JP3232325B2 - Manufacturing method of plastic shutter tub lid - 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 cover, and more particularly, to a bathtub cover that can be easily disposed of, does not cause pollution, can be recycled without being separated, and a method of manufacturing the same.

[0002]

2. Description of the Related Art As a lid for a bathtub, there is a plastic shutter type lid. Shutter-type bathtub lids are formed by connecting a number of strip-shaped bodies in parallel with a joint plate.They are foldable and fit well with the bathtub opening. It has become mainstream.

[0003] The main body of the shutter type bathtub lid is manufactured by extrusion molding, and a vinyl chloride resin has been mainly used as a raw material in view of ease of processing and low cost.

[0004]

However, when incinerated, this vinyl chloride resin has a drawback in that it generates a large amount of chlorine-based toxic and harmful gases, and has high heat calories at the time of incineration. Processing was a major problem.

[0005] For this reason, there has been a movement to regulate the use of vinyl chloride-based resin in daily necessities, and some countries have actually banned such use. In Japan, there is no doubt that its use will be restricted in the future, and there is a need for new materials to replace it.

[0006] Further, vinyl chloride resin is inferior in heat resistance and impact resistance. When a bathtub lid is made from the raw material, the resin is liable to be melted due to overheating, or to be damaged by handling or stepping on the lid. There was also the danger that unprepared toddlers and the elderly would encounter unexpected accidents. In addition, because of its relatively heavy weight, opening and closing it is not easy for infants and the elderly.

The inventor of the present invention has solved the above-mentioned problems relating to the bathtub lid, is easy to dispose of and can be recycled, is friendly to the global environment, is strong in strength, and prevents accidents caused by the bathtub. Research on a safe plastic shutter-type bathtub lid that can be performed, a flat cylindrical main body 1 having a flat bottom plate 2 extending in the longitudinal direction is extruded with a polypropylene-based resin or a polystyrene-based resin, and a plurality of main bodies 1 are formed. The bottom plates 2 are connected side by side by a ribbon-shaped joint plate 5 made of a soft synthetic resin so that the long sides thereof are not in contact with each other so that the long sides do not touch each other. A plastic shutter-type bathtub lid, which is closed with a cap 7 made of synthetic resin, is disclosed in Japanese Utility Model Application No. Hei.
No. 2491 (hereinafter referred to as prior application).

Although the bathtub lid according to the prior application was able to solve the above-mentioned disadvantages of the prior art, it still has the following problems, and it cannot be said that the bathtub lid is sufficiently complete as a bathtub lid. there were.

The bathtub lid is used in a high-temperature, high-humidity environment,
During use, these conditions fluctuate widely, and these fluctuations are repeated very many times. Also, in the case of overheating, the humidity and temperature increase significantly. Therefore, when used for a long time, the lid is likely to bend or the strength is likely to be reduced due to thermal deformation.

[0010] The above disadvantages can be overcome by cooling the extruded product once, annealing it at 120 to 130 ° C for about 5 to 10 minutes, and changing the atomic arrangement and molecular structure. It becomes complicated and costs increase.

The bathtub lid needs to have sufficient strength to prevent an accident caused by an infant, an elderly person or the like hanging on or stepping on it. In the case of over-heating (over-boiling), the temperature rises, thermal deformation occurs, and the strength decreases. Also, in consideration of the strength reduction during use as described above, it is necessary to sufficiently increase the initial strength of the lid, and if the strength decreases, the standard of JIS A5708 cannot be satisfied. To increase the strength sufficiently and increase the safety factor of the design strength, it is necessary to use a body with a large section modulus, and the weight of the lid increases,
There is a problem that the handling becomes difficult.

In order to prevent an accident, it is desirable that the slip coefficient is larger. An object of the present invention is to solve the problems of the prior art described above, as well as to solve the problems of the prior application, and it is easy to dispose, and recycling is possible. We need to provide a safe plastic shutter-type tub lid that is environmentally friendly, strong in strength, can prevent accidents caused by bathtubs, has a simple manufacturing process, is lightweight, and has improved performance even more. Is what you do.

