JP6650611B2 - Kitchen member and method of manufacturing the same - Google Patents

Description

  The present invention relates to a kitchen member made of a resin molded product called so-called artificial marble and a method of manufacturing the same.

  The texture of natural marble, for example, the artificial marble that produces a sense of quality such as a pattern and glossiness is used for a member such as a top plate of a kitchen device installed in a kitchen (hereinafter, referred to as a kitchen member). I have. The artificial marble is obtained by mixing a thermosetting resin as a base material with an inorganic filler, a low-shrinking agent, a pigment, and the like, and then molding the molded article into a predetermined shape by casting or the like to form a kitchen member. Since such artificial marble kitchen members are resin molded products, they are relatively inexpensive compared to natural marble and have excellent physical properties such as workability, workability, warm water resistance, strength, and weather resistance. Have.

The present applicant also proposes the artificial marble and a kitchen counter using the same in Patent Document 1 below. Specifically, the artificial marble described in Patent Document 1 contains a resin component and an inorganic filler, has a —CF ₃ group at one end on a molded surface, and a chlorosilyl group or an alkoxysilyl group at the other end. A silane-based surfactant having a chemical bond. In addition, the artificial marble described in Patent Literature 1 has fine irregularities whose surface does not exceed 500 μm is formed on the surface thereof.

  According to the artificial marble described in Patent Literature 1, the water repellency is improved by a synergistic effect of a reduction in surface free energy caused by a fluorocarbon group exposed on the surface and the fine irregularities formed on the surface. Therefore, the artificial marble has low activity with respect to the dirt component, the antifouling property is improved, and the adhesion of the dirt component to the surface of the artificial marble is reduced. As a result, it is possible to suppress the growth of bacteria and mold that feed on the dirt component.

JP 2001-190344 A

  However, the artificial marble up to now, including the artificial marble described in Patent Literature 1, is mainly composed of a thermosetting resin, and has a certain degree of warm water resistance as described above. However, when applied as a kitchen member, cooking utensils such as frying pans and pans used in the heating cooker cannot be directly placed on the kitchen member in a high temperature state. The portion of the kitchen member that comes into contact with the back surface of the bottom of the cooking utensil is usually denatured due to heat transfer from the cooking utensil, resulting in a scorch or the like, with a trace on the surface of the kitchen member. For this reason, when putting hot cooking utensils on kitchen members, auxiliary tools for suppressing heat transfer from cooking utensils such as pans are indispensable.

  Further, in the artificial marble described in Patent Document 1, as described above, fine irregularities having a roughness not exceeding 500 μm are formed. However, these irregularities are devised exclusively from the viewpoint of antifouling properties. is there. The description of Patent Document 1 does not suggest the relationship between the unevenness and the heat resistance, specifically, the significance of directly placing a cooking utensil in a high temperature state on a kitchen member.

The present invention has been made in view of the circumstances as described above, even when placed directly cookware in the high temperature state, noticeable traces the surface of the cookware by heat transfer from the back surface of the bottom of the cookware It is an object to provide a kitchen member that is difficult to manufacture and a manufacturing method for manufacturing the kitchen member.

In order to solve the above-mentioned problem, the kitchen member of the present invention is a kitchen member formed by molding a resin composition in which at least a filler is added to a thermosetting resin, and the kitchen member has a surface. Is formed only from the resin composition, the surface has a triangular irregular shape in a cross section thereof, and the top in the cross section of the surface has a curved shape whose ridge bulges outside the surface. has, and the height difference between the highest and lowest in the cross section of the surface, 50 [mu] m or more, and it is 400μm or less, in the cross section of said surface, valleys, its valley, the inside of said surface It is characterized in that it has a curved shape that swells .

  Further, in the method for manufacturing a kitchen member according to the present invention, the molding surface of the lower mold in the casting mold including the upper mold and the lower mold is formed by chemically polishing a square portion of an uneven pattern formed by etching. After the resin composition is injected into the lower mold, the upper mold and the lower mold are pressed and cured while heating the resin composition by the upper mold and the lower mold. The kitchen member is manufactured without coating the surface.

