Method for manufacturing urinal

Abstract

This invention prevents the decorative transfer of a resin sheet to a second mold. The method for manufacturing a urinal (1) disclosed herein includes a coating process, a pressing process, and a suction process. In the coating process, a resin sheet (2) is coated onto a first mold (3). In the pressing process, the resin sheet (2) is pressed into the first mold (3) using a second mold (4). In the suction process, the resin sheet (2) pressed into the first mold (3) is suctioned back into the first mold (3). The resin sheet (2) includes a decorated area (R1) and an undecorated area (R2). The first mold (3) includes a recess (32) for forming the basin (12) of the urinal 1. In the pressing process, the undecorated area (R2) of the resin sheet (2) is pressed into the recess (32) of the first mold (3) using the second mold (4).

Description

Methods of manufacturing urinals This disclosure relates to a method for manufacturing a urinal. Methods for manufacturing urinals using resin sheets are well-known (see, for example, Patent Document 1). In this method, a resin sheet is placed between a first mold and a second mold, and the second mold presses the resin sheet against the first mold, thereby deforming the resin sheet into a shape conforming to the first mold. [Prior Art Documents] [Patent Documents] [Patent Document 1] International Publication No. 2023 / 032798 In the aforementioned prior art, when a decoration is applied to a resin sheet, there is a risk that the decoration may be transferred to a second mold. The problem this invention aims to solve is to prevent the decorative transfer of resin sheets to a second mold. The disclosed method for manufacturing a urinal of the same type uses a thermoplastic resin sheet to manufacture a urinal with a basin. The method includes a coating process, a pressing process, and a suction process. The coating process covers the resin sheet onto a first mold used to form the urinal. The pressing process uses a second mold to press the resin sheet into the first mold. The suction process draws the resin sheet pressed into the first mold back into the first mold. The resin sheet includes a decorated area and an undecorated area. The first mold includes a recess for forming the basin of the urinal. In the pressing process, the undecorated area of ​​the resin sheet is pressed into the recess of the first mold using the second mold. In the suction process, the undecorated area is drawn into the recess of the first mold, and the decorated area is drawn into the portion of the first mold other than the recess. [Forms for Implementing the Invention] 1. One embodiment: The manufacturing method of the urinal according to the embodiment disclosed herein is described with reference to the accompanying drawings. However, the embodiment described below is only one of the various embodiments disclosed herein, and various modifications can be made according to the design, etc., as long as the purpose of this disclosure is achieved. Furthermore, the following schematic diagrams of the various embodiments are shown. The size and thickness of each component in the drawings and their respective ratios do not necessarily reflect the actual dimensions. (Urinary Turret) As shown in Figure 1, one embodiment of the urinal 1 is a floor-standing urinal specifically for urination. The urinal 1 has a concave basin 12 for receiving the user's urine. The urinal 1 is molded using a resin sheet 2. The urinal 1 has a hollow structure that opens to the rear. In the description of the structure of the urinal 1, the directions up and down, left and right, and front and back are used as a reference for the state in which the urinal 1 is set. The direction relative to the user of the urinal 1 is forward, and the basin 12 opens forward. The up and down, left and right, and front and back directions are mutually orthogonal. A more detailed description of the urinal 1's construction follows. The urinal 1 has a basin 12 comprising a vertically elongated receiving surface 121 and a bottom surface 125 connected to the lower end of the receiving surface 121. The receiving surface 121 is a concave curved surface recessed towards the rear. The bottom surface 125 extends forward from the lower end of the receiving surface 121. A drain outlet 13 is formed on the bottom surface 125. Urine and washing water that flow down upon contact with the receiving surface 121 collect on the bottom surface 125 and are discharged through the drain outlet 13. In addition to the basin 12, the urinal 1 also has a pair of side walls 14, a front wall 16 and an upper wall 18. A pair of sidewalls 14 are formed to extend rearward from the left and right ends of the receiving surface 121 of the basin 12. The pair of sidewalls 14 are located at a distance between each other in the left and right directions, separated by a distance from each other in the left and right directions. The pair of sidewalls 14 are inclined to the rearward side and are located at a distance between each other in the left and right directions. The front wall 16 includes a portion 161 that extends upward from the front end of the bottom surface 125 of the basin 12. This portion 161 extends forward and upward from the front end of the bottom surface 125 and faces the lower part of the receiving surface 121 in the front-back direction. The