JPH0516128A - Manufacture of counter - Google Patents

Abstract

PURPOSE:To form a gel coat layer of uniform thickness even in the case an opening of a counter is located close to an apron section by applying gel coat resin for coating separately to a mold main body and a slide mold when the counter such as washing stand is manufactured by using the mold main body and the slide mold placed on the upper face of the main body. CONSTITUTION:A gel coat layer 4 is formed by applying gel coat resin for coating to the upper face 1a of a mold main body 1, a standing section 1b and the like. On the other hand, the gel coat layer 4 is formed on the outer peripheral face 2a of a slide mold 2 in the similar way. The slide mold 2 is placed on the upper face 1a of the mold main body 1. Or else, gel coat resin is applied to the slide mold 2, which is placed on the upper face 1a of the mold main body 1, and then gel coat resin is applied to the mold main body 1. After that, the material resin for a counter is laminated in the usual method and released. A uniform gel coat layer 4 without resin accumulated between the standing section 1b of the mold main body 1 and the slide mold 2 is formed by the arrangement.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a counter which constitutes, for example, a wash basin or a vanity.

[0002]

2. Description of the Related Art A counter 10 constituting a wash basin, a vanity, etc., has a rectangular horizontal plate 1 as shown in FIG.
0a, an upright portion 10b extending upright from the front end of the horizontal plate portion 10a, and an apron portion 10c extending down from the rear end of the horizontal plate portion 10a. Has an opening 10d corresponding to the size of a washbasin (not shown) fixed to the lower surface of the counter 10. The counter 10 having such a shape is manufactured mainly by using the mold body 1 and the slide mold 2 shown in FIG. In addition, this slide type 2
Is for molding the opening 10d formed in the horizontal plate portion 10a of the counter 10.

The process of manufacturing the counter 10 using the mold body 1 and the slide mold 2 will be described below. First, the slide mold 2 is mounted on the upper surface 1a of the mold body 1 at a predetermined position. Place and fix. Then, as shown in FIG. 10, a gel coat resin 4 which is a surface layer of the counter 10 is sprayed onto the upper surfaces of the molds 1 and 2 by using a spraying device 3 to form a gel coat layer 4, and then, not shown. The upper mold and the horizontal mold are assembled to the mold body 1 and the slide mold 2, and a mixed slurry of a resin such as polyester, a filler, and a curing agent is poured onto the gel coat layer 4 and cured. When the hardening of the mixed slurry is completed, the mold body 1 and the slide mold 2, and other molds such as the upper mold and the horizontal mold are demolded, and the manufacturing of the counter 10 shown in FIG. 8 is completed.

[0004]

The position of the opening 10d formed in the counter 10 is not always formed at the center of the horizontal plate portion 10a, as shown in FIG. It may be formed on the front end side, the rear end side, the right end side, or the left end side of the horizontal plate portion 10a depending on the situation of the toilet room or the restroom where the counter 10 is installed, and is not always formed at a fixed position. .. Therefore, the position of the slide mold 2 mounted and fixed on the upper surface of the mold body 1 needs to correspond to the position of the opening 10d of the counter 10 to be manufactured.

However, the position of the slide mold 2 mounted and fixed on the mold body 1 is set so that the upright portion 1 of the mold body 1 is located.
a (This standing portion 1a is the apron portion 10 of the counter 10.
When the slide die 2 is mounted and fixed close to the standing portion 1a of the die body 1, the gap between the standing portion 1a and the slide die 2 is close. Since it is narrow, it is extremely difficult to form a gel coat layer having a uniform thickness on the surface of the standing portion 1a, the upper surface of the mold body 1, and the outer peripheral surface 2a of the slide mold 2, respectively.
As shown in FIG. 1, the gel coat resin is accumulated on the upper surface 1a of the mold body 1 to form the extremely thick gel coat layer 4, or the gel coat layer 4 is partially thin.
Results in being formed. Then, when the gel coat resin is accumulated in this way, the manufactured counter 10 has a color different from that of other portions due to the dark color of the gel coat resin only in the portion where the gel coat resin is accumulated, and vice versa. In the portion where the gel coat resin is applied extremely thinly, the color of the mixed slurry of the resin and the filler described above becomes darker than in other portions. The application of the gel coat resin may be performed by an operator or automatically by a spraying device. However, when the gel coat layer 4 having a uniform thickness is formed as described above, it is difficult for the operator to apply it. If skill is required, and if the spraying device is used to automatically perform the operation, it is necessary to reconfigure the program of the device to perform a delicate operation. However, if the above program is reconfigured each time the fixed position of the slide die 2 is changed, it becomes extremely complicated and prolongs the manufacturing time, so that it cannot be adopted.

