JP2006007439A - Manufacturing method of molded product and counter for bathroom - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method of a molded product causing no twist or warpage, and a counter for a bathroom. <P>SOLUTION: In the manufacturing method of the molded product by setting a surface material, which has the surface profile 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 rear 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, the shrinkage factor of the slurry at molding is adjusted to the vicinity of the shrinkage factor of the surface material by adding at least either one of a low shrink agent and glass short fibers to the slurry. <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 the spray-up method is used, there is an advantage that the molding workability of the reinforcing layer is good and molded products having partially different thicknesses can be easily molded.

JP-A-6-198660

However, in the case of the manufacturing method as described above, there is a difference in linear expansion coefficient between the acrylic resin constituting the surface material and the slurry forming the reinforcing layer, and the curing shrinkage ratio of the slurry is 9
Since it is as large as about / 1000, the molded product may be twisted or warped.
Therefore, it is conceivable that correction is performed with a clamp or the like for the purpose of suppressing deformation during after-curing. However, there is a problem that shrinkage cracking of the slurry tends to occur when correction is applied.

In view of the above circumstances, the present invention sets a surface material having a surface shape of a molded product obtained by vacuum forming an acrylic resin sheet in a casting mold having a mold surface of a back surface shape of the molded product, Fill a slurry containing unsaturated polyester resin and filler between the back surface of the casting mold and the back surface of the molded product, and cure the slurry to integrate the reinforcing layer on the back surface of the surface material. An object of the present invention is to provide a method for manufacturing a molded product that does not cause twisting or warping and a bathroom counter.

In order to achieve the above object, a method for producing a molded product according to the present invention includes a surface material having a surface shape of a molded product obtained by vacuum forming an acrylic resin sheet, and a mold surface having a back surface shape of the molded product. Set in the casting 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, and cure the slurry. In the method for producing a molded article in which a reinforcing layer is integrally formed on the back surface of the surface material, the slurry has a degree of shrinkage at the time of molding near the degree of shrinkage of the surface material by adding at least one of a low shrinkage agent and short glass fiber. It is characterized by being adjusted to become.

In the present invention, the low shrinkage agent is not particularly limited, but for example, those made of polystyrene resin or vinyl acetate resin, or a mixture thereof are 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.

In the present invention, the short glass fibers preferably have an average length of about 0.5 mm to 10 mm, and more preferably an average length of about 3 mm.
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 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.

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 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.

The production method of the present invention is not particularly limited, but it is preferable to form a primer layer on the back surface of the surface material before filling the slurry as in claim 2.
Although it does not specifically limit as a primer (gel coat) which forms a primer layer, A vinyl ester resin type thing is mentioned.

In addition, the molded product obtained by the production method of the present invention is not particularly limited.
Examples include bathroom counters.

In the method for producing a molded article according to the present invention, as described above, the slurry has a degree of shrinkage at the time of molding close to that of the surface material by adding at least one of a low shrinkage agent and short glass fibers. Since it is adjusted, the shrinkage | contraction at the time of hardening of a slurry can be suppressed, and the curvature and deformation | transformation by a shrinkage difference with a surface material can be prevented. In particular, if short glass fibers are used, cracks during slurry curing can also be prevented. Moreover, since the reinforcing layer is formed by casting, the back side of the molded product, that is, the uneven shape of the reinforcing layer can be accurately formed,
It is possible to stably obtain molded articles such as bathroom counters with excellent storage accuracy.

Moreover, if the primer layer is formed on the back surface of the surface material before filling the slurry as in claim 2, the adhesion strength between the surface material and the 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, and a reinforcing layer 4, and as shown in FIGS. 1 and 2, on the front side and the back side, respectively. Concavities and convexities are formed, and the thickness of each part is different from the adjacent part as necessary.
Further, as shown in FIG. 4, insert nuts 41 into which fixing bolts 42 are screwed are embedded in ten or more places (only two places are shown in FIG. 4) of the reinforcing layer 4.

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, 5 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 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.

(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) The surface material 2 is set in the casting mold, and the insert nut is set at a predetermined position in the casting mold.
(5) 70 to 100 parts by weight of unsaturated polyester resin, 250 to 300 parts by weight of filler, 20 to 30 parts by weight of low shrinkage agent (or short glass fiber 3 mm chopped strand 0.
5 to 3 parts by weight) is mixed to prepare a slurry.

(6) The prepared slurry is poured into a casting mold.
(7) After injecting a predetermined amount of slurry, the mold is clamped and the slurry is cured in a casting mold.

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

(10) After cure.
(11) 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.

It is a top view of the counter for bathrooms which is one embodiment of the molded article obtained with the manufacturing method of the molded article concerning the present 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 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 method for producing a molded article 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 method for producing a molded product, wherein the slurry is adjusted such that the degree of shrinkage at the time of molding is close to the degree of shrinkage of the surface material by adding at least one of a low shrinkage agent and short glass fibers . The method for producing a molded product according to claim 1, wherein a primer layer is formed on the back surface of the surface material before filling the slurry. The bathroom counter manufactured by the manufacturing method of the molded article of Claim 1 or Claim 2.

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