Method for producing urinal

Abstract

The present invention suppresses transference of a decoration of a resin sheet to a second mold. A method for producing a urinal (1) according to the present disclosure comprises a covering step, a pressing step, and a suction step. In the covering step, a first mold (3) is covered with a resin sheet (2). In the pressing step, a second mold (4) is used to press the resin sheet (2) into the first mold (3). In the suction step, the resin sheet (2) that has been pressed into the first mold (3) is suctioned to the first mold (3). The resin sheet (2) includes a decoration region (R1) in which a decoration is provided and a plain region (R2) in which no decoration is provided. The first mold (3) includes a recess (32) for molding a bowl part (12) of the urinal 1. In the pressing step, the plain region (R2) of the resin sheet (2) is pressed into the recess (32) of the first mold (3) by the second mold (4).

Description

Urinal manufacturing method

[0001] The present disclosure relates to a method for manufacturing a urinal.

[0002] A method for manufacturing a urinal using a resin sheet is 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 resin sheet is pressed against the first mold by the second mold, thereby deforming the resin sheet so that it has a shape that conforms to the shape of the first mold.

[0003] International Publication No. 2023 / 032798

[0004] In the above-described conventional techniques, if the resin sheet is decorated, there is a risk that the decoration may be transferred to the second mold.

[0005] The problem to be solved by the present disclosure is to prevent the decoration of the resin sheet from being transferred to the second mold.

[0006] A urinal manufacturing method according to one aspect of the present disclosure is a method for manufacturing a urinal having a bowl portion using a thermoplastic resin sheet, and includes the following steps: a covering step of covering a first mold for molding the urinal with the resin sheet; a pushing step of pushing the resin sheet toward the first mold using a second mold; and a suction step of sucking the resin sheet pushed into the first mold into the first mold. The resin sheet includes a decorated region and a plain region that is not decorated. The first mold includes a recess for molding the bowl portion of the urinal. In the pushing step, the plain region of the resin sheet is pushed into the recess of the first mold by the second mold. In the suction step, the plain region is sucked into the recess of the first mold, and the decorated region is sucked into the part of the first mold excluding the recess.

[0007] Fig. 1 is a perspective view of a urinal according to one embodiment. Fig. 2 is a perspective view showing one step in a method for manufacturing the urinal. Fig. 3 is a perspective view showing another step in the method for manufacturing the urinal. Fig. 4 is a cross-sectional view of a main part of a resin sheet used to mold the urinal. Fig. 5 is a perspective view of a first mold used to mold the urinal. Fig. 6 is a perspective view of a molded member molded using the resin sheet. Fig. 7 is a perspective view of a modified example of the urinal.

[0008] 1. One Embodiment A method for manufacturing a urinal according to an embodiment of the present disclosure will be described with reference to the accompanying drawings. However, the embodiment described below is merely one of various embodiments of the present disclosure, and various modifications can be made depending on the design, etc., as long as the object of the present disclosure can be achieved. Furthermore, each diagram illustrating the following embodiment is a schematic diagram, and the size and thickness of each component in the diagram and their respective ratios do not necessarily reflect the actual dimensions.

[0009] (Urinal) As shown in Figure 1, a urinal 1 in one embodiment is a stall urinal exclusively for urination. The urinal 1 has a concave bowl portion 12 used to receive urine from a user. The urinal 1 is molded using a resin sheet 2. The urinal 1 has a hollow structure that is open at the rear.

[0010] The up-down, left-right, and front-to-back directions used in describing the configuration of the urinal 1 are based on the installed state of the urinal 1. The front is the direction in which a user faces the urinal 1, and the bowl portion 12 is open to the front. The up-down, left-right, and front-to-back directions are perpendicular to one another.

[0011] The structure of the urinal 1 will now be described in more detail. The bowl portion 12 of the urinal 1 includes a receiving surface 121 that is long in the vertical direction, and a bottom surface 125 that connects to the lower end of the receiving surface 121. The receiving surface 121 is configured as a concave curved surface that is recessed backward. The bottom surface 125 extends forward from the lower end of the receiving surface 121. A drain port 13 is formed in the bottom surface 125. Urine and flushing water that hit the receiving surface 121 and flow down are collected in the bottom surface 125 and then discharged through the drain port 13.

