JPH03193315A - Manufacture of bathtub with cast layer - Google Patents
Manufacture of bathtub with cast layerInfo
- Publication number
- JPH03193315A JPH03193315A JP33386189A JP33386189A JPH03193315A JP H03193315 A JPH03193315 A JP H03193315A JP 33386189 A JP33386189 A JP 33386189A JP 33386189 A JP33386189 A JP 33386189A JP H03193315 A JPH03193315 A JP H03193315A
- Authority
- JP
- Japan
- Prior art keywords
- mold
- layer
- casting
- cast
- concave
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Pending
Links
- 238000004519 manufacturing process Methods 0.000 title claims description 16
- 238000005266 casting Methods 0.000 claims abstract description 54
- 229920005989 resin Polymers 0.000 claims abstract description 21
- 239000011347 resin Substances 0.000 claims abstract description 21
- 230000003014 reinforcing effect Effects 0.000 claims abstract description 12
- 238000000034 method Methods 0.000 claims abstract description 8
- 239000011152 fibreglass Substances 0.000 claims abstract description 4
- 238000000465 moulding Methods 0.000 claims description 6
- 239000004033 plastic Substances 0.000 claims description 2
- 229920003023 plastic Polymers 0.000 claims description 2
- 239000011342 resin composition Substances 0.000 abstract description 32
- 238000000926 separation method Methods 0.000 abstract 1
- 239000010410 layer Substances 0.000 description 86
- 238000005406 washing Methods 0.000 description 12
- 238000002347 injection Methods 0.000 description 11
- 239000007924 injection Substances 0.000 description 11
- 239000003677 Sheet moulding compound Substances 0.000 description 7
- 230000000873 masking effect Effects 0.000 description 7
- 238000012856 packing Methods 0.000 description 7
- 229920006337 unsaturated polyester resin Polymers 0.000 description 6
- 239000007921 spray Substances 0.000 description 5
- 239000003795 chemical substances by application Substances 0.000 description 4
- 239000000203 mixture Substances 0.000 description 4
- 239000011162 core material Substances 0.000 description 3
- 239000003822 epoxy resin Substances 0.000 description 3
- 239000003365 glass fiber Substances 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- 229920000647 polyepoxide Polymers 0.000 description 3
- 240000007182 Ochroma pyramidale Species 0.000 description 2
- 239000003086 colorant Substances 0.000 description 2
- 239000000945 filler Substances 0.000 description 2
- 239000006082 mold release agent Substances 0.000 description 2
- 239000012778 molding material Substances 0.000 description 2
- 230000002787 reinforcement Effects 0.000 description 2
- 238000007789 sealing Methods 0.000 description 2
- 239000002356 single layer Substances 0.000 description 2
- 239000002344 surface layer Substances 0.000 description 2
- 239000002023 wood Substances 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 1
- 239000003054 catalyst Substances 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 238000000576 coating method Methods 0.000 description 1
- 238000007796 conventional method Methods 0.000 description 1
- 238000005553 drilling Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000001746 injection moulding Methods 0.000 description 1
- 239000012779 reinforcing material Substances 0.000 description 1
- 238000011160 research Methods 0.000 description 1
- 239000010959 steel Substances 0.000 description 1
- 238000013022 venting Methods 0.000 description 1
Landscapes
- Moulds For Moulding Plastics Or The Like (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
Abstract
Description
【発明の詳細な説明】
〔産業上の利用分野〕
本発明は、別途、ガラス繊維強化プラスチックで成形し
製造された成形品（浴槽）を注形型凹型とし、かつ該凹
型を不飽和ポリエステル樹脂による注形樹脂層と一体化
し裏面補強層とした注形層付き浴槽の製造法の改良に関
する。[Detailed Description of the Invention] [Industrial Application Field] The present invention separately provides a molded product (bathtub) manufactured by molding glass fiber reinforced plastic into a concave casting mold, and the concave mold is made of unsaturated polyester resin. This invention relates to an improvement in the manufacturing method of a bathtub with a cast layer that is integrated with a cast resin layer and has a back reinforcing layer.
従来の注形法による高級浴槽の製造法では、注形型とし
て、凹凸両型共専用型を用いて注形するため、浴槽表面
全体がゲルコート層、又は注形層で構成される。それ故
、浴槽表面の１部分のみをゲルコート層、又は注形層と
したい場合、その部分だけを別途注形し、浴槽内面部に
接着する方法が取られている。その場合、内面層となる
注形成形品は非常に高い寸法精度が要求され、又、その
注形成形品の脱型後の変形等で裏面側になるＦＲＰ浴槽
との接着を完全にすることが出来ず、満足した高級浴槽
が得られなかった。In the conventional manufacturing method of high-quality bathtubs using the casting method, casting is carried out using a dedicated mold for both uneven and convex molds, so the entire surface of the bathtub is composed of a gel coat layer or a casting layer. Therefore, when it is desired to make only one part of the bathtub surface a gel coat layer or a cast layer, a method is used in which only that part is separately cast and adhered to the inner surface of the bathtub. In that case, the cast molded product that will become the inner layer is required to have extremely high dimensional accuracy, and due to deformation of the cast molded product after demolding, etc., it is necessary to ensure perfect adhesion to the FRP bathtub that will be the back side. Therefore, I was unable to obtain a luxurious bathtub that I was satisfied with.
