JP2004060158A

JP2004060158A - Catch basin and its molding method

Info

Publication number: JP2004060158A
Application number: JP2002215727A
Authority: JP
Inventors: Masafumi Kato; 加藤　雅史
Original assignee: Mitsubishi Plastics Inc
Current assignee: Mitsubishi Plastics Inc
Priority date: 2002-07-24
Filing date: 2002-07-24
Publication date: 2004-02-26
Anticipated expiration: 2022-07-24
Also published as: JP3936638B2

Abstract

<P>PROBLEM TO BE SOLVED: To provide a catch basin using a resin mold of a three-layer structure and its molding method for effectively improving impact resistance of a catch basin bottom part, and effectively utilizing a scrap and a used waste material generated when injectively molding or extrusively molding the resin mold. <P>SOLUTION: The bottom part of at least a basin body is formed as the three-layer structure having an intermediate layer, an inner layer and an outer layer for covering inside-outside surfaces of the intermediate layers. The intermediate layer is formed of a resin raw material including a refining agent. The inner layer and the outer layer are formed of an unused resin raw material including no refining agent. The scrap can be effectively utilized by forming the intermediate layer of the resin raw material including a reclaimed raw material obtained by crushing a resin scrap and a waste material. <P>COPYRIGHT: (C)2004,JPO

