strong jet of water. Excessively powerful jets of water can loosen deposits in the body, especially in older people, which can lead to health problems.

[0028] Further details and features will become apparent from the following description of preferred embodiments in conjunction with the figures. The respective features can be implemented individually or in combination with one another. The possibilities for achieving the object are not limited to the embodiments.

[0029] The exemplary embodiments are illustrated schematically in the figures. Identical reference numerals in the individual figures denote identical or functionally identical elements, or elements that correspond to one another in terms of their functions. In detail: Fig. 1 a schematic representation of a sit-down bathtub Fig. 2 a schematic representation of the deep-drawing mold; Fig. 3A is a plan view of a wall-mounted version of the sit-down bathtub; Fig. 3B is a plan view of a corner version of the seat bath; and Fig. 4 a side view of the tub of the sit-down bathtub with door.

[0030] Fig. Figure 1 shows a sit-in bathtub 1, the tub trough 2 with a seat 3, a back wall 4, a base 5, an apron 6, and a support flange 7. An open door 8 is also shown for completion. As described by the applicant in DE 10 2004 031 883 B4, the finished sit-in bathtub also has a door and paneling. The door and paneling are each separate molded parts and are not produced in the same process step as the tub trough. The tub trough 2 has a mounting surface 9 for the door 8. The door can be designed, as required, to open inwards or outwards, to be made up of one or more parts, or even to open upwards as a sliding door.

[0031] The tub trough advantageously has a height H of at least 85 cm, preferably 90 cm to 150 cm, particularly preferably 100 cm to 130 cm. According to a further aspect of the present invention, the tub trough has a depth T of at least 85 cm, preferably 86 cm to 140 cm, particularly preferably 90 cm to 120 cm.

[0032] The term "tub height" refers to the height of the tub from the bottom of the apron to the top of the tub, which is formed by a flange area, the support flange. The water inlet fittings and door locking components may be mounted in this flange area. The term "tub depth" refers to the height from the bottom of the tub to the support flange. The term "tub width" B refers to the shortest or longest width of the tub, from one side of the support flange to the other.

[0033] The upper end of the tub is formed by a support flange, as described above. Not included in these ranges are any attachments or superstructures at the upper end of the tub, the support flange, or the lower skirt that are added after the tub is manufactured and increase its height.

[0034] The preferred height of the bathtub H, measured from the end of the apron 6 to the upper edge of preferably 90cm-150cm, particularly preferably 100cm-130cm, allows for a water level well above the seat of the tub. Preferably, the seat 3 has a typical height S of approximately 40cm. This allows even people with walking disabilities to enjoy a pleasant bathing experience with a full-body sitz bath with a high water level.

[0035] In one embodiment, the longest width B of the tub is 96cm, the height H is 100cm, the depth D is 86cm, and the seat height S is 40cm.

[0036] In another embodiment, the longest width B of the tub is 110cm, the height H is 110cm, the depth D is 90cm, and the seat height S is 40cm.

[0037] In yet another embodiment, the longest width B of the tub is 100cm, the height H is 130cm, the depth D is 106cm, and the seat height S is 40cm.

[0038] A whirlpool system can also be integrated into the tub of the sit-in bathtub. For this purpose, it is advantageous for the tub to have air injection openings 16 in the floor 5 and / or on a seat surface 3. Air can be injected into the sit-in bathtub via the air injection openings, which are preferably arranged in a U-shape in the floor 5 and / or on a seat surface 3, thus enabling a bubble massage that is gentle on the heart and circulation.

[0039] Fig. Figure 2 shows a deep-drawing mold for a bathtub trough 10 on a frame 11. The deep-drawing mold for a bathtub trough 10 is tilted by approximately 30-50° relative to the upright position in which the finished seat tub will later be used, with the base parallel to the room floor. The seat surface of the deep-drawing mold 12, the rear wall of the deep-drawing mold 13, the support flange of the deep-drawing mold 14, and the door attachment surface of the deep-drawing mold 15 can thus be easily molded from the moldable, thermoplastic material during the deep-drawing process.

[0040] In one embodiment, the moldable, thermoplastic material, in particular a coextruded ABS / PMMA composite sheet, is heated in an oven on a frame until it reaches the desired viscosity, then moved out. The deep-drawing mold on the frame is raised using a lifting mechanism, the frame is sealed hermetically, and a vacuum is created. The viscous ABS / PMMA is drawn into the deep-drawing mold. By positioning the deep-drawing mold in this way, the moldable, thermoplastic material has less depth to overcome. More surface area is available, and the plastic does not become too thin during deep-drawing and does not burst. Using the specified process, it is therefore possible to produce a tub for a sit-down bathtub in a single deep-drawing step. There is no need for any molding or even the production of multiple parts of the tub that then have to be thermally formed together.

[0041] Fig. Figure 3A shows a top view of a wall-mounted version of the sit-in bathtub with a closed door. In one embodiment, the height of the tub is the same length as the distance L from the back wall of the tub to the door insert, or is 0.1%-30% shorter than this.

[0042] Fig. Figure 3B shows a top view a of a corner version of the sit-in bathtub with a closed door. In one embodiment, the height of the tub is the same length as the distance L from the rear wall (inside) of the tub to the door insert, or is 0.1%-30% shorter than this.

[0043] In one embodiment, the longest width B of the tub is 96cm, the height H 100cm, the depth D 86cm, distance L 80cm, seat height S 40cm.

[0044] In another embodiment, the longest width B of the tub is 110cm, the height H 110cm, the depth D 90cm, distance L 98cm, seat height S 40cm.

[0045] Fig. Figure 4 shows a side view of the tub of the sit-down bathtub with door 8, without side panels. It is clearly visible that the apron 6 of the tub extends beyond the floor 2. Reference symbol 1 sit-down bathtub 2 tub trough 3 Seat 4 Rear wall 5 Floor 6 apron 7 Support flange 8 Door 9 Door attachment surface 10 Deep-drawing mold tub trough 11 frame 12 Seat of the deep-drawing mold 13 Rear wall of the deep-drawing mold 14 Support flange of the deep-drawing mold 15 Door attachment surface of the deep-drawing mold 16 air injection openings B Width T Depth H Height L length S seat height

Claims

[1] Process for producing a molded part in the sanitary sector by means of deep drawing characterized by that the deep-drawing mold (10) is tilted by 10-80°, advantageously by 20-60°, particularly preferably by 45°, in relation to the position of the finished molded part during the deep-drawing process, the moldable, thermoplastic material is deep-drawn, after the deep-drawn molded part has hardened, it is removed from the deep-drawing mold. [2] Method according to claim 1, characterized by that the moldable, thermoplastic material is a plastic, preferably polymethyl methacrylate (PMMA), particularly preferably polymethyl methacrylate / acrylonitrile butadiene styrene (PMMA / ABS).

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