JP6240022B2 - Method for manufacturing water-use member - Google Patents

Description

  The present invention relates to a method for manufacturing members in a bathroom such as a bathtub, wash bowls and wash counters, toilet interior members, kitchen counters, and kitchen sinks.

  As a conventional method for producing a water-use member, a male mold and a female mold are provided, a resin is injected between the male mold and the female mold, and the resin is sprayed together with the glass fiber cut into the mold. There is a spray-up method, a hand lay-up method in which a glass mat obtained by bonding cut glass fibers with a binder is laid on a mold, and then the glass mat is impregnated with a resin with a roller or the like.

  An example of a method for manufacturing a water-use member using such a conventional method is Patent Document 1, for example. Patent Document 1 discloses a method for manufacturing a washing floor floor pan by laminating a compound made of silicon resin, polyethylene resin, or the like on a mold using any one of an injection method, a spray-up method, and a hand lay-up method. It is disclosed.

JP-A-8-142190

However, both the spray-up method and the hand lay-up method have a problem that the quality of the product depends on the skill level of the operator.
In addition, the spray-up method and the hand lay-up method are molding methods for composite materials using glass fibers (hereinafter also referred to as FRP). For molding materials other than compounds used for FRP molding, Not used. Therefore, for example, in the case of using, for example, a compound for artificial marble which improves the appearance and quality of the water-circulating member, the injection method is used exclusively, not the spray-up method or the hand lay-up method.

  However, in the injection method, since the space into which the resin is injected is blocked by the male mold and the female mold, the air trapped in this space enters between the resins and becomes bubbles, and the resin around the bubbles is cured. Causes delay and hardening inhibition. When curing delay or curing inhibition occurs, there arises a problem that defects such as cavities occur in the finished product.

  In addition, in the injection method, if the distance between the male mold and the female mold is too small, the resin does not flow in. Therefore, it is necessary to leave an interval enough for the resin to flow in, and it is difficult to reduce the thickness of the product. Here, as the thickness of the product increases, the residual stress generated during resin curing tends to accumulate inside. Therefore, the injection method that is difficult to reduce in thickness cannot prevent the residual stress from accumulating inside the product. In addition, since both hot water and low temperature water are used, the water-circulating member is often exposed to a rapid temperature change. If the residual stress described above is accumulated inside the product, the rapid temperature Due to the change, there is a problem that defects such as cracks and water leakage occur.

  Therefore, as a result of intensive studies by the inventor of the present application in order to solve the above-described problems, it is possible to manufacture a water-circulating member with a novel structure that has never been achieved so that a fluid flows on the surface of a mold. The knowledge that it might be.

  The present invention has been made on the basis of the above-mentioned knowledge, reduces the generation of bubbles and accumulation of residual stress, prevents the occurrence of defects such as cavities, cracks or water leaks, and depends on the skill level of the operator. The main object of the present invention is to provide a method for manufacturing a water-use member that is not performed.

  The present invention is a manufacturing method for manufacturing a water-circulating member, and in a state where the upper surface of the prototype of the water-circulating member is open, a fluid is allowed to flow on the surface of the prototype so that the use surface of the water-circulating member is A molding step for molding is provided.

  According to the above-described configuration, the worker can form the working surface of the water circulating member simply by flowing the fluid to the prototype, so that the quality of the product is the same as the spray-up method and the hand lay-up method. Is not affected by the level of proficiency. Further, since the space for flowing the fluid as in the injection method is not blocked, it is possible to prevent air from entering the fluid and generate bubbles, thereby preventing the occurrence of defects. In the present invention, the product can be thinned by adjusting the amount of the fluid flowing to the prototype. Therefore, accumulation of residual stress inside the product can be reduced, and occurrence of defects such as cracks and water leakage can be prevented. In addition, while the injection method requires two types, a male type and a female type, in the present invention, only the original type is used, so that the cost can be reduced as compared with the injection method.

  Moreover, as a specific aspect of the method for producing a water-circulating member of the present invention, a method further comprising a laminating step of laminating at least one layer on the molded body obtained through the molding step is cited. be able to.

By configuring in this way, various functions such as impact resistance and heat resistance can be added to the product by changing the material of the layer laminated on the molded body, and the functions desired by the user can be added to the product. can do.
In addition, since products with a multi-layer structure can be manufactured, the thickness of each layer can be reduced to reduce the accumulation of residual stress that occurs when the fluid is cured, resulting in the occurrence of defects such as cracks and water leaks. Can be prevented.
Furthermore, even if the thickness of each layer is reduced, the product as a whole can have a predetermined thickness, so that the strength of the product can be improved while suppressing the occurrence of defects such as cracks and water leaks.
In addition, when a relatively expensive compound for artificial marble is used, only the outside of the product is composed of a compound for artificial marble, and the inside is manufactured using a different compound (for example, a compound for FRP). Therefore, the cost can be reduced as compared with the conventional product manufactured using only the compound for artificial marble.

