DE102021113411B4 - Process for the production of a sanitary device - Google Patents

Abstract

Method for producing a sanitary facility, in which a sheet metal (1) cut to size is supplied, which has a base (2) and at least one edge section (3) protruding relative to the base (2), the edge section (3) being attached to the base ( 2) the adjoining edge is at least partially angled and in a subsequent step a trough-shaped contour is introduced at least in sections into the base area (2), characterized in that to form a trough-shaped contour the metal sheet (1) or at least the base area (2) of the Sheet metal (1) is subjected to pressure on a first side, which presses the sheet metal against a trough-shaped surface (10) of a mold (6) on a second side, forming a plastic deformation, and at least partial enamelling then takes place.

Description

The invention relates to a method for producing a sanitary facility according to the preamble of patent claim 1.

The sanitary facility is preferably a sanitary tub, in particular a sanitary tub made of steel enamel. However, the production of other sanitary items is also included. This sanitary facility can also be a sanitary basin, e.g. B. sinks, or panels that z. B. serve as a cladding element or veneers for other sanitary items.

When manufacturing sanitary facilities from steel enamel, a blank must be formed before the actual enamelling, which already essentially has the final shape of the sanitary facility. For this purpose, for example, to form a sanitary tub, a sheet metal cut to size can be formed in a deep-drawing process, with a base body having a tub shape being formed in the course of the shaping. This tub shape is required in order to convey water in the direction of a trough when the sanitary tub is installed, with a drain opening then being arranged at the deepest point of this trough.

It is generally known that sanitary facilities, in particular sanitary tubs, can be designed without a rim and then, depending on the type, only have an embossed tub shape. In addition, such sanitary tubs and also other sanitary facilities usually have edges that are angled relative to the base body, via which the dimensional stability of the base body is increased. In such a case, after the trough shape has been formed, the metal sheet is angled at lateral sections, such angling being not limited to specific configurations within the scope of the invention. Rather, an angled portion means that the metal sheet has lateral sections that are positioned opposite the base area. It is also known from practice that these bends can also be formed together with the embossing of the trough shape. Furthermore, although such rims are usually provided for reasons of stability, they can also be part of the tub shape of the relevant sanitary appliance. In such a case, the raised edges form a trough shape, which is supplemented by the embossing in the base area. Both configurations can be provided within the scope of the invention.

The tub shape and possibly also the edging of the edges are usually formed with the help of deep-drawing tools. This means that different tools have to be provided for each different design and each different size of facility, with the manufacturer not knowing just before the production of a new series in what quantity the sanitary facilities have to be produced. At the same time, there is always an effort to reduce warehousing. This can be achieved, for example, by designing the basic shape of the individual sanitary facilities to be the same for different tub shapes, so that different sanitary facilities can be manufactured starting from a sanitary facility blank.

From the DE 10 2015 010 508 A1 a method is also known in which the edge sections are first angled and then the surface is structured. This can be done, for example, by means of a coating. This is followed by deep drawing.

The present invention is based on the object of specifying a method which, compared to previous production methods, is characterized by a higher degree of cost efficiency and greater flexibility.

This object is achieved by a method according to patent claim 1. According to this, a sheet metal cut to size is first fed in, which has a base area and at least one edge section protruding relative to the base area, the edge section being at least partially angled at an edge adjoining the base area and in one thereon subsequent step, a trough-shaped contour is introduced at least in sections into the base area. Compared to previous manufacturing methods, the invention is characterized in particular by an unusual process sequence, with the edge sections first being bent before the actual contour is embossed into the base area. This makes it possible to form a sanitary blank that is only finished in a subsequent forming step. The sanitary blank can then be used for different tub shapes and is therefore initially not restricted in terms of its precise configuration.

Proceeding from this, the invention provides that the metal sheet or at least the base area of the metal sheet is subjected to pressure on a first side, which presses the metal sheet against a trough-shaped surface of a mold on a second side, forming a plastic deformation. Correspondingly, the molding tool provides the shape to be manufactured, which the sanitary facility will have after manufacture should show. Pressure can be applied in the usual way.

