JP4410090B2 - Drain trap and method for manufacturing the same - Google Patents

Description

  The present invention relates to a drain trap for guiding drainage generated in a bathroom, a washroom or the like to a downstream drainage facility such as a sewer pipe after storing the drainage in a storage unit having a deodorizing mechanism, and a method for manufacturing the drain trap.

  For example, a drain trap is known which is installed on the floor surface of a so-called unit bath. This type of drain trap is equipped with a deodorization mechanism in the hollow part that stores the waste water generated in the bathtub and wash basin, and has an intake of drainage that flows from the floor on the upper surface of the hollow part, and the bathtub and wash surface on the side. It has a drainage connection port connected to the base. Such a drain trap is a set of two divided bodies, that is, an upper divided body including an upper surface where an intake port is formed and a lower divided body other than the upper divided body, and each divided body is molded in advance by a resin. Then, the hollow portion is formed and manufactured by welding the divided surfaces to each other.

  As a technique for manufacturing such a drain trap, for example, one described in Patent Document 1 is known. This is manufactured by making the joints on the respective split surfaces flush, melting the hot plate against both joints, bringing the melted joints into contact with each other, and joining. According to the manufacturing technique of Patent Document 1, since the shape of the joint portion is the same, it is only necessary to apply a flush hot plate to the joint portion, and a complicated shape hot plate can be dispensed with.

  In addition, in Patent Document 2, after a pair of protrusions extending continuously or intermittently along the welded portion are resin-molded on the welded portions provided on the respective split surfaces, the welded portions are heated. A welding technique is disclosed in which a welded portion is brought into a molten state by being brought into contact with a plate and heated, and then the welded portions are pressed and welded together. According to the welding technique disclosed in Patent Document 2, even if the welded portion has some unevenness or distortion, the ridges in contact with the hot plate are melted, and the welded portion is evenly distributed by heat conduction from the ridges. It is possible to melt evenly by being heated, and thus it is possible to suppress the occurrence of thermal distortion and incompletely welded portions of the obtained resin molded product.

JP-A-6-306907 JP-A-4-166324

  However, the manufacturing technique of Patent Document 1 can only be applied to a drain trap in which the joints are flush with each other, and the shape of the joint is limited. When applied to a joint having a shape, there is a problem in that a possibility that a gap is generated is high.

  On the other hand, in the welding technique of Patent Document 2, the upper split body and the lower split body of the drain trap are respectively formed using an injection molding apparatus, and a separate welding apparatus is used for welding the split surfaces of both split bodies. As a result, a large number of devices are used in a series of manufacturing processes. Therefore, a problem has arisen in that a large installation space for these devices must be secured. In addition, a temporary storage space for the molded divided body must be secured between the molding process and the welding process, and there is a problem in that it takes time to set up the transfer from the molding apparatus to the welding apparatus. was there.

  Therefore, in view of the above problems, the present invention can be welded without a gap even when the dividing surface of the drain trap has a complicated shape including an inclined surface with respect to the reference surface. It is an object of the present invention to provide a drainage trap that can reduce the installation space and can save the labor of setup between processes, and a manufacturing method thereof.

In order to solve the above-mentioned problem, a drain trap according to the invention of claim 1 has a lid provided with a drainage intake port on the top surface, and an upper surface formed so as to coincide with the entire peripheral edge of the lid body. outflow pipe of the drainage is to have a hollow trap body comprising comprising a dividing plane which is split of the tub body projecting from the side wall portion, the lid body via the inclined surface plate portion serving as the up slope wherein a discharge pipe drain trap top ing provided with a tip end plate in contact Te, the lid and the tub body, will be molded separately by injecting primary molten resin, the trap body, the The lid and the casing are butted against each other at a split surface including an upslope, the molten resin is secondarily injected along the butted surface, and the lid and the casing are welded and hollow molded, The molten resin used in the secondary injection is the same as that used in the primary injection. The same material as the resin, abutting surfaces, formed by integrally welding by causing Tokeawa the primary injection and the secondary injection of each of the molten resin.

The drain trap according to the invention of claim 2 is a butting surface that comes into close contact with each other when the split surfaces of the lid and the housing are brought into contact with the peripheral end of the lid and the opening end of the housing. A band-shaped flange is projected, a groove is formed on at least one abutting surface of both collars, and in a state where both collars are butted, a tubular path along the abutting surface is formed by the groove. A small-diameter communication hole for communicating the inside and the outside of the tubular passage is formed in the collar portion of the lid, and the molten resin is secondarily injected into the tubular passage.

