JPH06106634A - Manufacture of cubic product from synthetic resin artificial marble plate and product thereof - Google Patents

Abstract

PURPOSE:To obtain a cubic product consisting of artificial marble having complicated shape, various colors, and quality superior to an integral product by finishing a rising part in such a manner that divided plate materials and two or more plate materials for bottom part are heated, they are molded with pressure in a mold, and the molded materials are set and adhered. CONSTITUTION:Two or more plate materials 1-1 for rising part having a dimension obtained by dividing a rising part 1 vertically are cut out. Two or more plate materials 2-1 for bottom part having a bottom part and its peripheral part are cut out. The plate material 1-1 for rising part and the plate material 2-1 for bottom part are previously heated to a predetermined temperature. Thereafter, the plate materials 2-1 for bottom part are pressed with pressure, in a state that two or more are superposed, between a pair of male and female press molds 3 and 4 having predetermined shapes, and cooled slowly. These plate materials are taken out from the molds 3 and 4 and end faces and necessary parts are trimmed. The finished two or more plate materials 1-1 for rising part and the plate materials 2-1 for bottom part are stuck to each other by an adhesive so as to integrate, in a state that they are butted or superposed.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention uses a synthetic resin artificial marble plate as a raw material to manufacture three-dimensional structural products such as bathtubs, kitchen sinks, wash balls, containers, and helmets having various shapes. Method and its products.

[0002]

2. Description of the Related Art In recent years, synthetic resin artificial marble, which is very similar in appearance, touch and volume to natural marble, has been used in various fields. This artificial marble is manufactured by mixing an inorganic material such as sodium hydroxide with a synthetic resin such as methyl methacrylate or unsaturated polyester.

[0003] The field of use is generally used for various top plates as interior materials for counters, tables, etc. like natural marble, but since it can be molded, it is used in other fields than natural marble. In recent years, especially in the era when there is a strong demand for novelty and individualization of the living environment, in order to meet the demand, for example, not only various rooftops in general houses, but sinks, bathtubs, washbasins for kitchens, etc. We are also expanding into three-dimensional products such as balls for business use.

However, most of these conventional three-dimensional structure products are formed by pouring raw materials into a mold or by injection molding, and it is also possible to manufacture a three-dimensional structure product by partially using a plate material. Has been done.

Of these, the method of manufacturing a three-dimensional structure product using a plate material is basically the same as the method of manufacturing a container by combining conventional wood plates. Cut out several plate materials of a size that fits the shape, cut out one plate material of the size that should become the bottom part, and abut the end faces of each plate material, etc. It is a thing.

[0006]

However, of the above-mentioned conventional manufacturing methods, the integrally molded product by injection molding or the like is suitable for mass production, and is suitable for industrial production because of its high productivity. However, in the era where novelty and individualization are required as described above, it is not suitable for high-mix low-volume production,
It is impossible to precisely meet the demands for its various shapes and colors.

On the other hand, in the case of the manufacturing method in which the above plate materials are simply combined and assembled, although it is suitable for manufacturing a three-dimensional product having a simple shape, it is difficult to obtain a product having a complicated shape, and the novelty and the like described above are required. I can't quite meet your request. Furthermore, the biggest drawback of this method is that the bottom surface of the product is used to ensure the reliability of drainage and to prevent dust from adhering to the corners, especially for products used around water such as kitchen sinks and wash bowls. Is an inclined surface facing downwards toward the drainage hole, and the inner surface of the bottom part and the rising part and the boundary part between the rising parts must be formed in an arc shape, but in this method, for example, for the inclined part of the bottom part, If you want to sacrifice the consumption of material, it is possible to perform surface processing using a sander or router, but it is absolutely impossible to make the inner surface of the boundary part arc-shaped unless you are prepared to waste the raw material. Is.

Therefore, an object of the present invention is to use a plate material of this kind of artificial marble, which has a complicated shape and various colors according to the user's request, and which has a quality higher than that of an integrally molded product such as injection molding. It is intended to provide a method for manufacturing a structural product and the product.

