JP2980313B2 - Floor pan for unit bath and molding method thereof - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a floor pan for a unit bath in which grooves are formed vertically and horizontally to prevent slipping, and a method of forming the floor pan.

[0002]

2. Description of the Related Art When compression molding a floor (usually made of FRP) of a unit bath, a technique of decorating the floor has already been put to practical use. As a means of decorating the floor surface, printed titanium paper (paper filled with titanium to improve concealment) is prepreg, set in a mold, and then set with a sheet molding compound (SMC). It is known to apply heat.

[0003]

In the conventional method, since paper is used, it is easily broken due to the flow of the SMC, the formability is difficult, and the floor pan for the unit bath is relatively prevented for slip prevention. Since the deep groove is formed, the paper cannot follow the depth of the groove and is broken. Further, there is also a disadvantage that mold is generated when there is a mistake in prepreg formation (for example, insufficient resin impregnation) due to paper.

Accordingly, the present invention provides a floor pan for a unit bath which prevents breakage and mold of a conventional decorative material such as titanium paper, is easy to prepreg, and is easy to form, and a method of forming the floor pan. With the goal.

[0005]

SUMMARY OF THE INVENTION In order to achieve the above object, the present invention relates to a floor pan for a unit bus in which grooves are formed longitudinally and laterally to prevent slipping, on a sheet molding compound or a bulk molding compound. An intermediate sheet obtained by prepregging a plain polyester nonwoven fabric is laminated, a surface sheet obtained by prepregging a decorated polyester nonwoven fabric on the intermediate sheet is laminated, and the laminate is formed by heating under pressure. .

[0006]

Preferred embodiments of the present invention will be described below with reference to the accompanying drawings.

FIG. 1 is a sectional view showing a state in which a molding material is set in a cavity between the molds 1 and 2. The molds 1 and 2 have grooves formed on a floor pan for a unit bath for preventing slip. 3 (see FIG. 2) is formed with a convex portion 1A. A surface sheet 4 in which a decorated polyester nonwoven fabric is prepregged is set on the mold 1, and an intermediate sheet 5 in which a plain polyester nonwoven fabric which is not decorated is prepregged is superimposed thereon, and further thereon. The sheet molding compound (SMC) or the bulk molding compound (BMC) 6 is placed. On the right side of FIG. 1, SMC or BMC 6 is set to form a bathtub. The weight of one nonwoven fabric is 150 to 250 g / M ² and the tensile strength is 10 kgf / 1.
5 mm or more is preferred. Pre-preg surface sheet 4
It is desirable that both the intermediate sheet 5 and the intermediate sheet 5 have a resin content of 25 to 40%. Also, the prepreg is converted to DAP
When producing with a prepolymer such as allyl phthalate), it is desirable to reduce the amount of acetone used as a solvent as much as possible or to substitute with toluene or the like.

[0008] The polyester non-woven fabric is obtained by processing polyester fiber into a non-woven fabric, and a prepreg is achieved by impregnating the non-woven fabric with a thermosetting resin.
The decorating means is usually performed by printing, and as a printing method, any of letterpress printing, gravure printing, offset printing, silk printing, transfer printing and the like can be adopted. As the resin to be impregnated into the nonwoven fabric, di-allyl-phthalate resin,
Unsaturated polyester resins, melamine resins, urea resins and the like can be suitably used.

FIG. 2 shows a floor pan 10 that has been compression molded.
The state where the decorative part 11 was formed is shown. Reference numeral 3 is a groove for preventing slip.

The SMC 6 is obtained by filling a thermosetting resin with glass fiber and adding a curing agent. As the thermosetting resin, an unsaturated polyester resin, an epoxy resin, a phenol resin or the like can be preferably used. Particularly, an unsaturated polyester resin is preferable. As the inorganic filler, various inorganic fibers and the like can be used in addition to glass fibers. Further, a curing accelerator and a thickener are added to SMC6. Further, if necessary, a low-shrinking agent, a pigment and the like can be added.

A preferred embodiment will be described below.

Example 1 (1) Weight per unit area: 200 g / M ² , Tensile strength: 15 kgf / 15
Print patterns and pictures etc. on mm polyester non-woven fabric. The melting point of this polyester is (160 ° C. or higher). The decorated polyester nonwoven fabric is impregnated with an unsaturated polyester resin so as to have a content of 30% to be prepreg, and the topsheet 4 is obtained. (2) A plain polyester nonwoven fabric having the same basis weight and tensile strength as in (1) is prepreg in the same manner as in (1) to obtain an intermediate sheet 5. The melting point of this polyester is (160 ° C. or higher). (3) Form SMC6 with unsaturated polyester, hardener, glass fiber and thickener. (4) Overlap and set on the mold 1 in the order of (3) to (1), tighten the molds 1 and 2, and heat and press.

