JPH11169312A - Bathtub having reinforced hot insulation material, and its molding - Google Patents

Abstract

PROBLEM TO BE SOLVED: To simplify the manufacturing process of a bathtub, reduce a working place, and reduce the cost for the manufacturing equipment by a method wherein on the product rear surface of a bathtub, a glass fiber reinforced foamed polyurethane resin of which the major material are glass fiber and a polyurethane resin, is fixed and integrated. SOLUTION: A bathtub 20 made of an acrylic resin which is obtained by molding by a vacuum molding method under a die opened state of a molding die 40, is placed on a male die 41 of the molding die 40 by a method of vacuum-suction or the like. On one surface in a female die 42 of the molding die 40, a glass fiber 31 being cut by a desired dimension is placed adjusting to the shape of a bathtub part of the female die 42 in a manner to be located on the product rear surface of the bathtub 20, and then, a desired amount of a foamed polyurethane resin 32 is sprayed from the top of the glass fiber 31. Then, by quickly fitting the male die 41 and the female die 42, and a mixture of the glass fiber 31 and the foamed polyurethane resin 32 is expanded in the molding die 40, and heated and pressurized, and thus, on the product rear surface of the bathtub 20 made of the acrylic resin, a reinforced heat insulation material 30 is fixed by integrated.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a tub with a reinforced heat insulating material having a reinforced heat insulating material on the back surface of a product and a method for forming the same.

[0002]

2. Description of the Related Art Conventionally, the following is known as a bathtub in which a reinforcing material and a heat insulating material are attached to the product back surface of the bathtub.

A) For example, as shown in FIG. 5A, in the case of a bathtub 1 made of an acrylic resin obtained by a vacuum forming method, a degreasing, an adhesive coating agent or a primer is applied to the back surface of the product of the bathtub 1. After performing surface treatment such as surface roughening,
A reinforcing material layer 2 is obtained by laminating FRP (fiber reinforced plastics) to a desired thickness, molding and curing the resultant, and fixing it to the product back surface of the bathtub 1. Next, an adhesive is applied to one or each of the reinforcing material layer 2 formed above and the separately formed foamed polyurethane foam material, and the foamed polyurethane foam material is wound around and bonded to the backside of the bathtub to form the heat insulating material layer 3. A foaming polyurethane resin is sprayed using a polyurethane spraying machine onto a reinforcing material layer 2 fixed to the product back surface of the bathtub 1 using a polyurethane spraying machine, and foamed and cured, as shown in FIG. 3, and a method of securing the heat retention performance of the bathtub 1 is generally adopted.

[0004] B) In the case of a bathtub by a cast molding method, glass fibers and polyester resin are simultaneously sprayed or laminated on the back surface of a bathtub made of a polyester resin or a bathtub made of an acrylic resin, and molded and cured. Before forming the reinforcing material layer 2 shown in FIG. 5 or forming the polyester resin bathtub 1 or the acrylic resin bathtub 1, the preformed reinforcing material layer 2 made of an FRP molded product is formed into a female mold. After fixing the reinforcing material layer 2 by forming a bathtub 1 made of polyester resin or a bathtub 1 made of acrylic resin, the foamed polyurethane foam material is reinforced in order to secure heat retention. A method of forming a heat insulating material layer 3 by winding and bonding on the material layer 2, or
There is also known a method in which a foamed polyurethane resin is sprayed on the reinforcing material layer 2 by using a polyurethane spraying machine to foam and cure, thereby forming the heat insulating material layer 3.

C) Further, in the case of a bathtub formed by a hand lay-up and spray-up method, a polyester resin layer colored to a desired hue and color is provided on the surface of the bathtub, and then a glass fiber is formed on the back of the product in the bathtub. And a polyester resin are sprayed or laminated at the same time to form and harden to form a reinforcing material layer, and then a foamed polyurethane foam material is wound around the reinforcing material layer and adhered to form a heat insulating material layer 3 in order to secure heat insulation. Alternatively, a method of spraying a foamed polyurethane resin onto the reinforcing material layer 2 using a polyurethane spraying machine to foam and cure the foamed polyurethane resin to form the heat insulating material layer 3 is also generally used.

