TW201806762A - Resin molded body and method of manufacturing the same, kitchen counter, floor pan for bathroom, toilet bowl and dressing table - Google Patents

Resin molded body and method of manufacturing the same, kitchen counter, floor pan for bathroom, toilet bowl and dressing table Download PDF

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Publication number
TW201806762A
TW201806762A TW106112142A TW106112142A TW201806762A TW 201806762 A TW201806762 A TW 201806762A TW 106112142 A TW106112142 A TW 106112142A TW 106112142 A TW106112142 A TW 106112142A TW 201806762 A TW201806762 A TW 201806762A
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Taiwan
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resin
resin molded
molded body
thermal
ceramic film
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TW106112142A
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Chinese (zh)
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柴田哲司
增川功一
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松下知識產權經營股份有限公司
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Publication of TW201806762A publication Critical patent/TW201806762A/en

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    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47B—TABLES; DESKS; OFFICE FURNITURE; CABINETS; DRAWERS; GENERAL DETAILS OF FURNITURE
    • A47B96/00—Details of cabinets, racks or shelf units not covered by a single one of groups A47B43/00 - A47B95/00; General details of furniture
    • A47B96/18—Tops specially designed for working on
    • A—HUMAN NECESSITIES
    • A47—FURNITURE; DOMESTIC ARTICLES OR APPLIANCES; COFFEE MILLS; SPICE MILLS; SUCTION CLEANERS IN GENERAL
    • A47K—SANITARY EQUIPMENT NOT OTHERWISE PROVIDED FOR; TOILET ACCESSORIES
    • A47K1/00—Wash-stands; Appurtenances therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B18/00—Layered products essentially comprising ceramics, e.g. refractory products
    • E—FIXED CONSTRUCTIONS
    • E03—WATER SUPPLY; SEWERAGE
    • E03C—DOMESTIC PLUMBING INSTALLATIONS FOR FRESH WATER OR WASTE WATER; SINKS
    • E03C1/00—Domestic plumbing installations for fresh water or waste water; Sinks
    • E03C1/12—Plumbing installations for waste water; Basins or fountains connected thereto; Sinks
    • E03C1/20—Connecting baths or bidets to the wastepipe
    • E—FIXED CONSTRUCTIONS
    • E03—WATER SUPPLY; SEWERAGE
    • E03D—WATER-CLOSETS OR URINALS WITH FLUSHING DEVICES; FLUSHING VALVES THEREFOR
    • E03D11/00—Other component parts of water-closets, e.g. noise-reducing means in the flushing system, flushing pipes mounted in the bowl, seals for the bowl outlet, devices preventing overflow of the bowl contents; devices forming a water seal in the bowl after flushing, devices eliminating obstructions in the bowl outlet or preventing backflow of water and excrements from the waterpipe
    • E03D11/02—Water-closet bowls ; Bowls with a double odour seal optionally with provisions for a good siphonic action; siphons as part of the bowl

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  • Engineering & Computer Science (AREA)
  • Health & Medical Sciences (AREA)
  • Public Health (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Hydrology & Water Resources (AREA)
  • Water Supply & Treatment (AREA)
  • Environmental & Geological Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Laminated Bodies (AREA)
  • Sink And Installation For Waste Water (AREA)
  • Sanitary Device For Flush Toilet (AREA)
  • Coating By Spraying Or Casting (AREA)

Abstract

To provide a low-cost resin molded body which has high durability and is lightweight usable for a water section housing equipment, the resin molded body includes a resin structure and a sprayed ceramic coating applied on at least a part of the surface of the resin structure.

Description

樹脂成形體及其製造方法、與廚房檯、浴室用地板、便器及洗臉化妝台Resin forming body, manufacturing method thereof, and kitchen table, bathroom floor, toilet and vanity table

本發明係關於一種應用於例如用水場所之住宅設備機器之樹脂成形體。The present invention relates to a resin molded body applied to, for example, a household equipment machine in a water-use place.

作為用水場所之住宅設備機器，可列舉系統廚房、整體衛浴、洗臉化妝台及廁所等。對該等用水場所之住宅設備機器要求容易安裝，且要求耐久性。例如，系統廚房中必須提高耐熱性而增加耐久性。系統廚房具備廚房檯(檯頂板)及水槽，作為廚房檯，於專利文獻1中揭示有一種使用大理石之廚房檯。該使用大理石之廚房檯就耐熱性及美觀之觀點而言被廣泛使用。又，專利文獻2中揭示有一種例如於包含不鏽鋼等金屬之母材形成有包含琺瑯玻璃之被覆層之水槽。 [先前技術文獻] [專利文獻] [專利文獻1]日本專利特開2003-70572號公報 [專利文獻2]日本專利特開2001-152367號公報Examples of residential facilities and equipment used in water places include system kitchens, bathrooms, vanity units, and toilets. The residential equipment and machines in these water-using places are required to be easy to install and durable. For example, in a system kitchen, heat resistance must be increased to increase durability. The system kitchen includes a kitchen table (table top plate) and a sink. As a kitchen table, Patent Literature 1 discloses a kitchen table using marble. This marble countertop is widely used in terms of heat resistance and aesthetics. Further, Patent Document 2 discloses a water tank in which a coating layer including enamel glass is formed on a base material including a metal such as stainless steel. [Prior Art Literature] [Patent Literature] [Patent Literature 1] Japanese Patent Laid-Open No. 2003-70572 [Patent Literature 2] Japanese Patent Laid-Open No. 2001-152367