[0013]

The present invention provides a halogen-free polypropylene resin or polystyrene resin.
A flat cylindrical main body 1 having a bottom plate portion 2 that is flat in the longitudinal direction by extrusion molding a resin composition obtained by mixing 30 parts by weight and an inorganic filler in an amount of 30 to 70 parts by weight under heating.
And a plurality of main bodies 1 arranged side by side at predetermined intervals so that their long sides do not touch each other in the lateral direction. The above-mentioned problem is solved by manufacturing the bathtub lid by connecting with a joint plate 5 made of a thermoplastic styrene elastomer containing no halogen into both end openings 6 of the main body 1 while applying ultrasonic vibration. Is something that you want

The halogen-free polypropylene resin used in the present invention means a propylene polymer, a copolymer (including a terpolymer) of propylene and EPR or EPDM, or a composite.

[0015] Polypropylene resins have the advantages of better heat resistance and mechanical strength than polyethylene resins, but have the drawback of poor moldability. However, such drawbacks can be solved by forming a composite compound. .

[0016] The halogen-free polystyrene resin is
It means a styrene polymer or a copolymer of styrene and butadiene (including a terpolymer).

Polystyrene-based resins have the advantages of good bending strength and moldability compared to polypropylene-based resins, but have the disadvantage of inferior impact strength. It can be solved by doing.

Examples of the inorganic filler include calcium carbonate, talc, mica, whiskers and the like, and finely ground whiskers such as finely ground glass fiber (milled fiber), and talc is particularly preferred.

A resin composition obtained by mixing a halogen-free polypropylene-based resin or polystyrene-based resin (hereinafter collectively referred to as “resin”) and an inorganic filler is extruded under heating to obtain a flat bottom plate in the longitudinal direction. A flat cylindrical main body having the portion 2 is manufactured.

The heating temperature varies depending on the type of the resin composition, but is 190 to 230 ° C., preferably 200 to 220 ° C.
C is appropriate. The method of mixing the present resin with the inorganic filler and the method of extruding the resin composition can use conventional methods, and thus detailed description is omitted.

The mixing ratio of the present resin to the inorganic filler is 70 to 30 parts by weight, preferably 55 to 45 parts by weight, and the inorganic filler is 30 to 70 parts by weight, preferably 45 to 45 parts by weight.
55 parts by weight.

The reasons for the limitation are as follows. If the amount of the inorganic filler is small, it is necessary to cool a molded product obtained by extrusion molding, and then put the molded product into a heating chamber again and perform an annealing treatment. If the annealing treatment is not performed, the body may be deformed by steam in the bath during use, and it is necessary to use a main body having a large section modulus in order to prevent the deformation. Annealing changes the atomic arrangement and molecular structure, and prevents the above-mentioned deformation.

By incorporating an inorganic filler, there is no need to perform an annealing treatment, and the above deformation can be prevented. Further, by mixing the inorganic filler, the rigidity of the main body 1 is increased, and a light-weight material having a small section modulus can be used, thereby reducing the cost. Furthermore, by incorporating an inorganic filler, it is possible to obtain a bath lid with improved slipperiness, improved slip resistance, less susceptibility to cracking, and higher safety. In addition, heat calories during incineration can be reduced.

If the amount of the inorganic filler is too large, there are disadvantages such as easy breakage and heavy weight due to impact. Therefore, the amount of the inorganic filler to be mixed is suitably within the above range.

By adding a total of 0.5 to 3 parts by weight of a stabilizer and a processing aid to 100 parts by weight of the resin composition, thermal stability, deterioration resistance and processability can be further improved. Can be. Examples of the stabilizer include an antioxidant and an ultraviolet absorber. Examples of the processing aid include metal soap and ethylene wax. As for the method of adding the stabilizer and the processing aid, a conventional method can be used, and a detailed description thereof will be omitted.

A plurality of the main bodies 1 are arranged side by side at predetermined intervals so that their long sides do not touch each other in the lateral direction, and a ribbon-shaped soft resin made of a halogen-free soft resin is provided between the bottom plates 2. Are connected by a joint plate 5. When a two-color extrusion molding machine is used, the main body 1 and the joint plate 5 are molded at once in the molding machine while being connected integrally.

A suitable material for the joint plate 5 is a halogen-free thermoplastic styrene-based elastomer.

When the main body 1 and the joint plate 5 are integrally molded by using a two-color extruder, the joint between the main body 1 and the joint plate 5 is in a superposed state, so that the connection between the two is extremely strong. is there.

The openings 6 at both ends of the main body 1 are closed with caps 7 made of thermoplastic styrene elastomer containing no halogen. If the amount of the inorganic filler in the resin composition constituting the main body 1 is large, it becomes difficult to bond them, and it is impossible to fix the cap with the adhesive.

In the present invention, the cap 7 is made of a halogen-free thermoplastic styrene elastomer having rubber elasticity. It is preferable that the joint plate 5 is made of the same material as the joint plate 5 in order to improve the recyclability and the joining property. As the elastomer, for example, Rheostomer (trade name: manufactured by Riken Vinyl Industry Co., Ltd.) can be suitably used.

The cap 7 is formed by integrally forming an insertion piece 8 formed slightly larger than the opening 6 on the back surface. The opening 6 is elastically closed by utilizing physical properties of the styrene-based elastomer such as strain, rebound resilience, and slip resistance. As the ultrasonic waves, those having a frequency of 15 KHz to 20 KHz are suitable.

[0032]

The outer appearance is not different from the conventional shutter type bathtub lid, and can be used in the same manner, but the main body is made of a polypropylene resin or a polystyrene resin containing no halogen.
It is made of a resin composition obtained by mixing 0 to 30 parts by weight of an inorganic filler and 30 to 70 parts by weight of an inorganic filler. Since both the joint plate and the cap are made of a synthetic resin containing no halogen, they are incinerated in an incinerator. However, unlike the PVC resin, there is no generation of toxic or harmful gas of a halogen type, the heat calorie during incineration is low, and the incinerator is unlikely to be damaged.

Further, recycling is easy, and after crushing the components without separating them into individual parts and then pelletizing them, they can be reused as raw materials for bathtub lids and various household daily necessities. Furthermore, heat resistance, impact resistance, and strength are higher than those of a vinyl chloride type, and an accident during boiling can be prevented.

Furthermore, the sliding resistance is high, the safety is high, and the watertightness of the joint with the cap is high. In addition, since the cap is made of a styrene-based elastomer, it has a cushioning property, and there is no danger of cracking even when leaning against the bathroom tile surface.

[0035]

Embodiment 1 An embodiment of a plastic shutter type bathtub cover according to the present invention will be described below in detail with reference to the drawings.

FIG. 1 is a plan view of one embodiment of a plastic shutter-type bathtub cover according to the present invention, FIG. 2 is a side view thereof, FIG. 3 is a partially enlarged plan view thereof, and FIG. 5 is a front view of the cap, and FIG. 6 is a side view of the cap.

In the figure, reference numeral 1 denotes a main body, which has a flat cylindrical shape, and a flat portion is a bottom plate portion 2. The inside of the main body 1 is a cavity 3, in which a reinforcing rib 4 is integrally provided. These are 50 parts by weight of a polypropylene resin, 50 parts by weight of talc, an antioxidant as a stabilizer and a processing aid, an ultraviolet absorber,
It is formed of a resin composition comprising a total of 1 part by weight such as a metal soap.

The main bodies 1 are arranged side by side at predetermined intervals so that their long sides do not touch each other, and are connected by a ribbon-shaped joint plate 5 made of a soft synthetic resin containing no halogen. A bathtub lid as shown in FIG.

The joint plate 5 must be flexible when the bathtub lid is folded or rolled, so that the joint plate 5 must be flexible and must be made of a soft synthetic resin. In consideration of this, it is preferable to use the same resin as the main body 1.

In this embodiment, the joint plate is formed of a thermoplastic styrene-based elastomer (trade name: LEOSTOMER manufactured by Riken Vinyl Industry Co., Ltd.), and has a width of about 2 mm with the bottom plate 2 of the main body 1 as shown in FIG. Are superimposed.

On the other hand, caps 7 are attached to the openings 6 at both ends of the main body 1, and the openings 6 are closed. 5 and 6, reference numeral 8 denotes an insertion piece protruding from the cap 7, and this part is inserted into the opening 6. FIG.
In FIG. 2, the cap 7 is attached only to the right end main body 1, but this is for clarifying the structure of the main body 1, and the caps 7 are actually attached to all the openings 6.

The cap 7 is made of a thermoplastic styrene-based elastomer (trade name: Rheosummer manufactured by Riken Vinyl Industry Co., Ltd.), and the insert 8 is formed slightly larger than the opening 6. It is inserted while applying ultrasonic waves of 20 KHz, and utilizes the inherent properties of styrene-based elastomers such as compression set, rebound resilience and slip resistance.
The opening 6 is elastically closed.

[0043]

[0044]

The plastic shutter-type bathtub lid according to the present invention has the above-mentioned structure. Even when incinerated in an incinerator, it is a halogen-based toxic or harmful gas such as vinyl chloride resin. No incineration occurs and there is no risk of damaging the incinerator. In addition, recycling is easy, and if it is pulverized as it is without being separated for each part and then pelletized, it can be reused as a raw material for various daily necessities such as a bathtub cover. It also has many advantages, such as better heat resistance, impact resistance, slip resistance, etc., compared to vinyl chloride, light weight, easy to manufacture, easy handling, and less accidents during boiling. It is extremely superior to conventional shutter-type bathtub covers.

[0045]

[Brief description of the drawings]

FIG. 1 is a plan view of one embodiment of a plastic shutter-type bathtub lid according to the present invention.

FIG. 2 is a side view thereof.

FIG. 3 is a partially enlarged plan view thereof.

FIG. 4 is a partially enlarged plan view thereof.

FIG. 5 is a rear view of the cap.

FIG. 6 is a side view of the cap.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Main body 2 Bottom plate part 3 Cavity 4 Reinforcement rib 5 Joint plate 6 Opening 7 Cap 8 Insertion piece

──────────────────────────────────────────────────続 き Continuation of the front page (56) References JP-A-4-323027 (JP, A) JP-A-58-122821 (JP, A) JP-A-59-178215 (JP, A) 163091 (JP, U) Japanese Utility Model 7-5487 (JP, U) Japanese Utility Model 47-23494 (JP, Y1) Japanese Utility Model 47-32974 (JP, Y1) (58) Fields surveyed (Int. Cl. ⁷ , DB name) B29C 69/00-69/02 A47K 3/00 B29C 47/00-47/96 B29C 65/00-65/82

Claims (1)

(57) [Claims] 1. A resin composition obtained by mixing 70 to 30 parts by weight of a halogen-free polypropylene-based resin or polystyrene-based resin and 30 to 70 parts by weight of an inorganic filler is extruded under heating and is stretched in the longitudinal direction. A flat cylindrical main body 1 having a flat bottom plate portion 2 is formed, and a plurality of main bodies 1 arranged side by side at predetermined intervals so that long sides thereof do not contact each other are formed in the bottom plate portion. The two are joined by a ribbon-shaped joint plate 5 made of a soft synthetic resin not containing halogen, and a cap 7 made of a thermoplastic styrene-based elastomer containing no halogen is applied to both end openings 6 of the main body 1 by ultrasonic vibration. A method for producing a plastic shutter-type bathtub lid, wherein the lid is fitted while being inserted.