D) In the case of a bathtub by a compression molding method such as SMC (sheet molding compound) or BMC (bulk molding compound), a design is generally made so that a molded product of the bathtub itself can secure sufficient strength. Therefore, there is no need to provide a reinforcing material layer. Therefore, on the product back side of the bathtub, a foamed polyurethane foam material for securing heat insulation is wrapped around and adhered to the bathtub back surface to form the heat insulating material layer 3, or the foamed polyurethane resin is formed by using a polyurethane spraying machine with the polyurethane backside. To form a heat insulating material layer 3 by foaming and curing.

[0007]

However, in A) described in the prior art, after forming the bathtub 1 made of an acrylic resin, the reinforcing material layer 2 is formed by laminating FRP.
And a step of forming a heat insulating material layer 3 by winding and bonding a foamed polyurethane foam material or a polyurethane spraying machine of a foamed polyurethane resin, the number of working steps is increased, the production cost is increased, and the reinforcing material is increased. Since FRP molding equipment for forming the layer 2 and equipment for forming the heat insulating material layer 3 and jigs and tools are required, there is a problem that equipment and the like also require a large amount of cost. Since each workplace for the process of forming the layer 2 and the process of forming the heat insulating material layer 3 is required, there is a large problem in securing the workplace area.

In the case of B) described in the prior art, the thickness of the reinforcing material layer 2 made of FRP is generally small and the heat insulation effect is poor, so that the heat retention cannot be improved. The heat insulating material layer 3 needs to be attached in the same manner as described in (1). Although it is possible to obtain a heat insulating effect even with the reinforcing material layer 2 made of FRP, the heat transfer property of FRP is better than that of foamed polyurethane and heat is easily radiated, so the thickness of the reinforcing material layer 2 itself must be increased. Not as a result, F
As the amount of RP used increases, the cost increases and the weight of the bathtub increases, which causes problems such as difficulty in material handling (transportation of the product) and time-consuming curing of FRP. Is not used. Therefore, the formation of the heat insulating material layer 3 is as shown in FIG.
The method is mainly performed by attaching and fixing a sheet-like polyurethane foam to the reinforcing material layer 2 using an adhesive or the like, but the surface of the reinforcing material layer 2 has irregularities of the natural surface of the FRP laminate. In addition, since the shape of the bathtub 1 itself is a curved surface, it takes a lot of time to attach and adhere the sheet-like polyurethane foam, and the polyurethane foam is apt to be unattached at the curved portion where the curved shape changes, and the reinforcing material layer There is a problem that a void c is formed between the polyurethane foam 2 and the sheet-like polyurethane foam, and the polyurethane foam comes off. As shown in FIG. 5 (b), in the method of spraying and foaming the foamed polyurethane resin on the reinforcing material layer 2 with a spraying machine to form the heat insulating material layer 3, the foamed polyurethane resin is easily formed using a polyurethane spraying machine. However, there is a problem that the working environment such as the polyurethane resin scatters around at the time of spraying or an odor due to the amine catalyst contained in the polyurethane resin is deteriorated,
Furthermore, in general, polyurethane spraying requires a lot of manual work and requires skill to spray uniformly, so that a worker with low skill tends to have an uneven foaming thickness of the polyurethane resin. There is also a problem that unevenness d is generated on the surface of the material layer 3 and the aesthetic appearance as a product is impaired.

Further, the case of the bath tub formed by the hand lay-up or spray-up method described in C) of the prior art and the case of the bath tub formed by the compression molding method such as SMC or BMC described in D) are B The strength is ensured by using a glass fiber whose length is longer than that of the glass used for forming the bathtub by the casting method described in the above), so it is strong and it is not necessary to provide a reinforcing material layer. In order to secure the heat insulation material layer 3, a sheet-like foamed polyurethane foam material is wound around the back surface of the bathtub 1 and adhered thereto, or the foamed polyurethane resin is sprayed on the product back surface of the bathtub 1 using a polyurethane spraying machine. It is necessary to secure the heat insulating material layer 3 by foaming and curing. For this reason, when the sheet-like polyurethane foam is bonded and attached, the bonding and attaching work is often performed. When the foamed polyurethane resin is sprayed, the working environment is deteriorated such that the polyurethane resin is scattered around when the foamed polyurethane is sprayed, or an odor is generated by an amine catalyst impregnated in the polyurethane resin. Has the same problem as described above.

