JP2006007440A - Manufacturing method of molded product and counter for bathroom - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a molded product good in the molding workability of a reinforcing layer, different in wall thickness partially, capable of being formed into a structure precise even in the profile of the rear and excellent in impact-resistant strength. <P>SOLUTION: In the manufacturing of the molded product by setting a surface material, which has the surface of the molded product obtained by the vacuum forming of an acrylic resin sheet, to the inside of a casting mold of which the mold surface has the rear profile of the molded product and filling the space between the of the surface material in the casting mold and the mold surface having the rear profile of the molded product with a slurry containing an unsaturated polyester resin and a filler to cure the slurry to integrally mold a reinforcing layer on the rear of the surface material, a fiber reinforced plastic layer is provided between the reinforcing layer and the surface material. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a method for manufacturing a molded article and a counter for a bathroom.

Conventionally, a reinforcing material layer made of fiber reinforced plastic is laminated on the back surface of the surface material of the bathroom counter or bathtub, which is formed by vacuum forming an acrylic resin sheet in a bathroom counter or bathtub of a bathroom unit. The manufacturing method for the molded product is adopted.
That is, according to this method of manufacturing a molded product, as described above, the surface material that is the surface material is formed by vacuum-forming an acrylic resin sheet, so that the molded product has a smooth and clean surface. Easy to get.

In addition, as a method for producing such a molded product, a surface material having a surface shape of a molded product obtained by vacuum forming an acrylic resin sheet is set in a casting mold having a mold surface having a back surface shape of the molded product. Then, a slurry containing an unsaturated polyester resin and a filler is filled between the back surface of the casting mold and the back surface of the molded product, and the slurry is cured to reinforce the back surface of the surface material. There has already been proposed a method of manufacturing a molded product that integrally molds (see, for example, Patent Document 1).
In other words, when trying to form a reinforcing layer using the conventional hand lay-up method or spray-up method, if a flat part such as a part received by the support bracket is required, a flat part is formed. However, if the reinforcing layer is cast-molded as in the above manufacturing method, the flat portion can be easily obtained only by molding. Therefore, compared with the case where the hand lay-up method or spray-up method is used, the workability of the reinforcing layer is better, and the molded product with a precise structure on the back side, such as partially different wall thickness, is easy. There is an advantage that it can be molded.

JP-A-6-198660

However, in the case of a molded product obtained by the manufacturing method as described above, the surface material is formed of an acrylic resin, and the reinforcing layer is formed of a hardened body of a slurry containing an unsaturated polyester resin and a filler. There was a problem in terms of impact.

In view of the above circumstances, the present invention has good workability of the reinforcing layer, and the back surface can have a precise structure such as partially different thickness, and has excellent impact strength. The purpose is to provide molded products.

In order to achieve the above object, a molded product according to the present invention is a casting material having a surface shape of a molded product obtained by vacuum molding of an acrylic resin sheet, and having a mold surface having a back surface shape of the molded product. Set in the mold, fill the slurry containing unsaturated polyester resin and filler between the back surface of the casting mold and the back surface of the molded product, cure the slurry, In a molded product in which a reinforcing layer is integrally formed on the back surface, a fiber reinforced plastic layer is provided between the reinforcing layer and the surface material.

In the present invention, it is preferable that a primer layer is provided between the surface material and the fiber reinforced plastic layer as in claim 2.

Although the thickness of the acrylic resin sheet used for this invention is not specifically limited, 2 mm-5 m
m is preferable, and 3 mm to 4 mm is more preferable.

The fiber reinforced plastic layer is not particularly limited, but may be formed by hand lay-up method or spray-up method directly on the back surface of the surface material, or after coating the back surface of the surface material or forming a primer layer. it can.
The fiber-reinforced plastic layer is preferably about # 300 or more and about 1 ply or more of hand layup.

Although it does not specifically limit as a primer (gel coat) which forms a primer layer, A vinyl ester resin type thing is mentioned.

As a slurry (resin concrete) used for forming the reinforcing layer, a known material can be used, but the degree of shrinkage at the time of molding can be controlled by adding at least one of a low shrinkage agent and short glass fiber. It is preferable to use a slurry adjusted so as to be close to the degree of shrinkage. That is, shrinkage at the time of hardening of the slurry can be suppressed, and warpage and deformation due to a shrinkage difference from the surface material can be prevented.

Although it does not specifically limit as a low shrinkage agent, For example, what consists of polystyrene-type resin and vinyl acetate type-resin, or what mixed these is preferable.
The addition amount of the low shrinkage agent is appropriately determined according to the thickness of the reinforcing layer, the shape of the molded product, etc., but is preferably 30 parts by weight or less with respect to 100 parts by weight of the unsaturated polyester resin. That is, as the amount of the low shrinkage agent is increased more and more, a non-shrinkage can be obtained. However, if the slurry is made non-shrink, the linear expansion coefficient of the surface material (acrylic resin) is reversed at the curing temperature. Therefore, when the obtained molded product is returned to room temperature, it may be warped toward the surface material side.

As the short glass fiber, those having an average length of about 0.5 mm to 10 mm are preferable, and those having an average length of about 3 mm are more preferable.
The addition amount of short glass fibers is appropriately determined according to the thickness of the reinforcing layer, the shape of the molded product, etc.
The amount is preferably 3 parts by weight or less with respect to 100 parts by weight of the unsaturated polyester resin. That is, if it exceeds 3 parts by weight, the slurry viscosity becomes too high and casting may become difficult.

