JP2006159614A - Water-section equipment and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an inexpensive high capacity proper means which improves the antifungal properties, abrasion resistance, antistaining properties and the like of the non-contact surface with a surface material of a synthetic resin foam, in enhancing heat insulating properties, soundproof properties or the like of the surface material by forming the synthetic resin foam to the back of the surface material in water section equipment such as a bathroom related unit, a sink related unit, a toilet related unit or the like. <P>SOLUTION: The water-related device is constituted by providing a coating layer 3, which is formed of a resin selected from an acrylic resin, a vinyl acetate resin, an epoxy resin and a silicone resin, on the non-contact surface with the surface material 1 of the synthetic resin foam of a laminate composed of the surface material 1 and the synthetic resin foam 2. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a watering device and a method for manufacturing the same.

  Conventionally, a synthetic resin foam layer has been provided on the back surface of a bathtub or sink sink for the purpose of heat insulation, sound insulation, sound insulation, vibration suppression, or the like. The surface of the synthetic resin foam is exposed on the surface of the synthetic resin foam layer that is not in contact with the bathtub or the sink sink. For this reason, sufficient mold resistance, abrasion resistance, stain resistance, etc. may not be obtained. If necessary, the surface of the synthetic resin foam is covered with a non-foamed synthetic resin sheet. Etc. and have responded.

On the other hand, in addition to covering the synthetic resin sheet, examples of attempts to reinforce with a urethane-based resin paint include the following. That is, a floating body including a reinforcing film made of a resin-based paint formed to a predetermined thickness on the surface of a base made of foam is disclosed (see Patent Document 1). Moreover, there is an example in which a urethane-based resin is spray-coated on the surface of a foamed polystyrene molded body as a foamed molded body for a temporary road structure (see Patent Document 2). Furthermore, a protective film-forming resin coating is applied as a decorative interior / exterior material for a building to form a protective layer, and a weather-resistant coating film is formed thereon with a fluororesin coating (see Patent Document 3). . In addition, an attempt has been made to protect the surface of a structure made of a polystyrene foam member such as a bungalow with a surface protective material obtained by mixing an aqueous modified acrylic emulsion resin with cement and silica sand (see Patent Document 4).
JP 2002-255085 A JP-A-9-95554 JP 2002-254540 A JP 2004-19382 A

  In the method of covering the surface of the synthetic resin foam with a non-foamed synthetic resin sheet, a synthetic resin sheet having the same shape as the synthetic resin foam is required. A special process was required. For these reasons, the burden is increased in terms of cost.

  Moreover, in the example which tried reinforcement by the above-mentioned urethane-type resin paint, reinforcement of the foam molded object used directly outside, such as a floating body, the foam molded object for temporary road structures, and the interior / exterior material for the decoration of a building It was intended. Other than urethane resins, there is only an invention that prevents the deterioration of structures such as bungalows by mixing and applying acrylic resin with cement or silica sand.

  The inventors of the present invention previously filed an application for creating a good coating layer on the surface of a foamed molded article used for a watering device using a urethane resin paint (Japanese Patent Application No. 2004-307294). The present invention improves this.

  That is, urethane-based resin paints are non-solvent, and those that do not dissolve or erode the surface of the foamed molded product are available, and there are also those with high viscosity that form a coating layer on the surface of the foamed molded product. The product could also be selected. However, such urethane-based resin paints are expensive in the first place and have high viscosity. Therefore, a special and expensive spray gun must be used, and a more versatile technique is desired. .

  The inventors of the present invention are eager to improve the mold resistance, wear resistance, stain resistance, etc. by forming a coating layer on the surface of the foamed molded product used in water-based equipment with a resin other than urethane resin. As a result of research, spray guns, etc. that are usually commercially available for adhesives made of acrylic resin, vinyl acetate resin, epoxy resin, silicon resin, which are usually used as adhesives and film coating materials, etc. The present invention succeeds for the first time in providing an improved watering device by forming a coating layer that is inexpensive, simple, and good in performance by applying to the surface of a foamed molded article using It came to make.