[0012] In addition to the bowl portion 12 , the urinal 1 has a pair of side walls 14 , a front wall 16 and a top wall 18 .

[0013] The pair of side walls 14 are formed to extend rearward from both left and right ends of the receiving surface 121 of the bowl portion 12. The pair of side walls 14 are positioned at a distance from each other in the left-right direction, sandwiching the bowl portion 12 therebetween. The pair of side walls 14 are inclined so that the further rearward the portions of the side walls 14 are, the greater the distance from each other in the left-right direction.

[0014] The front wall 16 includes a portion 161 that extends upward from the front end of the bottom surface 125 of the bowl portion 12. This portion 161 extends obliquely upward and forward from the front end of the bottom surface 125 and faces the lower part of the receiving surface 121 in the front-to-rear direction.

[0015] The upper wall 18 is located above the bowl portion 12. The upper wall 18 is formed to extend rearward from the upper end of the receiving surface 121 of the bowl portion 12.

[0016] The pair of side walls 14, the front wall 16, and the top wall 18 of the urinal 1 are formed continuously in the circumferential direction surrounding the bowl portion 12. The front wall 16 is positioned so as to connect the lower ends of the pair of side walls 14. The top wall 18 is positioned so as to connect the upper ends of the pair of side walls 14.

[0017] The urinal 1 further has an undercut portion 19. The undercut portion 19 is a portion of the bowl portion 12 that is not visible when the urinal 1 is viewed from the front. The undercut portion 19 is a portion that is surrounded by the lower portion of the bowl portion 12 and a portion 161 of the front wall 16, and is open upward.

[0018] (Method for Manufacturing Urinal) A method for manufacturing a urinal 1 according to one embodiment is a method for manufacturing the urinal 1 using a molding system 9 shown in FIG. 2 and other figures.

[0019] The molding system 9 is a system that uses the resin sheet 2 to manufacture the urinal 1 having the above-described configuration.

[0020] The molding system 9 includes a first mold 3 , a second mold 4 , a conveying device 5 and a lifter 6 .

[0021] (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 upper surface 301 of the base 30 which has a rectangular plate shape.

[0022] The first mold 3 has a shape that conforms to the outer shape of the urinal 1 that will ultimately be molded. The first mold 3 protrudes upward from the upper surface 301 of the base 30. The upwardly protruding surface of the first mold 3 forms a molding surface against which the resin sheet 2 is closely attached.

[0023] The first mold 3 is formed to be long in one direction, and a recess 32 that is long in one direction is formed on the top surface of the first mold 3. The recess 32 is a portion for molding the bowl portion 12 of the urinal 1. The recess 32 has a shape that corresponds to the bowl portion 12.

[0024] As shown in Figure 5 and other figures, recess 32 includes a surface 321 that corresponds to receiving surface 121 of bowl portion 12, and a surface 325 that corresponds to bottom surface 125 of bowl portion 12. Surface 321 is configured as a concave curved surface that is long in one direction. Surface 325 extends from one end of surface 321 in the longitudinal direction. A hole 33 that corresponds to drain port 13 is formed in surface 325.

[0025] Furthermore, the first mold 3 has a pair of wall portions 34 corresponding to a pair of 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 top wall 18 of the urinal 1.

[0026] The pair of wall portions 34 have a shape for molding the pair of side walls 14 of the urinal 1. The wall portion 36 has a shape for molding the front wall 16 of the urinal 1. The wall portion 38 has a shape for molding the top wall 18 of the urinal 1. The pair of wall portions 34, the wall portion 36, and the wall portion 38 of the first mold 3 are formed continuously in the circumferential direction surrounding the recess 32.

[0027] The first mold 3 further has a portion 39 that corresponds to the undercut portion 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 part of the wall portion 36.

[0028] 2 and other drawings, a plurality of air intake holes 31 are formed in the first mold 3. The air intake holes 31 are used to draw a vacuum into the resin sheet 2 to the first mold 3. The molding system 9 is configured to perform the vacuuming by sucking air through the air intake holes 31 using a suction means such as a vacuum pump.