そこで本発明者らは先に、凹凸型を用いて注形浴槽を製
造するに際して、ＦＲＰ製凹型と注形用不飽和ポリエス
テル樹脂組成物とを一体化成形し、該凹型を裏面補強層
としたことを特徴とする注形浴槽の製造方法を提案した
。（特願昭６３−９５１３４号）この製造方法について
、手順に従って説明する。Therefore, when manufacturing a cast bathtub using a concave-convex mold, the present inventors first integrally molded an FRP concave mold and an unsaturated polyester resin composition for casting, and used the concave mold as a back reinforcing layer. We proposed a method for manufacturing a cast bathtub characterized by the following. (Japanese Patent Application No. 63-95134) This manufacturing method will be explained according to the procedure.
（１）凸型成形型の周辺部全周をマスキングテープでも
ってマスキングする。(1) Mask the entire periphery of the convex mold with masking tape.
（２）凸型成形型の表面を離型剤を塗布する。(2) Apply a release agent to the surface of the convex mold.
（３）製品の表面層となる凸型成形型の表面にゲルコー
）Ｊｌを形成するゲルコート用不飽和ポリエステル樹脂
組成物等をスプレー又は刷毛で均一に塗布する。(3) An unsaturated polyester resin composition for gel coat, etc. for forming Gel Coat (Jl) is uniformly applied by spray or brush to the surface of the convex mold that will become the surface layer of the product.
（４） （１）の工程で貼り付けたマスキングテープを
除去する。(4) Remove the masking tape applied in step (1).
（５）硬化炉に入れて、ゲルコート層を硬化させる。(5) Place in a curing oven to cure the gel coat layer.
（６）他方、凹型となるＦＲＰ成形品の注形樹脂層を設
ける部分の表面を機械的、又は手動によりサンディング
処理する。(6) On the other hand, the surface of the portion of the concave FRP molded product where the casting resin layer is to be provided is mechanically or manually sanded.
（７）浴槽底面部等、注形成形特最高位置となる部分に
、樹脂組成物注入口及び空気抜き口をドリル等穴加工す
る。(7) Drill or otherwise drill a resin composition inlet and an air vent in the bottom of the bathtub, which is the highest position of the casting mold.
（８）ゲルコート層が硬化した凸型成形型の周囲全周に
シール用パツキンを溝に添ってはめ込む。(8) Fit a sealing gasket along the groove around the entire circumference of the convex mold in which the gel coat layer has been cured.
（９）サンディング処理及び穴加工した凹型成形品を凸
型成形型の上にかぶせ周囲を固定クランプで固定するこ
とにより凸型と凹型とを密着固定する。(9) The sanded and holed concave molded product is placed over the convex mold and the periphery is fixed with a fixing clamp to tightly fix the convex and concave molds.
（１０）凹型成形品の側面平面部等の変形しやすい箇所
に、別途作成した補強枠をはめ、樹脂組成物注入時の凹
型の変形防止を行う。(10) A separately prepared reinforcing frame is fitted to easily deformable parts such as side plane parts of the concave molded product to prevent deformation of the concave mold when the resin composition is injected.
（１１）凹凸両型のすき間に、不飽和ポリエステル樹脂
、充てん荊、硬化剤、促進剤、触媒、着色剤等を配合し
た樹脂組成物を凹型成形品の注入口より注入する。(11) A resin composition containing an unsaturated polyester resin, a filler, a curing agent, an accelerator, a catalyst, a coloring agent, etc. is injected into the gaps between the concave and convex molds through the injection port of the concave molded product.
（１２）注入後、エアーバイブレータ−で、樹脂組成物
中に内包した空気を抜く。(12) After injection, remove the air contained in the resin composition using an air vibrator.
（１３）硬化炉に入れて、樹脂組成物を硬化させる。(13) Place in a curing furnace to cure the resin composition.
（１４）硬化後、炉より取出し、凹凸両型を固定してい
るクランプ及び変形防止用補強枠を取除く。(14) After curing, take it out of the oven and remove the clamps fixing both the concave and convex molds and the reinforcing frame for preventing deformation.
（１５）凸型成形型に設けた離型用空気口より圧縮空気
を圧入して、凸型成形型を離型する。(15) Pressurize compressed air through the release air port provided in the convex mold to release the convex mold.
（１６）離型後、注形層と凹型成形品との境界部分の仕
上げを行う。(16) After releasing the mold, finish the boundary between the cast layer and the concave molded product.
この製造方法では凹型と補強層とを兼用したＦＲＰ成形
品を用いるため、従来のように後接着等の煩雑な工程を
経ることなく、ＦＲＰ浴槽の一部分に注形層が一体とな
った注形層材浴槽を容易に得ることが出来た。This manufacturing method uses an FRP molded product that serves as both a concave mold and a reinforcing layer, so the cast layer is integrated into a part of the FRP bathtub without the need for complicated processes such as post-adhesion as in conventional methods. A layered bathtub could be easily obtained.