As described above, in many conventional manufacturing methods, a reinforcing material layer of FRP is formed and fixed on the back surface of a bathtub product, and then a heat insulating material layer is attached. As the formation takes time and the types of materials used increase, the production cost increases
In addition, it takes time to bond the sheet-like polyurethane foam at the time of forming the heat insulating material layer, or when the heat insulating material layer is formed by spraying the foamed polyurethane resin, the working environment is deteriorated due to odor at the time of spraying. It had the problem of.

SUMMARY OF THE INVENTION The present invention has been made in view of the above-mentioned problems of the prior art, and can simplify the manufacturing process of a bathtub, reduce the area of a workplace, reduce the cost of manufacturing equipment, and reduce the working environment. It is an object of the present invention to provide a tub with a reinforced heat insulating material and a method for molding the tub so that deterioration can be prevented.

[0012]

In order to achieve the above object, a tub with a reinforced heat insulating material according to the present invention comprises a glass fiber-reinforced foamed polyurethane resin whose main material is glass fiber and polyurethane resin on the back of the bathtub. Are fixedly integrated.

Further, in the method of forming a bathtub with a reinforced heat insulating material according to the present invention, after forming a bathtub with one or a pair of forming dies, the bathtub is set on a male mold of the forming die and the product is placed on the back of the product of the bathtub. A glass fiber and a foamed polyurethane resin are charged, a male mold and a female mold are fitted, and a mixture of the glass fiber and the foamed polyurethane resin is foamed in a molding die. It is characterized in that the resin is joined and integrated.

[0014]

BEST MODE FOR CARRYING OUT THE INVENTION The bathtub used in the present invention is made of an acrylic resin by vacuum molding and casting, a compression molding method such as SMC or BMC, a polyester resin by hand lay-up and spray-up method. And any plastic such as an acrylic resin and a multilayer sheet such as PE, PP, ABS, etc., and the shape is not particularly limited.

Before placing the glass fiber and the foamed polyurethane resin on the back surface of the bathtub product, the surface to be bonded on the back surface of the bathtub product is subjected to surface treatment such as degreasing, applying an adhesive coating agent or primer, and roughening the surface. Is preferred. In addition, the mold can be molded using a resin mold such as an FRP mold in addition to a metal mold. The mold surface temperature at the time of molding the bathtub, glass fiber, and foamed polyurethane resin is 10 mm.
If the temperature is in the range of -80 ° C, a heating medium such as hot water may be circulated in the mold to secure a desired molding temperature, or an ambient temperature may be secured in a drying furnace or the like.

[0016]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Embodiments of a bathtub with a reinforced heat insulating material and a method of forming the same according to the present invention will be described below in detail with reference to FIGS.

FIG. 1A is an explanatory side view showing a step of setting a bathtub, a glass fiber, and a polyurethane foam resin into a mold according to an embodiment of a method of forming a bathtub with a reinforced heat insulating material according to the present invention. FIG. 2 (b) is a partially cutaway perspective view of a bathtub with a reinforced heat insulating material according to the present invention formed using the forming method shown in FIG. 1 (a), and FIG. 2 (a) is a forming method shown in FIG. 1 (a). FIG. 2 is an explanatory side view showing a step of setting a bathtub, glass fiber, and foamed polyurethane resin in a mold according to another embodiment.
2 (b) is a partially cutaway perspective view of a bathtub with a reinforced heat insulating material according to the present invention formed by using the forming method shown in FIG. 2 (a), and FIG. 3 (a) is a set shown in FIG. 1 (a). FIG. 3 (b) is a longitudinal sectional view showing a state of integral molding of the bathtub and the reinforced heat insulating material in the molding die after the process, and FIG. 3 (b) relates to the present invention molded by integral molding shown in FIG. 3 (a). FIG. 4 (a) is a longitudinal sectional view showing a state in which the bathtub and the reinforced heat insulating material are integrally formed in the molding die after the setting step shown in FIG. 2 (a). FIG. 4B is a side longitudinal sectional view of a tub with a reinforced heat insulating material according to the present invention formed by integral molding shown in FIG. 4A.

