JPH06143A - Bathtub manufacturing method - Google Patents

Abstract

PURPOSE:To produce the bath tub of the size and shape of a high degree of freedom meeting the users, taste and to provide the bath tub having the higher individuality. CONSTITUTION:This process for production of the bath tub consists in molding a foam made of plastic to the shape of the bath tub, laminating a reinforced layer by a combination of fibers and thermoplastic resin on the inside surface of the resulted bath tub mold to reinforce the inside surface, then applying colors on the surface of the cured layer.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a fiber reinforced resin bath.

[0002]

2. Description of the Related Art Conventionally, a fiber-reinforced resin bath is mainly formed by applying a gel coat to an FRP type and curing it, then laminating a thermosetting resin reinforced with glass fibers, curing, and then removing from the mold.
It is manufactured by heat-insulating the outside of the bath shape with a plastic foam. However, in the conventional technology,
Since it is manufactured using a mold by either method,
Only standardized products are available. Further, since it is necessary to remove the mold from the mold, there is a restriction on the product shape, and it has been difficult to manufacture a bathtub having a shape with a high degree of freedom to meet the taste of the user.

[0003]

SUMMARY OF THE INVENTION An object of the present invention is to solve the above-mentioned problems in the prior art and to manufacture a bathtub having a size and shape with a high degree of freedom, which suits a user's preference.
To provide a more unique bathtub.

[0004]

Means for Solving the Problems As a result of intensive studies on the method for producing a fiber-reinforced resin bathtub, the present inventors have found that
Unlike the conventional manufacturing method, if the bath is manufactured in a manufacturing process in which the inner surface is first formed in order from the outer heat retaining layer, the manufacturing process can be simplified and the size, shape, and pattern that the user likes The present invention has been accomplished by finding that a bathtub can be manufactured. That is, the present invention is formed by molding a plastic foam into a bath shape, laminating a reinforcing layer of a combination of fibers and a thermosetting resin on the inner surface of the obtained bath mold, and after curing, It relates to a method for manufacturing a bathtub, characterized in that the surface of the layer is colored.

In the present invention, the plastic foam used for producing the original shape of the bath includes a single foam of a thermoplastic resin such as polystyrene, polyethylene, polypropylene, polyvinyl chloride, polymethacrylate, or those foams. Mixtures or foams of copolymers and foams of thermosetting resins such as polyurethane can be used, and a block of the size of a bath of these foams or a plate-like one can be combined to form a rough bath. From the thing that was, knife, heat wire,
Process the foam with a saw, solvent, etc. to prepare it into the desired bathtub shape. If shaping fails due to excessive shaving, etc., apply foam to the relevant part and re-shape, or perform simple coloring on the original shape and make corrections while checking the final product's finished image etc. It is used as the original shape of a bathtub made of plastic foam. In addition, if you want to sacrifice the individuality of the bathtub shape to some extent, you may use a mold to mold the foamed plastics and use it as it is as the original shape of the plastic foam bathtub. Then, it may be used as a bathtub prototype of plastic foam.

When the original shape of the bath of the obtained plastic foam is a material which is relatively easily attacked by a solvent such as polystyrene or polymethacrylate, an epoxy resin, a non-styrene vinyl ester, etc. may be used, if necessary. Surface treatment of the foam. The epoxy resin used here is mainly a bisphenol A type epoxy resin, a novolac type liquid epoxy resin, or the like, which is mixed with an amine curing agent that is curable at room temperature. The non-styrene vinyl ester used here is a bisphenol A type epoxy resin or a vinyl ester obtained by adding (meth) acrylic acid to a novolac type epoxy resin, dissolved in a polyfunctional acrylic monomer, The thing which mix | blended the polymerization catalyst is used.

A plastic bath tub, which has been surface-treated as required, is provided with a reinforcing layer made of a combination of fibers and a thermosetting resin, either by the hand lay-up method or the spray-up method, or by their combination. Laminate, embed wood in the required parts, and reinforce the plastic bathtub original shape. As the fibers used here, glass fibers, organic fibers typified by polyethylene and polyester, carbon fibers and the like can be used, but glass fibers are mainly used. Depending on the purpose, the organic fiber may be used alone, or the organic fiber and the glass fiber may be used in combination. As the thermosetting resin used here, epoxy resin, phenol resin, urethane resin, etc. can be used, but the viscosity and curing time are easily adjusted, and relatively inexpensive unsaturated polyester resin is mainly used. It Also, vinyl ester resin may be used in combination in consideration of size, shape and durability.