[0029] (Second Mold) The second mold 4 is used to bring a part of the resin sheet 2 into close contact with the first mold 3. As shown in Fig. 2 etc., the second mold 4 is attached to the lower surface 401 of the base 40. The base 40 has, for example, a rectangular plate shape.

[0030] The second mold 4 protrudes downward from the lower surface 401 of the base 40. The second mold 4 has an outer shape that is long in one direction. The second mold 4 is configured to press a portion of the resin sheet 2 from above, thereby causing the portion of the resin sheet 2 to adhere closely to the recess 32 of the first mold 3.

[0031] The second mold 4 has an end surface 45 that constitutes one end surface in the longitudinal direction of the second mold 4, and a recessed portion 47 located above the end surface 45. The end surface 45 is, for example, a flat surface.

[0032] The end face 45 of the second mold 4 faces horizontally and faces the face 325 of the first mold 3 (i.e., the part of the first mold 3 corresponding to the bottom face 125 of the bowl portion 12) during the pushing process described below.

[0033] The recessed portion 47 of the second mold 4 faces a portion 39 of the first mold 3 (i.e., the portion of the first mold 3 that corresponds to the undercut portion 19 of the urinal 1) in the pushing step described below.

[0034] When the urinal 1 is molded, a portion of the resin sheet 2 is rolled up into the recessed portion 47 of the second mold 4. As a result, the undercut portion 19 of the urinal 1 is prevented from being molded to be thin.

[0035] Furthermore, a positioning protrusion 48 is provided on the lower surface 401 of the base 40. The protrusion 48 is a protruding piece that protrudes downward from the lower surface 401. The second mold 4 is positioned relative to the first mold 3 by inserting the protrusion 48 into the recess 32 of the first mold 3.

[0036] (Transport Device) The transport device 5 is configured to vertically move the first mold 3. The transport device 5 preferably includes an electric cylinder, an air cylinder, a hydraulic cylinder, an electromagnetic solenoid, or an electric motor as a driving means.

[0037] (Lifter) The lifter 6 is configured to move the second mold 4 in the up and down direction. The lifter 6 preferably includes an electric cylinder, an air cylinder, a hydraulic cylinder, an electromagnetic solenoid, or an electric motor as a driving means.

[0038] In one embodiment of the manufacturing method for a urinal 1, a molding system 9 equipped with the above-mentioned first mold 3, second mold 4, conveying device 5 and lifter 6 carries out the heating process, covering process, pushing process and suction process described below.

[0039] (Heating Step) In the heating step, the molding system 9 uses a heater to heat the resin sheet 2. The heated resin sheet 2 softens.

[0040] (Coating Step) The coating step is carried out following the heating step.

[0041] In the covering step, the resin sheet 2 heated in the heating step is placed over the first mold 3 for forming the urinal 1 (see FIG. 2).

[0042] Specifically, the resin sheet 2 softened by heating is held in a stretched state between a first mold 3 and a second mold 4 positioned above it. The first mold 3 and the resin sheet 2 positioned above the first mold 3 are positioned at a distance in the vertical direction. At this point, the first mold 3 and the resin sheet 2 are not in contact with each other. Similarly, the resin sheet 2 and the second mold 4 positioned above the resin sheet 2 are positioned at a distance in the vertical direction. At this point, the resin sheet 2 and the second mold 4 are not in contact with each other.

[0043] In the covering step, the resin sheet 2 is held in a stretched state between the first mold 3 and the second mold 4, and then air is blown from below to above the resin sheet 2 through the air supply path. As a result, the heated resin sheet 2 expands upward, and the resin sheet 2 is elongated.

[0044] Next, in the covering step, the lifter 6 is lowered. When the lifter 6 is lowered, the second mold 4 comes into contact with the upper surface of the resin sheet 2, and the second mold 4 is pressed against the resin sheet 2 softened by heating, thereby deforming the resin sheet 2. As a result, the surface of the second mold 4 is covered with the resin sheet 2.

[0045] (Pressing Step) The pressing step is carried out after the covering step.

[0046] In the pushing step, the conveying device 5 is raised. When the conveying device 5 is raised, 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.

[0047] At this time, the second mold 4 is pressed against the resin sheet 2 from above, so that the resin sheet 2 is pressed against the inner surface of the recess 32. In the pressing step, the lower end surface 45 of the recess 47 of the second mold 4 is positioned opposite the portion 39 of the first mold 3.