upper wall 18 is located above the basin 12. The upper wall 18 is formed to extend rearward from the upper end of the receiving surface 121 of the basin 12. The urinal 1 has a pair of side walls 14, a front wall 16, and an upper wall 18 continuously formed circumferentially around the basin 12. The front wall 16 is located at the position where the lower ends of the pair of side walls 14 are connected to each other. The upper wall 18 is located at the position where the upper ends of the pair of side walls 14 are connected to each other. The urinal 1 further has a bottom section 19. The bottom section 19 is the part of the basin 12 that cannot be visually seen when viewing the urinal 1 from the front. The bottom section 19 is the part surrounded by the lower part of the basin 12 and part 161 of the front wall 16, and opens upward. (Manufacturing method of urinal) One embodiment of the urinal 1 is manufactured by using the molding system 9 shown in Figure 2, etc. The molding system 9 is a system that uses resin sheet 2 to manufacture the urinal 1 with the above-mentioned structure. The molding system 9 includes a first mold 3, a second mold 4, a conveying device 5, and a lift 6. (First mold) The first mold 3 is used to shape the resin sheet 2 into the shape of the urinal 1. The first mold 3 is formed on the top 301 of the rectangular plate-shaped base 30. The first mold 3 is shaped to follow the outline of the final urinal 1. The first mold 3 protrudes upward from the top 301 of the base 30. The surface of the upwardly protruding first mold 3 is configured such that the resin sheet 2 fits snugly against the molding surface. The first mold 3 is formed in one direction, and a recess 32 in one direction is formed on the top of the first mold 3. The recess 32 is used to form the basin part 12 of the urinal 1. The recess 32 is shaped to correspond to the basin part 12. As shown in Figure 5, the recess 32 includes a surface 321 corresponding to the receiving surface 121 of the basin 12 and a surface 325 corresponding to the bottom surface 125 of the basin 12. The surface 321 is formed as a concave curved surface that extends in one direction. The surface 325 extends from one end of the surface 321 in the longitudinal direction. A hole 33 corresponding to the drain outlet 13 is formed on the surface 325. Furthermore, the first mold 3 has a pair of wall portions 34 corresponding to one of the side walls 14 of the urinal 1, a wall portion 36 corresponding to the front wall 16 of the urinal 1, and a wall portion 38 corresponding to the upper wall 18 of the urinal 1. A pair of wall portions 34 are shaped to form one of the side walls 14 of the urinal 1. A wall portion 36 is shaped to form the front wall 16 of the urinal 1. A wall portion 38 is shaped to form the upper wall 18 of the urinal 1. The first mold 3 has a pair of wall portions 34, 36 and 38 continuously formed circumferentially around the recess 32. The first mold 3 further has a portion 39 corresponding to the bottom cut 19 of the urinal 1. This portion 39 is surrounded by one longitudinal end of the recess 32 of the first mold 3 and a portion of the wall portion 36. As shown in Figure 2, a plurality of suction holes 31 are formed in the first mold 3. The suction holes 31 are used to vacuum-adsorb the resin sheet 2 onto the first mold 3. The molding system 9 is configured to perform vacuum adsorption by drawing air through the suction holes 31 using a suction mechanism such as a vacuum pump. (Second mold) The second mold 4 is used to make a portion of the resin sheet 2 fit tightly against the first mold 3. As shown in Figure 2, the second mold 4 is installed below the base 40 40 1. The base 40 is, for example, a rectangular plate. The second mold 4 protrudes downward from below the base 40 at 401. The second mold 4 has an elongated shape in one direction. The second mold 4 is configured such that by pressing a portion of the resin sheet 2 from above, a portion of the resin sheet 2 is pressed tightly against the recess 32 of the first mold 3. The second mold 4 has an end face 45 that forms one longitudinal end face of the second mold 4, and a recess 47 located above the end face 45. The end face 45 is, for example, a flat surface. The end face 45 of the second mold 4 faces the horizontal direction and, in the pressing process described later, faces the surface 325 of the first mold 3 (that is, the part of the first mold 3 corresponding to the bottom surface 125 of the basin 12). In the pressing process described later, the recessed portion 47 of the second mold 4 faces the portion 39 of the first mold 3 (that is, the portion of the first mold 3 corresponding to the bottom cut portion 19 of the urinal 1). During the molding of the urinal 1, a portion of the resin sheet 2 is rolled into the recess 47 of the second mold 4. As a result, the undercut portion 19 of the urinal 1 can be prevented from being molded into a thin shape. Furthermore, a positioning protrusion 48 is provided on the lower part 401 of the base 40. The protrusion 48 is a protrusion that protrudes downward from the lower part 401. By inserting the protrusion 48 into the recess 32 of the first mold 3, the second mold 4 positions the first mold 3. (Transfer Device) The transfer device 5 is configured to move the first mold 3 in the vertical direction. The transfer device 5 preferably includes