For example, as part of a deep-drawing process or a free-drawing process, the print can be applied to the second side using an embossing stamp. Finally, the sanitary facility blank is enameled.

According to a preferred embodiment, the metal sheet has in at least one corner area two edge sections separated from one another by a material notch, the edge sections adjoining one another after bending and are connected to one another in such a way that a peripheral edge is formed.

In this context, a material notch means that the metal sheet is cut to size before folding in such a way that the edge sections can easily be bent against one another, so that there is no excess material, particularly in corner areas. If the base area is a rectangular base area, this means that essentially square material notches are provided in the corner areas, so that the actual cut and chamfered sheet metal has a cross-shaped configuration corresponding to a circumferential fold.

The edge sections are then connected to one another after the bending and preferably before the introduction of the trough-shaped contour, so that a peripheral edge is formed at least along the bordering edge sections.

The material notches are formed by cutting before the edge sections are bent, with the cutting preferably taking place by means of laser cutting.

Alternatively, other types are also possible, e.g. B. in the form of a mechanical cut or in the form of a plasma cut.

The individual edge sections are preferably connected to one another in the form of an integral connection, in particular in the form of a welded connection.

Alternatively, it is provided that the metal sheet has two adjoining edge sections in at least one corner area, with the edge sections protruding in certain areas in the corner area and with a rotatably mounted forming roller being moved perpendicular to the base area along the edge sections for complete angling. This form roller is part of a corner former, the form of the form roller corresponding to that of the corner to be formed in the corner area. Accordingly, the forming roller preferably has a double-cone shape, in which the shape of the corner edge is determined by the adjacent cones.

The peripheral edge preferably has an inner radius of between 1 and 5 mm, particularly preferably between 1.5 and 4.5 mm and very particularly preferably between 2 and 4 mm. The outer radius is preferably between 4 and 8 mm, preferably between 4.5 and 7.5 mm and particularly preferably between 5 and 7 mm. This results in a visually appealing appearance for the user, which can also be well sealed against adjacent wall or floor surfaces.

In the case of welded corners, it must be ensured that the weld seam is formed with particular care, since pores or cavities can form in the weld seam during the course of welding, for example. These can then burst open, damaging an enamel layer arranged on top. Ultimately, however, this circumstance is consciously accepted within the scope of the invention, since the small bending radii not only result in a particularly high-quality appearance. Rather, the blank formed in this way can be standardized in a simple manner before the tub contour is introduced and can be used for a wide variety of types of sanitary facilities, in particular sanitary tubs.

An embodiment in which the plastic deformation takes place by applying a hydrostatic pressure is particularly preferred. In such a case, a liquid active medium is provided, which presses against the first side of the metal sheet at a pressure of between 800 and 1600 bar, preferably between 1000 and 1400 bar. To seal and encapsulate the active medium, an elastic membrane is preferably provided, which is arranged between the active medium and the metal sheet.

Such a method has the advantage that only one mold has to be provided, which reflects the shape of the sanitary facility to be manufactured. An additional embossing stamp is not required, resulting in high cost-effectiveness, which in particular enables the production of small series. In addition, due to the elasticity of the membrane and the high pressures, edges with comparatively small bending radii can be produced in all types of sanitary facilities, which enables a high-quality visual appearance.

Furthermore, due to the above fact, it is possible to also make incisions in the sanitary fixture by means of the hydrostatic molding process. For example, it is conceivable that not only a trough-shaped contour is formed by the embossing process, but also the drainage opening in the surface of the sanitary facility at the same time.