Although it does not specifically limit as a filler mixed in a slurry, For example, a cryogenic stone, a calcium carbonate, etc. are mentioned.
The particle size of the filler is preferably about 1 μm to 300 μm.
Although the addition amount of a filler is not specifically limited, When a cold water stone is used, about 250 to 300 weight part is preferable with respect to 100 weight part of unsaturated polyester resin.

As described above, the molded article according to the present invention is excellent in impact resistance because the fiber-reinforced plastic layer is provided between the reinforcing layer and the surface material. In addition, since the reinforcing layer is formed by casting, the back side of the molded product, that is, the concave and convex shape of the reinforcing layer can be accurately formed, and the molded product such as a bathroom counter with excellent fitting accuracy can be stabilized. Can be obtained.

Moreover, if the primer layer is formed on the back surface of the surface material as in claim 2, the adhesion strength between the surface material and the fiber-reinforced reinforcing layer can be increased.

Hereinafter, the present invention will be described in detail with reference to the drawings showing embodiments thereof.
1 to 4 show an embodiment of a bathroom counter obtained by the method for producing a molded product according to the present invention.

As shown in FIGS. 1 to 4, the bathroom counter 1 includes a surface material 2, a primer layer 3, a fiber reinforced plastic layer (hereinafter referred to as “FRP layer”) 4, and a reinforcing layer 5. Figure 1
And as shown in FIG. 2, the unevenness | corrugation is each formed in the surface side and the back surface side, and it is formed so that the thickness of each part may differ from the adjacent part as needed.
As shown in FIG. 4, insert nuts 51 into which fixing bolts 52 are screwed are embedded in ten or more places (only two places are shown in FIG. 4) of the reinforcing layer 5.

In addition, the bathroom counter 1 has a longitudinal dimension of about 1000 mm, a short dimension of 320 mm at the maximum, 185 mm at the minimum, a maximum of 31 mm, and a minimum of 6 mm.
The reference thickness is 15 mm.
In FIG. 4, B is a bathroom, 6 is a wall panel, 7 is a stay, 8 is a washing pan, 9 is a counter cover obtained by injection molding, and 10 is a wing nut.

Next, a method for manufacturing the bathroom counter A will be described with reference to FIG.
(1) An acrylic resin sheet having a thickness of 3 mm is vacuum-formed into the shape of the surface material 2 of the bathroom counter A.

(2) The surface material 2 obtained is washed to remove dirt such as oil, and the back surface of the surface material 2 is coated as necessary.
(3) A gel coat is applied to the back surface of the surface material 2 to form the primer layer 3.

(4) A 1-ply FRP layer 4 is formed on the primer layer 3 by a hand layup method using a glass fiber mat equivalent to about # 300.
(5) The surface material 2 on which the primer layer 3 and the FRP layer 4 are laminated is set in the casting mold so that the FRP layer 4 faces the inside of the mold, and the insert nut is set in a predetermined position in the casting mold. Set to.

(6) 70 to 100 parts by weight of unsaturated polyester resin, 250 to 300 parts by weight of filler, and 20 to 30 parts by weight of a low shrinkage agent (or 3 mm chopped strand of glass short fiber 3 mm).
5 to 3 parts by weight) is mixed, and the slurry is prepared so that the shrinkage at the time of molding becomes close to the shrinkage of the surface material.

(7) The prepared slurry is poured into a casting mold.
(8) After injecting a predetermined amount of slurry, the mold is clamped, and the slurry is cured in a casting mold to form the reinforcing layer 5.

(9) Open the mold and take out the obtained molded product from the casting mold.
(10) Remove burrs and the like.

(11) After cure.
(12) Apply finishing.

And since the counter 1 for bathrooms manufactured as mentioned above is formed by vacuum-molding the acrylic resin sheet, the surface material 2 that becomes the surface of the molded product can accurately obtain the drainage gradient on the counter surface. It is possible to reduce the remaining water on the counter surface.
In addition, since the FRP layer 4 is provided between the surface material 2 and the reinforcing layer 5, both the surface material 2 and the reinforcing layer 5 can improve the impact resistance by the function of the FRP layer 4. Therefore, the impact resistance strength of the bathroom counter 1 is improved.

Further, the reinforcing layer is formed using a slurry in which the degree of shrinkage at the time of molding is adjusted to be close to the degree of shrinkage of the surface material by adding at least one of a low shrinkage agent and short glass fibers. Therefore, the molding accuracy can be improved without twisting or warping.

The molded product according to the present invention is not limited to the above embodiment. For example, in the above embodiment, the molded product is a bathroom counter, but other molded products such as a bathtub may be used.

It is a top view of the counter for bathrooms which is one embodiment of the molded product concerning this invention. It is the XX sectional view taken on the line of FIG. It is sectional drawing explaining the laminated constitution of the bathroom counter of FIG. It is sectional drawing showing the construction state of the counter for bathrooms of FIG. It is a flowchart of a manufacturing process.

Explanation of symbols

1 Bathroom counter (molded product)
2 Surface material 3 Primer layer 4 Fiber reinforced plastic layer 5 Reinforcing layer

Claims (3)

A surface material having a surface shape of a molded product obtained by vacuum forming an acrylic resin sheet is set in a casting mold having a mold surface of the back surface of the molded product, and molding is performed on the back surface material of the casting mold. In a molded product in which a slurry containing an unsaturated polyester resin and a filler is filled between the mold surface of the back surface shape of the product, the slurry is cured, and a reinforcing layer is integrally formed on the back surface of the surface material.
A molded product, wherein a fiber reinforced plastic layer is provided between the reinforcing layer and the surface material. The molded article according to claim 1, further comprising a primer layer between the surface material and the fiber reinforced plastic layer.   The molded article according to claim 1 or 2, wherein the molded article is a bathroom counter.

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