According to a third aspect of the present invention, there is provided a drain trap manufacturing method comprising: a lid provided with a drainage intake port on the top surface; an upper surface formed to coincide with the entire peripheral edge of the lid; Has a hollow trap body having a split surface divided into two, and a casing projecting from the side wall, and the lid body is connected to the outflow pipe via an inclined plate portion that becomes an upward inclined surface. A method for producing a drain trap comprising a tip plate portion that is in contact with an upper portion, wherein the lid body and the casing are molded by a primary molding step in which molten resin is first injected and separately molded. After the lid body and the casing are abutted with each other at a dividing surface including an upslope, a molten resin made of the same material as the molten resin used in the primary molding step is secondarily injected along the abutting surface. Then, melt each molten resin of primary injection and secondary injection, Integrally welded to come mating surface configured to include a secondary molding step for blow molding the trap body.

In the drain trap manufacturing method according to the fourth aspect of the present invention, when the primary forming step abuts the respective divided surfaces of the lid and the housing on the peripheral end of the lid and the opening end of the housing, In the state where the band-shaped flange portion is protruded so as to be in close contact with the groove, and the groove-shaped portion is formed on at least one of the butted surfaces of the both flange portions, the groove-shaped portion is Forming a tubular path along the abutting surface, and forming a small-diameter communication hole in the collar portion of the lid for communicating the inside and outside of the tubular channel on the collar upper surface, and the secondary molding step configured to include a step of injecting secondary molten resin into the tubular passage.

According to the first and third aspects of the invention, the lid and the casing are molded by separately injecting the molten resin into a primary mold, and these divided bodies are molded by secondary injection of the molten resin to form a hollow trap body. As a result, even if the lid and the casing are abutted with a split surface having a complicated shape including an inclined surface with respect to the reference surface, the possibility that a gap may be generated on the abutting surface can be eliminated, and the drainage can be stored without leakage. A highly reliable drainage trap can be obtained. Furthermore, since the trap body can be formed by a pair of molds of the first mold and the second mold, the installation space for the apparatus can be reduced. Further, by combining the fixed mold and the movable mold, the primary and secondary molding processes can be performed with the same apparatus, and the setup effort between both processes can be saved.

According to the second and fourth aspects of the invention, when the mutual dividing surfaces of the lid and the housing are brought into contact with the peripheral end of the lid and the opening end of the housing, the abutting surfaces are brought into close contact with each other. A band-shaped flange is projected, a groove is formed on at least one abutting surface of both collars, and in a state where both collars are butted, a tubular path along the abutting surface is formed by the groove. A small-diameter communication hole for communicating the inside and outside of the tubular passage is formed in the collar portion of the lid, and the molten resin is injected into this tubular passage and welded. The reliability can be further improved by further improving the reliability. Furthermore, since the communication hole is provided in the collar portion of the lid, it is possible to easily confirm whether or not the welding resin has spread over the entire circumference of the tubular path when the welding resin is injected into the tubular path.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings. 1A and 1B show the appearance of a trap body formed according to the present invention. FIG. 1A is a plan view, FIG. 1B is a side view, and FIG. 2A and 2B are cross-sectional views of the trap body, wherein FIG. 2A is an enlarged cross-sectional view taken along line AA of FIG. 1A, FIG. 2B is an enlarged cross-sectional view of B portion of FIG. 2A, and FIG. It is an enlarged view. FIG. 3 is an explanatory cross-sectional view showing the assembled state of the drain trap.

  The drain trap 1 is a unit bath constructed by arranging a bathtub and a wash basin in a standardized unit formed by integrally molding a ceiling, a wall and a floor, for example, with a highly waterproof material. It is installed underneath, and is configured so that domestic wastewater generated in a bathtub or washstand is taken into the trap body 4 and temporarily stored, and then guided to a downstream drainage facility such as a sewage tank or a sewage pipe. The trap body 4 includes a lid 2 as an upper divided body having a domestic wastewater intake 15 and a bowl as a lower divided body having an upper surface formed to coincide with the entire peripheral edge of the lid 2. Two divided bodies with the body 3 are separately molded in advance with a molding resin, and then the entire peripheral end of the lid 2 and the opening end of the housing 3 are butted together and further welded along the butted surface Is formed into a hollow shape by welding.

