JP2001293736A - Method for molding tub using resin - Google Patents

Abstract

PROBLEM TO BE SOLVED: To mold a bathtub having an artificial marble pattern from a resin using lower and upper molds. SOLUTION: Lower and upper molds 10, 20 having a shape wherein a bathtub 1 is inverted are prepared and a peripheral trough 13 is provided to the outer periphery of the lower end of the lower mold. A plurality of molding materials P containing different pigments respectively are accumulated in the peripheral trough 13. The upper mold 20 is arranged outside the lower mold 10 so as to cover the mold 10 and the resin molding materials P in the peripheral trough 13 are compressed by the compression wall provided to the outer periphery of the lower end of the upper mold 20 to allow the resin molding materials P to flow in the cavity 14 between the molds 10, 20 in a full state. A vertical stripe pattern is developed on the upright wall surface of the tub main body 4 of the bathtub 1 and a randomly oriented stripe pattern is developed on the flange part around the upper end of the tub main body 4.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a certain compression molding method for resin-molding a tub such as a bathtub, a sink and a sink into an artificial marble pattern.

[0002]

2. Description of the Related Art In a tub having a depression such as a bathtub,
Japanese Patent Application Laid-Open No. 7-88849 discloses a method for producing an artificial marble molded article having a striped (stone) pattern. This is shown in FIG.
As shown in the figure, the lower mold 30 matching the shape of the product tab
A resin molding material P in which a base resin and a patterning resin containing a pigment are laminated is poured and stored, and the upper mold 31 is placed in the lower mold 30.
And press the resin molding material P to compress both molds 30 and 31
This is to fill the cavity 32 between them.

[0003] According to this, since the resin molding material P is cast so as to crawl inside the cavity 32, a vertical stripe pattern appears on the upright wall surface of the product tab, and an artificial marble tab can be obtained. Has become.

[0004]

However, according to the above-described molding method, in the product tab 1 shown in FIG. 4, a vertical stripe pattern appears on the inner peripheral wall surface of the tab body 4, but at the same time, the flange is formed. On the upper surface of the portion 5, a striped stripe pattern appears with directionality.

That is, the resin molding material P in the lower mold 30 is
When compressed, it rubs against the surface of the lower mold 30, but when observing the behavior of the resin molding material P, the resin molding material P hardly moves due to the frictional force in the central portion of the inner bottom surface of the lower mold 30,
When pressed by the upper die 31, the resin molding material P flows upward from the outer peripheral edge portion of the inner bottom surface of the lower die 30. Therefore, when the product tab 1 is viewed, the stripe pattern has no directionality on the inner bottom surface, and the stripe pattern has directionality on the upright wall surface of the tab body 4 and the upper surface of the flange portion 5.

The inventor of the present invention has found that a directional striped pattern appears on the upright wall and the inner bottom surface of the tub body 4 in a tub such as an artificial marble bathtub, and no directional pattern appears on the outer upper surface of the flange portion 5. When it is desired that a pattern appears, a tab of such a form cannot be obtained by the conventional method.

Therefore, in the method of the present invention, the method of storing the resin molding material in the lower mold is improved, and a vertical stripe pattern appears on the upright wall surface of the tab body, but the upper surface of the flange portion has no direction. The pattern comes out to get a high quality tab close to the real marble.

[0008]

As shown in FIG. 1, a method for molding a tab according to the present invention uses an upper die 20 and a lower die 10 to form a horizontal flange portion 5 on an upper end edge of an opening of a tab body 4.
Is a resin molding method for obtaining a tab 1 provided continuously. The lower mold 10 has a peripheral side wall 11, an upper wall 12 connected to the upper peripheral edge of the peripheral side wall 11, and a peripheral groove 13 provided outside the lower peripheral edge of the peripheral side wall 11. The upper mold 20 has a peripheral side wall 21.
And an upper wall 22 connected to the upper edge of the peripheral wall 21 and a compressed wall 2 formed to extend outside the lower edge of the peripheral wall 21.
And 3. Thus, as shown in FIG. 2, a step of pouring a plurality of resin molding materials P having different pigments into the orbital groove 13 of the lower mold 10 and storing the upper mold 20 on the outer side of the lower mold 10. Compression wall 23 is formed around circular groove 1 of lower mold 10.
3, the resin molding material P is filled in the cavity 14 formed between the lower mold 10 and the upper mold 20 as shown in FIG. I do.

[0009]

A plurality of resin molding materials P having different pigments are obtained by mixing a resin material in which a yellow pigment is mixed with a base resin such as polyester, and a resin material in which a white pigment is mixed with the same base resin. Or those obtained by laminating them vertically. The pigment is a concept including a dye, and the color is not particularly limited.