[0009]

In order to achieve this object, the present invention provides a method for producing a three-dimensional structure product having a rising portion and a bottom portion from a synthetic resin artificial marble plate containing an inorganic material, (1) Cutting out at least two or more rising part plate materials having a thickness substantially equal to that of the rising part and having a size sufficient to obtain a dimension in which the rising part is vertically divided, (2) and the bottom part in total. Cutting out at least two or more bottom plate materials having substantially the same thickness and having dimensions sufficient to include the bottom part and a part of the peripheral part of the peripheral part, (3) each plate material for the rising part After heating to a predetermined temperature in advance, each one is molded with a mold having a predetermined shape and gradually cooled, (4) After heating each of the bottom plate materials to a predetermined temperature in advance, the two or more sheets With the bottom plate of the Holding between a pair of male and female pressing molds and gradually cooling, (5) taking out all the plate materials from the mold, trimming each end face and necessary parts to finish to a predetermined size, (6) the finished In a state where two or more rising plate members are abutted against each other, the rising parts are formed by adhering and integrating with each other with an adhesive, (7) In a state in which the finished two or more bottom plate members are stacked. , (8) The bottom part and the peripheral partly rising part are simultaneously formed by bonding with an adhesive, and (8) the end parts of the bonding-integrated rising part and the partly rising part of the bottom are abutted to each other and bonded with an adhesive. Integrating, (9) polishing and finishing the adhesive part and the necessary part, a method for producing a three-dimensional structure product from a synthetic resin artificial marble plate, or (6) to ( 8) Finished 2 instead of All the plate materials are simultaneously bonded and integrated with an adhesive in a state where two or more bottom plate materials are stacked and the predetermined end surfaces of the finished two or more rising part plate materials and the predetermined end surface of the bottom part are butted. A method for producing a three-dimensional structure product from a synthetic resin artificial marble plate characterized by the following: and a three-dimensional structure product from the synthetic resin artificial marble plate produced by the above methods.

[0010]

It is known that an artificial marble plate of this kind is preheated to a predetermined temperature, then molded with a mold having a simple curved shape in the secondary plane, and gradually cooled to form a simple bending member. Has been. However, it was not expected that the artificial marble plate material originally developed for the top plate could be drawn.

The present invention has been made by paying attention to this point. First, it is possible to draw a smooth surface with a considerable curvature in a certain thickness range. I learned that if there are multiple plates, they can be drawn at the same time. At this time, each of the plurality of plate materials,
At the time of the deformation, each of them deforms independently while shifting between the contact surfaces, and has a desired shape without interfering with other plate materials. Therefore, it is possible to easily obtain a three-dimensional structure product having a desired shape, which has hitherto been considered impossible to manufacture from a plate material, by utilizing the above-described bending process and drawing process.

[0012]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be specifically described below based on illustrated embodiments. All figures relate to the present invention and are shown in FIG.
And FIG. 5 shows a kitchen sink structure which is an example of a three-dimensional structure product manufactured by the method of the present invention, and is an approximately rectangular parallelepiped box-shaped body having a four-sided rising portion 1 and a bottom portion 2. Inner surface of the corner of the four rising portions 1 and each rising portion 1
The inner surface of the boundary between the bottom portion 2 and the bottom portion 2 has an arc shape with a radius of approximately 30 mm. FIG. 6 shows another example of a sink structure manufactured by the method of the present invention.

According to the method of the present invention, three-dimensional structured products having various shapes as described above can be manufactured. Now, a method of manufacturing the kitchen sink shown in FIGS. 4 and 5 will be specifically described. As a raw material, a methylmethacrylate-based artificial marble plate (registered trademark of "Corrian" manufactured by DuPont) having a thickness of 13 mm and 6 mm was used. First, a pair of bottom molding dies 3 and 4 having a shape shown in FIG. 1 and a rising part dies (not shown) having the shape shown in FIG. 1 were manufactured using a veneer plywood 6 having a flannel 5 attached to the surface thereof. The flannel 5 is not always necessary, and satisfactory molding is possible without sticking the flannel 5. On the other hand, the thickness of the plate material 1-1 of the rising portion 1 as shown by the broken line in FIG.
Even if the above 13 mm raw material is cut into 805 mm x 190 mm, the above 6 mm thick raw material is 680 mm x 48 as the bottom plate 2 2-1.
Prepare two pieces each of which is cut to 0 mm and cut each
1-1 and 2-1 were heated to 150 to 170 ° C in an oven at 180 ° C.