しかしながら、凹型が専用成形型でなしにＦＲＰ成形品
であるためバラツキがみられて凹凸型のシールが常に完
全とはならなかった。また、注形用樹脂組成物の硬化収
縮にともなって裏面補強層が変形したり逆に剥離したり
する等の欠点もみられた。However, since the concave mold is not a dedicated mold but an FRP molded product, there are variations and the seal of the concave and convex mold is not always perfect. Further, there were also drawbacks such as deformation or peeling of the back reinforcing layer as the casting resin composition cured and shrank.
本発明の目的は、常時凹凸型のシールを完全に行うこと
ができ、しかも注形用樹脂組成物の硬化収縮による裏面
補強層への影響を少くして変形や剥離を防止し、両層の
密着性を向上させた注形層付き浴槽を提供することにあ
る。The purpose of the present invention is to be able to completely seal the uneven surface at all times, and to reduce the influence of curing shrinkage of the casting resin composition on the back reinforcing layer to prevent deformation and peeling, and to prevent deformation and peeling of both layers. An object of the present invention is to provide a bathtub with a cast layer that has improved adhesion.
本発明者らは、上記の課題を解決すべく鋭意研究した結
果、本発明を完成するに至った。The present inventors have completed the present invention as a result of intensive research to solve the above problems.
即ち、本発明は、凹凸型を用いて注形層付き浴槽を製造
するに際し、まず凹凸注形専用型を用いて単層ないしは
複層の注形樹脂層を成形し、次いでこの注形専用凹型に
代えてガラス繊維強化プラスチック製凹型を用いて最終
注形樹脂層を成形し、当該プラスチック製凹型を注形樹
脂層と一体化してそのまま裏面補強層としたことを特徴
とする注形層付き浴槽の製造法に関する。That is, when manufacturing a bathtub with a cast layer using a concave-convex mold, the present invention first molds a single or multi-layer cast resin layer using a concave-convex mold, and then uses this concave mold exclusively for casting. A bathtub with a cast layer, characterized in that the final cast resin layer is molded using a concave mold made of glass fiber reinforced plastic instead of the mold, and the concave plastic mold is integrated with the cast resin layer to directly serve as a back reinforcing layer. Concerning the manufacturing method.
以下図面に基づいて本発明の詳細な説明する。 The present invention will be described in detail below based on the drawings.
第１図に示す洗い場付浴槽を例にとり説明すると、ＦＲ
Ｐ製凹型Ｂとなる洗い基材浴槽成形品の１部分である浴
槽部分に注形７！（１＋２）を設ける場合、先ず第２注
形層用の凹型となるＦＲＰ成形品Ｂの表面に全注形層（
１＋２）の厚みに相当する厚さのシート・ワックス、バ
ルサコアー等を貼り付けて、これを型として、浴槽表面
側の成形型となる凸型注形型Ｃをエポキシ樹脂等の樹脂
とガラス繊維等の強化材とを用いて作成する。この場合
、ベースとなる凹型成形型Ｂは、通常のＦＲＰ成形品（
洗い場付浴槽）であるため、変形しない様に裏面側で充
分補強した上で凸型成形型Ｃを作成する必要がある。Taking the bathtub with washing area shown in Fig. 1 as an example, the FR
Casting 7 on the bathtub part, which is a part of the washing base bathtub molded product that becomes the concave type B made of P! When (1+2) is provided, first the entire cast layer (
Paste a sheet wax, balsa core, etc. with a thickness equivalent to the thickness of 1+2), use this as a mold, and use a convex casting mold C, which will be the mold on the bathtub surface side, with resin such as epoxy resin, glass fiber, etc. Created using reinforcing materials. In this case, the base concave mold B is a normal FRP molded product (
Since it is a bathtub with a washing area), the convex mold C needs to be sufficiently reinforced on the back side to prevent deformation.
次に、この様に作成した凸型成形型Ｃの表面に第１Ｎ目
の注形層１の厚みに相当する厚みのシート・ワックス、
バルサコアー等を貼り付けて、これを型として第１Ｎ注
形用の成形型となる専用凹型注形型Ａを凸型成形型Ｃ作
成と同じ要領で作成する。Next, on the surface of the convex mold C created in this way, a sheet wax having a thickness corresponding to the thickness of the 1Nth casting layer 1,
A balsa core or the like is attached, and using this as a mold, a special concave casting mold A, which will be a mold for No. 1N casting, is created in the same manner as the convex mold C was created.
この様にして作成した凸型成形型Ｃと第１Ｎ注形用凹型
成形型Ａ及び第２層注形用凹型ＦＲＰ成形品Ｂとが密閉
シール出来る様に、凸型成形型Ｃの全周にシールパツキ
ン４貼付は用溝を設けると共に、凹、凸型固定用クラン
プ５を取付ける。本発明の第２層注形用ＦＲＰ製凹型成
形型Ｂは別途シートモールデイングコンパウンド（以！
ｆＬｓＭＣと呼ぶ）等を用いてプレス成形して得られた
ＦＲＰ成形品であり、浴槽もしくは洗い基材浴槽として
そのままでも製品として使用出来るものである。The entire circumference of the convex mold C was made so that the convex mold C thus created, the concave mold A for first N casting, and the concave FRP molded product B for second layer casting could be tightly sealed. To attach the seal packing 4, a groove is provided and a concave and convex fixing clamp 5 is attached. The FRP concave mold B for casting the second layer of the present invention is made using a separate sheet molding compound (hereinafter referred to as "!").
This is an FRP molded product obtained by press molding using a material such as fLsMC, and can be used as a product as it is as a bathtub or a washing base bathtub.
次に本発明による製造方法について、手順に従って説明
する。Next, the manufacturing method according to the present invention will be explained step by step.
（１）凸型成形型Ｃの周辺部全周をマスキングテープで
もってマスキングする。(1) Mask the entire periphery of the convex mold C with masking tape.
（２）凸型成形型Ｃの表面に離型剤を塗布する。(2) Apply a mold release agent to the surface of the convex mold C.
（３）製品の表面層となる凸型成形型Ｃの表面に透明性
を有するゲルコート層を形成するため、硬化剤、促進剤
を配合したゲルコート用不飽和ポリエステル樹脂組成物
をスプレー又は刷毛で均一に塗布する。(3) To form a transparent gel coat layer on the surface of the convex mold C, which will be the surface layer of the product, spray or brush uniformly an unsaturated polyester resin composition for gel coat containing a curing agent and an accelerator. Apply to.
（４） （１）の工程で貼り付けたマスキングテープを
凸型成形型Ｃより除去する。(4) Remove the masking tape applied in step (1) from the convex mold C.
（５）硬化炉に入れて、ゲルコート層を硬化させる。(5) Place in a curing oven to cure the gel coat layer.
（６）ゲルコート層が硬化した後、硬化炉より取出し、
凸型成形型Ｃの周囲全周にシール用パツキン４を溝に添
ってはめ込む。(6) After the gel coat layer is cured, take it out from the curing oven,
A sealing gasket 4 is fitted around the entire circumference of the convex mold C along the groove.
（７）離型処理を施した第１Ｎ注形用凹型成形型Ａを凸
型成形型Ｃの上にかぶせ、凸型Ｃと凹型Ａとを密着固定
するため固定クランプ５でもって全周固定を行う。(7) Cover the concave mold A for No. 1 N casting, which has been subjected to mold release treatment, over the convex mold C, and fix the entire circumference with the fixing clamp 5 in order to tightly fix the convex mold C and the concave mold A. conduct.
（８）凹凸両型のすき間に第１注形層１を設けるため、
不飽和ポリエステル樹脂、充填剤、硬化剤、促進剤、着
色剤等を配合した樹脂組成物を凹型成形型Ａの注入口６
ａより注入し、樹脂組成物が空気抜ロアａより少しオー
バーフローするまで注入する。(8) In order to provide the first cast layer 1 in the gap between the concave and convex molds,
A resin composition containing an unsaturated polyester resin, a filler, a curing agent, an accelerator, a coloring agent, etc. is poured into the injection port 6 of the concave mold A.
Inject from the air vent lower a until the resin composition slightly overflows from the air vent lower a.
（９）樹脂組成物注入完了後、エアーバイブレータ−で
、樹脂組成物中に内包した微細な空気を抜く。(9) After the injection of the resin composition is completed, use an air vibrator to remove the fine air contained in the resin composition.
（１０）室温４５〜６０℃にコントロールした硬化炉に
入れて、樹脂組成物を硬化させる。(10) The resin composition is cured by placing it in a curing furnace whose room temperature is controlled at 45 to 60°C.
（１１）硬化後、炉より注形型を取出し、凹凸両型を固
定している固定クランプ５をはずす。(11) After curing, take out the casting mold from the oven and remove the fixing clamp 5 that fixes both the concave and convex molds.
（以下の工程が従来の製造方法と異なる。）（１２）第
１注形層用凹型成形型Ａのみを離型するため、凹型成形
型Ａに設けた離型用空気口８ａより１〜４ ｋｇ／ｃ１
１の圧縮空気を圧入、脱型する。(The following steps are different from the conventional manufacturing method.) (12) In order to release only the concave mold A for the first casting layer, air ports 1 to 4 kg/c1
Inject compressed air from step 1 and demold.
（１３）次に、第２注形層を設けるための凹型ＦＲＰ成
形品型（ＦＲＰ成形品）Ｂの内表面をサンディング、及
び脱脂処理を施し、且つ浴槽底面の注入成形特最高位置
となる部分に、直径１〜２０ｆｌの穴を樹脂組成物注入
口６ｂ及び空気抜きロアｂとしてドリル等で穴加工する
。(13) Next, the inner surface of the concave FRP molding mold (FRP molded product) B for providing the second casting layer is sanded and degreased, and the part that will be the highest position of the injection molding on the bottom of the bathtub Then, holes with a diameter of 1 to 20 fl are drilled using a drill or the like to serve as the resin composition inlet 6b and the air vent lower b.
（１４） （１２）の工程で脱型した凸型成形型Ｃに、
（１３）の工程で処理、加工した第２層注形用凹型成形
型（ＦＲＰ成形品）Ｂをかぶせ、凹凸両型を固定、クラ
ンプ５でもって密着固定する。(14) In the convex mold C removed in step (12),
The concave mold for casting the second layer (FRP molded product) B treated and processed in step (13) is placed over the mold, and both the concave and convex molds are fixed and tightly fixed with the clamp 5.
（１５）凹凸両型のすき間に、第２注形樹脂層２を設け
るため、第１層と同質の樹脂組成物又は接着性良好なる
樹脂組成物を樹脂注入口６ｂより注入し、樹脂組成物が
空気抜ロアｂよりオーバフローするまで注入する。(15) In order to provide the second cast resin layer 2 in the gaps between the concave and convex molds, a resin composition of the same quality as the first layer or a resin composition with good adhesiveness is injected from the resin injection port 6b, and the resin composition is Inject until it overflows from the air vent lower b.
（１６）注入完了後、エアーバイブレータ−で、樹脂組
成物中に内包した空気を抜く。(16) After the injection is completed, remove the air contained in the resin composition using an air vibrator.
（１７）室温４５〜６０℃にコントロールした硬化炉に
注形した注形型を入れて、樹脂組成物を硬化させる。(17) The resin composition is cured by placing the cast mold into a curing furnace whose room temperature is controlled at 45 to 60°C.
（１８）硬化後、炉より取出し、凹凸両型を固定してい
るクランプ５をはずす。(18) After curing, take it out of the oven and remove the clamp 5 that fixes both the concave and convex molds.
（１９）凸型成形型Ｃに設けた離型用空気口９より１〜
４ ｋｇ／ｃｄの圧縮空気を圧入し、凸型成形型Ｃのみ
離型する。(19) From the mold release air port 9 provided in the convex mold C
Compressed air of 4 kg/cd was injected, and only the convex mold C was released.
（２０）離型後、注形層（１＋２）と凹型成形品との境
界部分の仕上げを行う。(20) After releasing the mold, finish the boundary between the cast layer (1+2) and the concave molded product.
以上の工程により、本発明の注形浴槽が製造される。Through the above steps, the cast bathtub of the present invention is manufactured.
尚、第１注形層は、単層とするほか、必要によっては複
層としてもよい。In addition, the first cast layer may be a single layer or may be a multilayer layer if necessary.
本発明の製造方法は、樹脂組成物による注形層を第１層
と第２層とに別けて注形する。第１層（単層ないしは複
層）で専用凹型を用いることにより、凸、凹型のシール
を完全にすることが出来ると共に注形樹脂組成物の硬化
収縮による変形を吸収し、第２層で凹型と裏面補強層と
を兼用したＦＲＰ成形品を用い、これにより従来のよう
に後接着等のための煩雑な工程を経ることなく、浴槽の
一部分に注形層が一体となった波形層付浴槽を得うるこ
とが出来る。In the manufacturing method of the present invention, a cast layer made of a resin composition is separately cast into a first layer and a second layer. By using a dedicated concave mold in the first layer (single layer or multilayer), it is possible to completely seal the convex and concave shapes, as well as absorb deformation caused by curing shrinkage of the casting resin composition, and the second layer can form a concave shape. By using an FRP molded product that also serves as a back reinforcement layer and a back reinforcement layer, this bathtub with a corrugated layer is integrated into a part of the bathtub without the complicated process of post-adhesion etc. It is possible to obtain.
尚、本発明は、特に洗い場付浴槽等の特殊浴槽の浴槽部
分を注形層で高級化することに著しい効果を発揮するも
のである。The present invention is particularly effective in upgrading the bathtub portion of a special bathtub such as a bathtub with a washing area using a cast layer.
以下、本発明を具体的な実施例にもとづいて説明する。 The present invention will be explained below based on specific examples.
実施例１ 洗い基材高級浴槽の製造
第２層注形用凹型成形型Ｂとなる洗い場付浴槽を成形材
料であるＳＭＣを用いて、金型で高温高圧成形を行う。Example 1 Production of high-grade bathtub with washing base material A bathtub with a washing area, which is to be a concave mold B for casting the second layer, is molded at high temperature and pressure using a mold using SMC as a molding material.
しかる後に当該成形品の浴槽部分の内側面、底面及び上
縁面に、厚みが６〜１５ｍになる様にシート・ワックス
を貼り付けると共に裏面をコアー材及び木材で変形防止
のため補強を行う。Thereafter, sheet wax is applied to the inner surface, bottom surface, and upper edge surface of the bathtub portion of the molded product to a thickness of 6 to 15 m, and the back surface is reinforced with core material and wood to prevent deformation.
このシートワックスを貼り付けた成形品をベースにして
凸型成形型Ｃをエポキシ樹脂及びガラス繊維を用いて作
成し、裏面を木材、鋼材等で補強する。次に凸型成形型
Ｃの表面に第１注形層の厚みとなる５、５〜１３ｍのシ
ート・ワックスを貼り付けて、凸型成形型Ｃと同様にエ
ポキシ樹脂及びガラス繊維を用いて作成し、裏面補強を
行い、第１層注形用凹型Ａを得た。A convex mold C is made using epoxy resin and glass fiber based on the molded product to which sheet wax is applied, and the back side is reinforced with wood, steel, etc. Next, a sheet wax with a thickness of 5.5 to 13 m, which is the thickness of the first casting layer, is pasted on the surface of the convex mold C, and it is made using epoxy resin and glass fiber in the same way as the convex mold C. Then, the back surface was reinforced to obtain a concave mold A for casting the first layer.