[0008] Coloring is applied to the original shape of the bath tub in which a reinforcing layer made of a combination of fibers and thermosetting resin is laminated, and at the stage of finishing the bath, coloring and patterning may be performed with paint as a method of applying the color. Although it is possible, problems often occur in durability as a bath, and in many cases, coloring and patterning are mainly performed at the same time when a top coat layer using an unsaturated polyester resin or a vinyl ester resin is provided. When the topcoat layer is provided and colored and patterned at the same time, the surface smoothness cannot be obtained in the topcoat layer 1 layer because the fiber pattern of the reinforcing layer is exposed. For this reason, after forming a topcoat layer not containing wax and curing it, a topcoat layer containing wax and a pigment is formed and colored and patterned to complete the bath.

【Example】

Example 1 A plate-shaped polystyrene foam having a thickness of 15 cm and having outer dimensions of 90 cm in depth, 120 cm in width, and 60 cm in height was prepared using an epoxy resin as an adhesive. Then, the surfaces other than the portion in contact with the wall of the bathroom (a total of 6 surfaces including the front outer surface 1 side, the inner side surface, and the bottom surface) were cut with a knife, and the surface was processed like a rock bath. A mist of methylene chloride was partially made to have a rounded sharp-edged portion on the surface to be sprayed, and a bathtub prototype made of expanded polystyrene was produced. 100 parts by weight of a non-styrene vinyl ester (manufactured by Nippon Yupica Co., Ltd., trade name: NEOPOL 8414) on the entire surface of the obtained expanded polystyrene bathtub original form was added with a cobalt naphthenate solution (cobalt concentration: 6% by weight). 5 parts by weight and methyl ethyl ketone peroxide solution (concentration: 55% by weight)
A surface treatment agent to which 1.0 part by weight was added and mixed was applied, cured at room temperature for 30 minutes, and subjected to surface treatment of a foamed polystyrene bathtub original shape.

Next, using an unsaturated polyester resin (manufactured by Nippon Yupica Co., Ltd., trade name: Yupica 4556P) by spray-up method on the inside and outside surfaces other than the outside of the bottom surface, a total of 9 surfaces, a thickness of about 2 mm is used. Form a fiber reinforced thermosetting resin layer,
After gelation, it was cured in a hot air oven at 50 ° C. for 30 minutes. Then, on the outside of the bottom surface (the surface that contacts the floor of the bathroom), plywood and square timber are embedded by a spray-up method to attach the pedestal, and reinforcement is performed, and after gelation, it is cured in a hot air oven at 50 ° C for 30 minutes to foam. The original shape of the bathtub made of polystyrene was reinforced.

Next, a total of 6 surface-treated surfaces were topcoated with no wax (Japan Yupica Co., Ltd.).
Manufactured by Yupica UG-506 White), a top coat having a thickness of about 0.2 mm was applied. After curing at room temperature for 3 hours, a wax-added top coat (Japan Yupica Co., Ltd., trade name: Yupica UT-50)
Using 1), spray three colors of white, black, and brown to three colors at the same time with a spray gun having three discharge ports, and apply a top coat with a thickness of about 0.4 mm. , Painted a stone pattern. After finishing the application, before applying the gel, trace it in a streak with a 1 cm wide brush.
A pattern like a bonded part of stones was made, and the patterning was completed. After curing at room temperature for 1 hour, it was cured in a hot air oven at 60 ° C. for 30 minutes, and after cooling, drainage fittings were attached to complete a rock bath tub.

[0012]

According to the method of manufacturing a bathtub according to the prior art, it has been impossible to obtain a molded product having a high degree of freedom that satisfies the user. In other words, as long as molding is performed using a mold, unless many molded products are molded from one mold, it will not fit the profit base, and since there is a demolding process, it is virtually impossible to mold molded products with irregularities. there were. In the bathtub molding according to the molding method according to the present invention, since the mold according to the conventional technique is unnecessary, the cost for the mold is not required, and the bathtub can be manufactured at low cost. Furthermore, since there is no demolding process, it is possible to mold a bathtub having a complicated shape.

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Claims (4)

[Claims] 1. A plastic foam is molded into a bathtub shape, and a reinforcing layer made of a combination of fibers and a thermosetting resin is laminated on the inner surface of the obtained bathtub mold, and after curing, the cured layer. A method for manufacturing a bathtub, which comprises coloring the surface of the bathtub. 2. A plastic foam is formed into a bath shape, a primer is applied on the inner surface of the bath shape, and the inner surface that has been further cured is further combined with a fiber and a thermosetting resin. The bathtub manufacturing method according to claim 1, wherein a reinforcing layer is laminated. 3. The method of manufacturing a bath according to claim 1, wherein the thermosetting resin is an unsaturated polyester resin. 4. The method for producing a bath according to claim 1, wherein the fibers used in combination with the thermosetting resin are glass fibers and / or organic fibers.