JP4802733B2 - Molded product and manufacturing method thereof - Google Patents

Description

  The present invention relates to a molded article used for, for example, a bathtub, a wash basin, a multilayer panel, and other industrial products, and a method for producing the same.

  Conventionally, a bathtub has been used by using a low-rigidity resin body in which a surface layer and a back surface layer are held inside a mold, and a foam layer made of a foam resin material is interposed in a cavity portion between the surface layer and the back surface layer. It is known to form (for example, refer to Patent Document 1).

  However, the low-rigidity resin body disclosed in Patent Document 1 includes only the foamed layer 6 obtained by foaming and curing the foamed resin material 5 between the surface layer 2 and the back surface layer 3 as shown in FIG. When the molded product 1 is a bathtub 9 having a flange portion 1a attached to the bathroom wall surface 10, the flange portion 1a of the bathtub 9 is thinner than the bathtub body and has a flange. Since the tip drooping portion 1b bent from the portion 1a is further thinned, when the tip drooping portion 1b is locked to the back hanger 11 of the bathroom wall surface 10, the rigidity is insufficient, as shown in FIG. In this way, the rim portion 11a at the tip of the back hanger 11 may pierce the foam layer 6, or the tip hanging portion 1b may be broken after construction as shown in FIG. 5B, which may cause the rim portion 11a to crack. .

As a means for locally increasing the strength of the molded product 1, it is conceivable to insert a solid material into a portion corresponding to the tip hanging portion 1 b of the flange portion 1 a. In particular, it is difficult to install and hold a solid material in a thinly bent portion such as the tip hanging portion 1b of the flange portion 1a that is bent in a complicated manner.
Japanese Patent No. 3001752

  The present invention has been invented in view of the above-mentioned conventional problems, and can increase the rigidity of a molded product locally. For example, the flange is fixed to a back hanger fixed on a bathroom wall surface. In the case of a bathtub with a part, it is possible to easily increase the rigidity of the front end hanging part of the flange part, and the rim part of the back hanger is stuck into the front hanging part at the time of construction, the crack of the front hanging part after construction and It is an object of the present invention to provide a molded product that can prevent cracking of the rim portion, and to provide a method of manufacturing a molded product that is capable of easily forming the molded product and that is excellent in productivity.

Molded article according to claim 1 in order to solve the above problems, the cavity portion 4 between the surface layer 2 and the back layer 3, the foam layer 6 of soft foamed resin material 5 foamed cured, the foam layer A rigid reinforcing layer 8 having higher rigidity than 6 is interposed so as to be adjacent to each other , and a foamed resin material is also provided in the cavity portion 4 on the opposite side to the foamed layer 6 with the reinforcing layer 8 interposed therebetween. 5 are foamed layer 6 on the rear side of the soft foamed cured is interposed, both surfaces 6a of the respective foam layers 6, 6b and the double-sided 8a, 8b respectively the surface layer 2 and the backing layer 3 of the reinforcing layer 8 and in close contact with bets, the reinforcing layer 8, the foamed resin material 5 has a bubble 14 consecutive passable and the foamed resin material 5 which has entered inside the bubble 14 this successive curing inside the bubble 14 to have Ri open cell foam 7 Tona, successive bubbles of the open-cell foam 7 4 the foam resin material 5 passing through the inside is characterized that you have been foamed layer 6 is formed of the inner side by spread evenly in the cavity 4 of the rear side.

By adopting such a configuration, the reinforcing layer 8 having higher rigidity than the foamed layer 6 can be obtained using the foamed resin material 5 and the open cell body 7, so that it is easy to locally provide a portion having high rigidity. It becomes. Further, the foamed resin material 5 passes through the continuous bubbles in the open cell body 7 and evenly spreads to the inner cavity portion, so that it enters the open cell 7 and the continuous bubble 14 of the open cell body 7. The highly rigid reinforcing layer 8 can be formed by the foamed and cured foamed resin material 5.