an electric cylinder, pneumatic cylinder, hydraulic cylinder, solenoid, or electric motor as a drive mechanism. (Lift) The lift 6 is configured to move the second mold 4 in the vertical direction. The lift 6 preferably includes an electric cylinder, pneumatic cylinder, hydraulic cylinder, solenoid, or electric motor as the drive mechanism. In one embodiment of the manufacturing method of urinal 1, a molding system 9 having the first mold 3, the second mold 4, the conveying device 5 and the elevator 6 described above is used to perform the heating process, the coating process, the pressing process and the suction process described below. (Heating Process) In the heating process, the molding system 9 uses a heater to heat the resin sheet 2. The heated resin sheet 2 softens. (Coating process) The coating process is performed after the heating process. In the coating process, the resin sheet 2 heated in the heating process is coated onto the first mold 3 used to form the urinal 1 (see Figure 2). Specifically, the resin sheet 2, softened by heating, is held in an open state between the first mold 3 and the second mold 4 located above the first mold. The first mold 3 and the resin sheet 2 located above the first mold 3 are positioned at a distance apart in the vertical direction. At this point, the first mold 3 and the resin sheet 2 are not in contact. Similarly, the resin sheet 2 and the second mold 4 located above the resin sheet 2 are positioned at a distance apart in the vertical direction. At this point, the resin sheet 2 and the second mold 4 are not in contact. In the coating process, the resin sheet 2 is held in an open state between the first mold 3 and the second mold 4, and air is ejected upward from below the resin sheet 2 through the gas supply path. As a result, the heated resin sheet 2 expands upward and elongates. Next, in the coating process, the lifting machine 6 is lowered. As the lifting machine 6 lowers, the second mold 4 contacts the top of the resin sheet 2, and the second mold 4 is pressed against the resin sheet 2, which has been softened by heating, causing the resin sheet 2 to deform. As a result, the surface of the second mold 4 is covered with the resin sheet 2. (Push-in process) The push-in process is performed after the coating process. During the pressing process, the conveying device 5 is raised. As the conveying device 5 rises, the second mold 4 is inserted into the recess 32 of the first mold 3. The resin sheet 2 is sandwiched between the surface of the second mold 4 and the inner surface of the recess 32. At this time, the second mold 4 is pressed against the resin sheet 2 from above, pressing the resin sheet 2 against the inner surface of the recess 32. During the pressing process, the end face 45 of the recess 47 in the second mold 4 is located opposite to the portion 39 of the first mold 3. (Suction Process) The suction process is performed after the injection process. In the suction process, the resin sheet 2 is drawn onto the molding surface of the first mold 3 by vacuum adsorption. In this way, the molded component 1A shown in FIG6 is formed based on the resin sheet 2. Specifically, a vacuum suction mechanism, such as a vacuum pump, is used to draw air in through a plurality of suction holes 31 in the first mold 3. As a result, the resin sheet 2 sandwiched between the recess 32 of the first mold 3 and the second mold 4 is pressed tightly against the molding surface of the first mold 3 due to the negative pressure, thus forming the shape of the urinal 1. (Removal Process) The removal process is performed after the intake process. After the removal process, the elevator 6 is raised and the molding component 1A is removed from the first mold 3. Then, the molding component 1A removed from the first mold 3 is trimmed or NC (Numerically Controlled) to remove unnecessary parts from the molding component 1A, thereby obtaining the urinal 1. (Details of the resin sheet) The following is a more detailed description of the structure of the resin sheet 2 used to mold the urinal 1. The resin sheet 2 is a thermoplastic resin sheet having, for example, a rectangular shape. As shown in FIG4, the resin sheet 2 has a plurality of resin layers 21, 22. The plurality of resin layers 21, 22 are, for example, a first resin layer 21 and a second resin layer 22. The first resin layer 21 is the outermost resin layer constituting the resin sheet 2. This outermost layer forms the front layer of the molded urinal 1. The first resin layer 21 is formed of a first resin material containing, for example, PMMA (polymethyl methacrylate) resin. PMMA resin is an example of a resin material with excellent design properties, stain resistance, and chemical resistance. The design properties here include both transparency and gloss, or one of them. Furthermore, PMMA resin is an example of a resin material with excellent flame retardancy. The second resin layer 22 is a resin layer forming the layer below the first resin layer 21. The second resin layer 22 is formed of a second resin material containing at least one of, for example, ABS (acrylonitrile-butadiene-styrene) resin, PP (polypropylene) resin, PE (polyethylene) resin, PET (polyethylene terephthalate) resin, and ASA (acrylonitrile-styrene-acrylic rubber) resin. The aforementioned ABS resin, PP resin, PE resin, PET resin, and ASA resin are examples of resin