First, in FIG. 1B and FIG. 2B, the tub 10 with a reinforced heat insulating material has a structure in which a reinforced heat insulating material 30 is integrated with the back surface of the product of the bathtub 20. , Glass fiber 31 and foamed polyurethane resin 32
It is an integrated product with

The tub 10 with a reinforced heat insulating material has an excellent reinforcing function and a heat insulating function, and a gap exists between the reinforcing material layer and the heat insulating material layer as in the prior art. It has excellent functions without delamination and no irregularities on the surface of the heat insulating material layer, and also improves the appearance performance of the back surface of the product.

(Embodiment 1) Next, an embodiment of a forming step of the bathtub 10 with the reinforced heat insulating material will be described with reference to FIGS. 1 (a) and 3 (a).

As shown in FIG. 1A, the male mold 41 and the female mold 4
The bathtub 20 made of an acrylic resin obtained by molding by a vacuum molding method in a mold open state of the molding die 40 made of
Is placed on the male mold 41 of the molding die 40 by a method such as vacuum suction, and the glass fiber 31 cut to a desired size so as to be positioned on the back surface of the product of the bathtub 20 on one surface in the female mold 42 of the molding die 40. (Asahi Fiberglass Co., Ltd., trade name, M-86
09 number 650) according to the shape of the bathtub portion of the female mold 42, and then a foamed polyurethane resin 32 (manufactured by Polyurethane Chemical Co., Ltd., trade name: HM-1150, M -20S) is sprayed on the glass fiber 31 in a desired amount.

Immediately thereafter, as shown in FIG. 3 (a), the male mold 41 and the female mold 42 are fitted to each other by the mold clamping equipment 43 (see FIG.
The mixture of the foamed polyurethane resin 32 and the foamed polyurethane resin 32 is foamed in a mold 40, and heated and pressed to form a mixture on the back surface of the product of the bathtub 20 made of an acrylic resin, as shown in FIGS.
Glass fiber 31 and foamed polyurethane resin 3 shown in (b)
2 and a reinforced heat insulating material 30 made of a mixture of the above two materials was fixed and integrated. As a result, a tub 10 with a reinforced heat retaining material as shown in FIGS. 1B and 3B having strength and heat retaining properties is obtained.

(Example 2) Next, a bathtub 1 with a reinforced heat insulating material was used.
2 (a) and FIG. 4 (a), the bathtub 20 made of polyester resin obtained by the casting method is used as the male mold of the mold 40. 41, and cut into desired dimensions on the product back surface of the bathtub 20 by glass fiber 31 (manufactured by Asahi Fiberglass Co., Ltd.
The product name, M8609-number 650) is placed according to the shape of the bathtub 20, and then the foamed polyurethane resin 32 having a foaming ratio of 10 to 13 times (manufactured by Polyurethane Chemical Co., Ltd., trade name, HM-1150, M- 20S).

Immediately thereafter, the male mold 41 and the female mold 42 are fitted by the mold clamping equipment 43 shown in FIG. 2A as shown in FIG. Is foamed in a mold 40, and heated and pressed to form glass foam 31 shown in FIG. 2 (b) and FIG. 4 (b) on the back of the product of the bathtub 20 made of polyester resin. A reinforced heat insulating material 30 made of a mixture with a polyurethane resin 32 was fixed and integrated. As a result, FIG. 2B and FIG.
A tub 10 with a reinforced heat retaining material having strength and heat retaining properties as shown in FIG.

[0025]

As described above, the present invention has the following effects. A glass fiber reinforced foamed polyurethane resin mainly composed of glass fiber and polyurethane resin is fixed and integrated on the back of the product of the bathtub. The glass fiber reinforced foamed polyurethane resin fixed and integrated on the back of the product of the bathtub is a reinforcing material. Because it has both the function of
A tub with a reinforced heat retaining material having strength as a bath tub and excellent heat retaining properties is obtained.