  The reinforcing layer 8 according to claim 2 is a non-foamed filling portion 15 in which the foamed resin material 5 is cured in a non-foamed state inside the continuous bubbles 14 of the open-cell body 7, The reinforcing layer 8 according to claim 3 is cured in a low foaming state in which the foamed resin material 5 is lower than the foaming ratio of the foamed resin material 5 in the soft foamed layer 6 inside the continuous bubbles of the open cell body 7. In any case, the hard reinforcing layer 8 that is harder than the foamed portion of the foam layer 6 can be formed.

  In the invention according to claim 4, the molded product 1 includes a bathtub 9 having a flange portion 1 a that is locked to a back hanger 11 fixed to a bathroom wall surface 10, and the flange portion 1 a includes a back hanger 11. Since the inserted tip drooping portion 1b is provided and at least the tip drooping portion 1b is constituted by the reinforcing layer 8, the flange portion is engaged with the back hanger 11 fixed to the bathroom wall surface 10. Since the rigidity of the tip drooping portion 1b of 1a can be easily increased by the reinforcing layer 8, the rim portion 11a of the back hanger 11 is pierced into the tip drooping portion 1b as in the prior art, and the tip drooping portion 1b after construction is inserted. Each of the cracks and the rim portion 11a can be prevented.

The method for producing a molded article according to claim 5, the cavity portion 4 between the surface layer 2 and the back layer 3, the foam layer 6 in which the foamed resin material 5 foamed cured, rigid than the foam layer 6 A high-strength reinforcing layer 8 so as to be adjacent to each other, and at the back side of the cavity portion 4 opposite to the foamed layer with the reinforcing layer interposed therebetween, the foamed resin material 5 is foamed and hardened on the back side. and foam layer 6 is interposed, the production of each of both surfaces 6a of the foam layer 6, 6b and the double-sided 8a of the reinforcing layer 8, 8b molded articles respectively in close contact on the said surface layer 2 and the back surface layer 3 a method, inside the mold and holding the said surface layer 2 and the backing layer 3, in any position of the cavity portion 4 between the surface layer 2 and the backing layer 3, the foam resin material Via an elastic open cell 7 having a plurality of continuous bubbles 14 through which 5 can pass It is allowed, then, by injecting the foam resin material 5 to the cavity portion 4, to form a foam layer 6 a foaming resin material 5 in the cavity portion 4 other than the open-cell foam 7 is foamed and cured, the continuous The foamed resin material 5 that has entered the inside of the continuous bubbles 14 of the foam 7 is cured in a non-foamed state to form the reinforcing layer 8, and the foamed resin material 5 further passes inside the continuous bubbles 14 of the open foam 7. It is characterized in that it passes through the cavity part 4 on the back side through the entire area.

Method of manufacturing a molded article according to claim 6, the cavity portion 4 between the surface layer 2 and the back layer 3, the foam layer 6 in which the foamed resin material 5 foamed cured, rigid than the foam layer 6 A high-strength reinforcing layer 8 so as to be adjacent to each other, and at the back side of the cavity portion 4 opposite to the foamed layer with the reinforcing layer interposed therebetween, the foamed resin material 5 is foamed and hardened on the back side. and foam layer 6 is interposed, the production of each of both surfaces 6a of the foam layer 6, 6b and the double-sided 8a of the reinforcing layer 8, 8b molded articles respectively in close contact on the said surface layer 2 and the back surface layer 3 a method, inside the mold and holding the said surface layer 2 and the backing layer 3, in any position of the cavity portion 4 between the surface layer 2 and the backing layer 3, the foam resin material An elastic open-cell body 7 having a plurality of continuous bubbles 14 through which 5 can pass. Was Zaisa, then, by injecting the foam resin material 5 to the cavity portion 4, together with the foamed resin material 5 in the cavity portion 4 other than the open-cell foam 7 by foaming and curing to form the foam layer 6 The foamed resin material 5 that has entered the continuous bubbles 14 of the open cell body 7 is cured in a low foaming state lower than the foaming ratio of the foamed resin material 5 in the soft foamed layer 6 to form the reinforcing layer 8. In addition, the foamed resin material 5 passes through the inside of the continuous bubbles 14 of the open cell body 5 and spreads evenly to the cavity portion 4 on the back side .