[0048] (Suction Step) The suction step is performed following the pushing step.

[0049] In the suction step, the resin sheet 2 is sucked onto the molding surface of the first mold 3 by vacuuming. In this way, the molded member 1A shown in FIG.

[0050] Specifically, a vacuum is drawn using suction means such as a vacuum pump to suck air through the multiple air intake holes 31 in the first mold 3. As a result, the resin sheet 2 sandwiched between the recess 32 in the first mold 3 and the second mold 4 is tightly attached to the molding surface of the first mold 3 by the negative pressure, and is shaped into the shape of the urinal 1.

[0051] (Removal Step) The removal step is carried out following the suction step.

[0052] In the removal step, after the lifter 6 is raised, the molded member 1A is removed from the first mold 3. Then, the molded member 1A removed from the first mold 3 is subjected to trimming or numerically controlled (NC) processing to remove unnecessary portions from the molded member 1A, thereby obtaining the urinal 1.

[0053] (Details of Resin Sheet) The following describes the detailed structure of the resin sheet 2 used to form the urinal 1.

[0054] The resin sheet 2 is a thermoplastic resin sheet having, for example, a rectangular outer shape. As shown in Fig. 4, the resin sheet 2 has a plurality of resin layers 21 and 22. The plurality of resin layers 21 and 22 are, for example, a first resin layer 21 and a second resin layer 22.

[0055] The first resin layer 21 is a resin layer that constitutes the outermost layer of the resin sheet 2. The outermost layer here is the layer that forms the front surface of the urinal 1 after molding. The first resin layer 21 is formed from a first resin material that contains, for example, PMMA (polymethyl methacrylate) resin. PMMA resin is an example of a resin material that has excellent designability, stain resistance, and chemical resistance. Designability here includes both or either transparency and gloss. PMMA resin is also an example of a resin material that has excellent flame retardancy.

[0056] The second resin layer 22 is a resin layer that constitutes a layer below the first resin layer 21. The second resin layer 22 is formed from a second resin material containing at least one of ABS (acrylonitrile butadiene styrene) resin, PP (polypropylene) resin, PE (polyethylene) resin, PET (polyethylene terephthalate) resin, and ASA (acrylonitrile styrene acrylic rubber) resin. The above-mentioned ABS resin, PP resin, PE resin, PET resin, and ASA resin are examples of resin materials with excellent moldability. Here, moldability refers to the ability to be molded into a desired shape without cracking, including the ability to easily elongate when heated. The above-mentioned ABS resin, PP resin, PE resin, PET resin, and ASA resin are also examples of resin materials with excellent flame retardancy.

[0057] The urinal 1 of one embodiment is formed from a resin sheet 2 including a first resin layer 21 and a second resin layer 22, so that the outermost layer of the resin sheet 2 (i.e., the first resin layer 21) can be endowed with high designability and stain resistance. The lower layer of the resin sheet 2 (i.e., the second resin layer 22) can be endowed with high formability. Therefore, the resin sheet 2 as a whole has high designability, stain resistance, and chemical resistance, as well as high formability and flame retardancy.

[0058] 4, it is preferable that the thickness d2 of the second resin layer 22 is greater than the thickness d1 of the first resin layer 21. This allows the resin sheet 2 as a whole to exhibit high moldability.

[0059] 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 a recycled second resin material. The non-recycled layer 222 is a layer formed from a non-recycled second resin material, in other words, a virgin 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 FIG. 4 , the recycled layer 221 forms a lower layer of the non-recycled layer 222, but the recycled layer 221 may also form an upper layer of the non-recycled layer 222.

[0060] (Decorated Region and Plain Region) The resin sheet 2 forming the urinal 1 of one embodiment includes a decorated region R1 and a plain region R2.

[0061] The decorative region R1 is a region of the resin sheet 2 where the surface has been decorated by inkjet printing. In the decorative region R1, the surface of the first resin layer 21, which constitutes the outermost layer of the resin sheet 2, is decorated. The purpose of the decoration here is to impart design and functionality to the surface of the urinal 1. In particular, by imparting a pattern and / or color to the surface of the urinal 1, it is possible to significantly improve the design of the urinal 1.