The two plate materials for the heated rising portion 1-
After setting 1, 1-1 one by one in a female mold (not shown), set the male mold on the upper part and gradually deform the plate material 1-1 from above into a substantially U shape, and clamp it. The position of the male and female dies 3 is fixed by appropriate means. 1-2 in this state
After leaving it for a while and slowly cooling it at room temperature, take out the plate 1-1 from the mold. In the present embodiment, a pair of male and female forming dies are used for forming the plate member for the rising portion, but in the case of simply bending in one plane, a desired shape can be obtained by using the male mold alone or the female mold alone. It can be molded into

On the other hand, the molding of the bottom portion 2 adopts a unique method which is a feature of the present invention. That is, the two heated bottom plate materials 2-1 and 2-1 having the same shape, which are heated in the same manner as the rising plate material 1-1, are set in the female mold 4 shown in FIG. Then, the male mold 3 is set on this and gradually squeezed by pressing from above, and then the male and female 4 are fixed in position by means such as a clamper, left standing for 1 to 2 hours in this state and gradually cooled at room temperature. , Two plate materials that have a rising part in the periphery and have a slight slope toward the center of the bottom surface 2-
Remove 1,2-1 from the mold.

Here, the two sheets are pressed at the same time at the same time by pressing one sheet material having the above-mentioned bottom thickness (12 mm) at once in a dish or spherical shape with four rounded edges. Since the difference in the amount of deformation between the inner surface and the outer surface in a portion is too large, cracks and wrinkled uneven surfaces are generated. This is because, according to an experiment conducted by the present inventor, it has been found that if the thickness is about 6 mm, the above problems do not occur and extremely smooth molding is possible. Therefore, in the present invention, it is important to press-form the two base materials in a stacked state according to the thickness of the molded product, especially when molding the bottom portion.

Further, in the present embodiment, since the arc radius of the corner portion is small, when the plate materials 1-1 and 2-1 are rapidly pressed and deformed, cracks and turbidity are likely to occur. For each curved part of each female mold 3-2,4-2, for example, make a wedge-shaped cut in advance on the outer surface of the same part, and gradually bend the mold itself. Is being transformed.
However, it will be appreciated that such considerations are not necessary when the radius of the arc during molding is large.

Next, each molded product molded through the above steps is trimmed to design dimensions, and each end face and a necessary surface are polished and finished, and two plate materials for rising portions 1-1 , 1-1 are the end faces butted against each other as shown by arrow A in FIG. 2, and the two bottom plate members 2-1 and 2-1 are in a superposed state as shown in an enlarged view in FIG. Adhesive portions are adhered and integrated with an acrylic two-liquid mixed type adhesive to form a rising portion 1 and a bottom portion 2, respectively. continue,
The end surfaces of the rising portion 1 and the bottom portion 2 are abutted against each other as shown by an arrow B in FIG. 2 and the two are bonded and integrated by using the same adhesive.

After that, the rising portion of the solidified adhesive that sticks out from each adhesive portion is removed by a planer or a belt sander, and then the whole is ground with # 120 sandpaper,
Then, re-polish with sandpaper of # 150 or more, and finally finish with nylon scrubber to obtain a desired kitchen sink.

In the above description, the bonding and integration are performed separately for the rising portion 1 and the bottom portion 2 and then both are bonded, but it is also possible to perform all bonding at the same time. Further, in the illustrated example, the rising portion 1 is obtained by abutting two plate members 1-1, but this is further divided into several stages in the horizontal direction, and the color tone of each plate member 1-1, 1-1. If different, extremely innovative and colorful three-dimensional structure products can be obtained. Therefore, the present invention is not limited to the above embodiments, and various modifications can be made within the spirit of the invention.

[0021]

EFFECTS OF THE INVENTION As is clear from the above description, the present invention has a complicated shape from a synthetic resin artificial marble plate material which has been originally considered impossible but originally intended only for use as a ceiling plate, In particular, it enables the production of three-dimensional structured products that are suitable for small-volume production of other varieties that have curved surfaces. Therefore, the products produced are extremely fashionable and can be adapted to the times when novelty and individuality are required. Will be things.

[Brief description of drawings]

FIG. 1 is a partial perspective view showing an example of a male and female molding die for a bottom portion applied to a method of the present invention.

FIG. 2 is an assembled perspective view showing an example for explaining a method for manufacturing a three-dimensional structure product according to the present invention.

FIG. 3 is a partially enlarged view of a bottom portion in FIG.

FIG. 4 is a perspective view showing an example of a sink manufactured by the method of the present invention.

FIG. 5 is an explanatory diagram of a structure of the sink.

FIG. 6 is a perspective view showing another structural example of a product manufactured by the method of the present invention.

[Explanation of symbols]

 1 Rising part 1-1 (for rising part) plate material 2 Bottom part 2-1 (for bottom part) plate material 3 Male molding die for bottom 4 Female molding die for bottom 5 Nell 6 Plywood

Claims (3)

[Claims] 1. A method for producing a three-dimensional structure product having a rising portion and a bottom portion from a synthetic resin artificial marble plate containing an inorganic material, comprising: (1) having a thickness substantially equal to that of the rising portion, Cut out at least two or more rising part plate materials having a size sufficient to obtain a vertically divided part, (2) having a thickness approximately equal to the bottom part in total, and the bottom part and its periphery Cutting out at least two or more bottom plate materials having a size sufficient to include a part of the rising part, (3) after heating each plate material for the rising part to a predetermined temperature in advance, Forming with a mold having a predetermined shape and gradually cooling, (4) after heating each of the bottom plate materials to a predetermined temperature in advance,
Pressing between a pair of male and female pressing molds having a predetermined shape and gradually cooling in a state where the two or more bottom plate members are superposed, (5) taking out all the plate members from the mold, Trimming necessary parts to finish to a predetermined size, (6) forming a rising part by bonding and integrating the predetermined end faces of the finished two or more rising part plates with an adhesive. ) In a state in which the finished two or more bottom plate materials are overlapped with each other, they are bonded and integrated with an adhesive to form a bottom part and a peripheral part rising part at the same time, (8) The bonding integrated rising part An artificial marble made of synthetic resin, characterized in that the end surfaces of the partially raised portions of the bottom are abutted against each other and integrally bonded by an adhesive, (9) the adhesive portion and necessary portions are polished and finished. 3D structure products from boards Method of manufacturing. 2. A method for producing a three-dimensional structure product having a rising portion and a bottom portion from an artificial marble plate made of a synthetic resin containing an inorganic material, comprising: (1) having a thickness substantially equal to that of the rising portion, Cut out at least two or more rising part plate materials having a size sufficient to obtain a vertically divided part, (2) having a thickness approximately equal to the bottom part in total, and the bottom part and its periphery Cutting out at least two or more bottom plate materials having a size sufficient to include a part of the rising part, (3) after heating each plate material for the rising part to a predetermined temperature in advance, Forming with a mold having a predetermined shape and gradually cooling, (4) after heating each of the bottom plate materials to a predetermined temperature in advance,
Pressing between a pair of male and female pressing molds having a predetermined shape and gradually cooling in a state where the two or more bottom plate members are superposed, (5) taking out all the plate members from the mold, (6) In a state in which the finished two or more bottom plate materials are overlapped with each other, and trimming a necessary part to finish to a predetermined dimension, and a predetermined end surface of the finished two or more rising part plate materials; A synthetic resin artificial body characterized by comprising: simultaneously adhering and integrating all plate materials with an adhesive in a state where the predetermined end faces of the bottom part are abutted, (7) polishing the adhering part and a necessary part. A method of manufacturing a three-dimensional structure product from a marble plate. 3. A three-dimensional structure product comprising a synthetic resin artificial marble plate manufactured by the manufacturing method according to claim 1.