By adopting the configuration of the above claims 5 and 6, the open cell body 7 that becomes the reinforcing layer 8 is easily elastic before filling with the foamed resin material 5, thereby facilitating interposition in the cavity portion 4. After the filling of the foamed resin material 5, the foamed resin material 5 that has entered the continuous bubbles 14 is cured in either a non-foamed state or a low-foamed state, so that the foamed resin material 5 is foam-cured. Since the reinforcing layer 8 has higher rigidity than the foamed layer 6, the molded product 1 having increased rigidity at an arbitrary position can be easily produced at low cost. Further, the foamed resin material 5 passes through the inside of the continuous bubbles 14 of the open cell body 7 and evenly reaches the cavity part 4 on the back side, so that the open cell body 7 and the continuous cell 14 of the open cell body 7 are continuous. The stiffened reinforcing layer 8 can be formed by the foamed resin material 5 that has penetrated into the interior and foamed and hardened.

  In the molded product according to the present invention, the rigidity of the molded product can be locally increased, and a molded product that can be screwed at a portion having high rigidity can be easily obtained. In particular, when the molded product is a bathtub with a flange portion that is locked to a back hanger fixed to the bathroom wall surface, the rigidity of the tip hanging portion of the flange portion can be increased by a reinforcing layer, There is an advantage that the rim portion of the back hanger can be pierced, and the crack at the tip hanging portion and the rim portion after construction can be prevented.

  Furthermore, in the method for producing a molded article according to the present invention, it is easy to make an open cell body having elasticity interpose in the cavity portion and to make the surface layer and the back surface layer adhere to each other before filling with the foamed resin material. In addition, since the open cell body becomes a highly rigid reinforcing layer after filling with the foamed resin material, there is an advantage that a molded product with increased rigidity at an arbitrary position can be produced easily and at low cost.

  Hereinafter, the present invention will be described based on embodiments shown in the accompanying drawings.

  As shown in FIG. 1B, the molded product 1 of the present invention includes a foam layer 6 in which a foam resin material 5 is foam-cured in a cavity portion 4 between the front surface layer 2 and the back surface layer 3, and a foam layer 6. The reinforcing layer 8 having higher rigidity is interposed so as to be adjacent to each other, and both surfaces 6a and 6b of the foamed layer 6 and both surfaces 8a and 8b of the reinforcing layer 8 are in close contact with the surface layer 2 and the back surface layer 3, respectively. Is.

  The surface layer 2 is made of, for example, an elastomer layer, and the back surface layer 3 is made of, for example, an FRP layer. Of course, it is not limited to these materials, and may be a resin other than the above, a wood material, or a metal material such as stainless steel.

  The thickness (T, t1, t2) of the cavity portion 4 between the surface layer 2 and the back surface layer 3 is preferably 3 mm or more. The thickness of the foamed resin material 5 is preferably the thickness of the cavity portion 4, so that both surfaces 6 a and 6 b of the foamed layer 6 can be securely adhered to the front surface layer 2 and the back surface layer 3, respectively.

  The highly rigid reinforcing layer 8 is made of an elastic open cell body 7 having a plurality of continuous cells 14 (FIG. 3A) through which the foamed resin material 5 can pass. Examples include urethane sheets and polyethylene sheets. The plurality of bubbles 14 in the open cell body 7 are not closed cells but continuous bubbles, and the inner diameter of each bubble 14 is a size that allows the foamed resin material 5 before foaming to pass therethrough and the foamed resin material 5 The size that can be cured in a non-foamed state, for example, about 0.5 mm is set.

  In this example, the molded product 1 is used as a bathtub 9 having a flange portion 1a that is locked to a back hanger 11 fixed to a bathroom wall surface 10 shown in FIG. The flange portion 1 a is provided with a leading end hanging portion 1 b that is inserted into the back hanger 11. As shown to Fig.1 (a), the thickness T of the foam layer 6 of the bathtub main body, the thickness t1 of the foam layer 6 of the flange part 1a, and the thickness t2 of the reinforcement layer 8 of the tip drooping part 1b are T> t1> t2. It has become.

