JP4492294B2 - Watering device and manufacturing method thereof - Google Patents

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 resin-based 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). .
JP 2002-255085 A JP-A-9-95554 JP 2002-254540 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.

  In addition, in the example where the reinforcement with the resin-based paint described above is attempted, reinforcement of the foam molded body used directly outside such as a floating body, a foam molded body for a temporary road structure, and an interior / exterior material for decoration of a building is provided. Synthetic resin foam for the purpose of heat insulation or sound insulation, sound insulation, vibration suppression, etc. in watering equipment, and urethane on the non-contact surface with the surface material of the synthetic resin foam There has been no watering device provided with a coating layer made of a resin and improved in mold resistance, wear resistance, stain resistance, and the like.

The present invention has the following configuration.
(1) A watering device in which the back surface of the surface material is covered with a synthetic resin foam made of foamed styrene resin, foamed acrylic resin or foamed polyolefin resin molded by in-mold molding using foamable synthetic resin particles. A watering device in which a coating layer made of a urethane-based resin is provided on a non-contact surface with a surface material of a synthetic resin foam.
(2) The watering device according to (1), wherein the urethane resin is non-solvent.
(3) The watering device according to (1) or (2), wherein the thickness of the coating layer made of urethane resin is 0.05 mm or more and 3 mm or less.
(4) The watering device according to any one of (1) to (3), wherein the urethane-based resin contains an antibacterial agent and / or an antifungal agent.
(5) The watering device according to any one of (1) to (4), wherein an antibacterial agent and / or an antifungal agent is contained in the polyol.
(6) The watering device according to any one of (1) to (5), wherein a urethane-based resin is spray-coated on a non-contact surface with the surface material of the synthetic resin foam.
( 7 ) The watering device according to any one of (1) to ( 6 ), wherein the watering device is a bathroom-related device, a sink-related device, or a toilet-related device.
( 8 ) The water circumference according to any one of (1) to ( 7 ), having a coating layer formed by spray-coating a non-solvent urethane resin on a non-contact surface with the surface material of the synthetic resin foam Device manufacturing method.

  In a watering device in which a synthetic resin foam is formed on the back surface of the surface material, just by providing a coating layer of urethane resin on the non-contact surface with the surface material of the synthetic resin foam, the mold resistance, wear resistance, It is possible to improve contamination performance and the like with low cost and 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 urethane-based resin, these performances are excellent.

  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 located on the surface of the synthetic resin foam and serves as a direct use or outer layer of the user. For example, in the case of a bathroom, a bathtub, a bathroom wall room If it is an inner steel plate, a sink, a sink sink, a top plate, etc. are said.

  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 may be a urethane-based resin provided on the surface of the synthetic resin foam or another coating layer of paint.

  And in this invention, a synthetic resin foam is laminated | stacked on the back surface of this surface material. Further, the surface of the synthetic resin foam that is not in contact with the surface material, that is, the non-contact surface is coated with a urethane resin to form a coating layer.

  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 kind of the synthetic foam constituting the synthetic resin foam is not particularly limited, but is preferably a foamed styrene resin, a foamed acrylic resin, or a foamed polyolefin resin from the viewpoint of ease of handling, and foamed from the viewpoint of price. 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 foamed acrylic resins such as those disclosed in JP-A-2001-233986 can be suitably used.

  The foaming ratio of these synthetic resin foams is not particularly limited. However, when the device is formed of a surface material having a relatively weak strength such as thin stainless steel, the back surface of the synthetic resin foam can be firmly held. Since it is preferable for exhibiting a sound-damping effect, the strength is preferably 2 to 60 times, and more preferably 3 to 30 times, which is relatively strong.

  Although these synthetic resin foams can be used as they are, depending on the form of use, it is difficult to touch the eyes of the user, but if mold is generated on the surface, it is not preferable for aesthetics or hygiene. An agent and / or an antifungal agent can be contained inside or on the surface of the synthetic resin foam or urethane resin. 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 make it contain in the inside or surface of a urethane-type resin, you may apply | coat after apply | coating a urethane-type resin to a synthetic resin foam, and you may add or apply | coat to a urethane-type resin previously. Among them, it is preferable to contain an antibacterial agent and / or an antifungal agent in the urethane-based resin, and further include a method of adding it to each raw material in advance and then curing it, and it is more preferable to contain it in a polyol.

  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.

  Although these synthetic resin foams cover at least a part of the back surface of the surface material, it is more preferable because the effect of the present invention is enhanced by covering 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.

