JP2886823B2 - Waterproof bread molding method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for molding a waterproof pan used in a washing room of a bathroom such as a system bathroom, and more particularly to a method for molding a waterproof pan having a non-slip function.

[0002]

2. Description of the Related Art Conventionally, this type of waterproof pan has a waterproof pan body 1 formed of FRP as shown in FIG. 7, and a non-slip sheet 3 having an uneven surface 2 made of a material such as vinyl chloride resin. The non-slip sheet 3 was attached to the waterproof sheet body 1 by post-adhesion with an adhesive. On the upper surface of the waterproof pan main body 1, a recess 4 having the same depth as the thickness t of the peripheral edge of the anti-slip sheet 3 without the uneven surface 2 is formed in advance, and the anti-slip sheet 3 is fitted into the recess 4 and adhered. It is pasted with the agent.

[0003]

However, when the non-slip sheet 3 is pasted, there is a problem that extra work for the bonding step is required. Further, when the non-slip sheet 3 is pasted, the non-slip sheet 3 may protrude unless the recess 4 is formed to be several mm larger than the size of the non-slip sheet 3. For this reason, a groove is formed in the periphery, and it is necessary to coke with silicon or the like.

Although there is no technology for simultaneous molding, it has been limited to integrally molding a flat sheet having no uneven surface. That is, as shown in FIG.
When the gel coat layer 7 is formed by spraying the gel coat with the gel coat spray 6 on the non-slip sheet 3, the gel coat wraps around to the surface side of the non-slip sheet 3 as shown in FIG. Part). In order to prevent this, it is conceivable to attach a masking tape 8 as shown in FIG.
When the thickness of the masking tape 8 is increased, there is a problem that a step b is generated as shown in FIG. 9B.

[0005] The present invention has been made in view of the above description, and does not require a bonding step such as post-pasting.
Another object is to improve the adhesion reliability of the anti-slip sheet.

[0006]

In order to solve the above-mentioned problems, a method for forming a waterproof floor pan according to the present invention comprises the steps of recessing a sheet mounting surface 9 of a mold 5 by the height of the uneven surface 2 of the anti-slip sheet 3. Then, a concave portion 10 is formed, and the non-slip sheet 3 is set in the molding die 5 so that the concave and convex surface 2 of the non-slip sheet 3 fits in the concave portion 10 of the molding die 5. The flat surface 3a is affixed to the mold 5 with a double-sided tape 11 on the outer periphery of the recess 10 and then an FRP layer is formed on the mold 5 using an FRP material. In this case, simultaneous molding is possible without post-adhering unlike the conventional case, so that the conventional bonding step is not required, and there is no possibility that the gel coat flows into the uneven surface 2 unlike the conventional case. In addition, since the non-slip sheet 3 can be formed simultaneously, the non-slip sheet 3 can be firmly integrated, and the appearance can be improved because a groove cannot be formed in the peripheral edge of the non-slip sheet 3 as in the related art.

A non-slip sheet 3 made of vinyl chloride resin
It is also preferable that a permeation prevention layer 12 for preventing permeation of the solvent is laminated on the surface of the anti-slip sheet 3 opposite to the uneven surface 2. In this case, when molding, F
The solvent of the RP material is prevented from penetrating into the non-slip sheet 3 of the vinyl chloride resin, and a high quality product is obtained. That is, the styrene monomer in the unsaturated polyester resin may damage the vinyl chloride resin, but the presence of the permeation preventing layer 12 can surely prevent this.

It is also preferable that the permeation prevention layer 12 is formed by coating an epoxy resin. Further, it is also preferable that the nonwoven fabric 13 is attached to the surface of the anti-slip sheet 3 opposite to the uneven surface 2. In this case, the bonding performance of the FRP can be further improved by the nonwoven fabric 13 and the non-slip
Can be integrated.

[0009]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A non-slip sheet 3 is formed in advance from a material such as a vinyl chloride resin, and has an uneven surface 2 on one surface which is a surface side. The uneven surface 2 is not provided on the peripheral edge, and the peripheral edge is a flat surface 3a without unevenness. As shown in FIG. 2, a permeation preventing layer 12 for preventing permeation of the solvent is formed on the back surface of the anti-slip sheet 3. The anti-penetration layer 12 is formed, for example, by applying an epoxy resin to the anti-slip sheet 3. On the back side of the permeation preventing layer 12, a nonwoven fabric 13 is further stuck. This nonwoven fabric 13 is, for example, a polyester nonwoven fabric.

