JP3038127B2 - Bathtub - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a bathtub made of a multilayer resin obtained by subjecting a thermosetting resin molding material to heat and pressure molding using a split mold.

[0002]

2. Description of the Related Art Conventionally, a bathtub having a multilayer structure has been known. For example, in order to keep the temperature of the bathtub constant, a heat insulating material may be provided on the back surface of the coating bathtub (Japanese Utility Model Publication No. 56-5485).
No. 2), a glass mat is arranged on the back side of the bathtub body to improve the strength of the bathtub (Japanese Utility Model Laid-Open No. 3-11884), and flaky flakes are coated on the surface layer of the bathtub body in a translucent resin. Providing a dispersed layer (Japanese Utility Model Application Laid-open No.
No.).

[0003] Above all, decorativeness and heat insulation are very important for bathtubs, and multilayer bathtubs having these functions are known. For example, the covering member is fixed to the bathtub body with a screw or the like (Japanese Utility Model Publication No. 63-30317), or a colored layer or the like is sprayed on a mold in advance to form the main body (Japanese Utility Model Publication No. 63-37245). Get a bathtub,
A heat insulating material having a desired shape is previously placed in a bathtub main body and a heat insulating layer, and a foam layer is formed between both members by in-situ foaming and integrated to obtain a bathtub (Japanese Utility Model Application No. 61-343).
No. 4).

[0004]

However, in each of the above conventional examples, there is a problem that it takes a lot of time and cost to obtain a bathtub having a multilayer structure. The present invention has been made in view of the problems of the above conventional example,
It is an object of the present invention to provide a bathtub having a surface having excellent gloss and having a heat insulating property with a simple configuration in a bathtub made of a thermosetting resin molding material. It is in.

[0005]

In order to achieve the object of the present invention, a bathtub of the present invention comprises a base material for forming a bathtub 1;
A surface having surface gloss formed by injecting a surface material into a surface side of a substrate 2 made of a thermosetting resin molding material in a cured or semi-cured state in a bathtub 1 composed of a surface material and a back material. A material 3 and a back material 4 formed by injecting a heat insulating material having better heat insulating properties than the base material 2 into the back side of the cured or semi-cured base material 2 are integrally formed by the same mold. It was done.

[0006] It is also preferable to provide a back surface member 4 made of a heat insulating material at least on the bottom surface portion 5 and the upright surface portion 6 of the bathtub 1.

[0007]

According to the present invention having the above structure, the surface gloss formed by injecting a surface material into the surface side of the base material 2 made of a cured or semi-cured thermosetting resin molding material is controlled. The surface material 3 having the surface material 3 and the back surface material 4 formed by injecting a heat insulating material having better heat insulating properties than the substrate 2 into the back surface side of the cured or semi-cured substrate 2 are integrally formed by the same mold. Therefore, it is possible to obtain the bathtub 1 having a structure in which the base material 2, the surface material 3 having the surface gloss, and the back material 4 having the heat insulating property are integrated with a simple configuration. .

Then, the backing material 4 made of a heat insulating material is placed in the bathtub 1.
By providing it only on the bottom surface 5 and the rising surface 6, the back material 4 made of a heat insulating material can be effectively provided only on a portion of the bathtub 1 that requires heat insulation, reducing the amount of heat insulating material used and reducing the cost. Can be reduced.

[0009]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail with reference to the embodiments shown in the accompanying drawings. FIG. 1 shows an embodiment of a bathtub 1 according to the present invention. The bathtub 1 is configured by integrating a surface material 3 having surface gloss on the surface side of a base material 2 made of a thermosetting resin, and a back material 4 made of a heat insulating material on the back surface of the base material 2. In other words, the bathtub 1 having the above-described configuration includes a surface material 3 having a surface gloss formed by injecting a surface material into the surface side of the base material 2 made of a thermosetting resin molding material in a cured or semi-cured state; It is obtained by integrally forming a back material 4 formed by injecting a heat insulating material into the back surface of the cured or semi-cured substrate 2 using the same mold.

The bathtub 1 having such a configuration is formed by coating the inside of a mold commonly called IMC (in-mold coating). That is, as shown in FIG. 2, the mold is formed using a split mold 7 composed of a first mold 7a serving as a lower mold and a second mold 7b serving as an upper mold. In the embodiment shown in FIG. 1, the first mold 7a is a fixed mold, the second mold 7b is a movable mold, and the second mold 7 is formed by a cylinder device such as a hydraulic cylinder.
b moves up and down. The first molding die 7a is provided with an injection port 8a of a first injection machine 8,
A coating material 3a such as a molding resin for forming a layer of the surface material 3 can be injected from an injection port 8a by a coating material supply device 9 such as an injection cylinder. 1 in the figure
Reference numeral 0 denotes a tank containing the coating material 3a. Also 11
Is an on-off valve provided at the inlet 8a.

On the other hand, the second molding die 7b is provided with an injection port 12a of the second injection machine 12, and the resin material 4a having heat insulating property contained in the tank 14 is supplied to the second injection machine 12b.
Allows injection from the injection port 12a.
Here, an opening / closing valve 15 is provided at the inlet 12a. The surface material 3 having surface glossiness is provided on the surface side of the base material 2 made of a thermosetting resin by using the above-described mold apparatus.
To form a bathtub 1 having a structure in which a back material 4 made of a heat insulating material is integrated on the back surface of the base material 2, respectively, is performed as follows. That is, first, as shown in FIG. 2, the second mold 7b is raised to form the space 16, and in this state, the thermosetting resin molding material 2a which is the material of the base material 2 is formed.
Is placed on the first mold 7a. Here, as the thermosetting resin molding material 2a, unsaturated polyester resin called BMC (bulk molding compound), glass fiber, calcium carbonate, zinc stearate,
After impregnating a paste-like unsaturated polyester resin into a lump-shaped molding material containing a predetermined amount of a coloring agent or a glass fiber mat called SMC (sheet molding compound), the resin is chemically increased. Adhesive sheet-like molding materials are used, and these BMC and SMC
The thermosetting resin molding material 2a is placed on the molding die 7a and supplied.

Next, as shown in FIG. 3, the second molding die 7b is lowered and clamped to compress the thermosetting resin molding material 2a under pressure to form the container-like base material 2. Next, as shown in FIG. 4, the second molding die 7b is slightly raised to form a slight gap between the surface of the base material 2 and the first molding die 7a (here, the process shown in FIG. 4). The reason why the second mold 7b rises with the substrate 2 is that the second mold 7b has a mold structure called an undercut.) After a slight gap is formed between the surface of the substrate 2 and the first molding die 7a in this way, the glossiness (visual improvement), the hardness (hard to be scratched), and the surface roughness (scaled A gel coat (for example, a mixture of a vinyl ester resin and a styrene solution, a filler, an internal mold release agent, etc.) as a coating material 3a is improved by a first injector 8 from an inlet 8a to improve the Is injected into a slight gap between the surface side of the mold and the first molding die 7a, and when the injection of the coating material 3a is completed, the on-off valve 11 is opened.
Is closed, and re-compression molding is performed to integrally mold the surface material 3 made of the coating material 3a on the surface side of the container-like substrate 2 with the substrate 2. The timing of injecting the coating material 3a into the split mold 7 is performed in a state where the base material 2 is cured or semi-cured. In order to improve the adhesion between the base material 2 and the surface material 3 made of the coating material 3a, Is preferably performed in a semi-cured state of the substrate 2.

Thereafter, as shown in FIG. 5, the second mold 7b is slightly lifted to form a slight gap between the back surface of the container-shaped base material 2 and the second mold 7b (here, a gap is formed). The reason why the base material 2 is held by the first molding die 7a despite the elevation of the second molding die 7b is that the base material is held by the release device separately provided on the second molding die 7b. 2 is the second mold 7b
The release device disclosed in JP-A-6-63978 can be used as such a release device.) After a slight gap is formed between the back surface of the container-shaped base material 2 and the second mold 7b in this manner, the on-off valve 15 is opened and the heat-insulating resin material 4a is injected into the second injection machine. 12, pressurized and press-fitted into a slight gap between the back surface of the container-shaped base material 2 and the second molding die 7b from the injection port 12a, then close the on-off valve 15 and perform recompression molding. Here, the back material 4 has a lower thermal conductivity than the base material 2 and is more excellent in heat insulation than the base material 2. For example, a polyurethane resin (one-pack or two-pack urethane paint is used as the resin material 4a as the material of the back surface material 4. These materials are used for the reaction between unsaturated groups in molecules and oxygen in air, Silicone varnish using silicone varnish made of organosilicon polymer with siloxane bond as the basic structure. Either one may be used). Of course, it is also possible to use a foamable synthetic resin as the resin material 4a having heat insulating properties and to inject the same.
The timing at which the resin material 4a having heat insulation properties is injected into the split mold 7 is performed in a state where the base material 2 is cured or semi-cured, but the adhesion between the base material 2 and the back surface material 4 made of the resin material 4a is improved. In order to improve the performance, it is preferable to perform the process in a semi-cured state of the substrate 2.

Thereafter, the second molding die 7b is lifted and the mold is opened in a state where the base material 2, the surface material 3 and the back surface material 4 are completely cured, and the bathtub 1 is taken out in this state.
In the above molding, the molding temperature is set to the first molding die 7a and the second molding die 7a.
100-140 ° C. for both molding dies 7b, the molding pressure is about 1000 tonf when pressurized, the molding cycle is about 12 min,
The amount of the thermosetting resin molding material 2a to be the base material 2 is about 4
0 kg / 1 shot, coating material 3 which is the material of surface material 3
The injection amount of the resin material 4a, which is the material of the back material 4a and the back material 4, is about 800 cc / 1 shot.

The bathtub 1 thus obtained has a surface material 3 having excellent glossiness, hardness and surface roughness integrated on the surface of a container-shaped substrate 2 and a surface material 3 having a surface roughness. The back material 4 having heat insulating properties is integrated. FIG. 7 shows another embodiment of the present invention. In this example,
An example is shown in which a back material 4 made of a heat insulating material is provided on a bottom surface portion 5 and an upright surface portion 6 of the bathtub 1. That is, as shown in FIG. 7, the cross-sectional shape of the bathtub 1 generally raises the rising surface 6 from the outer peripheral end of the bottom surface 5, extends the flange 20 outward from the upper end of the rising surface 6, and extends the flange 20. In the bathtub 1 having such a general shape, water or hot water is filled in the standing surface portion 6 of the surface of the bathtub 1 shown in FIG. And flange 2
It is up to the intersection of 0, and the water or hot water that has been entered any more will flow out of the bathtub 1. Therefore, the backing material 4 made of a heat insulating material provided to prevent a drop in hot water temperature
Is unnecessary for the flange portion 20 and the hanging portion 21. For this reason, in this embodiment, as shown in FIG. This is provided only on the rear surface member 4 to reduce waste, thereby reducing costs. Here, in the bathtub 1 shown in FIG.
Although not provided on the back surface 23 of the first member 1, the back material 4 made of a heat insulating material may be provided on the back surface 22 of the flange portion 20.

By the way, what has already been described with reference to FIG. 1 is an example in which the back surface member 4 made of a heat insulating material is provided on the bottom surface 5, the standing surface 6, the back surface 22 of the flange portion 20, and the back surface 23 of the hanging portion 21 of the bathtub 1. Is shown.

[0017]

The bathtub according to the first aspect of the present invention is
A surface material with a surface gloss formed by injecting a surface material into the surface side of a base material made of a cured or semi-cured thermosetting resin molding material, and a back side of a cured or semi-cured base material It is obtained by integrally forming a backing material formed by injecting a heat insulating material having better heat insulating property than the base material with the same mold, so that the surface gloss is excellent and the commercial value is high and It is possible to obtain a bathtub having excellent heat insulation properties, and it is difficult for the hot water to be cooled, and has a heat retaining property with a simple configuration, thereby reducing costs.

According to the second aspect of the present invention, in addition to the effect of the first aspect of the present invention, the back material made of a heat insulating material is provided at least on the bottom surface and the upright surface of the bathtub. The cost can be further reduced without excessive use of a backing material made of a heat insulating material for preventing a drop in hot water temperature.

[Brief description of the drawings]

FIG. 1 is a sectional view of one embodiment of a bathtub of the present invention.

FIG. 2 is a cross-sectional view showing a manufacturing sequence of the same.

FIG. 3 is a cross-sectional view showing a manufacturing order of the same.

FIG. 4 is a cross-sectional view showing a manufacturing sequence according to the embodiment.

FIG. 5 is a cross-sectional view showing a manufacturing order of the above.

FIG. 6 is a cross-sectional view showing a manufacturing order in the same.

FIG. 7 is a sectional view of another embodiment of the bathtub of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Bathtub 2 Base material 3 Surface material 4 Back material 5 Bottom part 6 Standing part

Continuation of the front page (51) Int.Cl. ⁷ Identification code FI B29K 105: 04 B29L 22:00 (72) Inventor Masatsuri Kobayakawa 1048, Ojidoma, Kadoma, Osaka Prefecture Matsushita Electric Works, Ltd. (72) Inventor Matsumoto Masami Kazuma, Osaka Prefecture 1048 Kadoma, Matsushita Electric Works, Ltd. (56) References JP-A-48-84866 (JP, A) JP-A-51-46257 (JP, A) JP-A-56-109735 (JP, A) A) JP-A-5-50448 (JP, A) JP-A-6-55671 (JP, A) JP-A-6-320637 (JP, A) JP-A-7-68703 (JP, A) JP-A-8 JP-A-6-63978 (JP, A) JP-A-2-15343 (JP, U) JP-A-3-11884 (JP, U) JP-A-56-54852 (JP, Y2) ) Jiko 61-3434 (JP, Y2) Jiko 63-30317 (JP, Y2) Jiko 63-37245 (JP, Y2) (58) Fields investigated (Int. Cl. ⁷ , DB name) B29C 45/00-45/84 A47K 3/00 B29C 39/12

Claims (2)

(57) [Claims] 1. A base material for a bathtub, a surface material,
In a bathtub made of a back material, a surface material having a surface gloss formed by injecting a surface material into a front surface side of a base material made of a thermosetting resin molding material in a cured or semi-cured state; A bathtub obtained by integrally forming a backing material formed by injecting a heat insulating material having better heat insulating properties than the base material into the back surface side of the hardened base material using the same mold. 2. The bathtub according to claim 1, wherein a back surface material made of a heat insulating material is provided at least on a bottom surface portion and an upright surface portion of the bathtub.