ADVANTAGE OF THE INVENTION According to the kitchen member and its manufacturing method of this invention, even if the cooking utensil in a high temperature state is directly placed, the trace of the cooking utensil due to the heat transfer from the back surface of the bottom of the cooking utensil becomes less noticeable on the surface.

It is a perspective view showing an example of a kitchen counter which is one embodiment of a kitchen member of the present invention. FIG. 2 is a cross-sectional view of the kitchen counter shown in FIG. FIG. 3 is a sectional view of a main part showing another kitchen counter in the same manner as FIG. 2. (A) is a schematic sectional view showing an example of a casting mold used for manufacturing the kitchen counter shown in FIG. 1, and (b) is a diagram of the casting mold shown in (a). It is principal part sectional drawing which showed the lower type | mold typically. FIG. 5 is a cross-sectional view of a main part process schematically illustrating a process of manufacturing the lower mold illustrated in FIG. 4B.

  Drawing 1 is a perspective view showing an example of a kitchen counter which is one embodiment of a kitchen member of the present invention. FIG. 2 is a sectional view of the kitchen counter shown in FIG.

  The kitchen member 1 shown in FIG. 1 is a kitchen counter 1a. The kitchen member 1 including the kitchen counter 1a is formed by molding a resin composition in which at least a filler is added to a thermosetting resin. As shown in FIG. 2, the kitchen member 1 has a surface 2 formed of only the resin composition, and the surface 2 has a triangular corrugated shape in its cross section. The top 2 a in the cross section of the surface 2 has a curved shape in which the ridge line 3 expands outside the surface 2. Moreover, the height difference Δh between the highest position 4 and the lowest position 5 in the cross section of the surface 2 is 50 μm or more.

  Specifically, the kitchen counter 1a as the kitchen member 1 forms a top plate of a kitchen apparatus installed in a kitchen such as a house, and is a horizontally long member as shown in FIG. The main body 6 of the kitchen counter 1a is formed of a flat plate portion 7 having a rectangular shape in plan view. A first opening 8 and a second opening 9 penetrating from the front surface 2 to the back surface (not shown) are formed in the flat plate portion 7. The first opening 8 is a portion to which a sink (not shown) is attached, and the second opening 9 is a portion to which a heating cooker (not shown) such as a gas cooker or an electromagnetic cooker is attached.

  A back guard 10 is provided at one end 7a of the flat plate portion 7 in the longitudinal direction so as to rise vertically from the surface 2 of the kitchen counter 1a. At the other longitudinal end 7b of the flat plate portion 7 located opposite the one end 7a, a curtain plate portion 11 extending vertically from the front surface 2 to the back surface side of the kitchen counter 1a is provided.

  The thermosetting resin which is the main material of the resin composition forming the kitchen member 1 serving as the kitchen counter 1a is not particularly limited, and is a known monomer or a mixture of the monomer and the polymer. And the like can be selected as appropriate. For example, polyester resins such as unsaturated polyesters and acrylic resins such as melamine (meth) acrylate, glycidyl (meth) acrylate, and methyl (meth) acrylate are exemplified. The notation of (meth) acryl means acryl or methacryl. Specific examples of the (meth) acrylic monomer include methyl (meth) acrylate, ethyl (meth) acrylate, butyl (meth) acrylate, 2-ethylhexyl (meth) acrylate, and benzyl (meth) acrylate. And the like. In addition, as the thermosetting resin, a vinyl ester-based resin and an epoxy-based resin can also be cited as candidates.

  As the filler added at least to the thermosetting resin, an inorganic filler is generally exemplified. Specific examples include aluminum hydroxide, calcium hydroxide, magnesium hydroxide, powdered talc, powdered quartz, silica, diatomaceous earth, gypsum, powdered glass, marble, limestone, aluminum silicate, calcium silicate or borax. Particularly, silica is effective for improving the hardness of the surface 2 of the kitchen member 1. Calcium sulfite, calcium sulfate, barium sulfate, silicon dioxide, calcite, titanium oxide, antimony trioxide, calcium carbonate, nickel powder, iron powder, zinc powder, copper powder, and iron oxide are also candidates for the inorganic filler. Furthermore, glass beads, glass fibers or silica gel are also included. These inorganic fillers can be added to the thermosetting resin not only as one kind but also as a mixture of two or more kinds.

  In addition, the resin composition may include, in addition to the filler, various components such as a curing accelerator, an antibacterial agent, a pattern material, and a pigment in accordance with the production of the kitchen member 1 and physical properties required for the kitchen member 1. Addition is possible. The kitchen counter 1a shown in FIGS. 1 and 2 is formed by molding a resin composition to which a pigment is added, and has a deep color.

In the kitchen member 1 which is the kitchen counter 1a as described above, even if a cooking utensil (not shown) such as a frying pan or a pan in a high temperature state is placed on the surface 2, the cooking utensil is placed on the surface 2 shown in FIG. Can be received only at the top 2a. Moreover, since the top 2a has a curved shape that bulges out of the front surface 2 in its cross section, the contact with the back surface of the bottom of the cooking utensil is a point contact or nearly a point contact. Therefore, the heat load from the cooking utensil does not reach the entire surface 2. An air layer is formed between the back surface of the bottom of the cooking utensil and the valley 2b of the front surface 2 of the kitchen member 1, and this air layer functions as a heat insulating layer. Therefore, even when placed directly cookware in the high temperature state, the radiant heat from the cookware, to the bottom 12 of the trough portion 2b of the surface 2 is less likely to reach, cookware by heat transfer from the back surface of the bottom of the cookware Marks become less noticeable on the surface 2. The effect on the overall appearance of the kitchen member 1 is small. Further, the shape of the top portion 2a also prevents the back surface of the bottom portion of the cookware to be directly placed from being damaged.

  The above effect is more effective when there are about 500 to 2000 sets in a 5 cm square when one of each of the top 2a and the valley 2b is set as one set.

  Further, in the kitchen member 1, the surface 2 is formed only from the resin composition, and the surface 2 does not have the coating layer as described in Patent Document 1, so that the cooking utensil is directly placed. There is no concern about deterioration of the coating layer. The same antifouling property can be obtained by, for example, an antibacterial agent blended in the resin composition.

  Further, even if the surface 2 is damaged by a non-sharp object other than the cooking utensil, the non-sharp object can be received only by the top portion 2a, so that the overall appearance of the kitchen member 1 is little affected. In addition, since the surface 2 is uneven as described above, the scratch due to the contact with a sharp object is easily disintegrated into a triangular wave shape, and it is difficult to recognize the attached scratch as a scratch. Therefore, scars are not very noticeable. In particular, when the resin composition contains silica as the filler, the hardness of the surface 2 can be increased to 9H in pencil hardness, and the kitchen member 1 is hardly damaged in the first place.

  In addition, since the height difference Δh between the highest position 3 and the lowest position 4 in the cross section of the surface 2 is 50 μm or more, the radiant heat from the cooking utensil placed directly on the surface 2 reaches the bottom 12 of the valley 2 b of the surface 2. It has become difficult. Therefore, the kitchen member 1 can ensure heat resistance. The upper limit of the height difference Δh is preferably 400 μm. If the height difference Δh is 400 μm or less, dirt and the like hardly accumulate in the valley portion 2b, and the kitchen member 1, and eventually the kitchen counter 1a, are easily maintained.

  Further, as shown in FIGS. 1 and 2, the color of the kitchen member 1 is preferably a deep color. As described above, since the height difference Δh of the irregularities on the surface 2 is 50 μm or more, the kitchen member 1 is excellent in heat resistance. Generally, if the kitchen member 1 such as the kitchen counter 1a is of a dark color, the surface 2 receives radiant heat due to the direct placement of the cooking utensil in a high temperature state, and the surface 2 becomes an external problem such as whitening and gloss change. Traces are noticeable. However, as described above, since the kitchen member 1 is excellent in heat resistance, even if it has a deep color, such traces are hardly formed on the surface 2. Therefore, the deeper the color of the kitchen member 1 is, the more obvious the effect is that the trace is hardly formed. Of course, as apparent from this, the color of the kitchen member 1 may be light white.

  The kitchen member 1 has an appearance similar to a stone tone due to the surface 2 as described above, and can realize a luxurious texture of natural stone.

  In addition, the valley line 14 of the valley portion 2 b on the surface 2 of the kitchen member 1 can be formed into a curved shape bulging inside the surface 2. In this case, the triangular wave-shaped unevenness which is a cross section of the surface 2 has a sine wave or a shape close to a sine wave. Therefore, since there is no linear portion, the feel of the surface 2 of the kitchen member 1 tends to be smooth even from the magnitude of the height difference Δh.

  FIG. 3 is an essential part cross-sectional view showing another kitchen counter similarly to FIG. In FIG. 3, the portions denoted by the same reference numerals as those in FIG. 2 are the same portions as the kitchen member 1 as the kitchen counter 1 a shown in FIGS. 1 and 2. Therefore, in the following description, the description of the parts denoted by the same reference numerals will be omitted.

  In the kitchen member 1 as the kitchen counter 1a shown in FIG. 3, the surface 15 is slightly different from the surface 2 shown in FIG. The difference is that the ridge line 16 in the cross section of the top 2a is straight except for the top of the top 2a, the valley 17 in the valley 2b is straight, and the valley 2b Has an acute-angled shape.

  The kitchen member 1 having such a surface 15 also has the same effect as the kitchen member 1 shown in FIG. 2, but has a tendency that dirt tends to accumulate slightly on the bottom portion 18 as compared with the kitchen member 1 shown in FIG. is there. However, it is not that the accumulated dirt cannot be removed at all. Further, the feel of the surface 15 of the kitchen member 1 shown in FIG. 3 is slightly different from the feel of the kitchen member 1 shown in FIG. However, the feel of the surface 15 is based on the feeling of the user who uses the kitchen member 1, and there is an individual difference. Therefore, even with the surface 15 shown in FIG. 3, the feel is shown in FIG. It is presumed that some users feel that it is not inferior to the surface 2.

  FIG. 4A is a schematic cross-sectional view showing an example of a casting mold used for manufacturing the kitchen counter shown in FIG. 1, and FIG. 4B is shown in FIG. It is principal part sectional drawing which showed typically the lower type | mold of the casting mold.

  The kitchen member 1 shown in FIGS. 1 to 3 and which can be used as, for example, the kitchen counter 1a is formed by casting the resin composition. Various types of casting dies can be used for this casting. The casting dies 19 shown in FIGS. And a lower mold 23 having a concave portion 22 on the upper side. The upper die 21 has an edge portion 24 protruding downward on the outer peripheral portion, and the lower die 23 also has an edge portion 25 protruding upward on the outer peripheral portion. The recess 20 is formed inside the edge 24, and the recess 22 is formed inside the edge 25. The upper mold 21 is capable of moving up and down in the vertical direction, descends, and the edge 24 overlaps with the edge 25 of the lower mold 23. When the lower surface of the edge 24 and the upper surface of the edge 25 overlap, the recesses 20 and 22 form a cavity (not shown) that allows the resin composition to be injected.

  In addition, in the casting mold 19, both the upper mold 21 and the lower mold 23 have, except for the edges 24 and 25, hot water or hot water for curing the resin composition injected into the cavity. The pipe 26 for flowing the heat source is built in. As the heat source, not only a fluid such as hot water or hot water, but also a heater that generates heat by energization can be applied. When a heater is used, a heater wire can be wired instead of the pipe 26.