この様にして作成した凸型成形型Ｃに、注形樹脂層の境
目となる全周周辺部に幅５〜１０鶴、深さ１〜３ｆｌの
シールパツキン４用溝、凹型との密着固定用クランプ５
（１２〜１６ケ所）及び離型用空気口９（１ケ所）を、
第１層注形用凹型Ａに、注入時最高位置となる箇所に直
径２０〜５０ｗ１の注入口６ａ （１〜２ケ所）、直径
１〜２０ｎの空気抜ロアａ（４〜１０ケ所）及び側面下
部に離型用空気口８ａ （２〜４ケ所）を夫々後加工で
もって加工を行い、注形専用の凸型Ｃ１凹型Ａを得た。The convex mold C created in this way has a groove for the seal packing 4 with a width of 5 to 10 squares and a depth of 1 to 3 fl on the entire circumference, which is the boundary between the casting resin layers, for tightly fixing it to the concave mold. Clamp 5
(12 to 16 locations) and mold release air port 9 (1 location),
In the concave mold A for casting the first layer, there is an injection port 6a (1 to 2 places) with a diameter of 20 to 50W1 at the highest position during injection, an air vent lower a (4 to 10 places) with a diameter of 1 to 20N, and a side surface. The mold release air ports 8a (2 to 4 locations) were post-processed at the bottom to obtain a convex mold C1 and a concave mold A exclusively for casting.
次に、具体的製造工程に入る。先の凸型成形型Ｃのシー
ルパツキン用溝にシールパツキン４を嵌め込み、その上
にマスキングテープを２重に貼り付けてから、型表面を
離型材（ミラグレーズ）でもって離型処理を施す、その
後、型表面にゲルコート層として、下記表−１配合の樹
脂１．８〜２．２ｋｇをスプレーガンで吹付けを行い、
第１層目のマスキングテープのみを除去する。約１０分
間放置後、４５〜６０℃に温度コントロールした硬化炉
に１〜１．５時間入れて、ゲルコート層の樹脂を硬化さ
せる。凸型成形型Ｃを自然冷却後、更に中間層として下
記表−１配合の樹脂４．５〜５．０ ｋｇをスプレーガ
ンで吹付けを行い、第２層目のマスキングテープを除去
し前記硬化炉に入れて硬化させる。Next, we begin the specific manufacturing process. Fit the seal packing 4 into the seal packing groove of the convex mold C, apply masking tape twice on top of it, and then perform mold release treatment on the mold surface with a mold release material (Mira Glaze). , Spray 1.8 to 2.2 kg of the resin formulated in Table 1 below on the mold surface as a gel coat layer using a spray gun,
Remove only the first layer of masking tape. After being left for about 10 minutes, it is placed in a curing oven whose temperature is controlled at 45 to 60°C for 1 to 1.5 hours to cure the resin of the gel coat layer. After the convex mold C was naturally cooled, 4.5 to 5.0 kg of the resin blended in Table 1 below was sprayed as an intermediate layer using a spray gun, the second layer masking tape was removed, and the resin was cured. Put it in the oven to harden.
他方、第１層注形用凹型成形型への型表面を離型剤（ミ
ラグレーズ）でもって離型処理を施し、ゲルコート及び
中間層処理した凸型成形型Ｃと第２層注形用凹型成形型
Ａとをシールパツキン４を介して密閉固定すべく固定用
クランプ５でもって、凹凸両型をセットする。On the other hand, the mold surface of the concave mold for casting the first layer was subjected to mold release treatment with a mold release agent (Mira Glaze), and the convex mold C was subjected to gel coating and intermediate layer treatment, and the concave mold for casting the second layer. Both the concave and convex molds are set using a fixing clamp 5 to seal and fix the mold A through a seal packing 4.
凸型成形型Ｃと第１層注形用凹型成形型Ａとのすき間（
５，５〜１３ｆｌ）に、下記表−２配合の樹脂組成物２
０〜４５ｋｇを注入口６ａより注入し、空気抜ロアａよ
り樹脂組成物が少しオーバーフローしたのを確認した後
、凹凸セット型全体にエアーバイブレータ−を２〜５分
間がけて樹脂組成物及び型内に残っている空気を抜き、
室温４５〜６０ｔに温度コントロールした硬化炉に４〜
６時間入れて、第１注形層の硬化を行った。The gap between the convex mold C and the concave mold A for casting the first layer (
5,5 to 13 fl), resin composition 2 formulated in Table 2 below.
0 to 45 kg is injected through the injection port 6a, and after confirming that the resin composition has slightly overflowed from the air vent lower a, an air vibrator is applied to the entire uneven set mold for 2 to 5 minutes to remove the resin composition and the inside of the mold. Remove any remaining air from the
4~ in a curing furnace whose temperature is controlled at room temperature 45~60t
The first cast layer was cured for 6 hours.
硬化後、炉より取出し、固定クランプ５をはずし、凹型
成形型Ａのみ離型するため、凹型離型用空気口８ａより
１．５〜３．０ｋｇ／−に圧力コントロールした圧縮空
気を圧入し、凹型Ａの脱型を行い、第１注形層１の付着
した凸型成形型を得た。After curing, take it out of the oven, remove the fixing clamp 5, and in order to release only the concave mold A, pressurize compressed air with a controlled pressure of 1.5 to 3.0 kg/- from the concave mold release air port 8a, The concave mold A was demolded to obtain a convex mold to which the first casting layer 1 was attached.