  Among the above methods, it is preferable to use an acrylic adhesive in order to form the foamed resin in several blocks and adhere them to form a shape that matches the back surface shape of the surface material.

  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 may be 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 method of surface-coating the urethane resin on the non-contact surface with the surface material of the synthetic resin foam is not particularly limited, but a method of applying the urethane resin solution to the foamed resin molded body, the foam resin in the urethane resin solution There are a method of immersing the molded product, and a spray coating method in which a foamed resin molded product is spray-coated with a urethane resin. Especially, spraying is performed from the viewpoint of ease of painting, uniformity of the coating film and excellent appearance. The coating method is most preferred.

  The urethane-based resin used in the present invention is composed of an organic polyisocyanate (A) and an active hydrogen compound (B) typified by polyols, and contains a solvent-free, non-solvent, fast-curing two-component polyurethane resin. Is preferred. A method of spraying this polyurethane-based resin on a synthetic resin foam with a high-pressure sprayer to obtain a molded body having a urethane film is mentioned. In the present invention, it is most preferable to use, as the organic polyisocyanate (A), a mixture containing a polyol and a urethane prepolymer having an isocyanate group obtained from the organic polyisocyanate together with the organic polyisocyanate.

  The polyol constituting the urethane prepolymer is not particularly limited as long as it is a polymer compound having two or more hydroxyl groups in the molecule, but a linear structure compound is preferable, for example, polyester polyol, A polyether polyol is mentioned.

  Examples of polyester polyols include polyester polyols obtained by polycondensation of polyhydric alcohols with polybasic carboxylic acids and hydroxycarboxylic acids, and polycaprolactones obtained by ring-opening addition polymerization of lactones such as ε-caprolactone in the presence of glycols and the like. Diols are mentioned.

  Examples of the polyhydric alcohol used for polycondensation with polybasic carboxylic acid or hydroxycarboxylic acid include ethylene glycol, 1,2-propylene glycol, 1,3-propylene glycol, 2,3-butylene glycol, 1,4 -Butylene glycol, 2,2'-dimethyl 1,3-propanediol, diethylene glycol, 1,5-pentamethylene glycol, 1,6-hexamethylene glycol, cyclohexane 1,4-diol, cyclohexane 1,4-dimethanol, etc. Can be used alone or in combination of two or more.

  Examples of the polybasic carboxylic acid and hydroxycarboxylic acid include succinic acid, maleic acid, adipic acid, glutaric acid, pimelic acid, speric acid, azelaic acid, sebacic acid, phthalic acid, isophthalic acid, terephthalic acid, hexahydroterephthalic acid , Hexahydroisophthalic acid or the like can be used alone or in combination of two or more. Also useful are reaction products such as castor oil which is a condensate of polyhydric alcohol and hydroxycarboxylic acid, castor oil and ethylene glycol, propylene glycol and the like.

  Examples of polyether polyols include products obtained by addition polymerization of one or more alkylene oxides such as ethylene oxide, propylene oxide, and butylene oxide to compounds having two or more active hydrogens, and ring-opening polymerization of tetrahydrofuran. And polytetramethylene glycol obtained as described above.

  In this case, examples of the compound having two or more active hydrogens include polyhydric alcohols and polybasic carboxylic acids described above, amines such as ethylenediamine, hexamethylenediamine, and diethyltoluenediamine, ethanolamine, and propanolamine. And alkanolamines, polyphenols such as resorcin and bisphenol, and castor oil.

  Examples of other polyhydric alcohols that can be used in combination with the linear structure compound having a terminal hydroxyl group include the above-described polyhydric alcohols used for polycondensation with polybasic carboxylic acids and hydroxycarboxylic acids.

  As organic polyisocyanate (A), hexamethylene diisocyanate, lysine diisocyanate, isophorone diisocyanate, xylene diisocyanate, cyclohexane diisocyanate, toluidine diisocyanate, 2,4-tolylene diisocyanate, 2,6-tolylene diisocyanate, 4,4'-diphenylmethane Examples include diisocyanate, p-phenylene diisocyanate, m-phenylene diisocyanate, 1,5-naphthylene diisocyanate, triphenylmethane triisocyanate, and mixtures thereof.

  The active hydrogen compound (B) used in the present invention is not particularly limited, and amines such as polyhydric alcohols, polybasic carboxylic acids, hydroxycarboxylic acids, ethylenediamine, hexamethylenediamine, diethyltoluenediamine and the like. Alkanolamines such as ethanolamine and propanolamine, polyphenols such as resorcin and bisphenol, castor oil, and other polyols described above. These may be used alone or as a mixture of two or more.