materials with excellent moldability. This moldability refers to the property of being able to be molded into the desired shape without cracking, including the property of easy elongation upon heating. Furthermore, the aforementioned ABS resin, PP resin, PE resin, PET resin, and ASA resin are examples of resin materials with excellent flame retardancy. Since the urinal 1 in one embodiment is formed of a resin sheet 2 comprising a first resin layer 21 and a second resin layer 22, the outermost layer of the resin sheet 2 (i.e., the first resin layer 21) can have high design flexibility and stain resistance. The lower layer of the resin sheet 2 (i.e., the second resin layer 22) can have high moldability. Therefore, the resin sheet 2 as a whole has high design flexibility, stain resistance, and chemical resistance, and also has high moldability and flame retardancy. As shown in Figure 4, the thickness d2 of the second resin layer 22 should preferably be greater than the thickness d1 of the first resin layer 21. In this way, the resin sheet 2 as a whole can achieve high moldability. In one embodiment, the second resin layer 22 includes a recycled layer 221 and a non-recycled layer 222. The recycled layer 221 is a layer formed from recycled second resin material. The non-recycled layer 222 is a layer formed from unrecycled second resin material, in other words, an unused layer. The thickness d21 of the recycled layer 221 is preferably greater than the thickness d22 of the non-recycled layer 222. In the example of FIG4, the recycled layer 221 constitutes the lower layer of the non-recycled layer 222, and the recycled layer 221 may also constitute the upper layer of the non-recycled layer 222. (Decorative area and plain area) The resin sheet 2 of the urinal 1 in one embodiment includes a decorative area R1 and a plain area R2. The decorative area R1 is the area on the resin sheet 2 where decoration has been applied by inkjet printing. In the decorative area R1, decoration is applied to the surface of the first resin layer 21, which constitutes the outermost layer of the resin sheet 2. This decoration aims to give the urinal 1 a design and functional appearance. In particular, by applying either a pattern or a color to the surface of the urinal 1, the design of the urinal 1 can be greatly enhanced. Plain area R2 refers to the area of ​​resin sheet 2 other than the decorated area R1; in other words, it is the area of ​​resin sheet 2 that is not decorated on its surface. For example, only a portion of the surface of the resin sheet 2 to be molded is decorated by inkjet printing, and the decorated portion is called decorated area R1, while the portion not decorated by inkjet printing is called plain area R2. In one embodiment, the molding system 9 heats the resin sheet 2, which includes the decorative area R1 and the plain area R2, during the heating process. In one embodiment of the molding system 9, during the coating process, a resin sheet 2, including a decorative area R1 and a plain area R2, is placed over a first mold 3. At this time, a second mold 4 is positioned directly above the plain area R2 of the resin sheet 2, and a recess 32 of the first mold 3 is positioned directly below the plain area R2. In other words, the plain area R2 of the resin sheet 2 is positioned between the recess 32 of the first mold 3 and the second mold 4 located directly above this recess. The decorative area R1 of the resin sheet 2 is positioned directly above the portion of the first mold 3 excluding the recess 32. The plain area R2 has an elongated shape in one direction. During the coating process, the elongation of the plain area R2 is consistent with the elongation of the recess 32, and the elongation of the plain area R2 is consistent with the elongation of the second mold 4. When the second mold 4 descends, it presses against the unglazed area R2 of the resin sheet 2, thereby deforming the resin sheet 2. In particular, the unglazed area R2 of the resin sheet 2 deforms along the surface of the second mold 4. As a result, the surface of the second mold 4 is covered by the unglazed area R2 of the resin sheet 2. In one embodiment of the pressing process, when the first mold 3 rises, the plain surface area R2 of the resin sheet 2 is sandwiched between the surface of the second mold 4 and the inner surface of the recess 32 of the first mold 3. At this time, by pressing the plain surface area R2 of the resin sheet 2 from above with the second mold 4, the plain surface area R2 of the resin sheet 2 is pressed into the recess 32 of the first mold 3 by the second mold 4. In one embodiment of the suction process, a plain area R2 of the resin sheet 2, which is sandwiched between the recess 32 of the first mold 3 and the second mold 4, is attracted by vacuum suction to the molding surface of the recess 32 of the first mold 3. Furthermore, a decorative area R1 of the resin sheet 2 is attracted by vacuum suction to the molding surface of the portion of the first mold 3 other than the recess 32. In one embodiment of the removal process, an unnecessary portion of the peripheral portion of the decorative area R1 in the molding member 1A removed from the first mold 3 is removed, thereby manufacturing a urinal 1 with enhanced design through decoration. The surface of the manufactured urinal 1 includes a decorative surface 101 formed by the decorative area