JP4465597B2 - Artificial marble waterproof pan - Google Patents

Description

  The present invention relates to an artificial marble waterproof pan obtained by a press molding method.

Conventionally, many waterproof pans are manufactured by a press molding method using a molding material such as a sheet molding compound (hereinafter referred to as SMC) and a bulk molding compound (hereinafter referred to as BMC).
The waterproof pan made of SMC is high in strength and excellent in light weight, but single color products such as white and ivory are generally used, and the appearance is not high-class. On the other hand, the waterproof pan made of BMC is superior in texture and design than SMC and has a high-class feeling. On the other hand, since the strength is low, it is necessary to design the thick waterproof pan, which is heavy, inconvenient to transport and difficult to work. There is.

As a method for imparting a high-class feeling to a waterproof pan, a method of decorating the surface using diallyl phthalate resin-impregnated decorative paper (hereinafter referred to as DAP decorative paper) or a method of using SMC with a marble texture has been proposed. ing.
However, the former method of decorating the surface using DAP decorative paper or the like can produce various patterns, but it is inferior in texture, so it cannot wipe out a cheap impression of printed matter. In addition, the latter method using SMC with a marble texture is inevitably low in strength because the fiber reinforcing material in the SMC component must be shortened and / or low in order to impart a marble texture. Therefore, as in the case of BMC, it is necessary to design the waterproof pan with a large thickness, which is heavy, inconvenient to transport, and difficult to work.

In addition, as a method of reinforcing the molded product, a method of integrally molding using a reinforcing plate such as glass fiber reinforced plastic (hereinafter referred to as FRP) (for example, refer to Patent Document 1), or a single molding using glass fiber pre-impregnated with resin. A method (for example, refer to Patent Document 2) is proposed.
However, in order to increase the strength and rigidity of the waterproof pan, the rib is usually provided on the bottom surface side of the product. In the case of the press molding method, the fluidity of the molding material changes greatly due to the effect of the rib. However, a sufficient reinforcing effect cannot be obtained. In the method of integrally molding using the FRP reinforcing plate, the FRP reinforcing plate obstructs the flow of the molding material into the rib portion and easily causes a defective filling of the rib portion. There is difficulty in adhesion reliability. In addition, the method of integrally molding using glass fibers impregnated with resin in advance makes it difficult to obtain a sufficient reinforcing effect because the glass fibers are easily damaged by friction with a molding material that flows under high temperature and pressure.
Japanese Patent Application Laid-Open No. 6-237871 JP-A-5-32443

  SUMMARY OF THE INVENTION An object of the present invention is to solve the above-mentioned problems, and to provide a method for easily and stably obtaining an artificial marble waterproof pan having excellent lightness, convenient for transportation, high strength, and high quality. Is.

As a result of intensive studies in order to solve the above problems, the present inventors have completed the present invention.
That is, the present invention is an artificial marble waterproof pan provided with ribs on the bottom surface back surface obtained by press molding, wherein the bottom surface back surface is made of woven continuous fibers having holes in a lattice shape, and a molding material. A resin layer having a thickness of 30 to 300 μm , which is integrally formed of a sheet-like reinforcing material having a resin layer on one side in contact with the sheet-like reinforcing material, and in which a plurality of holes are opened in a lattice shape in the thickness direction. An artificial marble waterproof pan characterized in that it is a sheet-like fiber-reinforced plastic plate having the above.

  The artificial marble waterproof pan of the present invention is excellent in lightness convenient for transportation, has high strength and has a high-class feeling, and can be obtained easily and stably.

The present invention will be described in more detail below.
The artificial marble waterproof pan of the present invention is a waterproof pan having ribs on the bottom surface, and is used for preventing water leakage in a bathroom or the like. The shape of the ribs, the number of installations, and the positional relationship are not particularly limited, but usually the height is 10 to 100 mm and the thickness is 1 to 10 mm. It is preferable that two or more ribs are arranged so as to intersect at right angles in a lattice shape. Moreover, the kind of lid | cover used in combination with a waterproof pan is also contained in this invention.