  Further, if necessary, a urethane forming catalyst such as dibutyltin dilaurate, a pigment, a filler such as calcium carbonate, and the like can be added to the active hydrogen compound (B).

  The reactivity of the two-component polyurethane resin used in the present invention is preferably adjusted to about 3 to 120 seconds in gel time, although it depends on the shape of the foamed resin molding. This adjustment is performed mainly by adjusting the type of organic polyisocyanate (A), the presence or absence of the combined use of amines in the active hydrogen compound (B), the ratio, and the type and amount of the urethanization catalyst.

  As the high-pressure sprayer used for forming the coating film by the spray method, those used for in-situ foaming work of hard urethane foam for heat insulation can be generally used.

  In the synthetic resin foam surface-coated with the urethane resin thus obtained, the thickness of the urethane coating is not particularly limited, but is preferably 0.05 mm or more and 3 mm or less regardless of the coating method. More preferably, it is 0.1 mm or more and 2 mm or less, more preferably 0.2 mm or more and 1.7 mm or less, and most preferably 0.5 mm or more and 1.5 mm or less. The urethane coating can be used even if it is thin, but the surface hardness of the synthetic resin foam is low. Therefore, if the film thickness is too thin, the surface strength of the foamed molded product tends to decrease. Therefore, the film thickness is preferable from the viewpoints of the object, performance and strength of the present invention.

  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 of a urethane resin is provided.

  In this example, the synthetic resin foam 2 was a polystyrene foam. And the shaping | molding performed normal pre-foaming using expandable polystyrene particles (Kanepal VF manufactured by Kaneka Corporation), and obtained the pre-foamed particles having a bulk magnification of 60 times from the bathtub (length: 1598 mm × width). : 785 mm × height: 475 mm), which is obtained by filling a mold having a shape for forming a heat insulating layer and further heating with steam.

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

Example 1
200L drum can containing Styrotan 5321FR A liquid (mixture of organic isocyanate and urethane prepolymer) and B liquid (polyol) manufactured by Futsura Coating Co., Ltd. was connected to urethane spray system H-20 / 35 manufactured by Gasmer Co., and spray gun GX8 was installed. Setting was performed to enable urethane spray (liquid A: liquid B = 1: 1 weight ratio). Next, set the polystyrene foam for heat insulation of the bathtub in front of the booth for exhaust, and spray the urethane onto all surfaces of the foam except the surface in contact with the bathtub using a spray gun. A bathtub foam insulation polystyrene foam 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)
A urethane-coated polystyrene foam for bath insulation is obtained in the same manner as in Example 1 except that 0.1 parts by weight of a fungicide (Hello Coat GK manufactured by Get Co., Ltd.) is uniformly dispersed in 50 parts by weight of Liquid B. It was. 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)
A urethane-coated polystyrene foam for bath insulation was obtained in the same manner as in Example 1 except that the urethane 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 the polystyrene foam for bath insulation without urethane coating layer, the mold resistance according to the fungus resistance test method of JIS Z 2911 / plastic products is the area of the mycelium growth part recognized in the inoculated part of the test piece. Since it is more than 1/3 of the area, the result is displayed as 2, and only a result very inferior to the example was obtained. 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 (8)

A watering device in which the back surface of the surface material is covered with a synthetic resin foam made of foamed styrene resin, foamed acrylic resin or foamed polyolefin resin formed by in-mold molding using foamable synthetic resin particles , A watering device in which a coating layer made of urethane resin is provided on a non-contact surface with a surface material of a synthetic resin foam.   The watering device according to claim 1, wherein the urethane-based resin is non-solvent.   The watering device according to claim 1 or 2, wherein the coating layer made of urethane resin has a thickness of 0.05 mm to 3 mm.   The watering device according to any one of claims 1 to 3, wherein the urethane-based resin contains an antibacterial agent and / or an antifungal agent.   The watering device according to any one of claims 1 to 4, wherein an antibacterial agent and / or an antifungal agent is contained in the polyol.   The watering device according to any one of claims 1 to 5, wherein a urethane-based resin is spray-coated on a non-contact surface with the surface material of the synthetic resin foam. The watering device according to any one of claims 1 to 6 , wherein the watering device is a bathroom-related device, a sink-related device, or a toilet-related device. The production of a watering device according to any one of claims 1 to 7, further comprising a coating layer formed by spray-coating a non-solvent urethane resin on a non-contact surface with the surface material of the synthetic resin foam. Method.

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