Example 2 (1) Two pieces of decorated and plain polyester non-woven fabrics having the same basis weight and tensile strength as in Example 1 were overlaid, and an unsaturated polyester resin was added thereto. The prepreg is formed by impregnation so that the ratio becomes 30%. (2) The same SMC 6 as in the first embodiment is set on the mold 1,
The prepreg of (1) is superimposed on the SMC 6, the molds 1 and 2 are fastened, and heated and pressed.

In the floor pan for the unit bath thus obtained, the decorated polyester nonwoven fabric did not show any breakage or generation of mold. Also, the decorative portion did not bleed or flow. SMC or BMC6,
By setting the hardening characteristics of each material of the top sheet 4 and the intermediate sheet 5 somewhat later than general values, the positioning after charging the materials into the dies 1 and 2 becomes easy, and the yield of the product is improved. . Usually, the gel time is about 110 seconds, but it is desirable to set this to about 120 to 140 seconds.

Example 3 (1) Weight per unit area: 200 g / M ² , Tensile strength: 15 kgf / 15
Print patterns and pictures etc. on mm polyester non-woven fabric. The melting point of this polyester is (160 ° C. or higher). The decorated polyester nonwoven fabric is impregnated with an unsaturated polyester resin so as to have a content of 30% to be prepreg, and the topsheet 4 is obtained. (2) A plain polyester nonwoven fabric having the same basis weight and tensile strength as in (1) is prepreg in the same manner as in (1) to obtain an intermediate sheet 5. The melting point of this polyester is (160 ° C. or higher). (3) Two sheets, a top sheet 4 and an intermediate sheet 5, are punched in advance into a floor pan shape, and the punched sheet is SMC or BMC.
6 are superimposed and heated and pressed. That is, the decorative non-woven fabric and the plain non-woven fabric are separately prepregged, and the prepregs (the top sheet 4 and the intermediate sheet 5) are stacked and punched out at the same time. 5 adheres. The SMC or BMC 6 is overlaid on and integrated with the two sheets 4 and 5 in close contact. In addition, the decorative nonwoven fabric and the plain nonwoven fabric can be punched before prepreg, and then prepreg.

[0016]

As described above, according to the floor pan and the method of molding the same according to the present invention, the polyester non-woven fabric is not decorated, but the polyester non-woven fabric is unlikely to be broken. Even when the decorated polyester nonwoven fabric was prepreg, no generation of mold was observed. Furthermore, since a plain polyester non-woven fabric exists between the decorated polyester non-woven fabric and the SMC (BMC), it is possible to prevent the ink or the like in the portion decorated by printing or the like from being mixed into the SMC. At the same time, it is possible to prevent the filler in the SMC from protruding toward the decorated polyester nonwoven fabric. In the method of superimposing the top sheet and the intermediate sheet and punching them simultaneously, two
The sheets are integrated by the adhesive force of the prepreg, handling becomes easy, and air does not remain between the two sheets. As a result, blisters can be prevented from being formed on the molded product.

[Brief description of the drawings]

FIG. 1 is a sectional view showing a molding state.

FIG. 2 is a plan view of a molded floor pan.

[Explanation of symbols]

 1, 2 mold 3 groove 4 surface sheet 5 intermediate sheet 6 SMC or BMC 10 floor pan

Continuation of the front page (58) Field surveyed (Int. Cl. ⁶ , DB name) B29C 43/00-43/58 B32B 1/00-35/00 E03C 1/20

Claims (3)

(57) [Claims] 1. A floor pan for a unit bath in which grooves are formed longitudinally and laterally to prevent slippage, wherein an intermediate sheet in which a plain polyester nonwoven fabric is prepregged on a sheet molding compound or a bulk molding compound is laminated. A floor pan for a unit bath, which is formed by laminating a surface sheet obtained by prepregating a decorated polyester nonwoven fabric on the surface of the laminate and pressing and heating the laminate. 2. A method of forming a floor pan for a unit bath in which grooves are formed longitudinally and laterally to prevent slipping, wherein a surface sheet obtained by prepregging a decorated polyester nonwoven fabric and a sheet molding compound or a bulk molding compound. It is characterized in that it is set in a mold with an intermediate sheet made of plain polyester non-woven fabric prepreg interposed, then the mold is tightened and cured by applying pressure and heat to form a unit bath floor pan. Method of forming floor pan for unit bath. 3. The two face sheets and the intermediate sheet according to claim 2 or the two non-woven fabrics before prepreg are simultaneously punched into a floor pan shape, and the two non-woven fabrics before prepreg are punched. A method for forming a floor pan for a unit bath, comprising: forming a prepreg, laminating a sheet molding compound or a bulk molding compound on the punched product, and then heating and pressing the laminate to form a floor pan for a unit bath.