WO2017179545A1 - Corps moulé en résine et son procédé de fabrication, comptoir de cuisine, plancher de salle de bains, cuvette de toilettes et lavabo - Google Patents

Corps moulé en résine et son procédé de fabrication, comptoir de cuisine, plancher de salle de bains, cuvette de toilettes et lavabo Download PDF

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Publication number
WO2017179545A1
WO2017179545A1 PCT/JP2017/014694 JP2017014694W WO2017179545A1 WO 2017179545 A1 WO2017179545 A1 WO 2017179545A1 JP 2017014694 W JP2017014694 W JP 2017014694W WO 2017179545 A1 WO2017179545 A1 WO 2017179545A1
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WO
WIPO (PCT)
Prior art keywords
resin
molded body
resin molded
ceramic coating
body according
Prior art date
Application number
PCT/JP2017/014694
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English (en)
Japanese (ja)
Inventor
柴田　哲司
功一 増川
Original Assignee
パナソニックＩｐマネジメント株式会社
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Publication date
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Publication of WO2017179545A1 publication Critical patent/WO2017179545A1/fr

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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

Definitions

  • the present invention relates to a resin molded body used for, for example, water-related housing equipment.
  • Examples of water-related housing equipment include system kitchens, unit baths, vanities, and toilets. These water-based housing equipment are required to be easy to install and require durability. For example, in a system kitchen, it is necessary to improve heat resistance and improve durability.
  • the system kitchen includes a kitchen counter (counter top plate) and a sink.
  • a kitchen counter As a kitchen counter, Patent Document 1 discloses a kitchen counter using marble. This marble kitchen counter is preferably used from the viewpoint of heat resistance and aesthetics.
  • Patent Document 2 discloses a sink in which, for example, a base material made of a metal such as stainless steel is formed with a coating layer made of glazed glass.
  • an object of the present invention is to provide a lightweight, highly durable, and inexpensive resin molded body that can be used for, for example, water-based housing equipment.
  • the resin molded body according to the present invention includes a resin structure and a sprayed ceramic coating provided on at least a part of the surface of the resin structure.
  • FIG. 4B is a cross-sectional view taken along the line CC in FIG. 4A. It is sectional drawing which expands and shows a part of FIG. 4B.
  • FIG. 6B is a sectional view taken along line FF in FIG. 6B. It is a perspective view which shows the surface which opposes the surface in which the thermal spraying ceramic membrane
  • the resin molded body 1 according to the first embodiment 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, for example, a resin structure 10 that is a structure in which a counter part and a sink part are integrally formed by casting, and a thermal spray ceramic provided on the upper surface of the resin structure 10. And a coating 10c.
  • the resin molded body 1 configured as described above uses the resin structure 10 as a structure, the resin molded body 1 can be made lighter than a kitchen counter using marble.
  • the resin molded body 1 of the first embodiment is provided with the thermal sprayed ceramic coating 10c having high heat resistance on the surface of the resin structure 10, the heat resistance can be increased and, as a result, the durability can be increased. Therefore, according to the resin molding 1 of Embodiment 1, a lightweight and highly durable kitchen counter can be provided. Further, the sprayed ceramic coating 10c can be formed by spraying with a spray gun, as will be described later.
  • the resin molded body 1 of Embodiment 1 can reproduce, for example, a marble-like pattern or have a marble-like texture by the thermal sprayed ceramic coating 10c. Can be improved.
  • the resin molded body 1 will be described in detail.
  • the resin structure 10 is made by, for example, integrally molding a plate-shaped counter portion that is a cooking table and a tank-shaped sink portion by, for example, cast molding.
  • a thermosetting resin such as an epoxy resin, a vinyl ester resin, an unsaturated polyester resin, or an acrylic resin is used.