  As shown in FIG. 1, the lid body 2 includes a circular plate portion 12, a slant that is narrowed down to a predetermined width outward from a part of the peripheral edge of the circular plate portion 12, and extends so as to be an upward slope. It consists of a face plate portion 13 and a tip plate portion 14 formed at the tip of the narrowing via the slope plate portion 13, and the slope plate portion 13 makes the step between the circular plate portion 12 and the tip plate portion 14 a predetermined height T. It is formed in plate shape provided with. In the center of the circular plate part 12, when the drain trap 1 is installed in a unit bath, a drain intake 15 connected to an opening provided on the floor is provided.

  On the other hand, the housing 3 is composed of a bottom plate portion 17 and a side wall portion 18 erected so as to have a slight angle gradient from the entire circumference upward, and the standing tip of the side wall portion 18 is the whole of the lid body 2. It is formed in a bottomed bowl shape so as to be an open end that coincides with the peripheral end. On the side wall 18, two inflow pipes 20, 21 and one outflow pipe 22 communicating with the inside of the housing 3 are projected in a lateral direction from a predetermined position.

  The outflow pipe 22 protrudes horizontally from the position where the pipe upper portion is in contact with the distal end plate portion 14 and the tube axis thereof coincides with the narrowing direction of the inclined plate portion 13 of the lid 2 in the side wall portion 18. One of the two inflow pipes 20, 21 protrudes from the side wall 18 at the symmetrical position of the outflow pipe 22 with the lower part of the pipe 20 along the bottom surface of the housing 3. Similarly, the other inflow pipe 21 protrudes from the side wall 18 at a position orthogonal to the outflow pipe 22. The outflow pipe 22 is formed to have a pipe diameter of 50A, for example, and the inflow pipes 20 and 21 are formed to have a pipe diameter of 30A, for example. The outflow pipe 22 is provided so that the lower part of the pipe is higher than the upper parts of the inflow pipes 20 and 21.

  Further, as shown in FIG. 2, the peripheral end of the lid body 2 and the opening end of the housing 3 are abutting surfaces that are in close contact with each other when the divided surfaces of the lid body 2 and the housing 3 are abutted with each other. In addition, strip-shaped flange portions 24 and 25 are provided so as to protrude laterally over the entire circumference. Groove-shaped portions 26 and 27 having a substantially semicircular cross section are formed on the entire butting surfaces of both flange portions 24 and 25 over the entire circumference. The respective groove-like portions 26 and 27 are provided so as to form a tubular passage 28 having a substantially circular cross section in a state in which both flange portions 24 and 25 are abutted. Further, in particular, the collar portion 24 of the lid body 2 is provided with eight small-diameter communication holes 30 for communicating the inside of the tubular passage 28 with the outside at predetermined positions on the upper surface of the collar portion 24.

  As shown in FIG. 3, the drain trap 1 is a lock nut in which a female thread portion is formed on the inner periphery of the intake port 15 of the circular plate portion 12 in a state where the trap body 4 is formed by the lid body 2 and the housing 3. 6 is fitted through a rubber packing 7, and a deodorizing cylinder 8 having a male screw portion formed on the outer periphery thereof is screwed onto the female screw portion of the lock nut 6. The deodorizing cylinder 8 is formed so as to taper downward toward the center. When the deodorizing cylinder 8 is engaged with the lock nut 6, the tip protrudes from the upper side to the inside of the bowl-shaped deodorizing container 9 bonded to the bottom plate portion 17 of the casing 3, and is combined with the deodorizing container 9. Thus, a sealed water portion 11 that blocks off-odour from the downstream drainage facility is formed. The eye plate 16 is screwed into the receptacle of the deodorizing cylinder 8.

  The drain trap 1 is installed at a predetermined position of the unit bath. As shown in FIG. 1, the inflow pipes 32 and 33 are connected to the inflow pipes 20 and 21, respectively, and the outflow pipe 34 is connected to the outflow pipe 22. . One inflow pipe 32 is connected to the drain of the bathtub, and the other inflow pipe 33 is connected to the drain of the sink. The outflow pipe 34 is connected to a drainage facility located downstream of the drain trap 1.