That is, in the first aspect of the present invention, in a laminate composed of a surface material and a synthetic resin foam, an acrylic resin, a vinyl acetate resin, an epoxy resin, a non-contact surface with the surface material of the synthetic resin foam, The present invention relates to a watering device provided with a coating layer formed from a resin selected from silicon-based resins.
As a preferred embodiment,
(1) The resin forming the coating layer is an acrylic resin.
(2) The resin forming the coating layer is a non-solvent type,
(3) The thickness of the coating layer is 0.05 mm or more and 5 mm or less,
(4) An antibacterial agent and / or an antifungal agent is contained in the resin forming the coating layer.
(5) The resin that forms the coating layer is spray-coated.
(6) The synthetic resin foam is a foamed styrenic resin.
(7) The watering device is any of bathroom-related equipment, sink-related equipment, and toilet-related equipment.
The present invention relates to the above-mentioned watering device.

  In the second aspect of the present invention, the watering device described above is made of a resin selected from an acrylic resin, a vinyl acetate resin, an epoxy resin, and a silicon resin on a non-contact surface with the surface material of the synthetic resin foam. The present invention relates to a method for manufacturing a watering device, characterized in that it is provided with a coating layer.

  In a watering device in which a synthetic resin foam is formed on the back surface of the surface material, a non-contact surface with the surface material of the synthetic resin foam is selected from an acrylic resin, a vinyl acetate resin, an epoxy resin, and a silicon resin. By providing a coating layer made of a resin, it is possible to improve mold performance, wear resistance, contamination resistance, etc. at low cost and with high performance. Accordingly, it is possible to supply industrially superior watering equipment without the need for laminating a non-foamed sheet or the like on the non-contact surface. In particular, when an antibacterial agent and / or a fungicide is contained in the resin forming the coating layer, these properties are excellent. According to the present invention, an inexpensive ordinary resin adhesive can be provided on the surface of a synthetic resin foam easily and inexpensively by using a commercially available spray gun. Is extremely effective.

  In the present invention, a watering device refers to a device used in a location where a large amount of water is used, and specifically includes bathroom-related devices, sink-related devices, toilet-related devices, and the like.

  In the present invention, the surface material refers to a material that is directly used by the user or provided as an outer layer. For example, in the case of a bathroom, a bathtub, an indoor steel plate of a bathroom wall, a sink, a sink, a ceiling Say a board.

  As the material of the surface material, various materials such as FRP, stainless steel, glazed, acrylic, artificial marble (unsaturated polyester) can be used, and there is no particular limitation. In some cases, the surface material is a coating layer made of a paint such as an acrylic resin, a vinyl acetate resin, an epoxy resin, a silicon resin, or a urethane resin provided on the surface of the synthetic resin foam. May be.

  In the present invention, a synthetic resin foam is laminated on the surface material to constitute a laminate. Then, a coating layer made of an acrylic resin, a vinyl acetate resin, an epoxy resin, or a silicon resin is formed on the surface of the synthetic resin foam that is not in contact with the surface material, that is, the non-contact surface. It becomes a watering device.

  There is no restriction | limiting in particular as a synthetic resin foam used by this invention, Although it is possible to use the foaming molding manufactured by various manufacturing methods, the point which is easy to obtain a desired shape especially in moldability Therefore, it is a particularly preferable embodiment to employ a method in which foamable synthetic resin particles are used and molded into a desired shape by in-mold molding or the like.

  The type of foamed synthetic resin constituting the synthetic resin foam is not particularly limited, but from the viewpoint of ease of handling, a foamed styrenic resin, a foamed acrylic resin, and a foamed polyolefin resin are preferable. Styrenic resins are more preferred, and expanded polystyrene resins are most preferred. Any commercially available foamed styrenic resin can be used and is not particularly limited. Various foamed acrylic resins can be used, but a foamed acrylic resin as disclosed in JP-A-2001-233986 can be suitably used.

  The foaming ratio of the synthetic resin foam is not particularly limited, but when the watering device is formed of a relatively weak surface material such as thin stainless steel, the back surface can be held rigidly. Since it is preferable for exhibiting the sound-damping effect of the present invention, it is preferably 2 times to 60 times, and more preferably 5 times to 30 times, which is relatively strong.