  In the lower mold 23, a cutout 27 is formed in a part of the edge 25. The notch 27 functions as an inlet for injecting the resin composition into a cavity formed by the recesses 20 and 22 when the edges 24 and 25 overlap.

  In such a casting mold 19, a molding surface 29 is formed on the upper surface 28 of the concave portion 20 of the upper die 21, and a molding surface 31 is formed on the lower surface 30 of the concave portion 22 of the lower mold 23. A molding surface for molding the surfaces 2 and 15 of the kitchen member 1 shown in FIGS. 2 and 3 is a molding surface 31. Therefore, the molding surface 31 is formed in a shape corresponding to the surfaces 2 and 15 of the kitchen member 1. That is, as shown in FIG. 4B, the molding surface 31 has, for example, a triangular wave-shaped unevenness in its cross section so that the surface 2 of the kitchen member 1 shown in FIG. 2 can be formed. Have.

  That is, on the molding surface 31, a portion corresponding to the top 2 a in the cross section of the surface 2 of the kitchen member 1 in the cross section is the valley portion 31 a, and the valley line 32 has a curved shape bulging inside the molding surface 31. . On the molding surface 31, a portion corresponding to the valley 2 b in the cross section of the surface 2 of the kitchen member 1 in the cross section is the top portion 31 b, and the ridge line 33 has a curved shape bulging outside the molding surface 31. .

  The material of the upper mold 21 and the lower mold 23 forming the casting mold 19 as described above can be made of, for example, steel such as SCM440.

  FIG. 5 is a cross-sectional view of a main part process schematically illustrating a process of manufacturing the lower die illustrated in FIG. 4B. In the drawings of FIGS. 5A and 5B, the parts denoted by the same reference numerals as those of FIG. 4B are the same parts as the lower mold 23 shown in FIG. 4B. . Therefore, in the following description, the description of the parts denoted by the same reference numerals will be omitted.

  When the lower die 23 shown in FIG. 4B is manufactured, the flat upper surface portion before processing in the concave portion 22 of the lower die 23 is subjected to an etching process such as photoetching, for example. A part corresponding to the valley part 31a shown in FIG. The formed concavo-convex pattern is different from the molding surface 31 shown in FIG. 4B, and the cross section is not a curved shape but a straight shape, and the molding surface 31 has an angular portion 35.

  After the etching process, the ridge line 32 in the cross section of the top 31b is formed so as to become the forming surface 31 shown in FIG. Chemical polishing is performed so that the line 33 has a curved shape bulging out of the molding surface 31. This chemical polishing can be generally performed by a chemical polishing liquid. An appropriate chemical polishing liquid can be selected depending on the material of the lower mold 23. As shown in FIG. 5B, the valleys 31a and the tops 31b are formed on the molding surface 31 by the chemical polishing, and the lower mold 23 shown in FIG. 4B is manufactured.

  When manufacturing the kitchen member 1 such as the kitchen counter 1a shown in FIGS. 1 and 2, the upper mold 21 is replaced with the lower mold 23 in the casting mold 19 as shown in FIG. Then, the lower surface of the edge 24 and the upper surface of the edge 25 are overlapped. Then, a cavity is formed by the concave portion 20 of the upper die 21 and the concave portion 22 of the lower die 23, and the resin composition is injected from an injection hole formed by the cutout portion 27. Thereafter, a heat source such as hot water or hot water is passed through the pipe 26 built in the upper mold 21 and the lower mold 23 to heat the resin composition filled in the cavity, and the upper mold 21 and the lower mold 23 The resin composition is pressed. After a predetermined time has elapsed and the resin composition has cured, the upper mold 21 is raised, separated from the lower mold 23, and the molded product remaining in the lower mold 23 is taken out. The removed molded product is the kitchen member 1.