[發明所欲解決之問題] 然而，使用大理石之廚房檯有價格昂貴且由於較重故而安裝作業耗費功夫之問題。 又，專利文獻2中所揭示之水槽於將包含琺瑯玻璃之被覆層形成於包含不鏽鋼等金屬之母材時，必須以800℃以上之溫度進行焙燒，有價格昂貴之問題。 因此，本發明之目的在於提供一種例如可應用於用水場所之住宅設備機器、輕量且耐久性較高、價格低廉之樹脂成形體。 [解決問題之技術手段] 為了達成以上之目的，本發明之樹脂成形體包括：樹脂構造體、及設置於樹脂構造體之至少一部分之表面的熱噴塗陶瓷皮膜。 [發明之效果] 根據以如上所述之方式構成之本發明，可提供一種輕量且耐久性較高、價格低廉之樹脂成形體。[Problems to be Solved by the Invention] However, a kitchen table using marble has a problem that it is expensive and requires a lot of work for installation due to heavy weight. In addition, when the water tank disclosed in Patent Document 2 forms a coating layer including enamel glass on a base material including a metal such as stainless steel, it must be fired at a temperature of 800 ° C. or higher, which has the problem of being expensive. Therefore, an object of the present invention is to provide a resin molded body which is lightweight, has high durability, and is inexpensive, and can be applied to, for example, residential facilities and equipment in water-use places. [Technical means to solve the problem] In order to achieve the above object, the resin molded body of the present invention includes a resin structure and a thermal sprayed ceramic film provided on at least a part of the surface of the resin structure. [Effects of the Invention] According to the present invention configured as described above, it is possible to provide a resin molded body which is lightweight, has high durability, and is inexpensive.