[0062] The plain region R2 is the region of the resin sheet 2 excluding the decorated region R1, in other words, the region of the resin sheet 2 that is not decorated on the 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 the decorated region R1, and the portion not decorated by inkjet printing is the plain region R2.

[0063] In one embodiment, the molding system 9 heats the resin sheet 2 including the decorative region R1 and the plain region R2 in the heating step.

[0064] In one embodiment of the molding system 9, in the covering step, the resin sheet 2 including the decorative region R1 and the plain region R2 is placed over the first mold 3. At this time, the second mold 4 is placed directly above the plain region R2 of the resin sheet 2, and the recess 32 of the first mold 3 is placed directly below the plain region R2 of the resin sheet 2. In other words, the plain region R2 of the resin sheet 2 is placed between the recess 32 of the first mold 3 and the second mold 4 located directly above it. The decorative region R1 of the resin sheet 2 is placed directly above the portion of the first mold 3 excluding the recess 32.

[0065] The plain region R2 has an outer shape that is long in one direction. In the covering process, the longitudinal direction of the plain region R2 coincides with the longitudinal direction of the recess 32 and the longitudinal direction of the second mold 4.

[0066] When the second mold 4 descends, the second mold 4 is pressed against the upper surface of the plain region R2 of the resin sheet 2, thereby deforming the resin sheet 2. In particular, the plain region 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 with the plain region R2 of the resin sheet 2.

[0067] In one embodiment, when the first mold 3 is raised in the pushing step, the plain region 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, the second mold 4 is pressed from above against the plain region R2 of the resin sheet 2, and the plain region R2 of the resin sheet 2 is pushed into the recess 32 of the first mold 3 by the second mold 4.

[0068] In one embodiment, in the suction step, the plain region R2 of the resin sheet 2 sandwiched between the recess 32 of the first mold 3 and the second mold 4 is sucked by vacuuming onto the molding surface of the recess 32 of the first mold 3. Also, the decorative region R1 of the resin sheet 2 is sucked by vacuuming onto the molding surface of the first mold 3 excluding the recess 32.

[0069] In one embodiment, in the removal process, unnecessary portions of the molded member 1A removed from the first mold 3, which are included in the peripheral portion of the decorative area R1, are removed to produce a urinal 1 with enhanced design through decoration.

[0070] The surface of the manufactured urinal 1 includes a decorated surface 101 formed by the decorated region R1 of the resin sheet 2 and a plain surface 102 formed by the plain region R2 of the resin sheet 2.

[0071] The decorative surface 101 includes the surface of the portion of the urinal 1 excluding the bowl portion 12. The decorative surface 101 includes the entire surface of the portion of the urinal 1 excluding the bowl portion 12, but it is also preferable that the decorative surface 101 include a portion of that surface.

[0072] In detail, the decorative surface 101 includes the surfaces of the pair of side walls 14. The decorative surface 101 includes the entire surfaces of the pair of side walls 14, but preferably includes only a portion of the surfaces. Here, the surfaces of the side walls 14 include main surfaces 142 facing the left and right sides of the side walls 14 and end surfaces 145 facing forward. In one embodiment, the main surfaces 142 and end surfaces 145, which are continuous with each other, of the side walls 14 are decorated, but for example, only the main surfaces 142 or the end surfaces 145 may be decorated. In other words, the decorative surface 101 may include both or either of the main surfaces 142 and end surfaces 145 of the side walls 14.

[0073] The decorated surface 101 includes the surface of the front wall 16. The decorated surface 101 includes the entire surface of the front wall 16, but preferably includes a portion of the surface. Here, the surface of the front wall 16 includes a main surface 162 facing forward and an end surface 165 facing upward of the front wall 16. In one embodiment, the main surface 162 and the end surface 165, which are continuous with each other, of the front wall 16 are decorated, but for example, only the main surface 162 or the end surface 165 may be decorated.

[0074] The decorative surface 101 includes the surface of the upper wall 18. The decorative surface 101 includes the entire surface of the upper wall 18, but preferably includes a portion of this surface. Here, the surface of the upper wall 18 includes the main surface 182 of the upper wall 18 facing upward and the end surface 185 facing forward. In other words, the main surface 182 and the end surface 185, which are continuous with each other, of the upper wall 18 are decorated, but it is also possible to decorate only the main surface 182 or the end surface 185, for example. In other words, the decorative surface 101 only needs to include both or either the main surface 182 and the end surface 185 of the upper wall 18.