The molding die 5 for molding the waterproof pan A is formed in a shape as shown in FIG. 3, but the sheet mounting surface 9 on the upper surface of the molding die 5 is recessed from the upper surface to form a recess 10. The depth d of the recess 10 is the same as the height of the uneven surface 2 of the anti-slip sheet 3. The forming of the waterproof pan A with the molding die 5 is performed as follows. First, as shown in FIG. 1, the non-slip sheet 3 is mounted on the sheet mounting surface 9 so that the uneven surface 2 fits in the concave portion 10, and the flat surface 3 a on the peripheral edge of the non-slip sheet 3 is attached to the upper surface of the mold 5 by double-sided adhesive tape Affix with a double-sided tape 11 such as a double-sided adhesive tape. Next, as shown in FIG. 3, a gel coat such as a polyester resin is sprayed on the mold 2 with a gel coat spray 6 to form a gel coat layer 7 on the mold 2. At this time, a masking material 18 such as newspaper is overlaid on the non-slip sheet 3. Next, as shown in FIG. 4, an intermediate layer 14 of FRP (for example, polyester resin + glass fiber) is laminated, and then, as shown in FIG. 5, a wood reinforcing plate 15 and a reinforcing material 16 are bonded on the FRP intermediate layer 14. Then, as shown in FIG. 6, FRP (for example, polyester resin + glass fiber)
Of the waterproof pan A as shown in FIG.
Is molded. In the waterproof pan A thus formed, the non-slip sheet 3 is firmly integrated by simultaneous molding. In addition, since the permeation preventing layer 12 is provided on the back surface side of the anti-slip sheet 3, it is possible to prevent the solvent from permeating and swelling when the FRP is laminated. Also, the anti-slip layer 12 of the anti-slip sheet 3
Since the nonwoven fabric 13 is integrated with the back side of the substrate, the bonding performance with the FRP can be improved.

[0011]

According to the present invention, as described above, the sheet mounting surface of the molding die is recessed by the height of the uneven surface of the anti-slip sheet to form a concave portion, and the uneven surface of the anti-slip sheet is formed. Set it in the mold so that it fits in the concave part of the mold, and affix the flat surface of the anti-slip sheet with no irregularities on the outer periphery of the concave part to the mold with double-sided tape.
Since the FRP layer is formed from the material, it can be formed simultaneously without post-pasting as in the conventional case, and the process can be simplified without the need for the conventional bonding step. It is possible to obtain a good quality without the risk of flowing into the uneven surface of the non-slip sheet because it can be molded simultaneously,
Further, the appearance is improved because there is no groove on the periphery of the anti-slip sheet as in the prior art.

Further, in the invention according to claim 2 of the present invention, a non-slip sheet made of a vinyl chloride resin is used, and a permeation preventing layer for preventing the penetration of a solvent is provided on the surface opposite to the uneven surface of the non-slip sheet. Since the layers are laminated, the solvent of the FRP material is prevented from penetrating into the non-slip sheet of the vinyl chloride resin at the time of molding, so that a high quality product can be obtained. In the invention according to claim 4 of the present invention, since the nonwoven fabric is stuck on the surface opposite to the uneven surface of the anti-slip sheet,
The nonwoven fabric can further improve the adhesion performance of the FRP and can more securely integrate the anti-slip sheet.

[Brief description of the drawings]

FIG. 1 is a sectional view for explaining a molding method of the present invention,
The state which sets a non-slip sheet in a shaping | molding die is shown.

FIG. 2 is a cross-sectional view showing the anti-slip sheet according to the first embodiment.

FIG. 3 is a cross-sectional view illustrating a molding step of the above.

FIG. 4 is a cross-sectional view illustrating a molding step of the above.

FIG. 5 is a cross-sectional view illustrating a molding step of the above.

FIG. 6 is a sectional view illustrating a molding step of the above.

FIG. 7 is a cross-sectional view illustrating a conventional example.

FIG. 8 is a cross-sectional view for explaining a problem of another conventional example.

FIGS. 9A and 9B are cross-sectional views for explaining a problem of another conventional example.

[Explanation of symbols]

 2 Uneven surface 3 Non-slip sheet 3a Flat surface 5 Mold 9 Sheet mounting surface 10 Depression 11 Double-sided tape 12 Permeation prevention layer 13 Non-woven fabric

──────────────────────────────────────────────────続 き Continuation of the front page (56) References JP-A-4-55563 (JP, A) JP-A-6-328466 (JP, A) JP-A-7-137125 (JP, A) JP-A-8- 142190 (JP, A) JP-A-9-78649 (JP, A) JP-A-48-45420 (JP, U) JP-A-3-89769 (JP, U) JP-A 7-12567 (JP, U) (58) Field surveyed (Int. Cl. ⁶ , DB name) E03C 1/20 B29C 67/14

Claims (4)

(57) [Claims] 1. A concave portion is formed by recessing a sheet mounting surface of a molding die by the height of the uneven surface of the anti-slip sheet so that the uneven surface of the anti-slip sheet fits into the concave portion of the molding die. It is set in a mold, and a flat surface without unevenness on the periphery of the anti-slip sheet is attached to the mold with a double-sided tape at the outer periphery of the concave portion, and then an FRP layer is formed on the mold with an FRP material. Molding method of waterproof bread. 2. A non-slip sheet made of a vinyl chloride resin, and a permeation preventive layer for preventing permeation of a solvent is laminated on a surface opposite to the uneven surface of the non-slip sheet. Waterproof bread molding method. 3. The method according to claim 2, wherein the permeation preventing layer is formed by coating an epoxy resin. 4. The method for forming a waterproof pan according to claim 1, wherein a nonwoven fabric is stuck on the surface of the anti-slip sheet opposite to the uneven surface.