  • the resin structure 10 may contain an inorganic filler. By including the inorganic filler, the thermal expansion coefficient of the resin structure 10 can be reduced, and the thermal expansion coefficient of the thermal sprayed ceramic film to be deposited later can be brought close, and the heat resistance of the resin structure 10 can be increased.
  • the sprayed ceramic coating 10c is a coating in which flat ceramic particles 100 are deposited by fusing between adjacent ones.
  • the thermal sprayed ceramic coating 10c is formed by a large number of ceramic particles heated and melted or softened colliding with the surface of the resin structure 10 and sequentially depositing.
  • alumina (Al 2 O 3 ), mullite (Al 2 O 3 —SiO 2 ), titania (TiO 2 ), or the like can be used as the ceramic material for the thermal sprayed ceramic coating 10c.
  • the film thickness of the thermal sprayed ceramic coating 10c is not particularly limited, but is, for example, in the range of 0.01 to 3.0 mm, preferably in the range of 0.05 to 1.0 mm, and more preferably 0.2. It is set in the range of ⁇ 0.5 mm.
  • the sprayed ceramic coating 10c is a coating in which flat ceramic particles 100 are fused and deposited between adjacent ones, there are pores (gaps) between the ceramic particles 100 after spraying.
  • the thermal sprayed ceramic coating 10c may include a resin filled in the gap.
  • the resin 102 filled in the gaps between the ceramic particles 100 can further improve the durability by preventing water and oil from entering the sprayed ceramic coating 10c.
  • the resin 102 filled in the gap portion of the thermal sprayed ceramic coating 10c preferably contains fluorine or silicon, which makes it difficult to get dirty and facilitates cleaning.
  • the surface of the thermal sprayed ceramic film 10c is preferably a polished surface, which is excellent in aesthetics, can suppress the adhesion of dirt, and can be easily cleaned.
  • Ceramic underlayer 10a In the resin molded body 1 of the first embodiment, a ceramic base layer 10a may be included between the resin structure 10 and the thermal sprayed ceramic coating 10c as necessary.
  • the ceramic base layer 10a is made of, for example, a ceramic layer having a low packing density, for example, a large number of pores, as compared with the thermal sprayed ceramic coating 10c.
  • a resin layer in which ceramic particles are added and dispersed may be used as the ceramic base layer 10a. The ceramic base layer 10a suppresses the heat at the time of thermal spraying from being transmitted to the resin structure 10, and suppresses melting or deterioration of the resin.
  • the stress caused by the difference in thermal expansion coefficient between the thermal sprayed ceramic coating 10c and the resin structure 10 can be relaxed, the peeling of the ceramic base layer 10a can be prevented, and the durability of the resin molded body 1 can be improved.
  • the ceramic material of the ceramic base layer 10a mullite, alumina, titania, or the like can be used.
  • the ceramic underlayer 10a can be formed by a thermal spraying method with increased porosity. Or it can form by mixing and apply
  • the manufacturing method of the resin molding 1 is demonstrated, referring FIG. Resin Structure Molding Step
  • the resin structure 10 is formed by molding.
  • the resin molded body 1 for a kitchen counter according to the first embodiment is manufactured by, for example, injecting a monomer resin into a cavity of a clamped mold and curing it (cast molding).
  • the molding method of the resin structure 10 is not limited to cast molding, and may be molded by press molding or injection molding, for example.
  • the surface roughening by the above method for example, a sink-integrated kitchen counter like the resin molded body 1, the entire upper surface of the resin molded body 1 is roughened across the counter 11 and the sink 12. Even in such a case, the surface can be roughened with uniform surface roughness.
  • the adhesion between the resin structure 10 and the sprayed ceramic coating 10c is improved. Can be high. Further, by roughening the surface so as to have a surface roughness in the above range, the adhesion between the resin structure 10 and the ceramic underlayer 10a and between the resin structure 10 and the thermal sprayed ceramic coating 10c can be further increased.
  • a ceramic base layer 10a is formed on the surface of the roughened resin structure 10 (FIG. 3C).
  • the ceramic underlayer 10a is a ceramic layer having a lower packing density (in other words, a higher porosity) than the thermal sprayed ceramic coating 10c, and is formed of, for example, 20 to 50%.
  • the porosity of the ceramic base layer 10a is set in the range of 30% to 40%, for example.
  • the ceramic underlayer 10a can also be formed by mixing and applying ceramic particles with a resin binder.
  • the resin binder can be formed of an epoxy resin or an acrylic resin. This mixture of resin binder and ceramic particles can be disposed on the surface of the resin structure 10 roughened by spray coating, coating by a coater, brush coating, or the like.
  • the volume ratio of the resin binder to the ceramic particles after drying is 0.5 to 50%, preferably 5 to 30%.
  • Thermal spraying step Then, the ceramic particles melted or softened by the thermal spray gun 7 are collided on the ceramic base layer 10a to deposit the ceramic particles, thereby forming the thermal sprayed ceramic coating 10c.
  • the thermal spraying method flame spraying, arc thermal spraying, laser thermal spraying, plasma thermal spraying, and the like can be selected from various thermal spraying methods in consideration of the thermal spraying object, work environment, and the like.
  • different ceramic particles may be sprayed simultaneously using a plurality of spray guns 7 to form the sprayed ceramic coating 10c. In this way, for example, the decorativeness can be improved by changing the color of the surface.
  • thermal spraying process different ceramic particles may be sprayed alternately using a plurality of thermal spray guns to form the thermal sprayed ceramic coating 10c.
  • a sprayed ceramic coating having a plurality of functions such as corrosion resistance and heat resistance can be formed.
  • the resin is impregnated (filled) in the pores of the thermal sprayed ceramic coating 10c formed by thermal spraying and cured (sealing treatment).
  • the resin to be impregnated for example, an epoxy resin, an acrylic resin, a silicone resin, or the like can be used.
  • this sealing treatment when the thermal sprayed ceramic coating 10c is formed by thermal spraying, pores exist with a porosity of, for example, 1 to 10% in the coating immediately after thermal spraying. If such pores exist, a substance that causes corrosion may reach the resin structure 10 through the pores, and the resin structure 10 may be corroded. The sealing process is performed to prevent this. In addition, if resin is contained in the pores of the thermal sprayed ceramic coating 10c, that is, the gaps, the pores are blocked, and the gaps are not contaminated and cleaning is easy.
  • a kitchen counter that is lightweight, highly durable, and easy to clean can be manufactured.
  • the thermal sprayed ceramic coating 10 c is formed on the entire upper surface of the resin structure 10 across the kitchen counter part and the sink part of the resin structure 10.
  • the thermal sprayed ceramic coating 10 c may be provided on at least a part of the upper surface of the resin structure 10.
  • the sprayed ceramic coating 10 c may be provided only on the upper surface of the kitchen counter portion of the resin structure 10, or the sprayed ceramic coating 10 c may be provided only on the upper surface of the sink portion. .
  • the resin molded body 1 of Embodiment 1 described above as a preferred embodiment, the resin molded body 1 including the ceramic base layer 10a and the manufacturing method thereof have been described.
  • the ceramic base layer 10a is formed as necessary and is optional.
  • the thermal spraying process the thermal degradation of the resin structure 10 is suppressed by reducing the particle size of the ceramic particles to be sprayed or suppressing the temperature of the ceramic particles while maintaining melting or softening, and the ceramic base layer 10a is omitted. be able to.
  • the configuration in which the resin is included in the gap between the ceramic particles 100 of the sprayed ceramic coating 10c has been described.
  • the resin is arbitrarily filled in the gaps between the ceramic particles 100 as necessary.
  • the durability of the resin molded body 1 is improved and the resin filling between the ceramic particles 100 is eliminated. Also good.
  • the surface of the sprayed ceramic film 10c may be resin-coated without filling the resin between the ceramic particles 100.
  • FIG. 4A the resin molded body 2 of Embodiment 2 according to the present invention is a bathroom floor pan, and a wash floor 21 and a drain 22 on the wash floor side are integrally formed.
  • the resin molded body 2 according to the second embodiment includes, for example, a resin structure 20 that is a structure in which a washing section and a drainage section are integrally formed by press molding, and a resin structure.
  • a thermal sprayed ceramic coating 20 c provided on the upper surface of the body 20.
  • reference numeral 25 denotes a support portion that supports the bathroom floor pan.
  • the sprayed ceramic coating 20c is configured in the same manner as the sprayed ceramic coating 10c of the first embodiment, and details thereof are omitted. Further, in the resin molded body 2 of the second embodiment, the sprayed ceramic coating 20c may include a resin filled in the gaps between the ceramic particles, like the sprayed ceramic coating 10c of the first embodiment. Furthermore, the resin molded body 2 of Embodiment 2 may include a ceramic base layer as necessary, as in Embodiment 1.
  • a bathroom floor pan that is lightweight, highly durable, and inexpensive can be provided.
  • FIG. 5A the resin molded body 3 of Embodiment 3 according to the present invention is a toilet, and the bowl portion 31, the drain port portion 32, and the outer support portion 33 are integrally formed.
  • the resin molded body 3 of Embodiment 3 is a resin structure 30 that is a structure in which a bowl portion, a drain port portion, and an outer support portion are integrally formed by injection molding, for example. And a thermal sprayed ceramic coating 30 c provided on the upper surface of the resin structure 30.
  • the sprayed ceramic coating 30c is configured in the same manner as the sprayed ceramic coating 10c of the first embodiment, and details thereof are omitted. Further, in the resin molded body 3 of the third embodiment, the thermal sprayed ceramic coating 30c may include a resin filled in the gaps between the ceramic particles, like the thermal sprayed ceramic coating 10c of the first embodiment. Further, the resin molded body 3 of the third embodiment may include a ceramic base layer as necessary, as in the first embodiment.
  • a toilet bowl that is lightweight, highly durable, and inexpensive can be provided.
  • Embodiment 4 FIG.
  • the resin molded body 4 of Embodiment 4 which concerns on this invention is a wash counter as shown to FIG. 6A, and the counter part 41 and the wash bowl part 42 are comprised integrally.
  • the resin molded body 4 of Embodiment 4 includes a resin structure 40 that is a structure in which the counter portion and the wash bowl portion are integrally formed by, for example, cast molding, and a resin.
  • a thermal sprayed ceramic coating 40 c provided on the upper surface of the structure 40.
  • the sprayed ceramic coating 40c is configured in the same manner as the sprayed ceramic coating 10c of the first embodiment, and details thereof are omitted. Further, in the resin molded body 4 of the fourth embodiment, the sprayed ceramic coating 40c may include a resin filled in the gaps between the ceramic particles, like the sprayed ceramic coating 10c of the first embodiment. Furthermore, the resin molded body 4 of Embodiment 4 may include a ceramic base layer as necessary, as in Embodiment 1.
  • Embodiment 4 According to the resin molded body 4 of Embodiment 4 configured as described above, it is possible to provide a light, durable and inexpensive wash counter.
  • the resin molded body according to the present invention is not limited to the specific examples of Embodiments 1 to 4, and can be widely applied to, for example, water-based housing equipment, thereby being lightweight and durable. High-priced and inexpensive housing equipment can be provided.
  • a reinforcing rib 51 is provided on the back surface of the resin structure opposite to the surface on which the sprayed ceramic coating is provided. It may be. If it does in this way, the curvature or deformation
  • the resin molded body according to the present invention is lightweight and highly durable, and is inexpensive, so by applying to a kitchen counter, a bathroom floor pan, a toilet and a vanity, etc., it is lightweight and highly durable. It is possible to provide water-based housing equipment that can be easily installed at low cost.