[0075] The unfaced surface 102 includes the surface of the bowl portion 12. The unfaced surface 102 includes the entire surface of the bowl portion 12, but it is also preferable that the unfaced surface 102 include a portion of the surface.

[0076] In detail, the unformed surface 102 includes the receiving surface 121 of the bowl portion 12 and the bottom surface 125 of the bowl portion 12. The unformed surface 102 also includes the surface of the undercut portion 19. The unformed surface 102 may include at least one of the receiving surface 121 of the bowl portion 12, the bottom surface 125 of the bowl portion 12, and the surface of the undercut portion 19.

[0077] 2. Modifications The above embodiment is merely one of various embodiments of the present disclosure. The above embodiment can be modified in various ways depending on the design, etc., as long as the object of the present disclosure can be achieved.

[0078] Modifications of the above embodiment will be described below. In the description of the modifications, the same components as those described in the above embodiment will be denoted by the same reference numerals and detailed description will be omitted. The various modifications listed below can be applied in appropriate combination.

[0079] In one embodiment, at the boundary between the decorative region R1 and the plain region R2 of the resin sheet 2, a large contrast occurs between the regions R1 and R2 on both sides, but it is also preferable to provide a gradation to reduce the contrast here and blur the boundary.

[0080] That is, in the decorative region R1 of the resin sheet 2, a portion adjacent to the plain region R2 is preferably decorated with a gradation that approaches the plain color continuously or stepwise (see FIG. 7).

[0081] In other words, it is preferable that the portion of the decorative region R1 of the resin sheet 2 adjacent to the plain region R2 be composed of a gradation region R10 that approaches plain continuously or gradually, in order to blur the boundary between the decorative region R1 and the plain region R2.

[0082] Furthermore, in this case, it is preferable that the boundary line between the decorative region R1 and the plain region R2 of the resin sheet 2 has a serpentine shape (see FIG. 7). In other words, it is preferable that the boundary line between the gradation region R10 of the decorative region R1 of the resin sheet 2 and the plain region R2 has an irregular or regular serpentine shape. This makes the boundary between the decorative region R1 and the plain region R2 even more ambiguous. The above-mentioned boundary line is not an actually drawn boundary line, but a virtual boundary line.

[0083] In one embodiment, the decorative region R1 of the resin sheet 2 is decorated by inkjet printing, but the means for decorating the resin sheet 2 is not limited to this, and for example, the resin sheet 2 may be decorated by screen printing, or the resin sheet 2 may be decorated by adhering an appropriate decorative film.

[0084] 3. Summary As explained based on the above embodiment and modified examples, the manufacturing method for a urinal (1) of the first aspect is a method for manufacturing a urinal (1) having a bowl portion (12) using a thermoplastic resin sheet (2). The manufacturing method for a urinal (1) of the first aspect includes a covering step, a pushing step, and a suction step. The covering step is a step of covering the resin sheet (2) with a first mold (3) for molding the urinal (1). The pushing step is a step of pushing the resin sheet (2) toward the first mold (3) using a second mold (4). The suction step is a step of sucking the resin sheet (2) pushed into the first mold (3) into the first mold (3). The resin sheet (2) includes a decorated region (R1) and an undecorated plain region (R2). The first mold (3) includes a recess (32) for molding the bowl portion (12) of the urinal (1). In the pushing step, the plain region (R2) of the resin sheet (2) is pushed into the recessed portion (32) of the first mold (3) by the second mold (4). In the suction step, the plain region (R2) is sucked into the recessed portion (32) of the first mold (3), and the decorative region (R1) is sucked into the portion of the first mold (3) excluding the recessed portion (32).

[0085] According to this aspect, decoration can be applied to the urinal (1) except for the bowl portion (12), and the decoration of the resin sheet (2) is prevented from being transferred to the second mold (4).

[0086] In the manufacturing method of the urinal (1) of the second aspect, in the first aspect, the urinal (1) further has a pair of side walls (14) positioned at a distance from each other in the left-right direction on either side of the bowl portion (12). The portion of the first mold (3) excluding the recess (32) includes a pair of wall portions (34) for forming the pair of side walls (14).