Description

【０００１】
【発明の属する技術分野】
本発明は、排水枡及びその成形方法に関し、詳しくは、耐衝撃性、特に底部の耐衝撃性を向上させるとともに、樹脂スクラップや使用済みとなった廃材の有効活用を図れる排水枡及びその成形方法に関する。
【０００２】
【従来の技術】
従来から、排水枡として合成樹脂、例えばポリ塩化ビニル製の排水枡が用いられているが、排水枡の底部（インバート部）は、上方から落下する排水や、施工時に落下した工具、開蓋時に落下した石等によって破損する危険性がある。このため、排水枡の底部のみを耐衝撃性を有する別部材で形成して嵌め合わせることも行われているが、成形加工に手間が掛かってコストアップとなる。また、排水枡全体を耐衝撃性を有する材料、例えば改質剤を添加した樹脂原料で形成することもできるが、樹脂原料コストが大幅にアップしてしまう。
【０００３】
一方、樹脂原料からなる家電製品の筐体や、管継手等の建材製品を射出成形するとき、ゲート等の不要部材やスクラップが発生したり、合成樹脂管を連続して押出成形するとき、成形条件が安定するまでの初期段階に大量のスクラップが発生することがある。また、耐用年数が経過して老朽化した合成樹脂管を更新するとき、使用済みとなった廃材が大量に発生することがある。近年は、このような樹脂スクラップや使用済みとなった廃材の処分が大きな問題となっている。
【０００４】
【発明が解決しようとする課題】
従来、樹脂スクラップや使用済みとなった廃材は、焼却や埋立等により廃棄処分されていたが、樹脂スクラップ等を焼却処分する場合にはダイオキシン等が発生して環境を汚染するという問題が起きている。また、樹脂スクラップや廃材を地中に埋める場合には、埋める場所が問題となるのは勿論のこと、合成樹脂が長期間に亘って分解・腐食されないため、環境破壊の問題が提起されるに至っている。そこで、樹脂スクラップや使用済みとなった廃材を粉砕し、これを再生原料として利用することが提案されるに至っているが（特開２００１−４１３６２号公報等参照）、その対応は十分とは言い難いものであった。
【０００５】
そこで本発明は、排水枡底部の耐衝撃性を効果的に向上させることができるとともに、樹脂成形品を射出成形あるいは押出成形したときに発生したスクラップや使用済みとなった廃材を有効活用することができる三層構造の樹脂成形品を利用した排水枡及びその成形方法を提供することを目的としている。
【０００６】
【課題を解決するための手段】
上記目的を達成するため、本発明の排水枡は、円筒状をなす桝本体の上方が開口し、桝本体の側壁に排水管の接続部が形成された排水桝において、少なくとも前記枡本体の底部を中間層と該中間層の内外面を覆う内層及び外層とを有する三層構造に形成するとともに、前記中間層を、改質剤を含有する樹脂原料で形成し、前記内層及び外層を、前記改質剤を含有しない未使用の樹脂原料で形成したことを特徴とし、特に、前記中間層を形成する樹脂原料中の改質剤の混合割合が、改質剤を含有しない未使用の樹脂原料１００重量部に対して８〜１５重量部であることを特徴としている。
【０００７】
また、本発明の排水枡は、前記枡本体の全体を中間層と該中間層の内外面を覆う内層及び外層とを有する三層構造に形成するとともに、前記中間層を、樹脂スクラップや廃材を粉砕して得た再生原料及び改質剤を含有する樹脂原料で形成し、前記内層及び外層を、前記再生原料を含有しない未使用の樹脂原料で形成したことを特徴とし、特に、前記改質剤が前記枡本体の底部を形成する中間層にのみ含有されていることを特徴としている。
【０００８】
さらに、上記構成において、樹脂スクラップや廃材の再生原料の割合が、前記桝本体を構成する樹脂原料全体の１０〜８０重量％であること、前記再生原料が硬質塩化ビニル樹脂のスクラップや廃材からなる再生原料であり、前記未使用の樹脂原料が硬質塩化ビニル樹脂であることを特徴としている。
【０００９】
また、本発明の排水枡の成形方法は、第１の構成として、円筒状をなす桝本体の上方が開口し、桝本体の下部にインバート部を有するとともに、該インバート部に連通して桝本体の側壁に排水管の接続部が形成された排水桝の製造方法において、内金型と外金型とを型締めして桝本体の成形キャビティを形成し、該成形キャビティにおける桝本体のインバート部下面に相当する部位に形成したゲートから成形キャビティ内に未使用の樹脂原料を所定量射出し、次に改質剤を含有する樹脂原料を成形キャビティ内に射出することにより、前記改質剤を含有する樹脂原料からなる中間層を少なくとも前記枡本体の底部に形成して該中間層の内外面を改質剤を含有しない未使用の樹脂原料からなる内層と外層とで覆った状態にすることを特徴としている。
【００１０】
さらに、本発明の排水枡の成形方法は、第２の構成として、円筒状をなす桝本体の上方が開口し、桝本体の下部にインバート部を有するとともに、該インバート部に連通して桝本体の側壁に排水管の接続部が形成された排水桝の製造方法において、内金型と外金型とを型締めして桝本体の成形キャビティを形成し、該成形キャビティにおける桝本体のインバート部下面に相当する部位に形成したゲートから成形キャビティ内に未使用の樹脂原料を所定量射出し、次に樹脂スクラップや廃材を粉砕して得た再生原料を含有する樹脂原料を成形キャビティ内に所定量射出し、続けて改質剤を含有する樹脂原料を成形キャビティ内に射出することにより、桝本体の底部に改質剤を含有する樹脂原料からなる中間層を、底部を除く枡本体の全体に前記再生原料を含有する樹脂原料からなる中間層をそれぞれ形成して両中間層の内外面を改質剤及び再生原料を含有しない未使用の樹脂原料からなる内層と外層とで覆った状態にすることを特徴としている。
【００１１】
また、本発明の排水枡の成形方法は、第３の構成として、円筒状をなす桝本体の上方が開口し、桝本体の下部にインバート部を有するとともに、該インバート部に連通して桝本体の側壁に排水管の接続部が形成された排水桝の製造方法において、内金型と外金型とを型締めして桝本体の成形キャビティを形成し、該成形キャビティにおける桝本体のインバート部下面に相当する部位に形成したゲートから成形キャビティ内に未使用の樹脂原料を所定量射出し、次に樹脂スクラップや廃材を粉砕して得た再生原料及び改質剤を含有する樹脂原料を成形キャビティ内に射出して前記再生原料及び改質剤を含有する樹脂原料からなる中間層の内外面を再生原料及び改質剤を含有しない未使用の樹脂原料からなる内層と外層とで覆った状態とすることを特徴としている。
【００１２】
【発明の実施の形態】
図１は本発明の一形態例を示す排水桝の断面図、図２は図１に示した排水桝の製造工程を示す断面図である。この排水桝は、円筒状をなす桝本体１１の上方が開口し、桝本体１１の下部にインバート部１２を有するとともに、該インバート部１２に連通して桝本体１１の側壁に排水管の接続部１３ａ，１３ｂが形成されたものであって、樹脂成形品のスクラップや廃材を粉砕して得た再生原料及び改質剤を含有する樹脂原料で桝本体１１の中間層Ａを形成するとともに、該中間層Ａの内外面を再生原料及び改質剤を含有しない未使用の樹脂原料からなる内層Ｂと外層Ｃとで覆ったものである。
【００１３】
前記中間層Ａに用いられる耐衝撃性改質剤は、樹脂の種類に応じて適当なものを使用することができ、混合量も樹脂の種類や改質の程度に応じて適当に設定することができる。改質剤としては、ゴム系物質、例えばＭＢＳ樹脂等を使用することができ、その他の添加剤として、スズ安定剤、熱安定剤、滑剤、加工助剤、顔料、可塑剤、充填剤、耐電防止剤、紫外線吸収剤、難燃剤等の各種の添加剤を添加することができる。
【００１４】
好適な配合例としては、ポリ塩化ビニル１００重量部に対し、改質剤８〜１５重量部、安定剤０．５〜３重量部、滑剤０．１〜１．０重量部、加工助剤０．１〜１．０重量部、顔料０．１〜１．０重量部を挙げることができる。
【００１５】
また、樹脂スクラップや廃材を粉砕して得た再生原料は、ポリ塩化ビニル、ポリエチレン、ポリプロピレン等からなる樹脂成形品、例えばペットボトル、家電製品の筐体や管継手等の建材製品の廃材、射出成形の際に発生したゲート等の不要部材やスクラップを粉砕して得たものである。中間層Ａを構成する樹脂原料の主成分としては、再生原料のみ、あるいはこの再生原料に未使用の樹脂原料を混合したものを使用することができ、また、内層Ｂ及び外層Ｃを構成する樹脂原料としては、前記中間層Ａと相溶性のある樹脂原料であって、再生原料や改質剤を含有しないポリ塩化ビニル、ポリエチレン、ポリプロピレン等の未使用の樹脂原料が使用できる。
【００１６】
このように中間層Ａと、該中間層Ａの内外面を覆う内層Ｂ及び外層Ｃとして各種の樹脂原料が使用できるが、塩化ビニル樹脂からなる使用済みの廃材やスクラップが大量に発生している現状や、排水枡に接続する排水管として硬質塩化ビニル樹脂からなるパイプが多用されていることを勘案すると、中間層Ａには硬質塩化ビニル樹脂からなる再生原料が好適に使用でき、この中間層Ａの内外面を覆う内層Ｂ及び外層Ｃには、再生原料を含有しない未使用の硬質塩化ビニル樹脂が好適に使用できる。
【００１７】
また、排水枡を構成する樹脂原料全体に占める前記再生原料の割合は、１０〜８０重量％とするのが好ましい。この再生原料の割合が１０重量％未満では、廃材やスクラップを有効活用するという点では十分な効果が期待できず、逆にこの割合が８０重量％を超えると再生原料を含有しない樹脂原料からなる内層Ｂ及び外層Ｃが肉薄となるため、内層Ｂ及び外層Ｃから中間層Ａを構成する再生原料が部分的にはみ出して外観を損ねるという事態が発生することになる。因みに、サイズ１５０〜３５０の排水枡における側壁部分の肉厚は５〜２０ｍｍ程度となる。
【００１８】
前記排水枡は、射出成形によって製造されるものであって、次にこの製造工程を説明する。図２における符号５１，５２，５３は内金型、６１，６２は外金型であって、前記内金型と外金型とを型締めすることによって枡本体１１の成形キャビティが形成される。この成形キャビティ内に樹脂原料を射出するゲート６２Ｇは外金型６２に設けられており、枡本体１１のインバート部下面に相当する部位に設けられている。このように円筒状をなす枡本体１１の対称かつ中心部近傍位置となるインバート部下面にゲート６２Ｇを設けると、成形キャビティ内に射出した樹脂原料を末端部まで満遍なく行き渡らせることができとともに、ゲート６２Ｇの跡（ゲート口部６２Ｍ（図１参照））がインバート部下面に現われても人目に触れないという外観上の利点がある。