以下，一面參照圖式一面對本發明之實施形態之樹脂成形體進行說明。 實施形態1. 本發明之實施形態1之樹脂成形體1為水槽一體式廚房檯，檯11與水槽12係一體構成。實施形態1之樹脂成形體1具備：樹脂構造體10，其係例如藉由注模成形而將檯部與水槽部一體成形而成之構造體；及熱噴塗陶瓷皮膜10c，其設置於樹脂構造體10之上表面。 以如上所述之方式構成之樹脂成形體1由於使用樹脂構造體10作為構造體，故而與使用大理石之廚房檯相比可形成為輕量。又，實施形態1之樹脂成形體1由於在樹脂構造體10之表面設置有耐熱性較高之熱噴塗陶瓷皮膜10c，故而可提高耐熱性，結果可提高耐久性。 因此，根據實施形態1之樹脂成形體1，可提供輕量且耐久性較高之廚房檯。 又，如下所述，熱噴塗陶瓷皮膜10c可藉由利用熱噴塗槍進行熱噴塗而形成。藉此，可於檯11與水槽12之彎曲之交界或水槽12之底部之角等以均勻之膜厚且光滑地形成，可提供於美觀方面優異之樹脂成形體。 進而，實施形態1之樹脂成形體1可藉由熱噴塗陶瓷皮膜10c而例如再現大理石風格之花樣、或具有如大理石般之質感，可提昇美觀及設計性。 以下對樹脂成形體1進行詳細說明。樹脂構造體 10 於實施形態1之樹脂成形體1中，樹脂構造體10、例如作為流理台之板狀之檯部與槽狀之水槽部係例如藉由注模成形而一體製作。作為樹脂構造體10之樹脂材料，例如可使用環氧樹脂、乙烯酯樹脂、不飽和聚酯樹脂、丙烯酸系樹脂等熱硬化性樹脂。又，樹脂構造體10亦可包含無機填料。藉由包含無機填料，可降低樹脂構造體10之熱膨脹率而接近其後沈積之熱噴塗陶瓷皮膜之熱膨脹率，並且可提高樹脂構造體10之耐熱性。熱噴塗陶瓷皮膜 10c 於實施形態1之樹脂成形體1中，如圖2所示，熱噴塗陶瓷皮膜10c係扁平之陶瓷粒子100於鄰接間融合並沈積而成之覆膜。如下所述，該熱噴塗陶瓷皮膜10c係藉由經加熱而熔融或軟化之大量陶瓷粒子與樹脂構造體10之表面碰撞並依序沈積而形成。作為該熱噴塗陶瓷皮膜10c之陶瓷材料，可使用氧化鋁(Al2 O3 )、莫來石(Al2 O3 -SiO2 )、二氧化鈦(TiO2 )等。熱噴塗陶瓷皮膜10c之膜厚並無特別限定，例如設定為0.01～3.0 mm之範圍，較佳為設定為0.05～1.0 mm之範圍，更佳為設定為0.2～0.5 mm之範圍。 又，如上所述，熱噴塗陶瓷皮膜10c係扁平之陶瓷粒子100於鄰接間融合並沈積而成之覆膜，故而於熱噴塗後之陶瓷粒子100間存在氣孔(間隙)。該熱噴塗陶瓷皮膜10c亦可包含填充於間隙部之樹脂。填充於陶瓷粒子100間之間隙部之樹脂102可防止水或油侵入至熱噴塗陶瓷皮膜10c之內部，進一步提高耐久性。填充於熱噴塗陶瓷皮膜10c之間隙部之樹脂102較佳為包含氟或矽，藉此不易被污染，容易清潔。 又，熱噴塗陶瓷皮膜10c之表面較佳為研磨面，藉此，於美觀方面優異，且可抑制污垢之附著，進而容易清潔。陶瓷基底層 10a 於實施形態1之樹脂成形體1中，於樹脂構造體10與熱噴塗陶瓷皮膜10c之間亦可視需要包含陶瓷基底層10a。陶瓷基底層10a例如包含與熱噴塗陶瓷皮膜10c相比填充密度較低、例如孔隙較多之陶瓷層。又，亦可使用添加分散有陶瓷粒子之樹脂層作為陶瓷基底層10a。陶瓷基底層10a抑制熱噴塗時之熱被傳遞至樹脂構造體10，抑制樹脂之熔融或劣化。又，熱噴塗後可緩和起因於熱噴塗陶瓷皮膜10c與樹脂構造體10之熱膨脹率之差的應力，可防止陶瓷基底層10a之剝離而增加樹脂成形體1之耐久性。作為陶瓷基底層10a之陶瓷材料，可使用莫來石、氧化鋁、二氧化鈦等。陶瓷基底層10a可藉由使氣孔率增加之熱噴塗法而形成。或者，可藉由利用樹脂黏合劑混合上述陶瓷粒子並塗佈而形成。 繼而，一面參照圖3，一面對樹脂成形體1之製造方法進行說明。樹脂構造體成形步驟 於本製造方法中，首先，藉由成形而製作樹脂構造體10。例如，實施形態1之廚房檯用之樹脂成形體1係由例如向鎖模之模具之模腔內注入單體樹脂並使其硬化而製作(注模成形)。再者，樹脂構造體10之成形方法並不限定於注模成形，例如亦可藉由加壓成形或射出成形而成形。粗面化步驟 繼而，對樹脂構造體10表面之至少形成有熱噴塗陶瓷皮膜10c之部分進行粗面化(圖3(b))。具體而言，使用利用噴砂、蝕刻、砂紙之研磨，例如以使表面粗糙度為Rz＝1～100 μm、較佳為Rz＝5～50 μm、更佳為Rz＝10～30 μm之方式進行粗面化。藉由利用以上之方法進行粗面化，例如即便於如樹脂成形體1般為水槽一體式廚房檯，且遍及檯11及水槽12將樹脂成形體1之上表面整體進行粗面化之情形時，亦能夠以均勻之面粗糙度進行粗面化。 又，藉由該粗面化，可提高樹脂構造體10與陶瓷基底層10a間之密接性，於將熱噴塗陶瓷皮膜10c直接形成於樹脂構造體10上之情形時，可提高樹脂構造體10與熱噴塗陶瓷皮膜10c間之密接性。進而，藉由以成為上述範圍之表面粗糙度之方式進行粗面化，可進一步提高樹脂構造體10與陶瓷基底層10a間、樹脂構造體10與熱噴塗陶瓷皮膜10c間之密接性。底漆塗佈步驟 繼而，於經粗面化之樹脂構造體10表面形成陶瓷基底層10a(圖3(c))。陶瓷基底層10a係與熱噴塗陶瓷皮膜10c相比填充密度較低(換言之，氣孔率較高)之陶瓷層，例如係藉由為20～50%而形成。陶瓷基底層10a之氣孔率例如設定為30%～40%之範圍。 又，陶瓷基底層10a亦可藉由將陶瓷粒子與樹脂黏合劑混合並塗佈而形成。上述樹脂黏合劑可藉由環氧樹脂或丙烯酸系樹脂而形成。可將該樹脂黏合劑與陶瓷粒子之混合物藉由噴霧塗裝、利用塗佈機之塗佈、毛刷塗裝等配設於經粗面化之樹脂構造體10表面。藉由使乾燥後之樹脂黏合劑相對於陶瓷粒子之體積調配比率為0.5～50%、較佳為5～30%而形成。熱噴塗 步驟 並且，藉由自陶瓷基底層10a之上利用熱噴塗槍7使熔融或軟化之陶瓷粒子碰撞，使陶瓷粒子沈積而形成熱噴塗陶瓷皮膜10c。作為熱噴塗方法，考慮熱噴塗對象、作業環境等，可自火焰熱噴塗、電弧熱噴塗、雷射熱噴塗、電漿熱噴塗等各種熱噴塗方法中加以選擇。 於熱噴塗步驟中，亦可使用複數個熱噴塗槍7同時熱噴塗不同陶瓷粒子而形成熱噴塗陶瓷皮膜10c。如此，例如，可使表面之色彩具有變化而提高裝飾性。又，於熱噴塗步驟中，亦可使用複數個熱噴塗槍交替熱噴塗不同陶瓷粒子而形成熱噴塗陶瓷皮膜10c。如此，例如，可形成兼具耐蝕性與耐熱性等複數種功能之熱噴塗陶瓷皮膜。封孔樹脂 含浸步驟 使樹脂含浸(填充)於藉由熱噴塗而形成之熱噴塗陶瓷皮膜10c之氣孔並硬化(封孔處理)。作為含浸之樹脂，例如，可使用環氧樹脂、丙烯酸系樹脂或矽酮樹脂等。關於該封孔處理，若藉由熱噴塗而形成熱噴塗陶瓷皮膜10c，則於剛熱噴塗後之皮膜例如以1～10%之氣孔率存在氣孔。若存在此種氣孔，則成為腐蝕原因之物質可能通過氣孔到達至樹脂構造體10而腐蝕樹脂構造體10。封孔處理係為了防止該情況而進行。又，若於熱噴塗陶瓷皮膜10c之氣孔即間隙部包含樹脂，則由於氣孔被堵塞，故而間隙部不會被污染而容易清潔。 根據經由以上之步驟而製作之實施形態1之樹脂成形體1，可製造輕量且耐久性較高、並且容易清潔之廚房檯。 於以上之實施形態1之樹脂成形體1中，如圖1B及圖1C所示，遍及樹脂構造體10之廚房檯部及水槽部於樹脂構造體10之上表面整體形成熱噴塗陶瓷皮膜10c。 然而，本發明中，亦可於樹脂構造體10之上表面之至少一部分設置熱噴塗陶瓷皮膜10c。例如，於樹脂成形體1中，可僅於樹脂構造體10之廚房檯部之上表面設置熱噴塗陶瓷皮膜10c，亦可僅於水槽部之上表面設置熱噴塗陶瓷皮膜10c。 於以上之實施形態1之樹脂成形體1中，對作為較佳形態之包含陶瓷基底層10a之樹脂成形體1及其製造方法進行了說明。 然而，於本發明中，陶瓷基底層10a係視需要而形成者，是可選的。 例如，藉由使用耐熱性較高之樹脂構成樹脂構造體10，可抑制樹脂構造體10之熱劣化而省略陶瓷基底層10a。 又，於熱噴塗步驟中，藉由減小熱噴塗之陶瓷粒子之粒徑或一面維持熔融或軟化一面抑制陶瓷粒子之溫度，可抑制樹脂構造體10之熱劣化而省略陶瓷基底層10a。 於以上之實施形態1之樹脂成形體1中，對作為較佳形態之於熱噴塗陶瓷皮膜10c之陶瓷粒子100間之間隙包含樹脂之構成進行了說明。 然而，於本發明中，樹脂係視需要填充於陶瓷粒子100間之間隙者，是可選的。 例如，亦可藉由利用耐化學品性較高之樹脂構成樹脂構造體10及熱噴塗陶瓷皮膜10c之陶瓷粒子100而提高樹脂成形體1之耐久性，不進行陶瓷粒子100間之樹脂填充。 又，亦可不於陶瓷粒子100間填充樹脂，而對熱噴塗陶瓷皮膜10c之表面進行樹脂塗佈。 實施形態2. 如圖4A所示，本發明之實施形態2之樹脂成形體2為浴室用地板，沐浴區側之沐浴區地板部21與排水部22係一體構成。如圖4B及圖4C所示，實施形態2之樹脂成形體2具備：樹脂構造體20，其係例如藉由加壓成形而將沐浴區部與排水部一體成形而成之構造體；及熱噴塗陶瓷皮膜20c，其設置於樹脂構造體20之上表面。再者，於圖4B及圖4C中，標註符號25而表示者為支持浴室用地板之支持部。 於實施形態2之樹脂成形體2中，熱噴塗陶瓷皮膜20c係與實施形態1之熱噴塗陶瓷皮膜10c同樣地構成，省略其詳細情況。 又，於實施形態2之樹脂成形體2中，熱噴塗陶瓷皮膜20c與實施形態1之熱噴塗陶瓷皮膜10c同樣，亦可包含填充於陶瓷粒子間之間隙部之樹脂。 進而，於實施形態2之樹脂成形體2中，與實施形態1同樣，亦可視需要包含陶瓷基底層。 根據以如上所述之方式構成之實施形態2之樹脂成形體2，可提供輕量且耐久性較高、價格低廉之浴室用地板。 實施形態3. 如圖5A所示，本發明之實施形態3之樹脂成形體3為便器，桶身部31與排水口部32及外側支持部33係一體構成。如圖5B所示，實施形態3之樹脂成形體3具備：樹脂構造體30，其係例如藉由射出成形將桶身部與排水口部及外側支持部一體成形而成之構造體；及熱噴塗陶瓷皮膜30c，其設置於樹脂構造體30之上表面。 於實施形態3之樹脂成形體3中，熱噴塗陶瓷皮膜30c係與實施形態1之熱噴塗陶瓷皮膜10c同樣地構成，省略其詳細情況。 又，於實施形態3之樹脂成形體3中，熱噴塗陶瓷皮膜30c與實施形態1之熱噴塗陶瓷皮膜10c同樣，亦可包含填充於陶瓷粒子間之間隙部之樹脂。 進而，於實施形態3之樹脂成形體3中，與實施形態1同樣，亦可視需要包含陶瓷基底層。 根據以如上所述之方式構成之實施形態3之樹脂成形體3，可提供輕量且耐久性較高、價格低廉之便器。 實施形態4. 如圖6A所示，本發明之實施形態4之樹脂成形體4為洗臉檯，檯部41與洗臉盆部42係一體構成。如圖6B及圖6C所示，實施形態4之樹脂成形體4具備：樹脂構造體40，其係例如藉由注模成形將檯部與洗臉盆部一體成形而成之構造體；及熱噴塗陶瓷皮膜40c，其設置於樹脂構造體40之上表面。 於實施形態4之樹脂成形體4中，熱噴塗陶瓷皮膜40c係與實施形態1之熱噴塗陶瓷皮膜10c同樣地構成，省略其詳細情況。 又，於實施形態4之樹脂成形體4中，熱噴塗陶瓷皮膜40c與實施形態1之熱噴塗陶瓷皮膜10c同樣，亦可包含填充於陶瓷粒子間之間隙部之樹脂。 進而，於實施形態4之樹脂成形體4中，與實施形態1同樣，亦可視需要包含陶瓷基底層。 根據以如上所述之方式構成之實施形態4之樹脂成形體4，可提供輕量且耐久性較高、價格低廉之洗臉檯。 藉由以上之實施形態1～4，對將本發明之樹脂成形體應用於住宅設備機器之具體例進行了說明。 然而，本發明之樹脂成形體並非限定於實施形態1～4之具體例者，例如，可廣泛應用於用水場所之住宅設備機器，藉此，可提供輕量且耐久性較高、價格低廉之住宅設備機器。 於本發明中，亦可進而如圖7所示，除實施形態1～4所表示之較佳形態之外、或代替實施形態1～4所表示之較佳形態，於樹脂構造體中於與設置熱噴塗陶瓷皮膜之正面對向之背面具有加強肋51。 如此，可抑制熱噴塗時之樹脂構造體之翹曲或變形。Hereinafter, a resin molded body according to an embodiment of the present invention will be described with reference to the drawings. Embodiment 1. The resin molded body 1 according to Embodiment 1 of the present invention is a sink-integrated kitchen counter, and the counter 11 and the sink 12 are integrally formed. The resin molded body 1 according to the first embodiment includes a resin structure 10 which is a structure in which a table portion and a water tank portion are integrally formed by, for example, injection molding, and a thermal spray ceramic film 10c provided on a resin structure. The upper surface of the body 10. Since the resin molded body 1 configured as described above uses the resin structure 10 as a structure, it can be made lighter than a kitchen table using marble. In addition, since the resin molded body 1 of Embodiment 1 is provided with a thermally sprayed ceramic film 10c having high heat resistance on the surface of the resin structure 10, heat resistance can be improved, and as a result, durability can be improved. Therefore, according to the resin molded body 1 of the first embodiment, a light-weight and highly durable kitchen table can be provided. As described below, the thermal spray ceramic film 10c can be formed by thermal spraying with a thermal spray gun. Thereby, it is possible to form the resin molded body having a uniform film thickness and smoothness at the boundary between the bend of the stage 11 and the water tank 12 or the corner of the bottom of the water tank 12, etc. Furthermore, the resin molded body 1 of Embodiment 1 can reproduce a marble-like pattern or have a marble-like texture by thermally spraying the ceramic film 10c, thereby improving the appearance and design. The resin molded body 1 will be described in detail below. Resin Structure 10 In the resin molded body 1 of Embodiment 1, the resin structure 10, for example, a plate-like table portion serving as a fluid table and a groove-shaped water tank portion are integrally manufactured by, for example, injection molding. As the resin material of the resin structure 10, for example, a thermosetting resin such as an epoxy resin, a vinyl ester resin, an unsaturated polyester resin, or an acrylic resin can be used. The resin structure 10 may include an inorganic filler. By including the inorganic filler, the thermal expansion coefficient of the resin structure 10 can be reduced to be close to the thermal expansion coefficient of the thermal sprayed ceramic film deposited thereafter, and the heat resistance of the resin structure 10 can be improved. Thermal spraying a ceramic coating 10c in Embodiment 1 of the resin into the molded article 1, as