JPS59178219A - Molding method of bathtub - Google Patents

Abstract

PURPOSE:To increase a feeling that the upper edge part and the main body part in a bathtub are inseparably united as a unitary body and to improve the external appearance thereof by a method wherein the upper edge part of the bathtub is molded with casting resin in a unitary body with the FRP layer of the main body part and the surface is coated continuously with a transparent gel coat layer. CONSTITUTION:A mold 1 is coated with transparent gel coat liquid to provide a gelled transparent gel coat layer 2. Casting resin liquid is injected fully into the cavity 1a of a mold 1 to constitute a casting resin part 4 making the base body of the upper edge part A. The surface of the transparent gel coat layer 2 in the mold 1 corresponding to the main body part B of the bathtub excluding said casting resin part 4 is coated with colored gel coat liquid to provide a colored gel coat layer 5. Then, by using reinforced fiber such as glass fiber etc. and hardening resin liquid such as unsaturated polyester resin etc. a fiber reinforced resin layer 6 is provided by the hand layup method etc. After hardening the hardening resin liquid, it is removed from the mold to obtain a product.

Description

Detailed Description of the Invention The present invention relates to a method for molding a bathtub made of fiber reinforced resin (FRP), in which the upper edge of the bathtub is formed integrally with the FRP layer of the main body using casting resin, and the surface is made transparent. Continuous coating with a gel coat layer increases the sense of unity between the upper edge of the bathtub and the main body, thereby improving the appearance.

Conventionally, FRP sugar bathtubs have been widely used.

Some of such FRP bar stubs have a finish in which the upper edge A thereof meets the main body B in appearance and appearance as shown in FIG. This is because the upper edge A of the pasta tab is always visible to the public during bathing, and it is desirable to have a moderate aesthetic appearance.For example, by changing its color tone,
It is not possible to apply a marble pattern to the upper edge.

By the way, as a manufacturing method for this type of FRP bathtub, the main body part B is separately formed by a hand lay-up method, a spray-up method, a resin injection method, etc.
MI! ! There is a method of manufacturing the upper edge part A separately by a casting method using a hardening resin such as unsaturated polyester resin, epoxy resin, or polyurethane resin, and then joining the upper edge part A to the upper end of the main body part B. . Then, the upper edge A and the main body ff1s
The joint with B is finished with caulking. However, this method has the drawback that the caulking agent at the joint between the two may peel off or change color during use. Furthermore, since both are rigid materials, they do not fit well and do not come into uniform contact over the entire bonded surface, which tends to cause poor adhesion and may cause partial peeling, resulting in poor appearance. Furthermore, it is difficult to make the joint surface completely horizontal, and when the bathtub is filled with water, the joint surface may not be parallel to the water surface, causing problems such as giving an unnatural feeling. Paint them differently and then apply the FRP layer? There is also a method of integral molding. Although this method does not cause the above-mentioned bonding defects, it is necessary to use a masking method to make the color boundaries completely horizontal, which reduces work efficiency and also allows the difference in color tone to be directly applied to the surface. Because it is visible, it feels strange, lacks a sense of depth, and is inferior in texture. Also, there are design constraints and various changes. There are also disadvantages such as not being able to give.

This invention has been made in view of the above circumstances, and eliminates the problem of poor bonding between the upper edge and the main body and the deterioration of appearance due to this, and also eliminates the appearance of discomfort at the bonded portion, resulting in a natural fit. The purpose of this invention is to provide a method for molding a bathtub made of FJ'LP that provides a sense of depth and depth.

Hereinafter, the present invention will be described in detail with reference to FIG.

@Figures 2 to 5 show an example of the bathtub molding method of the present invention in the order of steps. Reference numeral 1 in the figure is a mold for molding a bathtub. This mold 1 is made of wood, FRP, etc., and is reinforced with steel or the like on the back side, and in this case is a male mold.

Further, in the figure, the mold 1 is placed so that the bathtub is finished in an inverted state. Furthermore, the mold 1 has four groove-shaped portions 1a formed in a portion corresponding to the upper edge of the bathtub.

First, a release agent such as a wax type is applied to the surface of the mold 1, and then a transparent gel coat layer 2 is provided as shown in FIG. This transparent gel coat layer 2 is made of, for example, liquid unsaturated polyester resin 100 parts by weight JttFflS, 1.0 parts by weight of methyl ethyl ketone peroxide as a hardening agent,
A transparent or translucent curable resin liquid such as an unsaturated polyester resin liquid to which 15 parts by weight of cobalt naphthenate + 15 parts by weight of ffk is added as a curing accelerator and 3 parts by weight of finely powdered silica as a thixotropy imparting agent? It is applied and gelled, and the thickness is 0.
．． It is said to be about 4 mm. Then, a masking tape 3 is pasted on the transparent gel coat layer 2, if necessary.

This masking tape 3 is used so that when you want to clearly indicate the boundary line between the casting resin and the colored gel coat layer, which will be described later, the tape 3 is applied horizontally in the direction in which the tape 3 is applied (the longitudinal direction of the tape 3). It is attached so that it looks like this. However, this is not particularly necessary as long as the viscosity of the casting resin liquid is sufficiently low and self-leveling properties can be obtained.