  In the drain trap 1 configured as described above, the drainage generated in the bathtub or the washroom is transferred from the inflow pipes 20 and 21 to the inside of the trap body 4 through the inflow pipes 32 and 33 connected thereto, respectively. Flows in. Similarly, drainage generated on the floor surface also flows from the receptacle of the deodorizing container 9 through the eye plate 16. Then, the wastewater stored inside flows into the outflow pipe 34 through the outflow pipe 22 and is sent to the drainage facility. At this time, the off-sea odor entering the unit bath from the downstream drainage facility or the like is blocked by the sealing portion 11 which is a deodorizing mechanism.

Next, the shaping | molding procedure of the trap main body 4 is demonstrated using Fig.4 (a)-(e). In addition, the trap main body 4 in the figure shows a schematic shape. The injection molding apparatus used in the main molding includes a first mold 42 that is a fixed mold, and a second mold 43 that is opposed to the first mold 42 and is movable in the vertical and horizontal directions in the drawing. And is configured.
In this injection molding apparatus, the first mold 42 molds the outer side surface portion of the lid body 2 and the inner side surface portion of the housing 3, and the second mold 43 forms the outer surface portion of the housing 3 and the inner side surface portion of the lid body 2. It is designed to be molded. Then, in a state where the molds 42 and 43 are matched with each other, a molten resin material for molding is primarily injected from the nozzle 47 through the sprue 45 into the cavities of the lid 2 and the casing 3, and the lid 2 And the casing 3 are molded (primary molding step, FIG. 4A).

After the lid 2 and the casing 3 are molded, when the second mold 43 moves to the right in the drawing so as to be detached from the first mold 42, the lid 2 is moved to the first mold 42. Further, the housing 3 is removed from the mold in a state of being matched with the second mold 43 (FIG. 4B).
Subsequently, in the present embodiment, the second mold 43 is moved downward in the drawing, and the lid 2 and the casing 3 are set so as to face each other with a gap (FIG. 4C).

Next, the second metal mold 43 is moved to the left side so that the abutting surfaces of the lid body 2 and the housing 3 are abutted with each other, and the tubular path formed by the grooves 26 and 27 between the lid body 2 and the housing 3 is formed. 28, the molten resin material for welding is secondarily injected from the nozzle 48 through the sprue 46 (secondary molding step, FIG. 4 (d)).
Thereafter, the trap body 4 is formed by removing the molds from both the molds 42 and 43 (FIG. 4E).
And the deodorizing mechanism etc. which consist of the deodorizing cylinder 8 and the deodorizing container 9 are integrated in the trap main body 4, and the drain trap 1 is formed (FIG. 3).

  According to such a drain trap 1, the divided surfaces of the lid body 2 and the housing 3 are provided with inclined surfaces with respect to a predetermined reference surface, and even when they are abutted at the divided surfaces, along the abutting surface Since the welding resin is used for welding, it is possible to eliminate the possibility of forming a gap on the mutual butting surfaces as well as the lid 2 and the casing 3, and it is possible to obtain a highly reliable drainage trap for storing drainage without leakage. Further, since the trap body 4 can be formed by a pair of molds of the first mold 42 and the second mold 43, the installation space of the apparatus can be reduced. Furthermore, the combination of the fixed mold and the movable mold allows the primary and secondary molding processes to be performed with the same apparatus, and the setup effort between the two processes can be saved.

  Further, the groove portions 26 and 27 are molded on the abutting surfaces of the lid body 2 and the casing 3, and the welding resin is injected and welded to the tubular path 28 formed by the groove portions 26 and 27. Further, the mutual adhesion of the butted surfaces of the flange portions 24 and 25 can be further enhanced, and the reliability of welding can be further improved. Moreover, it can prevent that molten resin protrudes and can improve the designability. Further, since the communication hole 30 is provided in the collar portion 24 of the lid body 2, whether or not the welding resin has spread over the entire circumference of the tubular path 28 when the welding resin is injected into the tubular path 28 is confirmed. Is easy to do.

The present invention is not limited to the above-described embodiment, and can be implemented by appropriately changing the shape and configuration of each part without departing from the spirit of the present invention, as exemplified below. .
(1) In this method, after the first molding step, before the lid body 2 and the casing 3 are abutted and welded in the second molding step, separate constituent members such as the deodorizing container 9 are previously provided in the casing 3. It is also possible to provide an assembling step for bonding inside.
(2) The molten resin used in the primary injection and the secondary injection may be made of the same material. By fusing the respective molten resins of the primary injection and the secondary injection, when the abutting surfaces are welded together, the resins are easily adapted to each other, and the reliability of welding can be further improved.
(3) The trap body is not limited to the horizontal type in which the outflow pipe protrudes from the side wall portion in the horizontal direction, but may be a vertical type in which the outflow pipe protrudes downward from the bottom surface portion.
(4) The trap body is not limited to two inflow pipes, and may be one or other plurality of projecting pipes.
(5) The trap body is not limited to a shallow bottom shape, but can also be formed in a deep bottom shape.