R1 of the resin sheet 2 and a plain surface 102 formed by the plain area R2 of the resin sheet 2. The decorative surface 101 includes the surface of the urinal 1 excluding the basin 12. The decorative surface 101 includes the entire surface of the urinal 1 excluding the basin 12, and it is also preferable to include a portion of the surface. Specifically, the decorative surface 101 includes the surfaces of a pair of sidewalls 14. The decorative surface 101 includes the entire surface of the pair of sidewalls 14, or preferably a portion of such surface. The surface of the sidewalls 14 includes a main surface 142 facing left and right and an end surface 145 facing forward. In one embodiment, decoration is applied to the continuous main surfaces 142 and end surfaces 145 of the sidewalls 14, but decoration may also be applied only to the main surfaces 142 or the end surfaces 145. That is, the decorative surface 101 only needs to include either the main surfaces 142 and the end surfaces 145 of the sidewalls 14. Decorative surface 101 includes the surface of the front wall 16. Decorative surface 101 may include the entire surface of the front wall 16, or preferably a portion thereof. The surface of the front wall 16 includes a front-facing main surface 162 and an upward-facing end surface 165. In one embodiment, decoration is applied to the continuous main surface 162 and end surface 165 of the front wall 16, but decoration may also be applied only to the main surface 162 or the end surface 165. Decorative surface 101 includes the surface of the upper wall 18. Decorative surface 101 may include the entire surface of the upper wall 18, or preferably a portion thereof. The surface of the upper wall 18 includes an upward-facing main surface 182 and a forward-facing end surface 185. That is, decoration is applied to the continuous main surface 182 and end surface 185 of the upper wall 18, or decoration may be applied only to the main surface 182 or the end surface 185. In other words, decorative surface 101 may simply include either the main surface 182 or the end surface 185 of the upper wall 18. Plain surface 102 includes the surface of basin 12. Plain surface 102 includes the entire surface of basin 12, or preferably includes a portion of that surface. In detail, the plain surface 102 includes the receiving surface 121 of the basin 12 and the bottom surface 125 of the basin 12. Furthermore, the plain surface 102 includes the surface of the undercut portion 19. The plain surface 102 only needs to include at least one of the receiving surface 121 of the basin 12, the bottom surface 125 of the basin 12, and the surface of the undercut portion 19. 2. Variations: The above-described embodiments are merely one example of the various embodiments disclosed herein. As long as the objectives of this disclosure are achieved, various modifications may be made according to design, etc., to the above-described embodiments. The following describes variations of the above embodiments. In the description of these variations, structures identical to those described in the above embodiments are given the same symbols, and detailed explanations are omitted. The various variations listed below can be appropriately combined and applied. In one embodiment, a large contrast is created between the decorative area R1 and the plain area R2 on both sides of the resin sheet 2. To make the contrast smaller and the boundary blurred, a gradient is also preferable. That is, it is also preferable to apply a continuous or phased gradient decoration that closely resembles the plain surface in the part of the decorative area R1 of the resin sheet 2 that is adjacent to the plain area R2 (see Figure 7). In other words, in order to blur the boundary between the decorative area R1 and the plain area R2, the part of the decorative area R1 of the resin sheet 2 that is adjacent to the plain area R2 should be composed of a gradient area R10 that continuously or gradually approaches the plain surface. Furthermore, at this point, the boundary line between the decorated area R1 and the plain area R2 of the resin sheet 2 should ideally be meandering (see Figure 7). In other words, the boundary line between the gradient area R10 of the decorated area R1 and the plain area R2 of the resin sheet 2 should ideally be irregularly or regularly meandering. Accordingly, the boundary between the decorated area R1 and the plain area R2 becomes more blurred. The aforementioned boundary line is not an actual drawn boundary line, but an imaginary one. In one embodiment, the decorative area R1 of the resin sheet 2 is decorated by inkjet printing. The means of decorating the resin sheet 2 are not limited to this. For example, the decoration can also be applied to the resin sheet 2 by screen printing, or by attaching a suitable decorative film. 3. As described in the above embodiments and variations, the manufacturing method of the urinal (1) of the first embodiment is a method of manufacturing a urinal (1) having a basin (12) using a thermoplastic resin sheet (2). The manufacturing method of the urinal (1) of the first embodiment includes a coating process, a pressing process, and a suction process. The coating process is a process of covering the resin sheet (2) onto a first mold (3) used to form the urinal (1). The pressing process is a process of pressing the resin sheet (2) into