  The artificial marble waterproof pan of the present invention is made of a molding material having a marble texture, and has the effect of giving a high-class feeling. Furthermore, since the bottom surface of the waterproof pan is integrally formed with a reinforcing material, the waterproof pan can be designed to be thinner, so that it is excellent in lightness that is convenient for transportation.

The molding material used in the press molding of the present invention contains at least (A) a polymerizable unsaturated monomer, (B) a thermosetting resin, (C) a filler, (D) a fiber reinforcement, and the like. It is a molding material for molding and includes SMC, BMC and the like.
Examples of the polymerizable unsaturated monomer (A) include styrene, vinyl toluene, chlorostyrene, α-methyl styrene, tert-butyl styrene, divinyl benzene, methyl methacrylate, vinyl acetate and the like.

Examples of the thermosetting resin (B) include unsaturated polyester resins, vinyl ester resins, acrylic resins, diallyl phthalate resins, and the like.
Examples of the filler (C) include known ones such as calcium carbonate, aluminum hydroxide, clay, alumina powder, talc, barium sulfate, silica powder, glass powder, glass beads, mica, and titanium oxide. These can be used alone or in combination of two or more.

Examples of the fiber reinforcement (D) include organic fibers such as glass fiber, metal fiber, ceramic fiber, carbon, aramid, vinylon, and polyester, and these can be used alone or in combination of two or more. Of these, glass fiber is preferable in consideration of economy. The average fiber length is preferably 0.1 to 25 mm. These are glass rovings cut into chopped strands, and more preferably have a fiber length of 1 to 12 mm.
Other than that, for example, pattern materials, ultraviolet absorbers, pigments, curing agents, thickeners, thickeners, low shrinkage agents, plasticizers, antioxidants, flame retardants, surfactants, water repellents, oil repellents Various known additives such as these can be added and mixed.

As a reinforcing material integrally formed on the bottom back surface of the artificial marble waterproof pan of the present invention, a sheet-like FRP plate obtained by impregnating a fiber reinforced material with a thermosetting resin and curing can be cited. In consideration of the filling property of the molding material, an FRP plate having a plurality of holes in the thickness direction is preferable.
By setting it as such an FRP board, the filling property to the rib part of a molding material can be improved, and it has the effect that the adhesive reliability of a FRP board and a molding material can be improved. In addition, it is preferable to have a resin layer on at least one surface of the FRP plate. By doing so, there is an effect that the friction with the molding material flowing under high temperature and high pressure can be reduced, that is, the strength can be increased to prevent the FRP plate from being damaged.

  The fiber reinforcement used for the reinforcing material is typically glass fiber, but other carbon fiber, aramid fiber, vinylon fiber, polyester fiber, and the like can be used, and these can be used alone or in combination. Examples of the form of the fiber reinforcing material include a woven fabric such as a roving cloth and a sheet-like base material such as a swirl mat, but preferably a woven fabric using continuous fibers such as a strand and a roving such as a roving cloth and a glass cloth. Of the form.

Examples of the thermosetting resin used for the reinforcing material include unsaturated polyester resin, vinyl ester resin, epoxy resin, acrylic resin, diallyl phthalate resin, and the like.
Such thermosetting resins include other known additives as required, for example, curing agents such as organic peroxides, internal mold release agents such as zinc stearate, fillers such as aluminum hydroxide, UV absorbers, oxidation An inhibitor, a pigment, a low shrinkage agent, a plasticizer, a flame retardant, a surfactant, a water repellent, an oil repellent, and the like can be blended and used.

  The plurality of holes in the thickness direction of the reinforcing material used in the present invention are preferably opened at equal intervals. The shape of the hole may be any shape such as a round shape, a square shape, or a triangular shape. The holes may be drilled into the reinforcing material without holes with a cone or the like. However, this method is labor intensive and expensive, so it is preferable to use a woven fabric with holes in a lattice shape, for example, as a fiber reinforcement. Reinforcement material with a plurality of holes at equal intervals in the thickness direction can be easily obtained by impregnating and curing the above-mentioned thermosetting resin with cloths woven in a weave method such as warp weave and leash weave. Can get to.