shown, the flat ceramic thermal sprayed coating 10c and fusion-based ceramic particles 100 deposited from the film 2 in the adjacent rooms. As described below, the thermal sprayed ceramic film 10c is formed by a large number of ceramic particles melted or softened by heating colliding with the surface of the resin structure 10 and being sequentially deposited. As the ceramic material of the thermal spray ceramic film 10c, alumina (Al 2 O 3 ), mullite (Al 2 O 3 -SiO 2 ), titanium dioxide (TiO 2 ), or the like can be used. The film thickness of the thermal spray ceramic film 10c is not particularly limited. For example, it is set in a range of 0.01 to 3.0 mm, preferably in a range of 0.05 to 1.0 mm, and more preferably in a range of 0.2 to 0.5 mm. Further, as described above, the thermal sprayed ceramic film 10c is a coating film formed by fusing and depositing the flat ceramic particles 100 between adjacent ones, so there are pores (gap) between the ceramic particles 100 after thermal spraying. The thermal sprayed ceramic film 10c may include a resin filled in the gap portion. The resin 102 filled in the gaps between the ceramic particles 100 can prevent water or oil from penetrating into the interior of the thermal spray ceramic film 10c and further improve durability. The resin 102 filled in the gap portion of the thermally sprayed ceramic film 10c preferably contains fluorine or silicon, so that it is not easily contaminated and easy to clean. In addition, the surface of the thermally sprayed ceramic film 10c is preferably a polished surface, thereby being excellent in appearance, suppressing the adhesion of dirt, and being easy to clean. The ceramic base layer 10a may include the ceramic base layer 10a between the resin structure 10 and the thermal sprayed ceramic film 10c in the resin molded body 1 of the first embodiment. The ceramic base layer 10a includes, for example, a ceramic layer having a lower packing density than the thermally sprayed ceramic film 10c, for example, having more pores. Moreover, as the ceramic base layer 10a, a resin layer in which ceramic particles are dispersed may be used. The ceramic base layer 10 a suppresses heat from being transmitted to the resin structure 10 during thermal spraying, and suppresses melting or deterioration of the resin. In addition, after thermal spraying, stress due to the difference in thermal expansion coefficient between the thermal sprayed ceramic film 10c and the resin structure 10 can be relieved, and peeling of the ceramic base layer 10a can be prevented to increase durability of the resin molded body 1. As the ceramic material of the ceramic base layer 10a, mullite, alumina, titanium dioxide, or the like can be used. The ceramic base layer 10a can be formed by a thermal spraying method that increases the porosity. Alternatively, it can be formed by mixing and coating the ceramic particles with a resin binder. Next, a manufacturing method of the resin molded body 1 will be described with reference to FIG. 3. Resin Structure Forming Step In this manufacturing method, first, a resin structure 10 is produced by molding. For example, the resin molded body 1 for a kitchen table of Embodiment 1 is produced by, for example, injecting a monomer resin into a cavity of a mold to be clamped and curing it (injection molding). The method of forming the resin structure 10 is not limited to injection molding. For example, it may be formed by press molding or injection molding. Roughening step Subsequently, at least a portion of the surface of the resin structure 10 where the thermal sprayed ceramic film 10c is formed is roughened (FIG. 3 (b)). Specifically, it is carried out by using sand blasting, etching, and sanding, for example, to make the surface roughness Rz = 1 to 100 μm, preferably Rz = 5 to 50 μm, and more preferably Rz = 10 to 30 μm. Roughened. By using the above method to roughen the surface, for example, when the entire surface of the resin molded body 1 is roughened over the table 11 and the water tank 12 even if it is a sink-integrated kitchen table like the resin molded body 1. , Can also be roughened with uniform surface roughness. In addition, by this roughening, the adhesion between the resin structure 10 and the ceramic base layer 10a can be improved. When the thermal sprayed ceramic film 10c is directly formed on the resin structure 10, the resin structure 10 can be improved. Adhesion to thermal sprayed ceramic film 10c. Further, by roughening the surface roughness within the above range, the adhesion between the resin structure 10 and the ceramic base layer 10a, and the resin structure 10 and the thermal sprayed ceramic film 10c can be further improved. Primer coating step Next, a ceramic base layer 10a is formed on the surface of the roughened resin structure 10 (Fig. 3 (c)). The ceramic base layer 10a is a ceramic layer having a lower packing density (in other words, a higher porosity) than the thermal sprayed ceramic film 10c, and is formed by, for example, 20 to 50%. The porosity of the ceramic base layer 10a is set in a range of, for example, 30% to 40%. The ceramic base layer 10a may be formed by mixing and coating ceramic particles with a resin binder. The resin adhesive may be formed by an epoxy resin or an acrylic resin. The mixture of the resin binder and the ceramic particles can be disposed on the surface of the roughened resin structure 10 by spray coating, coating by a coater, brush coating, or the like. It is formed by setting the volume blending ratio of the dried resin binder to the ceramic particles to be 0.5 to 50%, preferably 5 to 30%. Thermal spraying step Further, the thermal spraying gun 7 is used to collide molten or softened ceramic particles from the ceramic base layer 10a to deposit the ceramic particles to form a thermal sprayed ceramic film 10c. As the thermal spraying method, considering the thermal spraying object and the working environment, it can be selected from various thermal spraying methods such as flame thermal spraying, arc thermal spraying, laser thermal spraying, and plasma thermal spraying. In the thermal spraying step, a plurality of thermal spray guns 7 can also be used to thermally spray different ceramic particles simultaneously to form a thermal spray ceramic film 10c. In this way, for example, the color of the surface can be changed to improve the decoration. In the thermal spraying step, a plurality of thermal spray guns may be used to alternately thermally spray different ceramic particles to form a thermal spray ceramic film 10c. In this way, for example, a thermal sprayed ceramic film having multiple functions such as corrosion resistance and heat resistance can be formed. Sealing resin impregnation step The resin is impregnated (filled) with pores in a thermal sprayed ceramic film 10c formed by thermal spraying and hardened (sealing treatment). As the impregnated resin, for example, epoxy resin, acrylic resin, or silicone resin can be used. Regarding this plugging process, if a thermal sprayed ceramic film 10c is formed by thermal spraying, the film immediately after thermal spraying has pores at a porosity of 1 to 10%, for example. If such pores are present, a substance that causes corrosion may reach the resin structure 10 through the pores and corrode the resin structure 10. The plugging process is performed to prevent this. In addition, if the gaps, which are the pores of the thermally sprayed ceramic film 10c, contain resin, the pores are blocked, so the gaps are not contaminated and can be easily cleaned. According to the resin molded body 1 according to the first embodiment produced through the above steps, it is possible to manufacture a kitchen table which is lightweight, has high durability, and is easy to clean. In the resin molded body 1 of the first embodiment described above, as shown in FIGS. 1B and 1C, a thermal sprayed ceramic film 10 c is formed on the entire upper surface of the resin structure 10 over the kitchen table portion and the sink portion of the resin structure 10. However, in the present invention, a thermal spray ceramic film 10c may be provided on at least a part of the upper surface of the resin structure 10. For example, in the resin molded body 1, the thermal sprayed ceramic film 10c may be provided only on the upper surface of the kitchen table portion of the resin structure 10, or the thermal sprayed ceramic film 10c may be provided only on the upper surface of the water tank portion. In the resin molded body 1 of the first embodiment described above, the resin molded body 1 including the ceramic base layer 10a as a preferred embodiment and the method for manufacturing the resin molded body 1 have been described. However, in the present invention, the ceramic base layer 10a is formed as needed and is optional. For example, by constituting the resin structure 10 with a resin having high heat resistance, thermal degradation of the resin structure 10 can be suppressed, and the ceramic base layer 10a can be omitted. In the thermal spraying step, by reducing the particle diameter of the thermally sprayed ceramic particles or suppressing the temperature of the ceramic particles while maintaining melting or softening, the thermal degradation of the resin structure 10 can be suppressed and the ceramic base layer 10a can be omitted. In the resin molded body 1 of the first embodiment described above, a configuration in which the gap between the ceramic particles 100 in the thermal sprayed ceramic film 10c as a preferable form includes a resin has been described. However, in the present invention, a resin is optional in which the gaps between the ceramic particles 100 are filled as necessary. For example, the resin structure 10 and the ceramic particles 100 of the thermally sprayed ceramic film 10c can be made of a resin having a high chemical resistance to improve the durability of the resin molded body 1 without filling the resin between the ceramic particles 100. In addition, the resin may not be filled between the ceramic particles 100, and the surface of the thermal spray ceramic film 10c may be resin-coated. Embodiment 2. As shown in FIG. 4A, the resin molded body 2 according to Embodiment 2 of the present invention is a floor for a bathroom, and a bath area floor portion 21 and a drainage portion 22 on the bath area side are integrally formed. As shown in FIGS. 4B and 4C, the resin molded body 2 according to the second embodiment includes a resin structure 20, which is a structure formed by integrally molding a bathing area portion and a drainage portion by, for example, press molding; and heat The ceramic coating 20 c is spray-coated and is provided on the upper surface of the resin structure 20. In addition, in FIG. 4B and FIG. 4C, the code | symbol 25 is shown and it is a support part which supports a bathroom floor. In the resin molded body 2 of the second embodiment, the thermal sprayed ceramic film 20c is configured in the same manner as the thermal sprayed ceramic film 10c of the first embodiment, and the details are omitted. In addition, in the resin molded body 2 of the second embodiment, the thermal sprayed ceramic film 20c may include a resin filled in the space between the ceramic particles in the same manner as the thermal sprayed ceramic film 10c of the first embodiment. Furthermore, in the resin molded body 2 according to the second embodiment, as in the first embodiment, a ceramic underlayer may be optionally included. According to the resin molded body 2 of the second embodiment configured as described above, it is possible to provide a bathroom floor that is lightweight, durable, and inexpensive. Embodiment 3. As shown in FIG. 5A, the resin molded body 3 according to Embodiment 3 of the present invention is a toilet, and the barrel portion 31, the drain opening portion 32, and the outer support portion 33 are integrally formed. As shown in FIG. 5B, the resin molded body 3 according to the third embodiment includes a resin structure 30, which is a structure formed by integrally molding a barrel portion, a drain opening portion, and an outer support portion by injection molding, for example. The sprayed ceramic film 30 c is provided on the upper surface of the resin structure 30. In the resin molded body 3 of the third embodiment, the thermal sprayed ceramic film 30c has the same configuration as the thermal sprayed ceramic film 10c of the first embodiment, and the details are omitted. In addition, in the resin molded body 3 of the third embodiment, the thermal sprayed ceramic film 30c may include a resin filled in the space between the ceramic particles in the same manner as the thermal sprayed ceramic film 10c of the first embodiment. Further, in the resin molded body 3 according to the third embodiment, as in the first embodiment, a ceramic underlayer may be optionally included. According to the resin molded body 3 of the third embodiment configured as described above, it is possible to provide a toilet that is lightweight, durable, and inexpensive. Embodiment 4. As shown in FIG. 6A, the resin molded body 4 according to Embodiment 4 of the present invention is a washstand, and the table portion 41 and the washbasin portion 42 are integrally formed. As shown in FIG. 6B and FIG. 6C, the resin molded body 4 according to the fourth embodiment includes a resin structure 40, which is a structure formed by integrally molding a stage portion and a washbasin portion by injection molding, for example; The ceramic film 40 c is provided on the upper surface of the resin structure 40. In the resin molded body 4 of the fourth embodiment, the thermal sprayed ceramic film 40c is configured in the same manner as the thermal sprayed ceramic film 10c of the first embodiment, and details thereof are omitted. In addition, in the resin molded body 4 of the fourth embodiment, the thermal sprayed ceramic film 40c may include a resin filled in the gaps between the ceramic particles in the same manner as the thermal sprayed ceramic film 10c of the first embodiment. Further, in the resin molded body 4 according to the fourth embodiment, as in the first embodiment, a ceramic underlayer may be optionally included. According to the resin molded body 4 according to the fourth embodiment configured as described above, it is possible to provide a light-weight, high-durability, and inexpensive washbasin. Specific examples of applying the resin molded body of the present invention to residential equipment have been described in the first to fourth embodiments. However, the resin molded product of the present invention is not limited to the specific examples of Embodiments 1 to 4. For example, it can be widely used in residential equipment in water-using places, thereby providing lightweight, high durability, and inexpensive House equipment machines. In the present invention, as shown in FIG. 7, in addition to the preferred forms shown in Embodiments 1 to 4, or in place of the preferred forms shown in Embodiments 1 to 4, the resin structure is used in conjunction with The thermal sprayed ceramic film is provided with reinforcing ribs 51 on the front side and the back side. In this way, warping or deformation of the resin structure during thermal spraying can be suppressed.

1‧‧‧樹脂成形體
2‧‧‧樹脂成形體
3‧‧‧樹脂成形體
4‧‧‧樹脂成形體
7‧‧‧熱噴塗槍
10‧‧‧樹脂構造體
10a‧‧‧陶瓷基底層
10c‧‧‧熱噴塗陶瓷皮膜
11‧‧‧檯
12‧‧‧水槽
20‧‧‧樹脂構造體
20c‧‧‧熱噴塗陶瓷皮膜
21‧‧‧沐浴區地板部
22‧‧‧排水部
25‧‧‧支持部
30‧‧‧樹脂構造體
30c‧‧‧熱噴塗陶瓷皮膜
31‧‧‧桶身部
32‧‧‧排水口部
33‧‧‧外側支持部
40‧‧‧樹脂構造體
40c‧‧‧熱噴塗陶瓷皮膜
41‧‧‧檯部
42‧‧‧洗臉盆部
51‧‧‧加強肋
100‧‧‧陶瓷粒子
102‧‧‧樹脂1‧‧‧resin molding
2‧‧‧ resin molded body
3‧‧‧resin molding
4‧‧‧resin molding
7‧‧‧Thermal spray gun
10‧‧‧ resin structure
10a‧‧‧ceramic substrate
10c‧‧‧thermal spray ceramic film
11‧‧‧ Taiwan
12‧‧‧ Sink
20‧‧‧ resin structure
20c‧‧‧thermal spray ceramic film
21‧‧‧Floor of Bathing Area
22‧‧‧Drainage Department
25‧‧‧Support Department
30‧‧‧ resin structure
30c‧‧‧thermal spray ceramic film
31‧‧‧Barrel body
32‧‧‧ Drain outlet
33‧‧‧outer support
40‧‧‧ resin structure
40c‧‧‧thermal spray ceramic film
41‧‧‧ Taiwan
42‧‧‧Washbasin
51‧‧‧ rib
100‧‧‧Ceramic particles
102‧‧‧resin

圖1A為本發明之實施形態1之樹脂成形體(水槽一體式廚房檯)的立體圖。 圖1B為圖1A之A-A線之剖視圖。 圖1C為圖1A之B-B線之剖視圖。 圖2為將實施形態1之樹脂成形體之剖面放大表示的剖視圖。 圖3(a)～(e)為模式性地表示實施形態1之樹脂成形體之製造步驟之流程的圖。 圖4A為本發明之實施形態2之樹脂成形體(整體衛浴之地板)的立體圖。 圖4B為圖4A之C-C線之剖視圖。 圖4C為將圖4B之一部分放大表示之剖視圖。 圖5A為本發明之實施形態3之樹脂成形體(便器)的立體圖。 圖5B為圖5A之D-D線之剖視圖。 圖6A為本發明之實施形態4之樹脂成形體(盆一體式洗臉檯)的立體圖。 圖6B為圖6A之E-E線之剖視圖。 圖6C為圖6B之F-F線之剖視圖。 圖7為表示本發明之變化例之樹脂成形體之與形成熱噴塗陶瓷皮膜之表面對向之面的立體圖。FIG. 1A is a perspective view of a resin molded body (sink integrated kitchen counter) according to Embodiment 1 of the present invention. Fig. 1B is a sectional view taken along the line A-A in Fig. 1A. Fig. 1C is a sectional view taken along the line B-B in Fig. 1A. FIG. 2 is a cross-sectional view showing an enlarged cross-section of a resin molded body according to Embodiment 1. FIG. 3 (a) to 3 (e) are diagrams schematically showing the flow of the manufacturing steps of the resin molded article according to the first embodiment. FIG. 4A is a perspective view of a resin molded body (floor of a whole bathroom) according to Embodiment 2 of the present invention. Fig. 4B is a sectional view taken along the line C-C in Fig. 4A. FIG. 4C is a cross-sectional view showing a part of FIG. 4B in an enlarged manner. Fig. 5A is a perspective view of a resin molded body (toilet) according to Embodiment 3 of the present invention. Fig. 5B is a sectional view taken along the line D-D in Fig. 5A. FIG. 6A is a perspective view of a resin molded body (a basin-integrated washstand) according to Embodiment 4 of the present invention. FIG. Fig. 6B is a sectional view taken along the line E-E in Fig. 6A. Fig. 6C is a sectional view taken along the line F-F in Fig. 6B. FIG. 7 is a perspective view of a resin molded body facing a surface on which a thermal sprayed ceramic film is formed, showing a modification of the present invention.