the first mold (3) using a second mold (4). The suction process is a process of suctioning the resin sheet (2) pressed into the first mold (3) to the first mold (3). The resin sheet (2) includes a decorated area (R1) and an undecorated plain area (R2). The first mold (3) includes a recess (32) used to form the basin (12) of the urinal (1). In the pressing process, the plain area (R2) of the resin sheet (2) is pressed into the recess (32) of the first mold (3) using the second mold (4). In the drawing process, the plain area (R2) is drawn into the recess (32) of the first mold (3), and the decorated area (R1) is drawn into the portion of the first mold (3) excluding the recess (32). Based on this pattern, decorations can be applied to the parts of the urinal (1) other than the basin (12), which can prevent the decorations of the resin sheet (2) from being transferred to the second mold (4). The manufacturing method of the urinal (1) of the second state is the same as that of the first state, wherein the urinal (1) further has a pair of sidewalls (14) located at a distance between each other in the left and right directions, which are separated from the basin part (12). The portion of the first mold (3) other than the recess (32) includes a pair of wall portions (34) for forming a pair of sidewalls (14). Based on this pattern, decoration can be applied to one of the side walls (14) of the urinal (1), which can prevent the decoration of the resin sheet (2) from being transferred to the second mold (4). The method of manufacturing the urinal (1) of the third state is the same as that of the first state or the second state, wherein the urinal (1) further has an upper wall (18) located above the basin (12). The portion of the first mold (3) other than the recess (32) includes a wall portion (38) for forming the upper wall (18). Based on this pattern, decoration can be applied to the upper wall (18) of the urinal (1), which can prevent the decoration of the resin sheet (2) from being transferred to the second mold (4). The method of manufacturing the urinal (1) of the fourth state sample is to apply decoration by inkjet printing on the decoration area (R1) of the resin sheet (2) in any of the first to third state samples. Based on this pattern, the decorative transfer of the resin sheet (2) applied by inkjet printing to the second mold (4) can be suppressed. The method of manufacturing the urinal (1) of the fifth state sample is to apply decoration to the decorative area (R1) of the resin sheet (2) by attaching a decorative film in any of the states from the first state sample to the third state sample. Based on this state, the decorative transfer of the resin sheet (2) applied with the decorative film to the second mold (4) can be suppressed. The method of manufacturing the urinal (1) of the sixth state is to apply decoration to the part of the decorative area (R1) adjacent to the plain area (R2) in any of the states from the first state to the fifth state, so that it is continuously or in stages close to the plain surface. According to this pattern, since the boundary between the decorated area (R1) and the plain area (R2) is blurred, the visual disharmony of the urinal (1) after molding can be suppressed. The manufacturing method of the urinal (1) of the 7th state is that in the 6th state, the boundary line between the decorated area (R1) and the plain area (R2) is in a meandering shape. According to this pattern, since the boundary between the decorated area (R1) and the plain area (R2) is more blurred, the visual disharmony of the urinal (1) after molding can be better suppressed. 1: Urinal 1A: Molding component 2: Resin sheet 3: First mold 4: Second mold 5: Transport device 6: Elevator 9: Molding system 12: Basin 13: Drain 14: Side wall 16: Front wall 18: Top wall 19: Bottom cut 21: First resin layer 22: Second resin layer 30: Base 31: Suction hole 32: Recess 33: Hole 34: Wall 36: Wall 38: Wall 39: Part 40: Base 45: End face 47: Recess 48: 101: Protrusion Surface 102: Plain Surface 121: Supporting Surface 125: Bottom Surface 142: Main Surface 145: End Surface 161: Part 162: Main Surface 165: End Surface 182: Main Surface 185: End Surface 221: Recycled Layer 222: Non-Recycled Layer 301: Top 321: Surface 325: Surface 401: Bottom d1: Thickness d2: Thickness d21: Thickness d22: Thickness R1: Area where decoration is applied R2: Plain Surface Area R10: Gradient Area Figure 1 is a perspective view of one embodiment of the urinal. Figure 2 is a perspective view showing one process of the manufacturing method of the urinal described above. Figure 3 is a perspective view showing another process of the manufacturing method of the urinal described above. Figure 4 is a cross-sectional view of the main part of the resin sheet used to mold the urinal described above. Figure 5 is a perspective view of the first mold used to mold the urinal described above. Figure 6 is a perspective view of the molded component formed using the resin sheet described above. Figure 7 is a perspective view of a modified example of the urinal described above. 2: Resin sheet 3: First mold 4: Second mold 5: Transport device 6: Elevator 9: Molding System 30: Base 31: Intake port 32: concave part 34: Wall 36: Wall 39: Part 40: Base 45: End face 47: Depression 48: Protrusion 301: Above 321: Noodles 401: Below R1: Area to be decorated R2: Plain area