Therefore, the present invention has been proposed in order to solve the problems of the above-described conventional method of manufacturing a counter, in which the slide mold is placed and fixed at a position close to the rising portion of the mold body. In the case of producing a counter in which the opening of the counter is close to the apron part, the thickness of the gel coat layer as the surface layer of the counter may be partially thickened or thinned. It is an object of the present invention to provide a method for manufacturing a counter that can always be formed to have a uniform thickness without performing.

[0007]

DISCLOSURE OF THE INVENTION The present invention has been proposed in order to achieve the above object, and uses at least a mold main body and a slide mold mounted on the upper surface of the mold main body. The method of manufacturing a method according to claim 1, which comprises the step of separately applying a gel coat resin to at least the mold body and the slide mold.

That is, instead of placing the slide mold on the upper surface of the mold body as in the prior art, the gel coat resin is not simultaneously applied to the upper surface of the mold body and the slide mold.
In the present invention, for example, (1) first, the slide mold is coated with the gel coat resin, then the upper surface of the mold body is coated with the gel coat resin, and then the slide mold is mounted and fixed on the upper surface of the mold body. Alternatively, (2) a feature that the gel coat resin is applied to the slide mold in advance, the slide mold is placed and fixed on the upper surface of the mold body, and then the gel coat resin is applied to the upper surface portion or the standing portion of the mold body. Is to have. When the step described in (1) above is adopted, when the slide mold coated with the gel coat resin is placed on the upper surface of the mold body coated with the gel coat resin, the slide mold is coated on the upper surface of the mold body. It does not matter whether the gel coat resin is placed after the gel coat resin is slightly hardened to form a gel or the gel coat resin applied on the upper surface of the mold body is completely cured.

The method of applying the gel coat resin to the mold body or the slide mold may be performed by the operator holding the gun for ejecting the gel coat resin from the tip by hand.
Alternatively, a coating device such as a robot that has been conventionally used may be used. In addition, a step performed after applying the gel coat resin in this manner, that is, a step of laminating a mixed slurry including a resin as a main material of the counter, a filler, and a curing agent, and further, after the mixed slurry is cured, The known demolding step may use a conventional general method. However, when the above-mentioned step (1) is adopted as the step of applying the gel coat resin, since the gel coat layer is formed between the slide mold and the mold body, after demolding only the mold body, When removing the slide mold, it is necessary to cut the gel coat layer corresponding to the outer peripheral shape of the lower surface of the slide mold.

[0010]

According to the counter manufacturing method of the present invention,
The gel coat resin, which becomes the surface layer of the counter by curing, is separately applied to the mold body and the slide mold, and therefore, in the case of manufacturing a counter having an opening at a position close to the apron part. In addition, the gel coat resin is not accumulated between the standing portion formed on the mold body and the slide mold, or only a small amount of the gel coat resin is not applied, and a counter with a uniform gel coat layer is always manufactured. can do.

[0011]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A method of manufacturing a counter according to the present invention will be described in detail below with reference to the drawings. First, a first embodiment of the present invention will be described. Since the mold body and the slide mold described here are the same as those conventionally used, the same reference numerals are used for the description. The method for manufacturing the counter according to the first embodiment is such that a gel body and a slide die are separately coated with a gel coat resin in advance, and then the slide die is placed on the upper surface of the die body. A counter is obtained by combining the upper mold and the horizontal mold, injecting the mixed slurry into the mold to cure it, and then removing the mold.