尚、第２層注形用凹型成形型Ｂとなる洗い場打浴槽成形
品は凸型成形型Ｃを作成するために成形した成形品と同
一金型でもって、上型１２８〜１３５℃、下型１４０〜
１５０℃に昇温した後、成形材料ＳＭＣデイックマット
２４６７−ＧＮ （大日本インキ化学工業（株）製）
３８〜４２ｋｇを下型面上にチャージし、成形圧力１，
６００〜２，０００ ）ンでもって、６〜１０分間加圧
成形することによって得た。この成形品を第２層注形用
凹型成形型Ｂとして用いるために、浴槽底面中央部に下
記表−３配合の樹脂組成物を注入するための注入口６ｂ
として直径３０龍の穴を１ケ所、及び底面コーナ一部に
空気を抜くための空気抜ロアｂとして直径５〜１０１ｍ
の穴を４カ所、夫々穴加工すると共に注形層を付設する
ＳＭＣ洗い場打浴槽の浴槽部分を１１１００のサンドペ
ーパーでサンディング及び脱脂処理を施した。The molded product in the washing area casting bath, which becomes the concave mold B for casting the second layer, is the same mold as the molded product molded to create the convex mold C, and the upper mold is heated at 128 to 135°C, and the lower mold is heated at 128 to 135°C. 140～
After raising the temperature to 150°C, molding material SMC DICMAT 2467-GN (manufactured by Dainippon Ink and Chemicals Co., Ltd.)
Charge 38 to 42 kg onto the lower mold surface and set the molding pressure to 1,
It was obtained by pressure molding at 600 to 2,000 mm for 6 to 10 minutes. In order to use this molded product as a concave mold B for casting the second layer, an injection port 6b is used for injecting the resin composition of Table 3 below into the center of the bottom of the bathtub.
One dragon hole with a diameter of 30 mm, and a lower air vent b for venting air in a part of the bottom corner, with a diameter of 5 to 101 m.
In addition to drilling holes in four locations, the bathtub portion of the SMC wash bathtub to which the cast layer was attached was sanded and degreased using 11100 sandpaper.
その後、第１注形層１の付着した凸型成形型Ｃに前記前
処理を施した第２層注形用凹型成形型Ｂをかぶせて前工
程と同様にシールパツキン４を介して固定クランプ５を
用いて、凹凸両型を密着固定セットした。セット後、凸
型成形型Ｃと第２層注形用凹型成形型Ｂとのすき間（０
，５〜２．０ｍ）に、下記表−３配合の樹脂組成物３〜
５ ｋｇを注入口６ｂより注入し、空気抜ロアｂより樹
脂組成物が充分オーバーフローさせた後、凹凸セット型
全体にエアーバイブレータ−を２〜５分間かけて、型内
に残っている空気を抜き、室温４５〜６０℃に温度コン
トロールした硬化炉に３〜５時間入れて、第２注形層２
を硬化させた。After that, the concave mold B for casting the second layer, which has been subjected to the pretreatment described above, is placed over the convex mold C to which the first casting layer 1 has been attached, and the fixing clamp 5 is placed through the seal packing 4 in the same manner as in the previous step. Both the concave and convex molds were set in close contact using a . After setting, the gap between the convex mold C and the concave mold B for casting the second layer (0
, 5 to 2.0 m), resin compositions 3 to 3 formulated in Table 3 below.
After injecting 5 kg from the injection port 6b and allowing the resin composition to sufficiently overflow from the air vent lower b, apply an air vibrator to the entire uneven set mold for 2 to 5 minutes to evacuate the air remaining in the mold. , the second cast layer 2 is placed in a curing furnace whose temperature is controlled at a room temperature of 45 to 60°C for 3 to 5 hours.
hardened.
硬化後、炉より取出し、今回は凸型成形型Ｃのみを脱型
するため離型用空気口９より１．５〜３．０ｋｇ／−に
圧力コントロールした圧縮空気を圧入して、脱型した。After curing, it was taken out of the oven, and in order to demold only the convex mold C this time, compressed air with a pressure of 1.5 to 3.0 kg/- was injected through the mold release air port 9 to demold it. .
最後に、凸型Ｃを離型した注形浴槽付凹型成形品Ｂの、
注形層（１＋２）と凹型洗い場打浴槽Ｂとの境界部分を
仕上げることにより、第１図に示すごとき浴槽部分に注
形層を付設したＳＭＣ製洗い場付高級浴槽を得た。Finally, the concave molded product B with a cast bathtub from which the convex mold C was released,
By finishing the boundary between the cast layer (1+2) and the concave wash basin bathtub B, a high-class bathtub with a wash basin made of SMC with a cast layer attached to the bathtub part as shown in FIG. 1 was obtained.
得られた浴槽はグリーン色をしたＳＭＣ製洗い場浴槽と
一体となった極めて深みのある美しいグリーンの注形浴
槽部分を有するソリ変形の少ないＳＭＣ製洗い場付高級
浴槽であった。The obtained bathtub was a high-class bathtub with a washing area made of SMC that had a very deep and beautiful green cast bathtub part that was integrated with a green colored SMC washing area bathtub and had little warping deformation.
