JPS6033504B2 - Structure of bathtub etc. and its manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to the structure of a bathtub, a bathtub with a washing area, etc. manufactured using fiber-reinforced plastic (hereinafter simply referred to as "FRP").

As shown in Fig. 1, the structure of a conventional FRP bathtub consists of a gel coat layer c and a first back layer d formed by a known FRP molding method.
After forming the backup layer e and manufacturing the body b of the bathtub a, urethane resin is sprayed from the outside and foamed, or the urethane resin is injected between the bathtub body b and the apron (not shown) and foamed. The heat insulating material layer f was formed by a method such as attaching a separately molded product such as foamed polystyrene resin or the like.

However, in all of these structures, the gel coat layer c is provided to smooth and protect the surface, and then the first back layer d is applied to the gel coat layer c to eliminate the "bulging" defect (below the gel coat layer c). The gel coat layer c peels off from the first back layer d and swells during use of the bathtub a due to air bubbles remaining in the layer during molding. The first back layer d and the backup layer e maintain the strength of the bathtub a, and the heat insulating layer f is provided for the purpose of heat retention. This increased the molding process for the product and increased the cost of raw materials. In addition, especially when urethane resin is used for the heat insulating material layer f, secondary foaming may occur due to the humidity in the bathroom. has a low degree of thermal deformation, and if the hot water in bathtub a is overcooked or is blown dry, there is a risk that the urethane resin foam will be thermally deformed and lose its heat retaining effect as the heat insulating layer f. Further, the main body b is generally made of unsaturated polyester resin, and a heat insulating layer f made of a foam such as urethane resin or styrene resin, which is a different material, is adhered to the main body b made of unsaturated polyester resin. Since it is a material, there are doubts about its adhesion, and there is a risk that the main body b and the insulation layer f may peel off.
The present invention has been devised in view of the above-mentioned conventional drawbacks,
As shown in FIG. 2, the bathtub 1 according to the present invention has a surface with a thickness of 0.
This is a so-called gel coat layer 2 made of only 1 to 1 ribs of hot water-resistant unsaturated polyester resin, and the second layer is made of hot water-resistant unsaturated polyester resin and laminated with glass fibers 5 to a thickness of 0.5 to 2.
The first back layer 3 is a ribbed structure, and the third layer is made of unsaturated polyester resin containing aggregate 7 in an amount of 3 t% or more based on the amount of resin, and the total amount of glass fiber 6 having a length of 0.8 inches or less. This is the foamed resin layer 4 with a thickness of 2 to 10, which is molded and foamed by containing 5 M% or more and 1 fine t% or less.

This bathtub 1 is made by applying a hot water-resistant unsaturated polyester resin mixed with pigments, fillers, etc. as necessary to the surface of a mold 8 (not shown) using a known method such as a spray-up method, and then curing the resin. A gel coat layer 2 is formed, and then a glass cloth 5 or a glass mat or the like is coated on the gel coat layer 2 with a hot water-resistant unsaturated polyester resin mixed with pigments, fillers, etc. as required, together with a curing agent in a known hand-lay-up process. FRP of 0.5 to 2 willows is delaminated by an appropriate method such as laminating it by a known spray-up method or by laminating glass fiber roving or the like together with a hot water-resistant unsaturated polyester resin and a hardening agent as described above. The first backing layer 3 is formed by thoroughly defoaming and curing using a foam roll, and further, a foaming agent containing an appropriate acid is added to liquid A, which is a mixture of an unsaturated polyester resin and charcoal residue calcium as an aggregate 7. The unsaturated polyester resin was foamed and cured by applying a hardening agent by a known spray-up method while mixing liquid B containing aluminum hydroxide as a hardener 7 and glass fiber 6 having a length of 0.5 inch. This is to form a foamed resin layer 4. According to the structure of the bathtub 1 of the present invention, the foamed resin layer 4
Since the resin of the foamed resin layer 4 is mixed with glass fibers 6 of 5 wt% or more and 13 wt% or less based on the total amount and aggregates 7 of 3 skin t% or more based on the resin amount, the Young's modulus is increased. It exhibits high strength despite being foamed and contributes as a strength member of the bathtub 1, and the first back layer 3 has a minimum thickness of 0 to prevent the defect of ``blister'' that occurs in the gel coat layer 2. It only needs to have a thickness of 5 to 2 willows. ``It eliminates the need for a backup layer e in the structure of conventional FRP bathtubs, simplifies the manufacturing process, reduces raw material costs, and has great industrial effects. Not only is it effective, but because the foamed resin layer 4 contains aggregate 7 of 3 skin t% or more based on the amount of resin, it does not make a light sound when tapped like a conventional FRP bathtub, and has a heavy feel. This greatly contributes to improving the value of the product, such as by making a certain sound and increasing confidence in the product.Furthermore, since unsaturated polyester resin is used as the resin for the foamed resin layer 4, it has a high heat deformation temperature and has a high heat deformation temperature. Stable foamed resin that does not cause deformation of the foamed resin layer 4 even when the bathtub 1 according to the invention is overcooked or empty, and does not undergo secondary foaming due to moisture in the bathroom. A layer 4 is obtained.Furthermore, as shown at the bottom of FIG. 2, a material imparting further rigidity, such as wood 9, may be interposed between the first back layer 3 and the foamed resin layer 4. It is optional, and may be placed at an appropriate location or attached to the outside of the foamed resin layer 4, if necessary.