Here, in the step of applying the gel coat resin to the mold body described above, as shown in FIG. 1, the upper surface portion 1a of the mold body 1 (the portion for molding the horizontal plate portion 10a of the counter 10 shown in FIG. 8). , Standing portion 1b (counter 1 shown in FIG. 8
0 apron part 10c forming part), vertical part 1c
The gel coat resin G is sprayed by the spraying device 3 onto (the portion where the standing portion 10a of the counter 10 shown in FIG. 8 is molded) and the horizontal portion 1d (the portion where the upper surface of the standing portion 10b of the counter 10 shown in FIG. 8 is molded). By doing so, the gel coat resin 4 is formed. On the other hand, in the step of applying the gel coat resin to the slide mold, as shown in FIG.
The gel coat resin G is applied to the outer peripheral surface 2a by spraying to form the gel coat layer 4. The gel coat resin G is applied in this step as shown in FIG.
It is desirable to apply not only to the outer peripheral surface 2a of the slide die 2 but also to the peripheral end sides of the upper surface 2b and the lower surface 2c of the slide die 2 as shown in FIG. The reason for this is that, as shown in FIG. 3, the outer peripheral surface 2a of the slide mold 2 is simply
If the gel coat resin G is applied only to the slide mold 2
Is fixed on the upper surface 1a of the mold body 1 and coated with a mixed slurry which is a main raw material of the counter 10 to be manufactured. As a result, as shown by an arrow in FIG. This is because there is a high risk of entering between the gel coat layer 4 applied on the upper surface 1a and the slide mold 2, resulting in the formation of a substantially annular portion where the gel coat layer is not covered.

When the gel coat resin has been applied to the mold body 1 and the slide mold 2 as described above,
Next, as shown in FIG. 5, the upper surface portion 1a of the mold body 1 is
The slide mold 2 is placed on. The mounting position of the slide die 2 is determined according to the position of the opening 10d to be formed in the counter 10 shown in FIG. 8, and the opening 10 is provided at a position close to the apron portion 10c formed in the counter 10.
When it is necessary to form d, the slide die 2 is placed at a position close to the upright portion 1b of the die body 1. The slide mold 2 may be placed on the upper surface 1a of the mold body 1 after the gel coat resin G applied to the upper surface 1a of the mold body 1 is completely cured. Resin G and gel coat resin G applied to slide mold 2
In consideration of good adhesiveness with the upper surface portion 1 of the mold body 1
It is desirable to mount the slide mold 2 when the gel coat resin G applied to a becomes gel.

When the step of placing the slide die 2 is completed, then, as shown in FIG. 6, an upper die 7 and a horizontal die 8 are combined, and thereafter, a polyester resin, a filler, a curing agent and the like are used. The mixed slurry 5 is injected from an injection port (not shown). Then, after waiting a predetermined time, the mixed slurry 5 is hardened, and after the mixed slurry 5 is hardened, the molds 1, 2, 7 and 8 are demolded to obtain a counter 10 as a final product. When the slide die 2 is removed from the mold, since the gel coat layer 4 applied to the upper surface 1a of the die body 1 and cured is present on the entire lower surface of the slide die 2, the lower surface of the slide die 2 is removed. It is necessary to cut the gel coat layer 4 in accordance with the outer peripheral shape of.

According to the method of manufacturing the counter in the first embodiment described above, even when the space between the upright portion 1b of the die body 1 and the slide die 2 is extremely narrow, the upper surface portion 1a of the die body 1 is formed. Since it is not necessary to continuously apply the gel coat resin G to the upright portion 1b and the outer peripheral surface 2a of the slide die 2, the gel coat resin G is accumulated on the upper surface portion 1a of the die body 1,
Alternatively, it is possible to effectively avoid a situation where only a small amount is applied, and thus it is possible to manufacture a counter in which the uniform gel coat layer 4 is always formed.

Next, a second embodiment of the present invention will be described. The method of manufacturing the counter according to the second embodiment is such that after the gel coat resin is applied to the slide mold in advance,
The method is characterized in that the step of placing the slide mold on the upper surface of the mold body and then applying the gel coat resin to the upper surface and the standing portion of the mold body is included. In the second embodiment, the step of applying the gel coat resin to the slide mold in advance is performed by using the spraying device 3 as described with reference to FIG. 2 in the first embodiment. It is applied by spraying the gel coat resin G on the surface 2a. However, in this embodiment, as described in the first embodiment, it is not always necessary to apply the gel coat resin G to the peripheral edge side of the slide mold 2 on the back surface side. This is because, as described later, the slide mold 2 coated with the gel coat resin G is placed on the upper surface 1a of the mold body 1 and then the gel coat resin G is coated on the mold body 1. 1 does not have any adverse effect on the counter 10, which is a product, even if it intrudes between the slide mold 2 and the slide mold 2, and rather the gel coat resin G invades the mixed slurry when the mixed slurry is injected later. This is because it can be prevented from entering between the slide mold 2.