  According to the present invention, there is provided a method for producing a water-use member that reduces the generation of bubbles and the accumulation of residual stress, prevents the occurrence of defects such as cavities, cracks, or water leakage, and does not depend on the skill level of an operator. Can be provided.

(A) Schematic which shows the formation process of the member for water around in this embodiment. (B) Schematic which shows the formation process of the member for water around in this embodiment. (A) Schematic which shows the correction process of the member for water around in this embodiment. (B) Schematic which shows the correction | amendment process of the member for water around in this embodiment. (A) Schematic which shows the lamination | stacking process of the member for water around in this embodiment. (B) Schematic which shows the lamination | stacking process of the member for water around in this embodiment. Schematic which shows the bathtub in this embodiment. Sectional drawing which shows the AA cross section of the bathtub in this embodiment.

  An embodiment of the method for producing a water-use member of the present invention will be described below.

  The method for manufacturing a water-circulating member in the present embodiment manufactures a water-circulating member through a molding process, a correction process, and a lamination process in this order.

The molding process will be described in detail.
The forming step is a step of forming the use surface of the water-circulating member by causing the fluid S to flow on the surface of the original 1 with the upper surface of the original 1 of the water-circulating member being opened. In addition, the member for water around in this embodiment is a bathtub, and the prototype 1 is also a mold for a bathtub and has a convex shape.

First, as shown in FIG. 1 (a), the upper surface (projection direction of the convex shape) of the original mold 1 is opened (a state where it is not closed by another mold as in the injection method). As shown in (b), the fluid S is caused to flow on the surface of the prototype 1. The fluid S is a compound having a viscosity obtained by kneading resin, aluminum hydroxide, glass-based powder, and the like. In the present embodiment, a compound for artificial marble can be used.
The fluid S flows on the surface of the prototype 1 by gravity, but since it has viscosity, a part of the fluid S slowly flows while staying on the surface of the prototype 1 and is laminated so as to cover the surface of the prototype 1. .
Further, at this time, a wall 8 for damming the fluid S is provided on the end face of the master 1, and this wall 8 is made of urethane sponge tape or the like fixed perpendicular to the end face of the master 1. It is configured. Then, the fluid S is dammed by the wall portion 8 at the end face of the prototype 1.

  Next, a correction process for making the thickness of the fluid S stacked on the prototype 1 uniform is performed.

  First, as shown in FIG. 2A, the surface is smoothed with a roller or the like, and unnecessary portions are removed so that the fluid S has a uniform thickness. At this time, as shown in FIG. 2 (b), the thickness of the fluid S laminated on the upper part of the convex side surface in the molding process is smaller than the thickness of the fluid S laminated on other portions by gravity. Therefore, for example, spraying is performed on this portion. By the above process, the whole fluid S laminated | stacked on the original pattern 1 is made into uniform thickness. In addition, this thickness can be 1.5 mm-2 mm, for example.

Here, as described above, the conventional spray-up method is merely an FRP molding method, and has not been used for molding a material other than a compound used for FRP molding. Further, the compound for artificial marble used in this embodiment has a higher viscosity than the compound for FRP molding. For this reason, the idea of spraying a compound having a high viscosity on the prototype 1 with a spray in addition to not being for FRP has never been considered.
On the other hand, in the present invention, the conventional fixing concept described above is overturned, and the structure is based on a novel concept that has not been used in the past, such as spraying a compound for artificial marble having a relatively high viscosity rather than for FRP molding. Correction is performed.
At this time, for example, a spray nozzle diameter of 4 mm or more can be used.

  And the molded object 2 is shape | molded on the surface of the original pattern 1 as shown to Fig.3 (a) by hardening the fluid S which passed through the said formation process and correction | amendment process with a heat | fever, light, etc., for example. The surface of the molded body 2 becomes the use surface of the bathtub.

  Next, a laminating process for laminating a plurality of layers on the surface of the molded body 2 is performed. In the present embodiment, four layers are laminated on the molded body 2 as shown in FIG.