  Although the synthetic resin foam can be used as it is, depending on the form of use, it is difficult to touch the eyes of the user. An agent and / or an antifungal agent can be contained inside or on the surface of the synthetic resin foam, or can be contained inside or on the surface of the resin forming the coating layer.

  In order to contain the antibacterial agent and / or antifungal agent in the inside or the surface of the synthetic resin foam, it may be added or applied to the particles of the foamed synthetic resin in advance. For example, the back surface of the surface material may be formed by in-mold foam molding. After forming into the shape to cover, you may apply | coat or spray-apply etc. on the non-contact surface with the surface material of a synthetic resin foam. In any case, the addition and application method are not limited.

  In order to contain an antibacterial agent and / or an antifungal agent inside or on the surface of the resin forming the coating layer, the synthetic resin foam is selected from acrylic resin, vinyl acetate resin, epoxy resin and silicon resin. After coating the resin, it may be applied to the surface of the coating layer, or may be added in advance to a resin for forming the coating layer (hereinafter sometimes abbreviated as coating resin). Among them, it is preferable to contain an antibacterial agent and / or an antifungal agent in acrylic resin, vinyl acetate resin, epoxy resin, or silicon resin.

  These antibacterial agents and / or antifungal agents can be used without limitation unless they specifically impair the synthetic resin foam and the surface material. Examples of the antibacterial agent include ceramic antibacterial agents, silver antibacterial agents, calcium ceramics, and amorphous calcium phosphate.

  On the other hand, as an antifungal agent, for example, an imidazole antifungal agent, an iodo antifungal agent, a triazole antifungal agent, and a thiabendazole antifungal agent are common, but agents that exhibit antibacterial and antifungal properties If so, it can be used without any particular limitation.

  These synthetic resin foams may be laminated so as to cover at least a part of the back surface of the surface material, but it is more preferable because the effect of the present invention is enhanced by laminating so as to cover the entire back surface of the surface material.

  To cover the back surface of the surface material with the synthetic resin foam, the synthetic resin foam is divided into several blocks, and these are bonded together to create a shape that matches the shape of the back surface of the surface material. After being molded into a shape that matches the shape of the back surface of the surface material in advance or by a method of individually pasting the block-divided parts on the back surface of the surface material, or in-mold molding, Any of a method of pasting or a method of integrally forming the synthetic resin foam layer on the back surface of the surface material can be used as appropriate.

  Of the above methods, the synthetic resin foam is formed by dividing it into several blocks, and in order to create a shape that matches the back surface shape of the surface material by bonding them, dissolve the surface of these synthetic resin foams, Those that do not erode are preferable, and some of the acrylic adhesives are devised for these points, and it is preferable to use them.

  Further, in the above method, in order to integrally form the synthetic resin foam on the back surface of the surface material, in the mold, the foamable synthetic resin particles are introduced only on the back surface side of the surface material. The surface material is placed on the surface material, and the foamable synthetic resin particles are introduced only on the back side of the surface material, and then heated by a heating means such as steam, and the foamable synthetic resin particles and the foamable synthetic resin particles and the surface material After foaming and fusing the back surface, a method of removing from the mold can be applied.

For example, when the surface material is a metal surface material such as thin stainless steel, and the synthetic resin foam is integrally formed, the synthetic resin foam tends to hardly adhere to the metal surface material. However, for example, when at least the back surface of the metal surface material is subjected to a protective treatment often applied to a general metal, and the treatment agent is a thermoplastic resin, the synthetic resin foam and the metal There is a tendency that the adhesion with the surface material is improved and the integral formability with the metal surface material is improved. In addition, when this processing agent is a surface treatment with a polymethyl methacrylate resin or the like and, if necessary, a polymethyl methacrylate emulsion adhesive or the like, the adhesiveness tends to be good, which is preferable. When the surface treatment as described above is not performed on the back surface of the metal surface material, it is preferable to perform the surface treatment on at least the back surface of the metal surface material for the above reasons.

  In attaching the synthetic resin foam of the present invention to the back surface of the surface material, noise is reduced by interposing an elastic adhesive layer (elastic adhesive layer) between the back surface of the surface material and the synthetic resin foam. Even more preferable.