When the step of applying the gel coat resin G to the slide die 2 is completed, the slide die 2 is placed on the upper surface 1a of the die body 1 and, as shown in FIG. Thus, the gel coat resin G is applied to the standing portion 1b, the upper surface portion 1a, the vertical portion 1c, and the horizontal portion 1d of the mold body 1. Since the following steps are exactly the same as the method described in the first embodiment, the description thereof will be omitted.

Even in the case of such a method, as in the method of manufacturing the counter described in the first embodiment, the upper surface portion 1a of the mold body 1, the rising portion 1b and the outer peripheral surface of the slide mold 2 are formed. Since it is not necessary to continuously apply the gel coat resin to 2a, it is possible to effectively avoid the situation where the gel coat resin is accumulated on the upper surface portion 1a of the mold body 1 or only a small amount is partially applied. It is possible to manufacture a counter having a different gel coat layer. That is, according to the method described in the second embodiment, even when the slide mold 2 is placed in the vicinity of the upright portion 1b of the mold body 1, the gel coat resin is already applied to the slide mold 2. Since G is applied, it is not necessary to apply it to the outer peripheral surface 2a of the slide mold 2 in the subsequent step of applying the gel coat resin G. Therefore, it is possible to effectively prevent the accumulation of the gel coat resin due to the excessive application of the gel coat resin, and the application of an extremely small amount of the gel coat resin in order to avoid this accumulation, and thus, to always provide a uniform coating. A counter having a gel coat layer formed thereon can be manufactured without requiring any high skill.

[0019]

As is clear from the description of each of the above embodiments, according to the method of manufacturing a counter of the present invention, the gel coat resin applied to the mold body and the slide mold are separately applied. Therefore, even if it is necessary to place the slide mold very close to the standing portion of the mold body in order to manufacture a counter having an opening formed in the vicinity of the apron part, as in the conventional case, It is not necessary to apply the gel coat resin to the standing portion, the upper surface and the outer peripheral surface of the slide mold all at once. Therefore, the gel coat resin is excessively applied for the purpose of evenly applying to these places, and it is accumulated on the upper surface of the mold body, or the gel coat resin is not applied partially or extremely to avoid this accumulation. By applying only a small amount,
It is possible to effectively prevent that the thickness of the gel coat layer, which is the surface layer of the finally obtained counter, varies and the color is partially different.

In the present invention, since such a situation can be effectively prevented, the operator is not required to have a high level of skill, and the present invention is incorporated in a special device for spraying gel coat resin such as a robot. There is no need to change the existing program.

[Brief description of drawings]

FIG. 1 is a vertical cross-sectional view schematically showing a step of applying a gel coat resin to a mold body in a method of manufacturing a counter according to a first embodiment of the present invention.

FIG. 2 is a vertical cross-sectional view schematically showing a step of applying a gel coat resin to a slide mold in the method of manufacturing a counter according to the first embodiment of the present invention.

FIG. 3 is a vertical cross-sectional view schematically showing a state in which a slide mold having a gel coat resin applied only to the outer peripheral surface is placed on the upper surface of a mold body.

FIG. 4 is a vertical cross-sectional view schematically showing a state in which a gel coat layer is formed on the outer peripheral surface of the slide mold and the peripheral end sides of the upper surface and the lower surface.

FIG. 5 is a vertical cross-sectional view schematically showing a state where a slide mold is placed on the upper surface of the mold body.

FIG. 6 is a vertical sectional view schematically showing a state after the mixed slurry is injected.

FIG. 7 shows a method of manufacturing a counter according to a second embodiment of the present invention, in which a slide mold preliminarily coated with a gel coat resin is placed on the upper surface of the mold body and then the gel coat resin is applied to the mold body. It is a longitudinal cross-sectional view schematically showing the step of applying.

FIG. 8 is an external perspective view of a manufactured counter.

FIG. 9 is an external perspective view of a mold body and a slide mold.

FIG. 10 is a vertical sectional view schematically showing a conventional counter manufacturing method.

FIG. 11 is a vertical cross-sectional view schematically showing a state in which the gel coat resin is accumulated on the upper surface of the mold body.

[Explanation of symbols]

 1 type body 2 slide type 4 gel coat layer G gel coat resin

Claims (1)

Claim: What is claimed is: 1. A method of manufacturing a counter using a mold body and a slide mold mounted on the upper surface of the mold body, wherein at least the gel mold resin and the slide mold are each coated with a gel coat resin. A method of manufacturing a counter, comprising the step of applying separately.