10‧‧‧樹脂構造體 10‧‧‧ resin structure

10c‧‧‧熱噴塗陶瓷皮膜 10c‧‧‧thermal spray ceramic film

11‧‧‧檯 11‧‧‧ Taiwan

Claims (15)

一種樹脂成形體，其包含： 樹脂構造體、及 設置於上述樹脂構造體之至少一部分之表面的熱噴塗陶瓷皮膜。A resin molded body comprising: a resin structure; and a thermal sprayed ceramic film provided on a surface of at least a part of the resin structure. 如請求項1之樹脂成形體，其中樹脂構造體包含無機填料。The resin molded article according to claim 1, wherein the resin structure includes an inorganic filler. 如請求項1之樹脂成形體，其於上述樹脂構造體與熱噴塗陶瓷皮膜之間，具有與上述熱噴塗陶瓷皮膜相比填充密度較低之陶瓷層或添加分散有陶瓷粒子之樹脂層。For example, the resin molded article according to claim 1 has a ceramic layer having a lower packing density than the thermal sprayed ceramic film or a resin layer in which ceramic particles are dispersed between the resin structure and the thermal sprayed ceramic film. 如請求項1之樹脂成形體，其中上述樹脂構造體於與設置有熱噴塗陶瓷皮膜之正面對向之背面具有加強肋。The resin molded body according to claim 1, wherein the resin structure has a reinforcing rib on a back surface facing a front surface on which the thermal spray ceramic film is provided. 如請求項1之樹脂成形體，其中於上述熱噴塗陶瓷皮膜之間隙部包含樹脂。The resin molded article according to claim 1, wherein a resin is contained in the gap portion of the thermally sprayed ceramic film. 如請求項5之樹脂成形體，其中上述樹脂包含氟或矽。The resin molded article according to claim 5, wherein the resin contains fluorine or silicon. 如請求項1之樹脂成形體，其中上述熱噴塗陶瓷皮膜之表面為研磨面。The resin molded article according to claim 1, wherein the surface of the thermal sprayed ceramic film is a polished surface. 一種廚房檯，其包含如請求項1至7中任一項之樹脂成形體。A kitchen counter includes the resin molded body according to any one of claims 1 to 7. 一種浴室用地板，其包含如請求項1至7中任一項之樹脂成形體。A bathroom floor comprising the resin molded body according to any one of claims 1 to 7. 一種便器，其包含如請求項1至7中任一項之樹脂成形體。A toilet comprising the resin molded body according to any one of claims 1 to 7. 一種洗臉化妝台，其包含如請求項1至7中任一項之樹脂成形體。A face washing and dressing table including the resin molded body according to any one of claims 1 to 7. 一種樹脂成形體之製造方法，其包含： 成形樹脂構造體之成形步驟、及 於上述樹脂構造體之至少一部分之表面藉由熱噴塗而形成熱噴塗陶瓷皮膜之熱噴塗步驟。A method for manufacturing a resin molded body, comprising: a molding step of molding a resin structure; and a thermal spraying step of forming a thermal sprayed ceramic film on the surface of at least a part of the resin structure by thermal spraying. 如請求項12之樹脂成形體之製造方法，其於上述成形步驟與上述熱噴塗步驟之間包含形成與上述熱噴塗陶瓷皮膜相比填充密度較低之陶瓷層或添加分散有陶瓷粒子之樹脂層的基底層形成步驟。For example, the method for manufacturing a resin molded article according to claim 12, which includes forming a ceramic layer having a lower packing density than the thermal spray ceramic film or adding a resin layer in which ceramic particles are dispersed between the molding step and the thermal spraying step. A base layer forming step. 如請求項12之樹脂成形體之製造方法，其於成形步驟後包含對上述樹脂構造體之上述至少一部分之表面進行粗面化之粗面化步驟。The method for manufacturing a resin molded article according to claim 12, further comprising a roughening step of roughening the surface of the at least a part of the resin structure after the forming step. 如請求項12至14中任一項之樹脂成形體之製造方法，其中於熱噴塗步驟中，藉由複數之熱噴塗而形成上述熱噴塗陶瓷皮膜。The method for manufacturing a resin molded body according to any one of claims 12 to 14, wherein in the thermal spraying step, the thermal sprayed ceramic film is formed by a plurality of thermal sprays.
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