  Next, an example of the manufacturing process of the molded article 1 having the above configuration will be described with reference to FIG.

  First, the surface layer 2 is formed by applying a resin having a predetermined thickness on the mold surface of the lower mold 12 for forming the surface layer, and on the mold surface of the upper mold 13 for forming the back surface layer. Resin is applied to form the back layer 3. Next, an open-cell body 7 having elasticity such as a urethane sheet is installed at a position to be the leading end hanging portion 1 b of the flange portion 1 a of the bathtub 9. Here, the open cell body 7 is fixed to the inner surface of the surface layer 2 (or the inner surface of the back surface layer 3) with an adhesive. Then, as shown in FIG. 2, the mold surfaces of the upper mold 13 and the lower mold 12 are brought into contact with each other and clamped. At this time, both surfaces of the open cell body 7 are in close contact with the front surface layer 2 and the back surface layer 3, and a cavity portion 4 is formed between the front surface layer 2 and the back surface layer 3.

  Thereafter, the foamed resin material 5 is injected into the cavity portion 4 from the resin injection port 20 provided in the upper mold 13 through the small hole of the back surface layer 3. The foamed resin material 5 fills the cavity portion 4 as shown in FIGS. 1A to 1B. At this time, the inside of the continuous bubbles 14 of the open cell body 7 (see FIG. The foamed resin material 5 enters the state a)). As shown in FIG. 3A, when the cavity 4 a is also present on the back side of the open cell body 7, the foamed resin material 5 passes through the inside of the continuous cell 14 of the open cell body 7. The foamed resin material 5 is distributed evenly in the cavity portion 4a. And in the cavity part 4 (4a) other than the open-cell body 7, the foaming layer 6 is formed when the foamed resin material 5 foams, expands and hardens. Both surfaces 6a and 6b of the foam layer 6 are in close contact with the front surface layer 2 and the back surface layer 3, and function as a heat insulating layer. On the other hand, the foamed resin material 5 that has entered the continuous bubbles 14 of the open cell body 7 is cured without foaming as shown in FIG. That is, since the size of the bubbles 14 of the open cell body 7 is small enough to allow the foamed resin material 5 to enter and pass through but cannot foam as described above, the foamed resin material 5 inside the bubbles 14 is formed. Becomes a non-foamed filling portion 15 cured in a non-foamed state, and the non-foamed filling portion 15 forms a reinforcing layer 8 having rigidity higher than that of the foamed layer 6.

  Here, as another embodiment of the open cell body 7 constituting the reinforcing layer 8, as shown in FIG. 3C, the size of the continuous cell 14 of the open cell body 7 is such that the foamed resin material 5 is infiltrated. The foamed resin material 5 may be formed in such a size that it can be cured in a low foaming state lower than the foaming ratio of the foamed resin material 5 in the soft foamed layer 6. In this case, a low foam filling portion 16 is formed by curing the foamed resin material 5 that has entered the continuous bubbles 14 of the open cell body 7 in a low foaming state, and the foam layer 6 is foamed by the low foam filling portion 16. A hard and hard reinforcing layer 8 is formed compared to the portion. In addition, as a method of adjusting the expansion ratio of the foamed resin material 5 inside the continuous bubbles 14 in the low foam filling portion 16, for example, “the size of the bubbles 14” is changed, or “the type of the foamed resin material 5”. Can be considered. As an example, the expansion ratio can be adjusted by increasing / decreasing the infiltration pressure into the bubble 14 depending on the size of the inner diameter of the bubble 14. Further, when the viscosity of the foamed resin material 5 is increased, the pressure in the bubble 14 is increased or clogged due to the viscosity, so that the expansion ratio is lowered. When the viscosity of the foamed resin material 5 is decreased, the viscosity inside the bubble 14 is decreased. The expansion ratio can be increased by reducing pressure increase and clogging. Of course, this is merely an example, and the method for adjusting the expansion ratio of the foamed resin material 5 inside the bubbles 14 is not particularly limited.