When the upper mold 20 is pushed into the lower mold 10 during molding, the resin molding material P in the circumferential groove 13 is pushed by the compression wall 23. The resin molding material P pressed by the compression wall 23 flows from the circumferential groove 13 into the cavity 14 between the two dies 10 and 20 to be in a full state. After curing, the mold is opened and the product tab 1 is taken out. That is, the resin molding material P flows from the lower side to the upper side between the peripheral side walls 11 and 21 of both dies 10 and 20, and then the upper wall 1 of both dies 10 and 20 is formed.
It flows in from the entire circumference between 2.22 and merges. If an air vent hole is provided at the center of the upper mold 20, the resin molding material P will merge at the center between the upper walls 12 and 22 of both dies 10. The product tab 1 is formed such that the peripheral side standing wall 2 of the tab body 4 is formed by the peripheral side walls 11
The bottom wall 3 of the tab body 4 is formed by the top walls 12 and 22 of 0.20,
The flange portion 5 of the tab 1 is formed by the groove bottom wall 15 of the circumferential groove 13 of the lower die 10 and the compression wall 23 of the upper die 20.

When the resin molding material P in the circumferential groove 13 is compressed by the compression wall 23, the resin molding material P does not actively flow on the bottom of the circumferential groove 13 due to friction. This orbit 1
3 forms the upper surface of the flange portion 5 of the product tab 1. Therefore, the upper surface of the flange portion 5 of the product tab 1 is finished with a stripe pattern having no direction.

On the other hand, the cavity 14 between the two dies 10 and 20
2, a resin molding material P is provided between the peripheral side walls 11 and 21 at the lower end portion A of the peripheral side wall 11 of the lower mold 10 as shown in FIG.
It flows in like a crawling upward from
The resin molding material P at the lower end portion A flows so as to be stretched upward against friction. As the resin molding material P elongates and flows, the peripheral side walls 11 and 21 of both dies 10 and 20 are formed.
Looking at the peripheral standing wall 2 of the tab body 4 formed by the above, a strong vertical stripe pattern appears on the inner peripheral standing wall. Tab body 4
A stripe pattern also appears on the inner surface of the bottom wall 3 with a direction.

[0013]

According to the method of the present invention, a vertical stripe pattern is formed on the inner surface of the tab body 4, particularly on the inner peripheral surface of the peripheral standing wall 2, and a tab pattern having a non-directional stripe pattern is formed on the upper surface of the flange portion 5. 1
Is obtained as intended, which is advantageous for erecting the face.

[0014]

FIG. 4 shows a bathtub 1 which is a typical example of a product tub according to the present invention. The bathtub 1 has a peripheral standing wall 2
A tab body 4 having a bottom wall 3 and an open top surface; and a flange portion 5 horizontally and continuously connected to the outside of the peripheral edge of the upper end opening of the tab body 4.

In FIG. 1, a bathtub 1 is resin-molded using a lower mold 10 and an upper mold 20 fitted on the outside of the bath.
The lower die 10 includes a peripheral side wall 11, an upper surface wall 12 connected to an upper peripheral edge of the peripheral side wall 11, and a circumferential groove 13 provided outside the lower peripheral edge of the peripheral side wall 11 and having an open upper surface.

The upper mold 20 has a peripheral side wall 21, an upper surface wall 22 connected to an upper peripheral edge of the peripheral side wall 21, and a horizontal compression wall 23 formed to protrude outside a lower peripheral edge of the peripheral side wall 21. The peripheral side wall 21 and the upper surface wall 22 of the upper die 20 are formed in a similar shape slightly larger than the peripheral side wall 11 and the upper surface wall 12 of the lower die 10.

Prior to molding using both molds 10 and 20, a first resin material in which a yellow pigment is uniformly mixed with a base resin made of polyester and a white pigment are uniformly mixed in a base resin made of the same polyester. A second resin material is mixed in a non-uniform state to prepare a liquid resin molding material P, and as shown in FIG.
And poured into the circumferential groove 13 to store.

Next, as shown in FIG. 2, the upper mold 20 is put on the outside of the lower mold 10 and the compression wall 23 of the upper mold 20 is attached to the lower mold 1.
The resin molding material P in the circumferential groove 13 is gradually compressed. Thus, the compressed resin molding material P is caused to flow into the cavity 14 formed between the dies 10 and 20. That is, after the resin molding material P is pushed upward from below between the peripheral side walls 11 and 21 of both the dies 10 and 20, it flows from between the upper walls 12 and 22 of both dies 10 and 20 from all directions. .

In a state in which the upper mold 20 is pressed into the lower mold 10 at a specified value and fitted together, as shown in FIG.
4 is completely filled with the resin molding material P. In this state, the dies 10 and 20 are fastened, and the resin molding material P in the cavity 14 is cured. Finally, the two molds 10 and 20 are unfastened and separated, and the bathtub 1 is taken out as a molded product.