【００１９】
前記ゲート６２Ｇには射出成形機のノズル７１が当接できるようになっており、ノズル７１内に設けられた第一樹脂流路７２から再生原料や改質剤を含有しない未使用の樹脂原料が射出され、第二樹脂流路７３から再生原料及び改質剤を含有する樹脂原料が射出されるようになっている。射出成形操作は、内金型と外金型とを型締めして成形キャビティを形成した後、まず最初に、第一樹脂流路７２から再生原料や改質剤を含有しない未使用の樹脂原料を所定量射出する。次いで、樹脂スクラップや廃材を粉砕して得た再生原料及び耐衝撃性を向上させるための改質剤を含有する樹脂原料を第二樹脂流路７３から成形キャビティ内に射出し、該キャビティ内を樹脂原料でほぼ充満させる。
【００２０】
このとき、先に成形キャビティ内に射出された未使用の樹脂原料中に後から射出された再生原料及び改質剤を含有する樹脂原料が潜り込み、双方の樹脂原料がキャビティの末端部まで満遍なく行き渡る。すなわち、中間層Ａとなる再生原料及び改質剤を含有する樹脂原料の表面がスキン層（内層Ｂ及び外層Ｃ）で覆われた状態でキャビティの末端部まで満遍なく行き渡るため、内層Ｂ及び外層Ｃから中間層Ａがはみ出すこともない。なお、最初に射出する再生原料及び改質剤を含有しない未使用の樹脂原料と、その後で射出する再生原料及び改質剤を含有する樹脂原料の割合は、中間層Ａと内層Ｂ及び外層Ｃの肉厚や、樹脂原料の種類等を考慮して適宜設定することができる。
【００２１】
最後に、第一樹脂流路７２から再生原料及び改質剤を含有しない未使用の樹脂原料を少量成形キャビティ内に射出する。これにより、ゲート６２Ｇに対応するゲート口部６２Ｍを再生原料及び改質剤を含有しない樹脂原料で覆うことができるとともに、次のショットのためにノズル７１の先端部の滞留樹脂を再生原料及び改質剤を含有しない未使用の樹脂原料に置換することができる。以上の成形工程を経て、内金型及び外金型を型開きすると、図１に示したように外観良好な排水桝が得られる。
【００２２】
なお、上記説明では、樹脂製排水枡の中間層として、改質剤及び再生原料の双方を含有した樹脂原料を全体に使用したが、再生原料を使用せずに改質剤のみを含有させることによって排水枡全体の耐衝撃性を向上させることができ、また、改質剤を使用せずに再生原料のみを含有させることによってスクラップや廃材の有効活用が図れる。そして、改質剤及び再生原料の双方を含有させることにより、耐衝撃性の向上とスクラップや廃材の有効活用が図れることになる。
【００２３】
さらに、前記製造工程において、第一樹脂流路７２から再生原料を含有しない未使用の樹脂原料を射出した後、第二樹脂流路７３から成形キャビティ内に射出する樹脂原料を、最初に改質剤を含有せずに再生原料を含有する樹脂原料を射出し、続けて改質剤を含有する樹脂原料あるいは改質剤及び再生原料の双方を含有した樹脂原料を射出することにより、桝本体１１の底部、即ちインバート部１２の部分の中間層Ａを改質剤を含有した樹脂原料からなる耐衝撃性に優れたものとし、排水枡の他の部分は、改質剤を含有せずに再生原料を含有した樹脂原料からなる中間層Ａとすることができる。
【００２４】
このとき、第二樹脂流路７３から最初に射出する再生原料を含有した樹脂原料の射出量を、該樹脂原料の射出によってキャビティの７〜８割が満たされる量とし、次に射出する改質剤を含有した樹脂原料でキャビティを満たすように設定することにより、通常の排水枡におけるインバート部１２の中間層Ａを改質剤によって耐衝撃性を向上させたものにすることができる。これにより、改質剤の使用量を最小限に抑えて必要部分の耐衝撃性を向上させながら、再生原料の有効利用も図れることになる。
【００２５】
【発明の効果】
以上説明したように、本発明によれば、三層構造の中間層に改質剤を含有する樹脂原料を使用して排水枡底部（インバート部）の耐衝撃性を向上させるようにしたので、排水枡全体の樹脂に改質剤を添加したものに比べて低コストで所要の耐衝撃性を得ることができる。さらに、中間層に再生原料を含有させることにより、樹脂成形品を射出成形あるいは押出成形したときに発生したスクラップや、老朽化して使用済みとなった廃材を有効活用することができる。また、改質剤や再生原料を含有する中間層の樹脂原料を内層や外層からはみ出させることなく、外観良好な三層構造の蓋が得られる。
【図面の簡単な説明】
【図１】本発明の一形態例を示す排水桝の断面図である。
【図２】排水桝の製造工程を示す断面図である。
【符号の説明】
１１…桝本体、１２…インバート部、１３ａ，１３ｂ…接続部、５１，５２，５３…内金型、６１，６２…外金型、６２Ｇ…ゲート、６２Ｍ…ゲート口部、７１…ノズル、７２…第一樹脂流路、７３…第二樹脂流路、Ａ…中間層、Ｂ…内層、Ｃ…外層[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a drainage basin and a method for forming the same, and more particularly, to a drainage basin capable of improving the impact resistance, particularly the impact resistance at the bottom, and effectively utilizing resin scrap and used waste material, and a method for forming the same. About.
[0002]
[Prior art]
Conventionally, a drainage basin made of synthetic resin, for example, polyvinyl chloride has been used as a drainage basin. The bottom (inverted portion) of the drainage basin has drainage that falls from above, a tool that has dropped during construction, There is a risk of damage due to falling stones. For this reason, although only the bottom of the drainage basin is formed and fitted with another member having impact resistance, the molding process is troublesome and the cost is increased. Further, the entire drainage basin can be formed of a material having impact resistance, for example, a resin raw material to which a modifier is added, but the cost of the resin raw material is greatly increased.
[0003]
On the other hand, when injection molding of housing materials for home appliances made of resin raw materials and building materials such as pipe joints, unnecessary members such as gates and scraps are generated, and when extruding synthetic resin pipes continuously, molding A large amount of scrap may be generated in the initial stage until the conditions are stabilized. Further, when renewing an aging synthetic resin pipe after its useful life, a large amount of used waste material may be generated. In recent years, disposal of such resin scraps and used waste materials has become a major problem.
[0004]
[Problems to be solved by the invention]
Conventionally, resin scraps and used waste materials have been disposed of by incineration or landfill.However, when incinerating resin scraps, there is a problem that dioxin is generated and pollutes the environment. I have. In addition, when burying resin scraps and waste materials in the ground, not only the place where they are buried becomes a problem, but also the problem of environmental destruction is raised because the synthetic resin is not decomposed or corroded for a long time. Has reached. Therefore, it has been proposed to pulverize resin scraps and used waste materials and use them as recycled materials (see Japanese Patent Application Laid-Open No. 2001-41362). It was difficult.
[0005]
Therefore, the present invention is to improve the impact resistance of the bottom of the drainage basin effectively, and to effectively utilize the scrap and the used waste material generated when the resin molded product is injection-molded or extruded. It is an object of the present invention to provide a drainage basin using a resin molded product having a three-layer structure and a molding method thereof.
[0006]
[Means for Solving the Problems]
In order to achieve the above object, the drainage basin of the present invention is a drainage basin in which the upper part of a cylindrical main body is opened and a connection part of a drainage pipe is formed on a side wall of the main body of the drainage basin. A three-layer structure having an intermediate layer and an inner layer and an outer layer covering the inner and outer surfaces of the intermediate layer, the intermediate layer is formed of a resin material containing a modifying agent, the inner layer and the outer layer, It is characterized by being formed from an unused resin raw material not containing a modifier, and in particular, the mixing ratio of the modifier in the resin raw material forming the intermediate layer is preferably an unused resin raw material containing no modifier. It is characterized by 8 to 15 parts by weight for 100 parts by weight.
[0007]
In addition, the drainage basin of the present invention is configured such that the entire basin body is formed in a three-layer structure having an intermediate layer and an inner layer and an outer layer covering the inner and outer surfaces of the intermediate layer. Characterized in that the inner layer and the outer layer are formed of an unused resin material not containing the recycled material, and the inner layer and the outer layer are formed of a resin material containing a recycled material obtained by pulverization and a modifier. It is characterized in that the agent is contained only in the intermediate layer forming the bottom of the main body.
[0008]
Further, in the above configuration, the ratio of the recycled material of the resin scrap and the waste material is 10 to 80% by weight of the entire resin material constituting the box body, and the recycled material is formed of the scrap and the waste material of the hard vinyl chloride resin. It is a recycled material, and the unused resin material is a hard vinyl chloride resin.
[0009]
In addition, the method of forming a drainage basin according to the present invention, as a first configuration, has an opening at an upper portion of a cylindrical main body, an invert portion at a lower portion of the main body, and a main body communicating with the invert portion. In a method for manufacturing a drainage basin having a drain pipe connecting portion formed on a side wall of the basin, a mold cavity of the basin body is formed by clamping an inner mold and an outer mold, and an inverting portion of the basin body in the molding cavity is formed. By injecting a predetermined amount of unused resin material into the molding cavity from the gate formed at the portion corresponding to the lower surface, and then injecting the resin material containing the modifying agent into the molding cavity, An intermediate layer made of a resin material to be contained is formed at least on the bottom portion of the box body, and the inner and outer surfaces of the intermediate layer are covered with an inner layer and an outer layer made of an unused resin material not containing a modifier. As a feature That.
[0010]
Furthermore, the method of forming a drainage basin according to the present invention is characterized in that, as a second configuration, the upper part of the cylindrical basin body is opened, and the basin body has an inverting part at the lower part thereof and communicates with the inverting part. In a method for manufacturing a drainage basin having a drain pipe connecting portion formed on a side wall of the basin, a mold cavity of the basin body is formed by clamping an inner mold and an outer mold, and an inverting portion of the basin body in the molding cavity is formed. A predetermined amount of unused resin material is injected into the molding cavity from a gate formed at a portion corresponding to the lower surface, and then a resin material containing recycled material obtained by pulverizing resin scrap and waste material is placed in the molding cavity. By injecting a fixed amount, and subsequently injecting the resin material containing the modifying agent into the molding cavity, the intermediate layer made of the resin material containing the modifying agent is formed at the bottom of the box body, and the entire box body excluding the bottom is removed. Above An intermediate layer made of a resin material containing a raw material is formed, and the inner and outer surfaces of both intermediate layers are covered with an inner layer and an outer layer made of an unused resin material containing no modifier and recycled material. It is characterized by.
[0011]
The method of forming a drainage basin according to the present invention has, as a third configuration, an opening at the top of a cylindrical main body, an invert portion at a lower portion of the main body, and communication with the invert portion. In a method for manufacturing a drainage basin having a drain pipe connecting portion formed on a side wall of the basin, a mold cavity of the basin body is formed by clamping an inner mold and an outer mold, and an inverting portion of the basin body in the molding cavity is formed. A predetermined amount of unused resin material is injected into the molding cavity from the gate formed at the portion corresponding to the lower surface, and then a resin material containing a recycled material and a modifier obtained by pulverizing resin scrap and waste material is molded. A state in which the inner and outer surfaces of the intermediate layer made of the resin material containing the recycled material and the modifier are injected into the cavity and covered with an inner layer and an outer layer made of the unused resin material not containing the recycled material and the modifier. To do It is characterized.
[0012]
BEST MODE FOR CARRYING OUT THE INVENTION
FIG. 1 is a sectional view of a drainage basin showing one embodiment of the present invention, and FIG. 2 is a sectional view showing a manufacturing process of the drainage basin shown in FIG. This drainage basin has an opening at the top of a cylindrical main body 11, has an inverting portion 12 at the lower portion of the main body 11, and communicates with the inverting portion 12 to connect a drainage pipe to a side wall of the main body 11. 13a and 13b, the intermediate layer A of the box body 11 is formed from a recycled raw material obtained by pulverizing scraps and waste materials of a resin molded product and a resin raw material containing a modifier. The inner and outer surfaces of the intermediate layer A are covered with an inner layer B and an outer layer C made of a recycled material and an unused resin material containing no modifier.
[0013]
As the impact modifier used in the intermediate layer A, an appropriate one can be used according to the type of the resin, and the mixing amount is appropriately set according to the type of the resin and the degree of the modification. Can be. As the modifier, a rubber-based substance, for example, MBS resin, can be used, and as other additives, tin stabilizer, heat stabilizer, lubricant, processing aid, pigment, plasticizer, filler, electric resistance Various additives such as an inhibitor, an ultraviolet absorber, and a flame retardant can be added.
[0014]
Preferable examples of blending are as follows: 8 to 15 parts by weight of a modifier, 0.5 to 3 parts by weight of a stabilizer, 0.1 to 1.0 part by weight of a lubricant, 0 0.1 to 1.0 part by weight, and 0.1 to 1.0 part by weight of a pigment.
[0015]
Recycled raw materials obtained by pulverizing resin scraps and waste materials are used as resin molded products made of polyvinyl chloride, polyethylene, polypropylene, etc., for example, waste materials of building materials such as plastic bottles, housings of household electric appliances and fittings, and injection. It is obtained by crushing unnecessary members such as gates and scrap generated during molding. As a main component of the resin raw material constituting the intermediate layer A, a recycled raw material alone or a mixture of the recycled raw material and an unused resin raw material can be used, and the resin constituting the inner layer B and the outer layer C can be used. As a raw material, a resin raw material that is compatible with the intermediate layer A and that is not used, such as a recycled raw material or a polyvinyl chloride, polyethylene, or polypropylene that does not contain a modifier, can be used.