Furthermore, it is not essential that the gel coat layer 2 be one layer;
It is also optional to supplement the effect of the first back layer by dividing the layer into two layers: a resin-only layer and a laminated layer of extremely thin cloth such as glass fiber or non-woven fabric such as Milled Fiber 1 Surface Mat. In the above description, a bathtub was used as an example, but it goes without saying that the same procedure can be carried out in a bathtub with a washing area, for example.
In order to make the present invention more clear, an example of the present invention in which a bathtub 1 is molded will be described below. ■ On the mold 8, a hot water-resistant unsaturated polyester resin commonly used for bathtub molding, a hardening agent, and a pigment are mixed and molded using a known spray-up method and cured to form a gel coat with a thickness of 0.2. layer 2
to form.

■ On the gel coat layer 2, the same resin as above, a curing agent/pigment, and a fine powder of calcium carbonate and a length of 1 as a filler are added.
A seed layer of 1 inch glass fiber 5 is formed by a known spray-up method, sufficiently defoamed using a defoaming roll, and then cured to form the first back layer 3 on the 1-thickness side.

■ Mix the resin "unsaturated polyester resin" and aggregate A [Carbonic acid resuume] 10 t% (based on the amount of resin) and make A.
Make a liquid.

■ The foaming agent "Ceraphorme" (trade name) is 5% (based on the amount of resin), the curing agent [BPO] is t% (based on the amount of resin), and the aggregate B [aluminum hydroxide] is 5% (based on the amount of resin). (based on the amount) to make Solution B.

■ The above-mentioned liquid A and liquid B are mixed on the above-mentioned first back layer 3, and then 0.5 inch long glass fiber 6 is mixed with 1 t% of the total amount of liquid A and liquid B, and a known spray-up is performed. The foamed resin layer 4 is formed by foaming and curing the neck layer using a method.

When the strength of the fragment of the bathtub 1 formed in the above manner was measured, the bending strength was 5 kg/Kyo Mata, and the tensile strength was 4 kg/K.
It was found that the bathtub 1 exhibited extremely high strength and could fully demonstrate its strength as a bathtub 1. Furthermore, as mentioned above, since the aggregate 7 is contained in an amount of 15% based on the amount of resin, the bathtub has an excellent texture with an extremely heavy feel that is not found in conventional FRP bathtubs. In the above explanation, the amount of glass fiber 6 mixed into the foamed resin layer 4 was set to be 5 wt% or more based on the total amount, but if it is less than this, the bending strength of the bathtub 1 will be insufficient, which is not preferable, and 13 wt%
In the above case, when molding is carried out by the spray-up method, the glass fiber 6 may not adhere to the molding surface, or the molding surface becomes porous, resulting in extremely poor surface quality, resulting in poor workability. If the length is 0.8 inches or more, when molded by the spray-up method, the glass fibers 6 will not be buried inside the foamed resin layer 4 and will protrude from the molding surface, resulting in unfavorable surface properties.
The glass fiber 6 no longer functions as a reinforcing material.

Also, aggregate A to be mixed into liquid A for molding the foamed resin layer 4.
Although calcium carbonate is exemplified as an example, salts having other carbonate groups such as magnesium carbonate may also be used, and one that can be easily obtained may be selected. Furthermore, if the desired performance such as strength and rigidity cannot be obtained with only aggregate A added to liquid A, it is optional to add aggregate B to liquid B, and in addition to the aluminum hydroxide mentioned above, It is sufficient to mix silica stone or other bone village B that meets the desired performance, but it is recommended to add acid to the B solution in order to react with the carbonate group of the aggregate A contained in the A solution, generate carbon dioxide gas, and cause foaming. Since the foaming agent containing the acid is mixed therein, the aggregate B must avoid salts that react with the acid.

[Brief explanation of drawings]

Figure 1 shows the structure of a conventional FRP bathtub.
FIG. 2 shows the structure of the bathtub according to the present invention. In the figure, 1 is a bathtub, 2 is a gel coat layer, 3 is a first back layer, 4 is a foamed resin layer, 5 and 6 are glass fibers, and 7 is an aggregate. Figure 1 Figure 2

Claims (1)

[Claims] 1. The surface is a gel coat layer of a hot water-resistant unsaturated polyester resin, the second layer is a first back layer made of a hot water-resistant unsaturated polyester resin reinforced with glass fiber, and the third layer is made of a resin amount. Contains 30wt% or more of aggregate and contains 5wt% of glass fibers with a length of 0.8 inches or less based on the total amount.
A structure of a bathtub or the like, characterized in that the foamed resin layer is formed by foaming an unsaturated polyester resin containing 13 wt% or more. 2. The structure of a bathtub or the like according to claim 1, characterized in that at least a part of the aggregate used in the foamed resin layer is a salt having a carbonate group, such as calcium carbonate. 3. Molding and curing a hot water-resistant unsaturated polyester resin and a curing agent, as well as pigments and other fillers if necessary, by an appropriate method such as a spray-up method on a mold to form a gel coat layer, and then molding a gel coat layer on the gel coat layer. An unsaturated polyester resin, a curing agent and glass fiber, and if necessary, a pigment and other fillers are molded by an appropriate method such as a spray-up method, thoroughly defoamed, and then cured to form a first back layer. Mix liquid A, which is a mixture of a resin and a salt having a carbonate group as an aggregate, and liquid B, which is a mixture of a blowing agent and a curing agent containing an appropriate acid, and if necessary, an aggregate that does not react with acids such as aluminum hydroxide, and then 1. A method for manufacturing bathtubs, etc., comprising spraying glass fibers having a length of 0.8 inches or less on the first backing layer while mixing and foaming and curing to form a foamed resin layer.