Claims

1. A method for manufacturing a urinal, using a thermoplastic resin sheet to manufacture a urinal having a basin portion, the method comprising: a coating process, covering the resin sheet onto a first mold for forming the urinal; a pressing process, pressing the resin sheet into the first mold using a second mold; and a suction process, suctioning the resin sheet pressed into the first mold to the first mold; the resin sheet comprising a decorated area and an undecorated plain area; the first mold comprising a recess for forming the basin portion of the urinal; in the pressing process, pressing the plain area of ​​the resin sheet into the recess of the first mold using the second mold for pressing the plain area of ​​the resin sheet; in the suction process, suctioning the plain area to the recess of the first mold; and suctioning the decorated area to a portion of the first mold other than the recess.

2. The method for manufacturing the urinal as described in claim 1, wherein, The urinal further has a pair of sidewalls located at a distance between each other in the left and right directions, and the portion of the first mold other than the recess includes a pair of wall portions for forming the pair of sidewalls.

3. The method for manufacturing the urinal as described in claim 1, wherein, The urinal further has an upper wall located above the basin, and the portion of the first mold other than the recess includes a wall portion for forming the upper wall.

4. The method for manufacturing the urinal as described in claim 1, wherein, The area on the resin sheet to be decorated was decorated using inkjet printing.

5. The method for manufacturing the urinal as described in claim 1, wherein, The decorative area of ​​the resin sheet is decorated by attaching a decorative film.

6. A method for manufacturing a urinal as described in any of claims 1 to 5, wherein, The portion of the area where the decoration is applied that is adjacent to the plain area is decorated in a manner that approaches the plain area continuously or in stages.

7. The method for manufacturing the urinal as described in claim 6, wherein, The boundary between the decorated area and the plain area is serpentine.

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