[0016]
As described above, various resin materials can be used for the intermediate layer A, the inner layer B and the outer layer C covering the inner and outer surfaces of the intermediate layer A, but a large amount of used waste materials and scraps made of vinyl chloride resin are generated. Considering the current situation and the fact that a pipe made of hard vinyl chloride resin is frequently used as a drain pipe connected to a drainage basin, a recycled material made of hard vinyl chloride resin can be suitably used for the intermediate layer A. For the inner layer B and the outer layer C covering the inner and outer surfaces of A, an unused hard vinyl chloride resin containing no recycled material can be suitably used.
[0017]
Further, it is preferable that the ratio of the recycled material to the entire resin material constituting the drainage basin is 10 to 80% by weight. If the proportion of the recycled material is less than 10% by weight, a sufficient effect cannot be expected in terms of effectively utilizing waste materials and scraps. Conversely, if the proportion exceeds 80% by weight, the resin material does not contain the recycled material. Since the inner layer B and the outer layer C become thinner, a situation occurs in which the recycled raw material constituting the intermediate layer A partially protrudes from the inner layer B and the outer layer C to impair the appearance. Incidentally, the wall thickness of the side wall portion of the drainage basin having a size of 150 to 350 is about 5 to 20 mm.
[0018]
The drain basin is manufactured by injection molding. Next, the manufacturing process will be described. In FIG. 2, reference numerals 51, 52, and 53 denote inner dies, and 61 and 62 denote outer dies. The molding cavities of the box body 11 are formed by clamping the inner dies and the outer dies. . A gate 62G for injecting the resin material into the molding cavity is provided on the outer mold 62, and is provided on a portion corresponding to the lower surface of the invert portion of the main body 11 of the box. When the gate 62G is provided on the lower surface of the invert portion which is symmetrical and located near the center of the cylindrical main body 11 in this way, the resin material injected into the molding cavity can be evenly distributed to the end portion, and the gate Even if the mark of 62G (gate opening 62M (see FIG. 1)) appears on the lower surface of the invert portion, there is an advantage in appearance that it is not visible.
[0019]
A nozzle 71 of an injection molding machine can be brought into contact with the gate 62G, and an unused resin material containing no recycled material or modifier is supplied from a first resin flow path 72 provided in the nozzle 71. The resin material containing the recycled material and the modifier is injected from the second resin flow channel 73. In the injection molding operation, after the inner mold and the outer mold are clamped to form a molding cavity, first, the first resin flow path 72 passes through the first resin flow path 72 an unused resin material containing no recycled material or modifier. Is injected by a predetermined amount. Next, a recycled raw material obtained by pulverizing resin scraps and waste materials and a resin raw material containing a modifier for improving impact resistance are injected into the molding cavity from the second resin flow path 73, and the inside of the cavity is discharged. Almost filled with resin material.
[0020]
At this time, the resin raw material containing the regenerated raw material and the modifier injected later into the unused resin raw material previously injected into the molding cavity, and both resin raw materials spread evenly to the end of the cavity. . That is, since the surface of the resin material containing the regenerating material and the modifying agent to be the intermediate layer A is evenly distributed to the end of the cavity while being covered with the skin layer (the inner layer B and the outer layer C), the inner layer B and the outer layer C The intermediate layer A does not protrude from the surface. In addition, the ratio of the recycled raw material and the unused resin raw material not containing the modifying agent to be injected first, and the ratio of the recycled raw material and the resin raw material containing the modifying agent to be subsequently injected is determined by the intermediate layer A, the inner layer B and the outer layer C. Can be appropriately set in consideration of the thickness of the resin, the type of the resin material, and the like.