The edge sections can be formed in different ways in the course of the angling. In principle, it is sufficient if the edge sections are bent over or edged, in particular bent over or edged vertically. It is within the scope of the invention that different edge sections are angled in opposite directions. The edge is then preferably bent again, so that an edge with a substantially C-shaped cross section is formed. This allows the forces to be better transferred to the ground. In addition, the overall rigidity of the edge is also increased. However, a renewed angling can also take place in such a way that an edge with a substantially S-shaped cross section is formed. Repeated angling of sections arranged one behind the other is also within the scope of the invention. This applies equally to bends where the edge is bent over a continuous radius. This then results in an edge design in the form of a rounded edge section. Of course, such a continuous edge can also extend only over a partial area of the edge section, or different forms of edge design can be combined with one another.

In principle, the enamel can be arranged over the entire surface. However, it is also conceivable that, for example, the contact area is free of enamelling, since this is already susceptible to the enamel coating flaking off due to the high mechanical loads.

• 1 ein zugeschnittenes Blech vor der Abwinklung der Randabschnitte,
• 2, 3, 4 einen Sanitäreinrichtungsrohling aus einem Blech gemäß der 1 mit abgewinkelten Randabschnitten,
• 5 eine schematische Darstellung des Formschrittes zur Einbringung der wannenförmigen Kontur,
• 6 einen Sanitäreinrichtungsrohling nach dem in 5 gezeigten Formschritt.

The invention is explained in more detail below using an exemplary embodiment. Show it:

• 1 a cut sheet metal before bending the edge sections,
• 2 , 3 , 4 a sanitary device blank from a sheet according to 1 with angled edge sections,
• 5 a schematic representation of the molding step for introducing the trough-shaped contour,
• 6 a sanitary facility blank according to the in 5 shown form step.

The 1 until 6 show in chronological order the method according to the invention, in which a sanitary device is formed by forming a sheet metal 1 that has been cut to size. In the present case, the sanitary facility is a sanitary tub, in particular a shower tub, which is enamelled after the shaping process has been completed.

The starting point for the manufacture of the sanitary facility is the in 1 shown sheet metal 1. In the example shown, the sheet metal 1 has a substantially rectangular basic shape consisting of a rectangular base area 2 and a total of four edge sections 3 projecting relative to the base area 2. The protruding edge sections 3 are formed in that material notches 4 are introduced into the metal sheet 1 by means of laser cutting. The material notches 4 are essentially square, so that the edge sections 3 together with the rectangular base area 2 result in an essentially cross-shaped configuration of the chamfered sheet metal 1 . Through the material notches 4, a certain amount of material is removed in the corner areas of the sheet 1, which would be excess after bending the edge sections 3 and would thus be a hindrance for the formation of corner areas with narrow and high-quality radii.

It goes without saying that the metal sheet 1 can also have different shapes within the scope of the invention. Here, the shape of the sheet 1 depends on the shape of the sanitary facility to be manufactured. For example, it is possible for the metal sheet 1 to be designed in the shape of a trapezoid or a segment of a circle, so that the material notches 4 can then also take on different shapes accordingly. In addition, it is also conceivable that the metal sheet 1 does not have angled edge sections 3 over the entire circumference. For example, it is conceivable that starting from the 1 shown sheet 1 only two or three edge sections 3 are provided, which are then angled in a next step.

This step is in the 2 shown. Here shows the 2 the sanitary facility blank after angling of the edge sections 3, whereby a three-dimensional sheet metal construct is formed starting from the two-dimensional sheet metal 1, without the base area 1 already having a trough-shaped contour. In addition, the enlargement of the corner area shows in particular that the edge sections 3 directly adjoin one another there, but are not yet connected to one another via a common peripheral edge. In addition, it can also be clearly seen that the edge sections 3 have laterally beveled end sections 5 that pass through renewed angling relative to the other parts of the end sections 3 form a support area on which the finished sanitary facility rests in an installed state. This chamfer represents a chamfer which was previously introduced into the metal sheet 1 by the laser cutting, so that these end sections 5 adjoin one another in a again angled state. The 3 shows in this context a cross section through the sanitary facility blank, the support area having already been formed by bending the end sections 5 so that an essentially C-shaped contour results in the edge sections 3 .