An embodiment of the drain trap concerning the present invention is shown, (a) is a top view showing the appearance of a trap body, (b) is the side view, and (c) is the front view. 1 shows a cross section of the trap body of FIG. 1, wherein (a) is an AA line enlarged cross-sectional view, (b) is a B portion enlarged cross sectional view, and (c) is a C portion enlarged cross sectional view. It is a section explanatory view showing one embodiment of a drain trap concerning the present invention. One embodiment of the manufacturing method of the drain trap concerning the present invention is shown, and (a)-(e) is a molding procedure explanatory view of a trap main part.

Explanation of symbols

1 .... Drain trap, 2 .... Cover body as upper divided body, 3 .... Cast body as lower divided body, 4 .... Trap body, 12 .... Circular plate portion, 13 .... Slope plate portion, 14 ..Tip plate part, 15 ..Inlet, 17 ..Bottom plate part, 18 ..Side wall part, 20, 21 ..Inflow pipe, 22 ..Outflow pipe, 24,25.・ Groove part, 28 ・ ・ Tubular passage, 30 ・ ・ Communication hole.

Claims (4)

A lid having a drainage intake on the top surface, and a housing having an opening formed on the top surface so as to coincide with the entire peripheral edge of the lid and a drainage outflow pipe projecting from the side wall. hollow trap body consisting comprises a divided surface becomes chromatic to the who, the lid is in the name Ru drain trap comprises a tip end plate in which the outlet pipe upper contacts through the slant plate portion serving as the up slope There,
The lid body and the casing are molded separately by primary injection of molten resin,
Trap body, abutting together and the tub body and the lid by dividing plane including the upstream slope, by injecting secondary molten resin along the abutment surfaces, the hollow is welded to said trough body and the lid member Molded,
The molten resin used in the secondary injection is made of the same material as the molten resin used in the primary injection, and the butt surface is integrally welded by melting the molten resin of the primary injection and the secondary injection. Become
Drainage trap characterized by that. A band-shaped collar portion is projected from the peripheral edge of the lid body and the opening end of the housing so as to be an abutting surface that comes into close contact with each other when the divided surfaces of the lid body and the housing are abutted against each other.
Forming a groove-like portion on at least one abutting surface of both flange portions ,
In the state where the both buttocks are butted together, a tubular path along the butted surface is formed by the groove-shaped portion,
In the lid part of the lid, a small-diameter communication hole for communicating the inside of the tubular path and the outside is drilled in the upper part of the collar part,
Formed by the secondary injecting a molten resin into said tubular passage,
The drain trap according to claim 1. A lid having a drainage intake on the top surface, and a housing having an opening formed on the top surface so as to coincide with the entire peripheral edge of the lid and a drainage outflow pipe projecting from the side wall. A drain trap having a hollow trap body provided with a divided surface, and the lid body having a tip plate portion in contact with the upper portion of the outflow pipe through a slope plate portion that becomes an upward slope. A method,
The lid and the casing are abutted against each other at a primary molding step in which molten resin is primarily injected and separately molded, and the molded lid and the casing are separated by a split surface including an ascending slope . After that, along the butt surface, the molten resin made of the same material as the molten resin used in the primary molding process is secondarily injected, and the molten resin of the primary injection and the secondary injection are melted together to make a butt A secondary molding step of integrally welding the surfaces and hollow-molding the trap body, and
A method for manufacturing a drain trap. The primary molding process
A band-shaped collar portion is projected from the peripheral edge of the lid body and the opening end of the housing so as to be an abutting surface that comes into close contact with each other when the divided surfaces of the lid body and the housing are abutted against each other.
A groove-like portion is formed on at least one abutting surface of both collar portions, and in a state where both collar portions are abutted, a tubular path along the abutting surface is formed by the groove-shaped portion, and a tubular path is formed on the collar portion of the lid. Including a step of drilling a small-diameter communication hole in the upper surface of the buttock for communicating the inside and the outside ,
The secondary molding process
Comprising the step of injecting secondary molten resin into said tubular passage,
The method for producing a drain trap according to claim 3 .

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