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

Abstract

L'invention concerne un corps moulé en résine léger, durable et peu coûteux qui peut être utilisé, par exemple, dans un équipement domestique de pièce humide. Le corps moulé en résine comprend une structure en résine et un film en céramique pulvérisé disposé sur au moins une partie d'une surface de la structure en résine.
PCT/JP2017/014694 2016-04-12 2017-04-10 Corps moulé en résine et son procédé de fabrication, comptoir de cuisine, plancher de salle de bains, cuvette de toilettes et lavabo WO2017179545A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
JP2016-079639 2016-04-12
JP2016079639A JP6785438B2 (ja) 2016-04-12 2016-04-12 樹脂成形体の製造方法

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WO2017179545A1 true WO2017179545A1 (fr) 2017-10-19

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TW (1) TW201806762A (fr)
WO (1) WO2017179545A1 (fr)

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2019208092A1 (fr) * 2018-04-23 2019-10-31 パナソニックＩｐマネジメント株式会社 Corps moulé en résine
WO2020217584A1 (fr) * 2019-04-25 2020-10-29 パナソニックＩｐマネジメント株式会社 Corps moulé en résine, matériau de construction mettant en œuvre un corps moulé en résine, et procédé de fabrication de corps moulé en résine

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN110475900A (zh) * 2017-04-14 2019-11-19 松下知识产权经营株式会社 树脂成型体及其制造方法、以及厨房台面、浴室用地板、便器和洗脸梳妆台

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JPH11350574A (ja) * 1998-06-05 1999-12-21 Inax Corp 防汚性物品および防汚性物品の製造方法
JP2001025437A (ja) * 1999-07-13 2001-01-30 Tiger Vacuum Bottle Co Ltd 保温容器
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JP2001270015A (ja) * 2000-03-23 2001-10-02 Tocalo Co Ltd 耐摩耗性に優れるプラスチック基複合材料およびその製造方法
JP2012091484A (ja) * 2010-10-27 2012-05-17 Nippon Yuteku Kk 繊維強化プラスチック基複合材料及びその製造方法
WO2013099040A1 (fr) * 2011-12-26 2013-07-04 新日鉄マテリアルズ株式会社 Matériau composite renforcé en fibres résistant à l'usure et son procédé de fabrication
JP2014091998A (ja) * 2012-11-06 2014-05-19 Panasonic Corp 暖房機能付き床パン

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JP2003119087A (ja) * 2001-10-17 2003-04-23 Ngk Insulators Ltd 複合コーティング材料、積層体、耐蝕性部材、耐ハロゲンガスプラズマ用部材および複合コーティング材料の製造方法
JP4736963B2 (ja) * 2006-06-02 2011-07-27 株式会社村田製作所 積層セラミック電子部品の製造方法

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Publication number Priority date Publication date Assignee Title
JPH1161373A (ja) * 1997-08-27 1999-03-05 Pentel Kk 電気化学的な生物制御用または防汚用部材
JPH11350574A (ja) * 1998-06-05 1999-12-21 Inax Corp 防汚性物品および防汚性物品の製造方法
JP2001025437A (ja) * 1999-07-13 2001-01-30 Tiger Vacuum Bottle Co Ltd 保温容器
JP2001079068A (ja) * 1999-09-14 2001-03-27 Shinshu Ceramics:Kk 光触媒処理体
JP2001270015A (ja) * 2000-03-23 2001-10-02 Tocalo Co Ltd 耐摩耗性に優れるプラスチック基複合材料およびその製造方法
JP2012091484A (ja) * 2010-10-27 2012-05-17 Nippon Yuteku Kk 繊維強化プラスチック基複合材料及びその製造方法
WO2013099040A1 (fr) * 2011-12-26 2013-07-04 新日鉄マテリアルズ株式会社 Matériau composite renforcé en fibres résistant à l'usure et son procédé de fabrication
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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2019208092A1 (fr) * 2018-04-23 2019-10-31 パナソニックＩｐマネジメント株式会社 Corps moulé en résine
CN111670116A (zh) * 2018-04-23 2020-09-15 松下知识产权经营株式会社 树脂成型体
JPWO2019208092A1 (ja) * 2018-04-23 2020-12-10 パナソニックＩｐマネジメント株式会社 樹脂成形体
EP3785903A4 (fr) * 2018-04-23 2021-06-23 Panasonic Intellectual Property Management Co., Ltd. Corps moulé en résine
WO2020217584A1 (fr) * 2019-04-25 2020-10-29 パナソニックＩｐマネジメント株式会社 Corps moulé en résine, matériau de construction mettant en œuvre un corps moulé en résine, et procédé de fabrication de corps moulé en résine
JPWO2020217584A1 (ja) * 2019-04-25 2021-12-02 パナソニックＩｐマネジメント株式会社 樹脂成形体、樹脂成形体を用いた建築部材、および樹脂成形体の製造方法

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JP2017189890A (ja) 2017-10-19
TW201806762A (zh) 2018-03-01

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