The product / bath 1 thus obtained is a double mold 10
20 peripheral side walls 11 and 21, peripheral side standing wall 2 of tab body 4
However, the bottom wall 3 of the tab body 4 is formed by the upper walls 12 and 22 of both dies 10 and 20, respectively, and the groove bottom wall 15 of the circumferential groove 13 of the lower die 10 and the compression wall 23 of the upper die 20 are formed. Thus, the flange portion 5 is formed. The outer surface facing the cavity 14 of the lower die 10 forms the inner peripheral surface of the tab body 4 and the outer upper surface of the flange portion 5, and the inner surface of the upper die 20 forms the outer rear surface of the tab body 4 and the lower rear surface of the flange portion 5. Will be done.

In the bathtub 1, what is noticeable in appearance is a pattern that appears on the surface of the upright wall on the inner periphery of the tub body 4 and on the outer upper surface of the flange portion 5. When the resin molding material P in the circumferential groove 13 is compressed by the compression wall 23, the resin molding material P is pressed downward against the inner surface of the groove bottom wall 15 and is in frictional contact. Therefore, the resin molding material P is used for the groove bottom wall 1.
5 hardly flows toward the peripheral side wall 11 of the lower mold 10. As a result, a white pattern with no direction appeared on the outer upper surface of the flange portion 5 formed on the inner surface of the groove bottom wall 15.

In the resin molding material P flowing into the cavity 14 from the circumferential groove 13, the lower end portion A along the peripheral side wall 11 of the lower mold 10 is in frictional contact with the peripheral side wall 11. The resin molding material P of the lower end portion A creeps up while being stretched on the outer surface of the peripheral side wall 11 of the lower mold 10 and flows along the outer surface of the upper surface wall 12. Due to this stretching action, a white striped pattern flowing in the vertical direction appeared abundantly on the inner peripheral surface of the peripheral standing wall 2 of the tab body 4. Upper mold 2
If an air vent hole is provided in the center of the upper surface wall 22 of the zero, a white stripe pattern from the outer periphery toward the center appears with a direction on the inner surface of the bottom wall 3 of the tab body 4.

The air vent hole is formed in the upper wall 22 of the upper die 20.
Not only at the center of the upper wall 22 but also at a plurality of places on the upper wall 22 or in a distributed manner on the peripheral side wall 21. Further, the resin molding material P in the circumferential groove 13 may be compressed by the compression wall 23 while the upper mold 20 is rocked with respect to the lower mold 10. In combination, a vertical stripe pattern in which the vertical wall surface of the tab body 4 of the product tab 1 is changed can be formed in a group cloud shape.

The tub 1 of the present invention is not limited to a bath tub, but is widely applicable to a wash basin, a sink, and the like. In this case, the flange portion 5 does not need to be formed with a uniform width from the peripheral edge of the upper end opening of the tub body 4. In addition, the entire surface may not be formed horizontally and may be formed so as to have uneven steps.

[Brief description of the drawings]

FIG. 1 is a sectional view showing a sectional shape of a lower mold and an upper mold.

FIG. 2 is a cross-sectional view showing a state in which an upper mold is combined with a lower mold.

FIG. 3 is a cross-sectional view in a state where an upper mold is combined with a lower mold.

FIG. 4 is a schematic perspective view of a bathtub.

FIG. 5 is a cross-sectional view illustrating a conventional manufacturing method.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Tab 2 Peripheral standing wall 3 Bottom wall 4 Tab main body 5 Flange part 10 Lower die 11 Lower peripheral wall 12 Lower die upper surface wall 13 Circular groove 14 Cavity 15 Groove bottom wall 20 Upper die 21 Upper peripheral wall 22 Upper Top wall of mold 23 Compressed wall P Resin molding material

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) E03C 1/18 E03C 1/18 // B29L 31:44 B29L 31:44

Claims (1)

[Claims] 1. A resin molding method for a tab 1 in which a horizontal flange portion 5 is continuously provided at an upper end edge of an opening of a tab main body 4. A peripheral side wall 11, an upper surface wall 1 connected to an upper end peripheral edge of the peripheral side wall 11.
2, a lower mold 10 having a circumferential groove 13 provided outside a lower peripheral edge of a peripheral side wall 11, a peripheral side wall 21, and an upper surface wall 2 connected to an upper peripheral edge of the peripheral side wall 21.
2. Pour a plurality of resin molding materials P having different pigments into the orbital groove 13 of the lower die 10 using the upper die 20 having the compression wall 23 formed to protrude outside the lower peripheral edge of the peripheral side wall 21; The upper mold 20 is put on the outside of the lower mold 10, and the compression wall 23 of the upper mold 20 is pushed into the circumferential groove 13 of the lower mold 10, and the resin molding material P in the circumferential groove 13 is compressed by the compression wall 23. And a cavity 14 formed between the lower mold 10 and the upper mold 20 is filled with a resin molding material P.