  Thus, from the expansion ratio of the foamed resin material 5 in the non-foamed filling portion 15 or the soft foamed layer 6 in which the foamed resin material 5 that has entered the continuous bubbles 14 of the open-cell body 7 is cured in a non-foamed state. The hard reinforcing layer 8 that is harder than the foamed portion of the soft foam layer 6 can be formed by any one of the low foam filling portions 16 cured in a low low foam state. That is, by using the foamed resin material 5 and the open cell body 7, the reinforcing layer 8 having higher rigidity than the foamed layer 6 can be easily obtained. For example, the molded product 1 that can be screwed at the site of the reinforcing layer 8 is obtained. can get.

  Furthermore, by adjusting the expansion ratio of the foamed resin material 5 inside the bubbles 14 according to the purpose of use, the molded product 1 having light weight and / or high strength can be molded.

  Moreover, in the case where the molded product 1 is the bathtub 9 having the flange portion 1a that is locked to the back hanger 11 fixed to the bathroom wall surface 10, the surface layer 2 is formed of an elastomer layer, so that the cushioning property is improved. It is obtained and the skin contact property becomes good. In addition, since the tip drooping portion 1b of the flange portion 1a is reinforced with the reinforcing layer 8, the rigidity of the tip drooping portion 1b is enhanced, and the rim portion 11a of the back hanger 11 is stuck into the tip hanging portion 1b during construction, It is possible to prevent cracking of the tip drooping portion 1b and cracking of the rim portion 11a after construction. Furthermore, by adopting a structure in which the front hanging portion 1b of the flange portion 1a is locked to the back hanger 11, there is an advantage that the bathroom can be easily remodeled, and most of the vibration generated in the bathtub 9 remains as it is. 10 can be prevented from propagating to 10 and the noise can be reduced.

  Moreover, at the time of molding, the reinforcing layer 8 is formed simply by injecting the foamed resin material 5 into the cavity portion 4 with the open cell body 7 interposed at a position corresponding to the tip hanging portion 1b of the flange portion 1a in the cavity portion 4. Therefore, the manufacturing man-hours and costs can be greatly reduced. Moreover, even when the portion where the open cell body 7 is installed has a thin bent shape like the tip hanging portion 1b of the flange portion 1a, foaming is possible. Before the resin material 5 is filled, the elastic open-cell body 7 can be easily installed by inserting it into the cavity portion 4 of the narrow tip hanging portion 1b. Therefore, even in such a thin bent portion, the reinforcing layer It is possible to increase the production efficiency because it takes less time to form 8.

  The molded product and the manufacturing method thereof according to the present invention are applicable not only to a bathtub having a flange part but also to a bathtub having no flange part, and further, for example, a washstand, a multilayer panel, and other industrial products other than a bathtub. Widely applicable to fields.

The manufacturing process of the molded product of one Embodiment of this invention is shown, (a) is sectional drawing which illustrates typically the initial stage by which the foaming resin material was inject | poured into the cavity part, (b) is a foaming resin material being an open cell It is sectional drawing which illustrates typically the state by which the inside of a body was impregnated and the reinforcement layer was formed. It is explanatory drawing of the state which has arrange | positioned the surface layer and the back surface layer between the lower mold | type and upper mold | die for manufacturing the molded product same as the above. (A) is a schematic diagram for explaining a stage before the foamed resin material is impregnated in the open cell body, (b) is a continuous cell inside the open cell body, and the foamed resin material is cured in a non-foamed state. (C) is another embodiment, and the foamed resin material is in a low foaming state in which the foamed resin material is lower than the foaming ratio of the foamed resin material in the soft foamed layer inside the continuous cell of the open cell body. It is a schematic diagram when it hardens | cures with. When a molded article same as the above is a bathtub, it is a schematic cross-sectional view for explaining a state in which a front hanging portion of a flange portion of the bathtub is locked to a back hanger fixed to a bathroom wall surface. (A) is explanatory drawing of the state which the rim | limb part of the back hanger stabbed into the conventional foaming layer, (b) is explanatory drawing of the state which the tip drooping part of the conventional flange part damaged.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Molded product 2 Surface layer 3 Back surface layer 4 Cavity part 5 Foamed resin material 6 Foamed layer 6a, 6b Both sides 7 Open cell body 8 Reinforcement layer 8a, 8b Both sides 9 Bathtub 10 Bathroom wall surface 11 Back hanger 11a Tip drooping part 14 Continuous bubble 15 Non-foaming filling part 16 Low foaming filling part