第１図は本発明によって得られた実施例１の洗い場打浴
槽の縦断面図、第２図は第１層目の注形層を注形するた
めに凹、凸画型をセットした状態の断面図、第３図は第
１層目の注形を完了し、更に第２層目の注形層を注形す
るために、凹凸両型をセントした状態の断面図である。
図中、Ａは第２層目注形用凹型成形型、Ｂは第２層目注
形用凹型成形品、Ｃは５専用成形型、■は樹脂組成物に
よる第１層目の注形層、もしくは第１層目となる凹凸両
型の隙間、２は樹脂組成物による第２層目の注形層、も
しくは第２層目となる凹凸両型の隙間、３は補強枠、４
はシールパツキン、５は凹凸両型固定クランプ、５ａ、
５ｂは樹脂組成物注入口、７ａ、７ｂは空気抜口、８ａ
は第１層用凹型離型用空気口、９は凸型離型用空気口、
１０は洗い場、１１は排水トラップ、１２は補強リプを
示す。Fig. 1 is a longitudinal sectional view of the washing area casting bath of Example 1 obtained by the present invention, and Fig. 2 shows the state in which concave and convex patterns are set for casting the first casting layer. The cross-sectional view and FIG. 3 are cross-sectional views in a state where both the concave and convex molds are placed in order to complete the casting of the first layer and to further cast the second layer. In the figure, A is a concave mold for casting the second layer, B is a concave molded product for pouring the second layer, C is a mold exclusively for 5, and ■ is the first layer made of resin composition. , or a gap between the concave and convex molds that will be the first layer, 2 is the second casting layer made of a resin composition, or a gap between the concave and convex molds that will be the second layer, 3 is the reinforcing frame, and 4
is a seal packing, 5 is a concave and convex fixed clamp, 5a,
5b is a resin composition inlet, 7a and 7b are air vents, 8a
9 is a concave mold release air port for the first layer, 9 is a convex mold release air port,
10 is a washing area, 11 is a drain trap, and 12 is a reinforcing lip.
Claims (1)
まず凹凸注形専用型を用いて単層ないしは複層の注形樹
脂層を成形し、次いでこの注形専用凹型に代えてガラス
繊維強化プラスチック製凹型を用いて最終注形樹脂層を
成形し、当該プラスチック製凹型を注形樹脂層と一体化
してそのまま裏面補強層としたことを特徴とする注形層
付き浴槽の製造法。1. When manufacturing a bathtub with a cast layer using an uneven mold,
First, a single or multi-layer casting resin layer is molded using a mold exclusively for uneven casting, and then a final molding resin layer is molded using a concave mold made of glass fiber reinforced plastic instead of the concave mold exclusively for casting. A method for manufacturing a bathtub with a cast layer, characterized in that the plastic concave mold is integrated with a cast resin layer to directly serve as a back reinforcing layer.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP33386189A JPH03193315A (en) | 1989-12-22 | 1989-12-22 | Manufacture of bathtub with cast layer |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| JP33386189A JPH03193315A (en) | 1989-12-22 | 1989-12-22 | Manufacture of bathtub with cast layer |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| JPH03193315A true JPH03193315A (en) | 1991-08-23 |
Family
ID=18270768
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| JP33386189A Pending JPH03193315A (en) | 1989-12-22 | 1989-12-22 | Manufacture of bathtub with cast layer |
Country Status (1)
| Country | Link |
|---|---|
| JP (1) | JPH03193315A (en) |
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO2009025226A1 (en) * | 2007-08-22 | 2009-02-26 | Seiei Co., Ltd. | Forming mold, and molding method |
| US7936037B2 (en) | 2005-02-18 | 2011-05-03 | Semiconductor Energy Laboratory Co., Ltd. | Photoelectric conversion device and manufacturing method of the same, and a semiconductor device |
| JP2011143645A (en) * | 2010-01-15 | 2011-07-28 | Housetec Inc | Artificial marble molding |
| US8138004B2 (en) | 2005-05-20 | 2012-03-20 | Semiconductor Energy Laboratory Co., Ltd. | Photoelectric conversion device, manufacturing method thereof and semiconductor device |
-
1989
- 1989-12-22 JP JP33386189A patent/JPH03193315A/en active Pending
Cited By (8)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US7936037B2 (en) | 2005-02-18 | 2011-05-03 | Semiconductor Energy Laboratory Co., Ltd. | Photoelectric conversion device and manufacturing method of the same, and a semiconductor device |
| US8138004B2 (en) | 2005-05-20 | 2012-03-20 | Semiconductor Energy Laboratory Co., Ltd. | Photoelectric conversion device, manufacturing method thereof and semiconductor device |
| US8207591B2 (en) | 2005-05-20 | 2012-06-26 | Semiconductor Energy Laboratory Co., Ltd. | Photoelectric conversion device |
| WO2009025226A1 (en) * | 2007-08-22 | 2009-02-26 | Seiei Co., Ltd. | Forming mold, and molding method |
| JP2009067046A (en) * | 2007-08-22 | 2009-04-02 | Seiei:Kk | Molding die and molding method |
| JP4669031B2 (en) * | 2007-08-22 | 2011-04-13 | 株式会社セイエイ | Molding apparatus and molding method |
| US9238337B2 (en) | 2007-08-22 | 2016-01-19 | Seiei Co., Ltd. | Molding die and molding method |
| JP2011143645A (en) * | 2010-01-15 | 2011-07-28 | Housetec Inc | Artificial marble molding |
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