In the molding method, a bathtub is set on a male mold of a molding die, glass fiber and a foamed polyurethane resin are charged into the back of the product of the bathtub, and the male mold and the female mold are fitted to each other to form a glass fiber. The mixture of foam and polyurethane resin is foamed in the mold, and the glass fiber reinforced foam polyurethane resin is joined and integrated on the back of the product in the bathtub. In order to form, the function of the reinforcing material and the heat insulating material must be secured at the same time at the time of molding, and the glass fiber and the polyurethane resin reinforced with the heat insulating material are fixed and integrated on the back of the product in the bathtub, and the reinforcing material and the heat insulating material Since the above functions can be obtained at the same time, the manufacturing process of the bathtub can be simplified, the work area can be reduced, and the cost of manufacturing equipment can be reduced. In addition, deterioration of the working environment can be prevented.

[Brief description of the drawings]

FIG. 1 (a) shows one embodiment of a method for forming a bathtub with a reinforced heat insulating material according to the present invention, and is an explanatory side view showing a step of setting a bathtub, glass fiber, and a polyurethane foam resin in a forming die; (B) is a partially cutaway perspective view of a bathtub with a reinforced heat insulating material according to the present invention formed using the forming method shown in (a),

FIG. 2 (a) shows another embodiment of the method for forming a bathtub with a reinforced heat insulating material according to the present invention, which is different from FIG. 1, and shows a step of setting a bathtub, glass fiber and foamed polyurethane resin in a forming die. FIG. 1B is a partially cutaway perspective view of a bathtub with a reinforced heat insulating material according to the present invention formed using the forming method shown in FIG.

FIG. 3A is a longitudinal sectional view showing a state in which a bathtub and a reinforced heat insulating material are integrally formed in a molding die after the setting step shown in FIG. 1A, and FIG. 1 is a side longitudinal sectional view of a bathtub with a reinforced heat insulating material according to the present invention formed by integral molding shown in FIG.

4 (a) is a longitudinal sectional view showing a state in which a bathtub and a reinforced heat insulating material are integrally formed in a molding die after the setting step shown in FIG. 2 (a), and FIG. 4 (b) is (a) 1 is a side longitudinal sectional view of a bathtub with a reinforced heat insulating material according to the present invention formed by integral molding shown in FIG.

FIG. 5 shows a conventional example, in which (a) shows FR on the product back surface of the bathtub.
FIG. 4B is a side longitudinal cross-sectional view of a bathtub in which a reinforcing material layer formed by laminating P and a heat insulating material layer formed by winding and sticking a sheet-like polyurethane foam are shown. It is a side sectional view of the bathtub which formed the heat insulating material layer by spraying.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... Bathtub 2 ... Reinforcement material layer 3 ... Heat insulation material layer c ... Void d ... Unevenness 10 ... Bathtub with reinforced heat insulation material 20 ... Bathtub 30 ... Reinforced heat insulation material 31 ... Glass fiber 32 ... Foamed polyurethane resin 40 ... Mold 41 ... Male Mold 42: Female mold 43: Mold clamping equipment

Continued on the front page (51) Int.Cl. ⁶ Identification symbol FI B32B 17/04 B32B 27/40 27/40 B29C 67/22 // B29K 75:00 105: 12 B29L 9:00 31:00 (72) Invention Person Tetsuro Koyama 3-58, Inadashinmachi, Higashiosaka City, Osaka Prefecture Within the Hirata Cooperative Association (72) Inventor Kazuichi Toriya 1653-23 Ayabe Fukaya, Tsuyama City, Okayama Prefecture Hirata Cooperative Association Tsuyama Plant

Claims (2)

[Claims] 1. A tub with a reinforced heat insulating material, wherein a glass fiber reinforced foamed polyurethane resin containing glass fiber and a polyurethane resin as a main raw material is fixed and integrated on the back surface of the product of the bath tub. 2. A bath tub is formed by one or a pair of forming dies, and the bath tub is set on a male die of a forming die, and glass fiber and a foamed polyurethane resin are put on a product back surface of the bath tub. A reinforced heat insulating material characterized in that a female mold is fitted and a mixture of the glass fiber and the foamed polyurethane resin is foamed in a mold, and a glass fiber reinforced foamed polyurethane resin is joined and integrated on the product back surface of the bathtub. Bathtub molding method.