Next, as shown in FIG. 3, a casting resin solution is injected to fill the concave ffflla of the mold 1, and the upper edge 11fflla is filled.
A cast resin part 4 is formed which will become the base body of the molded resin part 4. The resin liquid for casting is not particularly limited as long as it is a curable resin liquid with little curing shrinkage, but unsaturated polyester resins, epoxy resins, urethane resins, etc. are used. For example, unsaturated polyester resin 1oofHtt 1.0 parts by weight of methyl ethyl ketone peroxide, 0.5 parts by weight of subaru naphthenate, 150 parts by weight of alumina hydrate as a filler.
A room temperature curable white unsaturated polyester resin liquid mixed with parts by weight is used. Also, this casting resin! 4 may be colored in a pastel tone, or crushed pieces of natural stone such as marble may be mixed in, or Burl pigment may be dispersed in order to enhance the cosmetic properties.

Furthermore, it is desirable that the casting resin liquid has a low viscosity if possible. If the viscosity is low, the resin liquid will self-level, and the liquid surface after injection will naturally become a horizontal surface, which will allow the masking tape 3 to be attached. can be made unnecessary. Then, before the resin liquid hardens, the previously applied masking tape 3 is peeled off, and the end 11 of the part of the cast resin part 4 in contact with the transparent gel coat layer 2 is made horizontal.

Next, as shown in FIG. 4, the surface of M transparent gel coat layer 2 of mold 1 corresponding to body WB of the bathtub excluding the casting resin part 4 is colored M. Le Cote@5 is provided. The colored gel coat layer 5 is a colored opaque gel coat layer that determines the color of the entire bathtub, and is colored pale blue, blue, flesh color, etc., and is different from the color tone of the above-mentioned casting resin part 40. For example, to form the pale blue colored gel coat layer 5, 100 layers of unsaturated polyester resin!
Methyl ethyl ketone peroxide 1. Parts of OWC, 0.5 parts by weight of cobalt naphthenate, 4 parts of finely powdered silica
．． 0 parts by weight of layer, 20 parts by weight of titanium white, 0 parts by weight of titanium yellow, 0 parts by weight of phthalocyanine blue paste
．． Add and mix 4 parts by weight of the gel coat liquid to a thickness of [14
It can be obtained by applying it on a tomosphere and turning it into a gel.

Note that the colored gel coat layer 5 is not limited to one layer, but may be stacked in two to three layers as necessary. In the case of two or more layers, the colored gel coat layer should be transparent or translucent so that various patterns can be applied, and the next fake should be opaque.

Next, as shown in Fig. 5, the entire mold 1 is reinforced with reinforcing fibers such as glass fibers and a curable resin liquid such as unsaturated polyester resin by a hand lay method, a spray up method, etc. Resin P6 is formed. After each layer is cured and integrated, the molded product is released from the mold 1 to obtain a bathtub in which the main body part B and the upper edge part A are integrated.

According to this bathtub molding method, in the obtained bathtub, the cast resin part 4 forming the base of the upper edge A is integrally bonded to the fiber reinforced resin layer 6 and the transparent gel coat layer 2. , the upper edge part A and the main body part B are integrated, and the upper NA will not come off from the main body part B even if a strong external force is applied.

Furthermore, even if the colored gel coat layer 5 and the cast resin part 4 are formed with different colors and textures, their surfaces are coated with the continuous transparent gel coat #2, so they are different from the colored gel coat M5 and the cast resin part 4. The discomfort caused by the mold resin part 4 is reduced,
A natural sense of unity and depth can be obtained, as well as a smooth surface skin. Furthermore, two molding methods, casting and FRP molding, are used in the same mold to obtain a bathtub in which the upper edge part A and the main body part B are integrated, which saves time and effort during manufacturing. This reduces manufacturing costs. In addition, since the cast resin part 4 that forms the upper edge can be made of a material that is completely different from the material that makes up the main body B'P, it is possible to give the upper edge A a variety of cosmetic properties. Therefore, for example, the upper edge A can be finished with imitation marble.

As explained above, in the bathtub molding method C of the present invention, a transparent gel coat layer is coated over the entire bathtub mold.
After girding, a casting resin liquid is injected into the part of the mold corresponding to the upper edge of the bathtub, and then a colored gel coat layer is provided on the other parts of the mold, and then an FRP layer is formed.

Therefore, the bathtub obtained by this molding method is
The upper edge and the main body are firmly integrated, resulting in high strength. In addition, when improving cosmetics by using different colors between the upper edge and the main body, the presence of a transparent gel coat layer on the surface reduces the sense of discomfort and provides a natural sense of unity and depth, resulting in an improved texture. Makes an excellent bathtub. Furthermore, work steps are omitted, making it possible to reduce manufacturing costs.

[Brief explanation of the drawing]

No. 1 is a partially sectional perspective view showing the upper part and main body of the bathtub, and Figs. 2 to 5 are cross-sectional views of essential parts showing an example of the bathtub molding method of the present invention in the order of steps. be. A. Upper edge of surface, 1. Inter-mold, 1a. Curved recess, 2.
Transparent gel coat layer, 4...Casting #I fat part, 5. Curved colored gel coat layer, 6...Fiber reinforced resin layer. District 1 Figure 2 Figure 3

Claims (1)

[Claims] After applying gel coat liquid to the mold and allowing it to gel, reinforcing TA# and curable resin liquid are applied on top of this. In the method of forming a bathtub made of fiber reinforced resin by laminating, coating and curing,
After applying a transparent gel coat solution to the entire surface of the mold and allowing it to gel,
A casting resin liquid is injected into the area S< which corresponds to the upper edge of this type of bathtub and cured, and then a colored gel coat liquid is applied to the area other than the part where the casting resin liquid was injected and gelled. A bathtub molding method featuring: