JPH01264809A - Manufacture of cast bathtub - Google Patents

Abstract

PURPOSE:To enable the title method to provide easily a cast layer of an artificial marble tone, by a method wherein a recessed mold made of glass fiber- reinforced plastic and a casting unsaturated polyester resin composite are molded integrally and the recessed mold is made a backside reinforcement layer. CONSTITUTION:In the case where a cast layer 3 is provided on a part (bathtub part) of a recessed mold 2 (bathtub molded product with a washing place) made of FRP, a sheet, wax, balsa and a core corresponding to a thickness of the cast layer 3 are stuck to the surface of the FRP molded product 2 for the recessed mold, to begin with. A protrusion molding mold 1 becoming a molding mold of a surface side of the bathtub is manufactured by using the same as a mold by making use of epoxy resin and a reinforcing material. In this instance, the recessed mold 2 made of the FRP is of the molded product for the recessed mold, made of the FRP and obtained separately through press molding of a sheet molding compound. The same becomes a product as a bathtub or the bathtub with the washing place even as it is.

Description

Detailed Description of the Invention [Industrial Application Field] The present invention, when manufacturing a cast bathtub made of unsaturated polyester resin, separately molds glass fiber reinforced glass sticks and molds the manufactured product into a concave mold for casting. The present invention relates to a method for manufacturing a cast bathtub, characterized in that the concave mold is integrated with a cast resin layer to form a back reinforcing layer. and,
The purpose of this is to use the concave mold for reinforcing the back surface of the casting bathtub for casting work and reinforcement processing work. To provide a method for producing a cast bathtub which is significantly improved and which can easily provide an artificial astronomical stone-like cast layer only on the bathtub part in a special bathtub such as a washable bathtub.

[Prior art]

In the conventional manufacturing method of an artificial celestial stone bathtub, a convex type and a concave type are respectively created as exclusive molds for casting, and the bathtub is generally manufactured using the following procedure.

(1) Release the surface of the concave and convex image molds (generally resin molds) with wax, etc. 1F! : To give.

(2) An unsaturated polyester resin or the like that forms a transparent gel coat layer is uniformly applied by spray or brush to the convex surface that will become the surface layer of the bathtub.

(3) l! ! The product is placed in a convex mold metal curing furnace coated with F resin, and the dull coat layer is cured.

(4) On the other hand, the concave mold that forms the back side of the bathtub is made of glass fiber-reinforced glasstics (hereinafter referred to as FRP) made of glass fibers such as cast-molded no-reinforcement mats, tube strand mats or glass cloth, and unsaturated polyester resin. ) layer is laminated on the inner surface of the concave mold and cured.

(5) Set the concave and convex molds subjected to the above pretreatment, seal the outer peripheries of both molds, and fix the molds with flangs.

(6) A resin composition containing unsaturated polyester resin, filler, curing agent, coloring agent, etc. is injected through the concave injection port.

(After power injection, use vibrator, apply resin feces, 4
Remove the air trapped in the wound.

(8) Thereafter, the resin composition is placed in a curing furnace and cured.

(9) After curing, remove the flang that fixed both the concave and convex molds,
The mold is removed to obtain a cast bathtub.

[Problem to be solved by the invention]

As described above, in the conventional manufacturing method of high-quality bathtubs using the casting method, the entire surface of the bathtub is composed of a gel coat layer or a casting layer because casting is carried out using a dedicated mold for both uneven and convex molds. . Ninth, if you want to make only one part of the bathtub surface a gel coat layer or cast layer, you can separately cast only that part and then glue the cast molded product such as the bathtub to that part.

Extremely high dimensional accuracy was required for the cast molded product, and due to deformation of the cast molded product after curing, it was not possible to achieve complete adhesion, so a satisfactory bathtub could not be obtained. Means for Solving All Problems] That is, the present invention, when manufacturing a cast bathtub using a concave-convex mold, integrally molds an FRP concave mold and an unsaturated polyester resin composition for casting, and then molds the concave mold. The present invention provides a method for manufacturing a cast bathtub, which includes a back reinforcing layer and the following features:

〔composition〕

The present invention will be described in detail below based on the drawings.

To explain the washability bath metal side shown in Figure 1, FR
When providing the casting layer 3 in one part (bathtub part) of the concave mold 2 made of P (washable bathtub molded product), first the FRP molded product 2 for the concave mold is provided.
A sheet, wax, pulsar, core, etc. with a thickness corresponding to the thickness of the casting layer 3 is pasted on the surface of the molding layer 3, and this is used as a mold to form a convex mold 1, which will be a mold for the bathtub surface side.All epoxy resin, etc. It is made using resin and reinforcing material. in this case,
The base concave molded product 2 is a normal FRP molded product (bathtub), and it is necessary to sufficiently reinforce the FRP molded product (bathtub) so that it does not deform before creating the convex molded product.

In order to seal the entire circumference where the convex mold 1 and the FRP molded product 2 made in this way come into contact, a sealing groove is provided around the entire circumference of the convex mold 1, and a fixing flang 5 is provided.
Install. The FRP concave mold 2 of the present invention is a molded product for concave molds, is made of FRP, and is obtained by separately press-molding a sheet molding compound, etc., and can be used as a product as it is as a bathtub or washable bathtub. .

Next, the manufacturing method according to the present invention will be explained step by step.

(1) Mask the entire periphery of the convex mold l with a masking chive.

(2) Apply a mold release agent to the entire surface of the convex mold 10.

(3) Form a dull coat layer on the surface of the convex mold 1 that will become the surface layer of the product. Mix a curing agent and an accelerator and uniformly apply an unsaturated polyester resin composition for dull coat with a spray or brush. .

(4) Remove the nine masking tags pasted in step (1).

(5) Enter the curing oven to harden the gel coat layer.

(The following steps are different from conventional manufacturing methods) (6) On the other hand,
The surface of the portion of the concave FRP molded product 2 where the casting resin layer 3 is to be provided is mechanically or manually sanded. Since the surface of the FRP molded product 2 is usually smooth, this is important in improving the interlayer adhesive strength with the molded resin layer 3.

(Force) Drill holes with a diameter of 1 to 10 m for the grease-resistant composition inlet 6 and the air vent lower in the bottom of the bathtub, etc., which will be the highest position of the casting mold.

(8) Fit the sealing gasket 4 along the groove around the entire circumference of the convex mold 1 in which the dull coat layer has been cured.

(9) After sanding and drilling, the next molded product 2 is placed over the convex mold 1 and fixed with the fixing flang 5 all around the periphery, thereby fixing the convex mold 1 and the concave mold 2 in close contact.

al. Separately prepared reinforcing frames 8 are fitted to easily deformable parts such as side plane parts of the concave molded product 2 to prevent deformation of the concave mold when the resin composition is injected.

01) Unsaturated polyester resin,
A resin composition containing a filler, a curing agent, an accelerator, a catalyst, a coloring agent, etc. is injected through the injection port 6 of the concave molded product 2, and the resin composition is injected until it overflows from the air vent lower.

(6) After the injection is completed, use an air vibrator to remove fine air from the resin composition.

(2) The resin composition is cured by placing it in a curing furnace whose room temperature is controlled at 45 to 60°C.

0 After curing, take it out of the oven and remove the clamp 5 that completely fixes both the concave and convex molds and the reinforcing frame 8 for preventing deformation.

αe The convex mold 1 is equipped with 1 to 4 air ports for release mold 9.
Fully pressurize the compressed air of kg/cR and release the 6-hole mold 1 completely.

αQ After releasing the mold, finish the boundary between the cast layer 3 and the concave molded product.

In this way, one cast bathtub of the present invention is manufactured.

〔effect〕

The manufacturing method of the present invention uses FRP that serves both as a concave mold and a reinforcing layer.
Finally, using a molded product, the cast layer is integrated into a part of the FRP bathtub, and a bathtub with a carefully cast layer can be easily obtained without requiring complicated processes such as post-adhesion as in the conventional method.

In particular, the present invention allows the bathtub part of a special bathtub such as a washable bathtub to be easily changed into a high-grade bathtub, for example, an artificial celestial stone bathtub, etc., and is more luxurious than the FRP bath 1 that is normally manufactured as an FRP molded product. It can be used as a bathtub.

Hereinafter, the present invention will be explained based on specific examples.

[Example 1] Manufacture of a high-quality washable bathtub A recessed molded article 2 A high-quality washable bathtub was molded at high temperature and pressure using a molding material, ie, a sheet mold compound (hereinafter referred to as 5h1c). However, the inner surface, bottom surface, and upper edge surface of the bathtub part of the bathtub molded product are then coated with a thickness of 6 to 1511 mm.
Paste sheet wax so that it becomes i+. To paste this wax, next, based on the molded product, a convex mold 1 was created using resin and lath fiber, and the back side was made of wood,
Reinforce with steel, etc. Molded in this way, the nine-convex mold l
All installation is done by post-processing to create a groove for the seal gasket with a width of 5 to 10 m and a depth of 1 to 3 m, fixing clamps 5 (8 to 12 locations), and mold release air vent 9 (1 location) around the periphery of the mold. ,
A convex mold 1 was obtained.

Next, we begin the specific manufacturing process. 7- of the convex mold 1
Seal number 4 in the groove for Luno amount y? [After inlaying and pasting a double layer of masking cheese on top of it, the entire surface of the mold was treated with a mold release agent (Mira Glaze) to release the gold foil.]
Thereafter, as a gel coat layer on the surface of the mold, resins 1.8 to 2.2 of the following Hikari-1 formulation are sprayed with a #all spray gun to completely remove only the first layer of masking chips. Approximately 1
After being left for 0 minutes, it is placed in a curing furnace whose temperature is controlled at 45 to 60°C for 1 to 1.5 hours to cure the resin of the gel coat layer. After naturally cooling the convex mold 1, the following composition was added as an intermediate layer! , 1lW4.5~5. All spraying was carried out using an Okg spray gun, 7 m of masking data of the second layer was removed, and the mixture was placed in the curing oven and cured.

Table-1 On the other hand, the bathtub with washing area which is concave mold 2 is convex mold 1.
Next, using the same mold as that used for molding, raise the temperature to 128-135°C for the upper mold and 140-145°C for the lower mold.
38-42 kfe (manufactured by Dainippon Ink & Chemicals) was charged on the lower surface, and the molding pressure was 1.600-2.000 tons, followed by pressure molding for 6-10 minutes.

Next, in the SMC washable bathtub with concave shape 2 obtained by pressure compression molding, only the bathtub part where the cast layer is attached is Q.
The surface was sanded with Sando 14-+100, and the cast layer and concave molded product (S
Improves adhesion with the MC) layer.

Furthermore, a hole 1 with a diameter of 30 mm was made as an injection port 6 for injecting resin compound 9 in the center of the bottom of the bathtub of the concave molded product 2.
and a part of the bottom corner as an air vent lower part with a diameter of 5 to 1 mm to vent the air in the resin compound and the air in the mold.
Four 0yn holes were drilled.

A nine-convex mold 1 which has been subjected to gel coat and intermediate layer treatment and a concave washing clarifying tank 2 which has been sanded and holed are held together by a fixing flang 5 through a seal packing 4 to set both concave and convex molds t. After setting, a reinforcing frame 8 was placed over the top of the recessed washable bathtub 2 to prevent deformation (swelling) of the side surface of the bathtub 2, and was fixed so as to be integrated with the mold.

In the gap between the 6-hole mold 1 and the concave washable bathtub 2, pour 0 to 25 kg of the resin composition 2 in Table 2 below into the injection port 6.
After confirming that the resin composition overflows from the air vent lower, apply an air vibrator to the entire uneven set mold for 2 to 5 minutes to evacuate the resin composition and any air remaining in the mold. Then, the cast layer was cured by controlling the temperature at room temperature of 45 to 60°C and placing it in a hardening furnace.

Table 2 After curing, take it out of the oven, remove the reinforcing frame 9 and fixed flang 5, and release from the mold at 1.5 to 3.0 Yu/'cIL.
Pressure-controlled compressed air was injected into the mold 2 through the release air port of the convex mold 1, and only the convex mold 1 was released.

Finally, in the cast bathtub that has been released from the convex mold 11, the boundary between the cast layer and the concave washable bathtub is finished, thereby attaching the cast layer to the bathtub part as shown in FIG.
A high-grade bathtub made of SMC with excellent washability was obtained.

The obtained bathtub was a high-quality washable bathtub made of SMC, which had a green colored SMC washable bathtub and a cast bathtub part with an extremely deep and beautiful green tone.

[Brief explanation of the drawing]

FIG. 1 is a longitudinal sectional view of a bathtub of Example 1 obtained by the present invention, and FIG. 2 is a sectional view of the bathtub in a non-casting state with concave and convex molds set for casting. In the figure, 1 is a convex mold, 2 is a concave release molded product made of FRP, and the gap between the concave and convex molds that will become the casting layer or the casting layer, 4 is the seal packing, and 5 is the concave and convex mold. Fixed flang, 6 is resin (and ~ object = engineering inlet, 7 is air vent, 8
Reference numeral 1 indicates a reinforcing frame for preventing concave deformation, 9 indicates an air opening for mold release, 10 indicates a washing area, 11 indicates a drainage trap, and 12 indicates a reinforcing lip. Agent Patent Attorney Katsutoshi Takahashi

Claims (1)

[Claims] 1. When manufacturing a cast bathtub using a concave-convex mold, a concave mold made of glass fiber reinforced plastic and an unsaturated polyester resin composition for casting are integrally molded, and the concave mold is used as a back reinforcing layer. A method for manufacturing a cast bathtub.