[0087] According to this aspect, the pair of side walls (14) of the urinal (1) can be decorated, and the decoration on the resin sheet (2) is prevented from being transferred to the second mold (4).

[0088] In the manufacturing method for a urinal (1) of the third aspect, in the first or second aspect, the urinal (1) further has an upper wall (18) located above the bowl portion (12). The portion of the first mold (3) excluding the recess (32) includes a wall portion (38) for forming the upper wall (18).

[0089] According to this embodiment, the upper wall (18) of the urinal (1) can be decorated, and the decoration of the resin sheet (2) is prevented from being transferred to the second mold (4).

[0090] In the manufacturing method for the urinal (1) of the fourth aspect, in any one of the first to third aspects, the decorative region (R1) of the resin sheet (2) is decorated by inkjet printing.

[0091] According to this embodiment, the transfer of the decoration of the resin sheet (2) by inkjet printing to the second mold (4) is suppressed.

[0092] The manufacturing method for the urinal (1) of the fifth aspect is any one of the first to third aspects, wherein the decorative region (R1) of the resin sheet (2) is decorated by adhering a decorative film.

[0093] According to this embodiment, the decoration of the resin sheet (2) by the decorative film is prevented from being transferred to the second mold (4).

[0094] The sixth aspect of the method for manufacturing a urinal is any one of the first to fifth aspects, in which the portion of the decorated area (R1) adjacent to the plain area (R2) is decorated so as to approach plainness continuously or in stages.

[0095] According to this aspect, the boundary between the decorative area (R1) and the plain area (R2) becomes unclear, so that the occurrence of a visually incongruous feeling in the molded urinal (1) is suppressed.

[0096] A seventh aspect of the method for manufacturing a urinal is the sixth aspect, wherein the boundary line between the decorative region (R1) and the plain region (R2) has a serpentine shape.

[0097] According to this aspect, the boundary between the decorative area (R1) and the plain area (R2) becomes even more ambiguous, further reducing the occurrence of a visually incongruous feeling in the molded urinal (1).

[0098] DESCRIPTION OF SYMBOLS 1 Urinal 12 Bowl portion 14 Side wall 18 Upper wall 2 Resin sheet 3 First mold 32 Recess 34 Wall portion 38 Wall portion 4 Second mold R1 Decorative region R2 Plain region

Claims

1. A method for manufacturing a urinal having a bowl portion using a thermoplastic resin sheet, comprising: a covering step of covering a first mold for molding the urinal with the resin sheet; a pushing step of pushing the resin sheet toward the first mold using a second mold; and a suction step of sucking the resin sheet that has been pushed into the first mold into the first mold, wherein the resin sheet includes a decorated area and a plain area that is not decorated, and the first mold includes a recess for molding the bowl portion of the urinal, wherein in the pushing step, the second mold pushes the plain area of ​​the resin sheet into the recess of the first mold, and in the suction step, the plain area is sucked into the recess of the first mold and the decorated area is sucked into the part of the first mold excluding the recess.

2. A method for manufacturing a urinal as claimed in claim 1, wherein the urinal further has a pair of side walls positioned at a distance from each other in the left-right direction on either side of the bowl portion, and the portion of the first mold excluding the recess includes a pair of wall portions for forming the pair of side walls.

3. A method for manufacturing a urinal as claimed in claim 1 or 2, wherein the urinal further has an upper wall located above the bowl portion, and the portion of the first mold excluding the recess includes a wall portion for forming the upper wall.

4. A method for manufacturing a urinal according to any one of claims 1 to 3, wherein the decorative area of ​​the resin sheet is decorated by inkjet printing.

5. A method for manufacturing a urinal according to any one of claims 1 to 3, wherein the decorative area of ​​the resin sheet is decorated by adhering a decorative film.

6. A method for manufacturing a urinal according to any one of claims 1 to 5, wherein the decorative area is decorated in a portion adjacent to the plain area so as to approach the plain area continuously or in stages.

7. The method for manufacturing a urinal according to claim 6, wherein the boundary line between the decorative area and the plain area has a serpentine shape.

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