  First, a first reinforcing layer 3 that reinforces the molded body 2 by laminating a compound made of a reinforcing fiber such as glass fiber and a thermosetting resin on the molded body 2 and curing the compound is provided. Next, a compound containing a fine hollow body made of a soft resin or an organic or inorganic material is laminated on the first reinforcing layer 3, and the cushion layer 4 that absorbs the impact is provided by curing the compound. Then, a second reinforcing layer 5 is provided by laminating a reinforcing fiber such as a glass fiber and a thermosetting resin on the cushion layer 4 and curing the compound. Finally, the fluid S is laminated on the surface of the second reinforcing layer 5, and the back layer 6 serving as the back surface of the bathtub is provided by curing the fluid S.

  Here, in the laminating step, as a method of laminating the layers, a method of laminating the fluid S as in the molding step may be used, or a conventional injection method, a spray-up method, or a hand lay-up method. Etc. may be used. Moreover, you may perform the correction process which correct | amends the thickness of the layer laminated | stacked between each lamination process uniformly. Then, when all the above steps are completed, the master 1 and the wall 8 are removed.

  After going through the above steps, a bathtub 7 as shown in FIG. 4 is manufactured. As shown in FIG. 5, the cross section of the bathtub 7 cut along the line AA includes the first reinforcing layer 3, the cushion layer 4, the second reinforcing layer 5, and the back layer 6 on the molded body 2 from the inner surface of the bathtub 7. It becomes the structure laminated | stacked in order toward the outer surface.

  The method for manufacturing a water-circulating member of the present embodiment configured as described above has the following special effects.

  The operator can form the working surface of the water circulating member simply by flowing the fluid S through the prototype 1, so that the quality of the product depends on the skill level of the operator like the spray-up method and hand lay-up method. It will not be done. Moreover, since the space which flows the fluid S like the injection method is not obstruct | occluded, it can prevent that air enters the fluid S and generation | occurrence | production of a defect can be prevented. In the present invention, the product can be thinned by adjusting the amount of the fluid S flowing to the prototype 1. Therefore, accumulation of residual stress inside the product can be reduced, and occurrence of defects such as cracks and water leakage can be prevented. In addition, while the injection method requires two types, a male type and a female type, the present invention uses only the prototype 1 so that the cost can be reduced compared to the injection method.

Further, by changing the material of the layer laminated on the molded body 2 (first reinforcing layer 3, cushion layer 4, second reinforcing layer 5, back layer 6), functions such as impact resistance and heat resistance are added to the product. The function desired by the user can be added to the product.
Further, since a multilayered product can be manufactured, the thickness of each layer (the first reinforcing layer 3, the cushion layer 4, the second reinforcing layer 5, and the back layer 6) is reduced and generated when the fluid S is cured. It is possible to reduce the accumulation of residual stress, and to prevent the occurrence of defects such as cracks and water leaks.
Furthermore, even if the thickness of each layer is reduced, the product as a whole can have a predetermined thickness, so that the strength of the product can be improved while suppressing the occurrence of defects such as cracks and leaks.
In addition, only the outside of the product is composed of a compound for artificial marble, and the inside is manufactured using a different compound (for example, a compound for FRP, etc.), so it is manufactured using only a compound for artificial marble. Cost can be reduced as compared with the conventional product.

  The present invention is not limited to the above embodiment.

  In the above embodiment, a bathtub is manufactured. However, the present invention is not particularly limited as long as it is a watering member. For example, a kitchen sink, a bowl for washing, or the like may be manufactured.

  In order to improve the quality of the product, a gel coat such as a clear gel coat may be applied to the original mold before the molding step.

  Furthermore, in the correction process, the structure in which the compound for artificial marble is sprayed can be used in the molding process, for example. In this case, the fluid S can be laminated on the original by spraying a compound for artificial marble on the original with a spray.

  The present invention can be variously modified without departing from the spirit of the present invention.

DESCRIPTION OF SYMBOLS 1 ... Prototype 2 ... Molded object 7 ... Bathtub S ... Fluid

Claims (3)

A manufacturing method for manufacturing a water-circulating member,
In a state where the upper surface of the prototype of the water-circulating member is open, a molding process for forming a use surface of the water-circulating member by flowing a fluid on the surface of the original ,
A correction step of correcting the thickness of the surface layer by spraying the fluid on the surface layer laminated on the surface of the prototype after the molding step ;
The manufacturing method of the member for water around whose said fluid is a compound for artificial marble . The manufacturing method of the member for watering of Claim 1 which further comprises the lamination process which laminates | stacks at least 1 layer on the molded object obtained through the said formation process and the said correction | amendment process .   The method for producing a water-use member according to claim 1 or 2, wherein the water-use member is a bathtub or a sink for a wash surface.