Following this, the edge sections 3 bordering one another are materially bonded to one another. In the example shown, this is done by means of welding, as a result of which a peripheral edge is formed in the corner areas and the welded edge sections 3 are no longer visible from the outside, in particular after an enamelling step. The weld seams are then ground or subjected to post-processing.

A sanitary facility blank formed in this way can now be produced in large numbers and used for various contours to be introduced into the base surfaces. In the example shown, such a contour is introduced by means of a hydrostatic process, for which purpose the sanitary facility blank which has already been formed is placed on a mold 6 which already has the finished trough-shaped contour. In particular, the mold 6 has a trough 7 in which a drainage opening 8 is arranged. In principle, the section of this drainage opening 8 can already be introduced in the molding step using the hydrostatic method. However, it is also possible that this only takes place afterwards by means of a separate step. For example, the drain opening 8 can be cut by a laser for this purpose. However, other cutting methods are also possible. In principle, the introduction of such a trough 7 can also initially be dispensed with, so that this only takes place in a subsequent method step. For example, a circular opening can be made in the bottom of the trough 7 to cut the drainage opening 8 .

Alternatively, it is also possible to make a circular incision in the wall surrounding the bottom of the trough 7 .

How 5 clearly shows that the pressure required for the shaping is applied to the sheet metal 1 or only to the base area 2 of the sheet metal 1 via a hydrostatic pressure P in the form of an active medium M. Here, the hydrostatic pressure P does not act directly on the metal sheet via the active medium M. Rather, an elastic membrane 9 is provided between the metal sheet 1 and the active medium M, which transmits the pressure P to the metal sheet 1 . This pressure P presses the membrane 9 and at the same time also the base 2 onto the trough-shaped surface 10 of the mold 6, as a result of which the base 2 is given a trough-shaped contour as a result of plastic deformation. Alternatively, instead of the hydrostatic process, a deep-drawing process can also be carried out using two tools that are matched to one another. However, the advantage of a hydrostatic method is that only one mold 6 is required, so that work can be carried out in a particularly cost-efficient manner. In principle, it is also possible to withdraw.

The 6 then shows the sanitary facility blank after the shaping process according to FIG 5 . In addition, a drainage opening 8 has already been introduced into the base area 2 .

Claims (8)

Method for producing a sanitary facility, in which a sheet metal (1) cut to size is supplied, which has a base (2) and at least one edge section (3) protruding relative to the base (2), the edge section (3) being attached to the base ( 2) the adjoining edge is at least partially angled and in a subsequent step a trough-shaped contour is introduced at least in sections into the base area (2), characterized in that to form a trough-shaped contour the metal sheet (1) or at least the base area (2) of the Sheet metal (1) is subjected to pressure on a first side, which presses the sheet metal against a trough-shaped surface (10) of a mold (6) on a second side, forming a plastic deformation, and at least partial enamelling then takes place. procedure after claim 1 , characterized in that the metal sheet (1) has in at least one corner region two edge sections (3) separated from one another by a material notch, the edge sections (3) adjoining one another after the bending and are connected to one another in such a way that a peripheral edge is formed. procedure after claim 2 , characterized in that an integral connection is provided as the connection. procedure after claim 1 , characterized in that the metal sheet (1) has two adjoining edge sections (3) in at least one corner area, with the edge sections (3) protruding in the corner area in areas and with a rotatably mounted forming roller perpendicular to the base area (2) along for complete angling the edge portions (3) is moved. procedure after claim 1 until 4 , characterized in that the edge has an inner radius of between 1 and 5 mm, preferably between 1.5 and 4.5 mm, particularly preferably between 2 and 4 mm. Procedure according to one of Claims 1 until 5 , characterized in that the edge has an outer radius of between 4 and 8 mm, preferably between 4.5 and 7.5 mm, particularly preferably between 5 and 7 mm. Procedure according to one of Claims 1 until 6 , characterized in that a hydrostatic pressure (P) is applied via an elastic membrane (9) to the first side of the shaped sheet. Procedure according to one of Claims 1 until 7 , characterized in that the edge section (3) is angled by at least one further step in end sections (5).

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