The elastic adhesive layer (hereinafter, sometimes simply referred to as an adhesive layer) is elastic as long as it has elasticity, does not attack the synthetic resin foam or the surface material, and does not impair the effects of the present invention. Can be used without limitation. Among these adhesive layers, it is preferable to use a modified silicone resin. The modified silicone resin is excellent in adhesiveness and can follow the shape of the back surface of the surface material, that is, a three-dimensional shape having a depth formed by deep drawing or the like, against a rapid temperature change. Excellent in properties. Furthermore, it is excellent in sound damping, sound insulation and vibration damping. In the present invention, the modified silicone resin is sometimes referred to as a modified silicone resin adhesive.
In addition, an acrylic resin or an acrylic resin adhesive is also preferably used. The above-mentioned modified silicone resin is optimal for use because it has elastic properties, other properties, cost, and pretreatment is simple or unnecessary.

  When the synthetic resin foam is affixed to the back surface of the surface material, an adhesive is applied to the contact surface of the synthetic resin foam with the surface material and / or the back surface of the surface material, and both are brought into contact with each other. It can be made to adhere easily by pressing at a pressure of about 03 MPa to 0.2 MPa.

  The coating resin such as acrylic resin, vinyl acetate resin, epoxy resin, and silicon resin used in the present invention is particularly limited unless the surface of the synthetic resin foam to be applied is dissolved or eroded by the coating resin. Commercially available products can be used. For example, examples of acrylic resins include non-solvent aqueous emulsion type one-part cold crosslinking acrylic copolymer resins, aqueous reaction curable acrylic urethane resin paints, aqueous reaction curable special acrylic resin top coatings, acetic acid An example of the vinyl resin is a vinyl acetate resin emulsion type film coating agent (containing 50 to 60% methanol), and an example of the epoxy resin is a two-component room temperature curing type epoxy resin adhesive. Among them, it is preferable to use a non-solvent resin because it can form a good surface property without affecting the surface of the synthetic resin foam.

  As a method of forming a coating layer by coating the surface using a coating resin such as an acrylic resin, a vinyl acetate resin, an epoxy resin, or a silicon resin on the non-contact surface with the surface material of the synthetic resin foam, Although not particularly limited, there are a method of applying the coating resin solution to the foamed resin molded body, a method of immersing the foamed resin molded body in the coating resin solution, and a spray coating method in which the coating resin is spray coated on the foamed resin molded body. Among them, the spray coating method is most preferable because it is particularly easy in painting, uniform in coating film and excellent in appearance.

  When forming a coating layer using these coating resins by the spray method, the spray machine to be used does not need to have a special specification, such as spraying with air or direct spraying with liquid pressurized. The normal coating machine used in the can be used well.

  The coating layer thus obtained is preferably from 0.05 mm to 5 mm, more preferably from 0.1 mm to 3 mm, more preferably from 0.2 mm to 1.5 mm, and most preferably from 0.2 mm to 1. 0 mm or less. Although the coating layer can be used even if it is thin, since the surface hardness of the synthetic resin foam is low, if the thickness is too thin, the surface strength of the foamed molded product tends to decrease. Therefore, the said thickness of a coating layer is preferable from the point of the objective of this invention, performance, and intensity | strength.

  The specific structure of the present invention is as shown in FIG. This figure represents a conceptual cross-sectional view of the watering device of the present invention, 1 is a surface material, 2 is a synthetic resin foam, and the non-contact surface with the surface material of the synthetic resin foam, A coating layer 3 formed by a coating resin such as an acrylic resin is provided.

  In this example, the synthetic resin foam 2 was a polystyrene foam. And the shaping | molding performs normal pre-foaming using an expandable polystyrene particle (Corporation | KK Kaneka Co., Ltd., brand name: Kanepal VF), and the obtained pre-expanded particle of 60 times the bulk magnification is made into a bathtub (length). : 1598 mm x width: 785 mm x height: 475 mm), a mold having a shape for forming a heat insulating layer is filled, and further heated by steam.