  That is, in the manufacturing method of the kitchen member 1, the molding surface 31 of the lower mold 23 of the casting mold 19 including the upper mold 21 and the lower mold 23 has a square portion 35 in an uneven pattern formed by etching. Is a curve formed by chemical polishing. The method for manufacturing the kitchen member 1 is as follows. The resin composition is poured into the lower mold 23, and the resin composition is heated and clamped by the upper mold 21 and the lower mold 23 while being cured. The kitchen member 1 is manufactured without coating the surface.

  As described above, the manufacturing method of the kitchen member 1 is to form the surface 2 having a triangular corrugated surface by casting, which is essentially the method of forming the surface of the molded product by polishing. Is different. In the case of forming an uneven surface by polishing the molded product, the resin component is reduced on the surface, and the interface between the filler and the thermosetting resin added to the resin composition is formed on the surface of the molded product. It becomes easy to be exposed. As a result, dirt or the like enters the interface and the antifouling property is apt to be reduced. Therefore, it is indispensable to coat the surface of the molded article with an antibacterial agent or the like to secure the antifouling property.

  However, in the method for manufacturing the kitchen member 1 using the casting mold 19 shown in FIGS. 4A and 4B, since the surface 2 of the kitchen member 1 is formed only of the resin composition, Is unnecessary, and the manufacture of the kitchen member 1 with a certain degree of antifouling property is facilitated. Moreover, the uneven surface 2 of the kitchen member 1 to be manufactured does not naturally occur due to a filler or the like added to the resin composition, but is uneven in a triangular waveform in cross section. It is substantially equal over the entire surface 2 of the kitchen member 1. Therefore, it is possible to stably manufacture the kitchen member 1 having excellent quality.

  When the kitchen member 1 shown in FIG. 3 is manufactured, the molding surface 31 of the lower mold 23 is changed to a shape corresponding to the surface 15 in the casting mold 19 shown in FIG. I just need.

  The present invention is not limited to the above embodiment. The kitchen member can be applied to a sink or the like in addition to the kitchen counter. In addition, the components that can be added to the resin composition can be appropriately selected from various types according to the production of kitchen members and the characteristics required for kitchen members. Further, the shape, size, structure, and the like of the casting mold used for the casting of the kitchen member can be appropriately changed. The molding conditions can be appropriately determined according to the components of the resin composition.

DESCRIPTION OF SYMBOLS 1 Kitchen member 2 Surface 2a Top 2b Valley 3 Ridge line 4 Highest 5 Lowest 14 Valley line Δh Height difference 19 Casting mold 21 Upper mold 23 Lower mold 31 Molding surface 35 Square part

Claims (4)

A kitchen member formed by molding a resin composition in which at least a filler is added to a thermosetting resin,
The kitchen member has a surface formed of only the resin composition, and the surface has a triangular wave-shaped unevenness in a cross section thereof,
The top in the cross section of the surface has a curved shape whose ridge line swells outside the surface, and the height difference between the highest position and the lowest position in the cross section of the surface is 50 μm or more and 400 μm or less. And
The kitchen member according to claim 1, wherein in the cross section of the surface, the valley has a curved line whose valley line expands inside the surface. The kitchen member according to claim 1, wherein the kitchen member has a surface formed of only the resin composition and has no coating layer. The kitchen member according to claim 1, wherein a color of the kitchen member is a dark color. A kitchen member manufacturing method for manufacturing the kitchen member according to any one of claims 1 to 3,
  Of the casting mold composed of the upper mold and the lower mold, the molding surface of the lower mold is a curved surface formed by chemical polishing at the angular portion in the concavo-convex pattern formed by etching.
  After the resin composition is injected into the lower mold, the upper mold and the lower mold heat and compress the resin composition while curing the resin composition, and then manufacture the kitchen member without coating the surface of a molded product. A method of manufacturing a kitchen member.