[0021]
Lastly, a small amount of unused resin raw material containing no recycled raw material and modifier is injected into the molding cavity from the first resin flow channel 72. As a result, the gate opening 62M corresponding to the gate 62G can be covered with the regenerating material and the resin material not containing the modifying agent. It can be replaced with an unused resin raw material containing no filler. When the inner mold and the outer mold are opened after the above-described molding process, a drainage basin having a good appearance is obtained as shown in FIG.
[0022]
In the above description, as the intermediate layer of the resin drainage basin, a resin material containing both a modifying agent and a recycled material is used as a whole, but only the modifying agent is contained without using a recycled material. Thereby, the impact resistance of the entire drainage basin can be improved, and the scrap and waste material can be effectively used by containing only the recycled material without using the modifying agent. By containing both the modifier and the recycled material, the impact resistance can be improved and scrap and waste materials can be effectively used.
[0023]
Further, in the manufacturing process, after injecting an unused resin raw material containing no recycled material from the first resin channel 72, the resin material injected into the molding cavity from the second resin channel 73 is first modified. Injecting a resin raw material containing a regenerating raw material without containing an agent, and subsequently injecting a resin raw material containing a modifying agent or a resin raw material containing both the modifying agent and the regenerating raw material, Of the bottom portion, ie, the intermediate layer A of the invert portion 12 is made of a resin material containing a modifying agent and has excellent impact resistance, and the other portion of the drainage basin is regenerated without containing the modifying agent. An intermediate layer A made of a resin raw material containing the raw material can be obtained.
[0024]
At this time, the injection amount of the resin raw material containing the regenerated raw material first injected from the second resin flow path 73 is set to an amount that fills 70 to 80% of the cavity by injection of the resin raw material, By setting the resin material containing the agent so as to fill the cavity, it is possible to improve the impact resistance of the intermediate layer A of the invert portion 12 in the ordinary drainage basin by the modifier. As a result, the recycled material can be effectively used while minimizing the amount of the modifier used and improving the impact resistance of the necessary parts.
[0025]
【The invention's effect】
As described above, according to the present invention, the impact resistance of the bottom of the drainage basin (inverted portion) is improved by using a resin material containing a modifier in the intermediate layer having a three-layer structure. The required impact resistance can be obtained at low cost as compared with a resin obtained by adding a modifier to the resin of the entire drain basin. Further, by including a recycled material in the intermediate layer, scrap generated when the resin molded product is injection-molded or extruded, and aging and waste materials that have been used can be effectively used. Further, a lid having a good appearance can be obtained without extruding the resin material of the intermediate layer containing the modifying agent and the recycled material from the inner layer and the outer layer.
[Brief description of the drawings]
FIG. 1 is a sectional view of a drainage basin showing one embodiment of the present invention.
FIG. 2 is a cross-sectional view illustrating a manufacturing process of the drainage basin.
[Explanation of symbols]
11: Masu body, 12: Invert part, 13a, 13b ... Connection part, 51, 52, 53 ... Inner die, 61, 62 ... Outer die, 62G ... Gate, 62M ... Gate opening, 71 ... Nozzle, 72 ... first resin flow path, 73 ... second resin flow path, A ... middle layer, B ... inner layer, C ... outer layer