Claims (6)

The cavity between the surface layer and the backing layer, and the foamed layer of the soft foamed resin material is foamed and cured, with the foam layer and the reinforcing layer of the high stiffness harder than is interposed so as to be adjacent, across the reinforcing layer being foamed layer of soft opposite the far side far side also foamed resin material into the cavity portion is foamed and cured in the intervening the above foamed layer, both sides and the reinforcing of the above foamed layer and in close contact with both surfaces of the layer, each said surface layer and said backing layer, said reinforcing layer, said foamed resin which has entered inside the bubble and that the continuous has bubbles the foamed resin material is continuously passable wood Ri is Do from open cell foam that is cured inside the bubble, foaming the foaming resin material passing through the bubble internal consecutive of the open cell body of the rear side by spread evenly in the cavity portion of the rear side It characterized that you have layers are formed Molded article.   The molded article according to claim 1, wherein the reinforcing layer is a non-foamed filling portion in which the foamed resin material is cured in a non-foamed state inside the continuous cells of the open-cell body.   The reinforcing layer is a low foam filling portion in which the foamed resin material is cured in a low foaming state lower than the foaming ratio of the foamed resin material in the soft foamed layer inside the continuous cells of the open cell body. The molded article according to claim 1, wherein   The molded article constitutes a bathtub having a flange portion that is locked to a back hanger fixed to the bathroom wall surface, and a flange portion is provided with a tip hanging portion that is inserted into the back hanger. The molded article according to any one of claims 1 to 3, wherein the molded article comprises a reinforcing layer. The cavity between the surface layer and the backing layer, and the foamed layer of the soft foamed resin material is foamed and cured, with the foam layer and the reinforcing layer of the high stiffness harder than is interposed so as to be adjacent, across the reinforcing layer being foamed layer of soft opposite the far side far side also foamed resin material into the cavity portion is foamed and cured in the intervening the above foamed layer, both sides and the reinforcing of the above foamed layer both sides of the layers, respectively a method of manufacturing a molded product obtained by close contact with the said surface layer and the backing layer, the inner mold retaining the said surface layer and said backing layer, said surface layer and said backing layer at any position of the cavity between, the foamed resin material is interposed resilient open-cell foam having a plurality of continuous air bubbles can pass, then, injecting the foamed resin material into the cavity by, the cavity odor And forming the foamed layer by foaming and curing the foamed resin material, a reinforcing layer made of continuous penetrates inside the bubble was the foamed resin material is cured in a non-foamed state unfoamed filled portion of the open-cell foam A method for producing a molded product, characterized in that the foamed resin material passes through the inside of the continuous cells of the open cell body and spreads evenly to the cavity portion on the back side . The cavity between the surface layer and the backing layer, and the foamed layer of the soft foamed resin material is foamed and cured, with the foam layer and the reinforcing layer of the high stiffness harder than is interposed so as to be adjacent, across the reinforcing layer being foamed layer of soft opposite the far side far side also foamed resin material into the cavity portion is foamed and cured in the intervening the above foamed layer, both sides and the reinforcing of the above foamed layer both sides of the layers, respectively a method of manufacturing a molded product obtained by close contact with the said surface layer and the backing layer, the inner mold retaining the said surface layer and said backing layer, said surface layer and said backing layer at any position of the cavity between, the foamed resin material is interposed resilient open-cell foam having a plurality of continuous air bubbles can pass, then, injecting the foamed resin material into the cavity by, the cavity odor The foam resin material by foaming cure thereby forming the foamed layer, the foamed resin material having entered inside bubbles continuous in the open-cell foam, lower than the expansion ratio of the foamed resin material in the foam layer of the soft It is cured in a low foamed state to form a reinforcing layer composed of a low foam filling portion , and further, the foamed resin material passes through the inside of the continuous cells of the open cell body and spreads evenly to the cavity portion on the back side. A method for producing a molded product, comprising:

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