  Next, with respect to the polystyrene foam for bath insulation (thickness was set to 15 mm to 30 mm) thus obtained, an example in which a coating layer 3 made of an acrylic resin is provided on a non-contact surface with a bathtub as a surface material. Show. In actual use, a bathtub, which is a surface material, is laminated and bonded to the surface of the polystyrene foam for thermal insulation of a bathtub having the acrylic resin fat coating layer obtained in this way on the surface where the acrylic resin coating layer does not exist. , Product. The said Example is only an illustration, Comprising: This invention is not restrict | limited at all by these Examples.

Example 1
EMX-7411 (acrylic copolymer resin as an acrylic resin) manufactured by Cemedine Co., Ltd. is filled into an MG gun, which is an architectural coating gun manufactured by Anest Iwata Co., Ltd., and compressed air is connected to the spray gun. Made it possible. Next, the polystyrene foam for heat insulation of the bathtub is set in front of the booth for exhaust, and by using the spray gun, acrylic resin is sprayed on all surfaces of the foam excluding the surface in contact with the bathtub, so that about 1 A polystyrene foam for bathtub insulation having an acrylic resin coating layer of 0.0 mm was obtained. About the obtained foam, the mold resistance according to JIS Z 2911 / mold resistance test method of plastic products (note that the type of mold used is the first group b))). The growth of mycelium was not recognized in the part, and the display of the result was 0, which was a very good result. Excellent wear resistance and contamination resistance.

(Example 2)
Example 1 except that 0.1 parts by weight of a fungicide (trade name: Hello Coat GK) was uniformly dispersed in EMX-7411 (acrylic copolymer resin) manufactured by Cemedine Co., Ltd. Thus, an acrylic resin-coated polystyrene foam for bath insulation was obtained. About the obtained foam, the mold resistance according to JIS Z 2911 / mold resistance test method of plastic products is a very good result with a result display of 0, and the wear resistance and stain resistance are also good. Similar to Example 1, it was excellent.

(Example 3)
An acrylic coated polystyrene foam for bath insulation was obtained in the same manner as in Example 1 except that the acrylic coating layer was 0.25 mm. About the obtained foam, the mold resistance according to JIS Z 2911 / mold resistance test method of plastic products is a very good result with a result display of 0, and the wear resistance and stain resistance are also good. It was good.

(Comparative Example 1)
Evaluation similar to Example 1 was performed without covering any polystyrene foam for bath insulation. For polystyrene foam for bath insulation that does not have a coating layer with a coating resin such as acrylic resin, the mold resistance in accordance with JIS Z 2911 / mold resistance test method for plastic products is the mycelium recognized in the inoculated part of the test piece Since the area of the growth part of this was more than 1/3 of the total area, the result display was 2, and only a very inferior result was obtained compared to the example. The abrasion resistance and contamination resistance were also inferior to those of the examples, and the results showed the excellence of the examples.

It is the figure which showed the cross-sectional concept of the water supply apparatus of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Surface material 2 Synthetic resin foam 3 Covering layer

Claims (9)

  In a laminate consisting of a surface material and a synthetic resin foam, a non-contact surface with the surface material of the synthetic resin foam is formed from a resin selected from an acrylic resin, a vinyl acetate resin, an epoxy resin, and a silicon resin. A watering device provided with a coating layer.   The watering device according to claim 1, wherein the resin forming the coating layer is an acrylic resin.   The watering device according to claim 1 or 2, wherein the resin forming the coating layer is a non-solvent type.   The watering device according to any one of claims 1 to 3, wherein the coating layer has a thickness of 0.05 mm to 5 mm.   The watering device according to any one of claims 1 to 4, wherein the resin forming the coating layer contains an antibacterial agent and / or an antifungal agent.   The watering device according to any one of claims 1 to 5, wherein the resin that forms the coating layer is spray-coated.   The watering device according to any one of claims 1 to 6, wherein the synthetic resin foam is a foamed styrene resin.   The watering device according to any one of claims 1 to 7, wherein the watering device is any one of a bathroom-related device, a sink-related device, and a toilet-related device.   A resin selected from an acrylic resin, a vinyl acetate resin, an epoxy resin, and a silicon resin on a non-contact surface with a surface material of a synthetic resin foam. A method for producing a watering device, characterized in that a coating layer comprising:

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