Claims

In a drainage basin in which the upper part of the cylindrical main body is open and a drainage pipe connection portion is formed on the side wall of the main body, at least the bottom of the main body is an intermediate layer and an inner layer that covers the inner and outer surfaces of the intermediate layer. While forming a three-layer structure having an outer layer, the intermediate layer was formed of a resin material containing a modifier, and the inner layer and the outer layer were formed of an unused resin material not containing the modifier. A drainage basin characterized by that.

The mixing ratio of the modifying agent in the resin material forming the intermediate layer is 8 to 15 parts by weight with respect to 100 parts by weight of the unused resin material not containing the modifying agent. The drainage basin described.

The entire body of the masu is formed in a three-layer structure having an intermediate layer, an inner layer and an outer layer covering the inner and outer surfaces of the intermediate layer, and the intermediate layer is formed of a recycled material obtained by pulverizing resin scraps and waste materials and a modified material. The drain basin according to claim 1, wherein the inner layer and the outer layer are formed of an unused resin material that does not contain the recycled material.

The drainage basin according to claim 3, wherein the modifying agent is contained only in an intermediate layer forming a bottom of the basin body.

4. The drainage basin according to claim 3, wherein the proportion of recycled material of resin scrap and waste material is 10 to 80% by weight of the entire resin raw material constituting the main body of the basin.

4. The drain basin according to claim 3, wherein the recycled material is a recycled material made of scrap or waste material of a hard vinyl chloride resin, and the unused resin material is a hard vinyl chloride resin.

A method for manufacturing a drainage basin in which the upper part of a cylindrical basin body is open and has an invert portion at a lower portion of the basin body, and a drainage pipe connection portion is formed on a side wall of the basin body in communication with the invert portion. The inner mold and the outer mold are clamped to form a molding cavity of the box body, and unused resin is introduced into the molding cavity from a gate formed at a portion corresponding to the lower surface of the invert portion of the box body in the molding cavity. By injecting a predetermined amount of the raw material and then injecting the resin raw material containing the modifying agent into the molding cavity, an intermediate layer made of the resin raw material containing the modifying agent is formed at least at the bottom of the box body. A method for producing a drainage basin, wherein the inner and outer surfaces of the intermediate layer are covered with an inner layer and an outer layer made of an unused resin raw material containing no modifier.

A method for manufacturing a drainage basin in which the upper part of a cylindrical basin body is open and has an invert portion at a lower portion of the basin body, and a drainage pipe connection portion is formed on a side wall of the basin body in communication with the invert portion. The inner mold and the outer mold are clamped to form a molding cavity of the box body, and unused resin is introduced into the molding cavity from a gate formed at a portion corresponding to the lower surface of the invert portion of the box body in the molding cavity. A predetermined amount of raw material is injected, and then a predetermined amount of a resin raw material containing a regenerated raw material obtained by pulverizing resin scrap and waste material is injected into a molding cavity, and then a resin raw material containing a modifying agent is injected into the molding cavity. To form an intermediate layer made of a resin material containing a modifier on the bottom of the box body, and an intermediate layer made of the resin material containing the recycled material on the entire box body except the bottom. Method of manufacturing a catch basin, characterized by a state in which the inner and outer surfaces of both the intermediate layer is covered with the inner layer and the outer layer of virgin resin material containing no modifier and regrind Te.

A method for manufacturing a drainage basin in which the upper part of a cylindrical basin body is open and has an invert portion at a lower portion of the basin body, and a drainage pipe connection portion is formed on a side wall of the basin body in communication with the invert portion. The inner mold and the outer mold are clamped to form a molding cavity of the box body, and unused resin is introduced into the molding cavity from a gate formed at a portion corresponding to the lower surface of the invert portion of the box body in the molding cavity. A predetermined amount of raw material is injected, and then a resin raw material containing a regenerated raw material and a modifier obtained by pulverizing resin scrap and waste material is injected into a molding cavity, and a resin raw material containing the regenerated raw material and the modifier is formed. A method for producing a drainage basin, characterized in that the inner and outer surfaces of an intermediate layer composed of an inner layer and an outer layer composed of a recycled material and an unused resin material not containing a modifier are covered with an inner layer and an outer layer.