  Since the reinforcing material obtained by the above method usually has a concave and convex portion on the surface in a pattern of a fiber reinforcing material, the friction with the molding material that flows under high temperature and high pressure during press molding tends to increase. That is, since the reinforcing material is easily damaged, it is necessary to reduce the friction of the surface of the reinforcing material that comes into contact with the molding material. For this reason, in order to reduce friction with the molding material, it is preferable to fill the recesses and projections with a resin layer on the surface of the reinforcing material. If the both sides of the reinforcing material are made to have a resin layer by the above-mentioned manufacturing method, it becomes very difficult to produce a reinforcing material having a plurality of holes at equal intervals in the thickness direction. The material has a resin layer on one side in contact with the molding material.

The resin layer of the reinforcing material having a resin layer on one surface is preferably 30 to 300 μm.
In order to form a resin layer on one side of the reinforcing material, for example, a thermosetting resin compound is applied to a film such as polyethylene or polypropylene with a uniform thickness, and then woven by a weaving method such as imitation weave. The glass cloth is put on, and then a rubber roller is lightly passed over the glass cloth and left for a while until the thermosetting resin compound is cured. Thereafter, a reinforcing material having a resin layer on one side can be obtained by removing the film. The thermosetting resin compound-impregnated glass cloth may be hardened at room temperature or may be hardened by heating (for example, about 60 to 100 ° C.).

The hole opening ratio of the reinforcing material of the present invention is preferably 0.1 to 70%, the fiber content is preferably 20 to 80% by weight, and the thickness of the reinforcing material is preferably 0.1 to 5 mm. The weight of the material is preferably 100 to 5000 g / m ² and is appropriately selected depending on the thickness of the bottom portion of the waterproof pan.

  The artificial marble waterproof pan according to the present invention is performed by a press molding apparatus to which a mold is attached. That is, the above-mentioned reinforcing material is arranged in advance on the back side of the bottom surface of a general waterproof bread mold for press molding having ribs on the bottom surface, and then the molding material having a marble texture is put into the mold, and the press It can be obtained by heating and pressure molding with a machine. The press molding conditions are the same as the press molding conditions such as general SMC and BMC. The molding temperature is preferably 40 to 180 ° C., the molding pressure is preferably 1 to 20 MPa, and the pressing time is preferably 1 to 60 minutes. Although it is the range, it may be appropriately selected depending on the composition content of the molding material to be used, the shape and size of the molded product, and the like. By the press molding operation, it is possible to easily and stably obtain an artificial marble waterproof pan that is excellent in lightness and convenient for conveyance, has high strength, and has a high-class feeling.

  EXAMPLES Hereinafter, although an Example demonstrates this invention in detail, this invention is not limited to this. “Part” and “%” in the text are based on weight unless otherwise noted.

[Example 1]
A waterproof pan was molded using a mold for molding SMC waterproof pan for bathrooms, using W-2198 [BMC with marble texture, manufactured by Shin-Dick Kako Co., Ltd.]. Molding conditions were such that the mold temperature was 145 ° C. for the upper mold (product surface side), 125 ° C. for the lower mold (back surface side), the molding pressure was 10 MPa, and the pressing time was 8 minutes. The amount of BMC input was adjusted so that the thickness of the bottom surface of the waterproof pan was 4 mm.
At this time, one FRP plate cut to the size of the bottom surface of the waterproof pan is placed on the bottom surface of the lower die of the mold so that the surface side having the resin layer faces upward, and the BMC is placed on the bottom to integrally form the PAN. did. The FRP plate is composed of WA580-100 [unit weight 489 g / m ² imitation woven glass cloth, manufactured by Nittobo Co., Ltd.] and Dicklight UE-3505 [vinyl ester resin, manufactured by Dainippon Ink & Chemicals, Inc.] from one side. The glass content is 65%, the opening ratio of the holes in the thickness direction is 6 area%, the weight is 750 g / m ² , and the thickness is about 0.8 mm. Further, the holes of the FRP plate were square and opened at regular intervals in a lattice shape, and a resin layer having a surface of 150 μm on one side surface was smooth.
The obtained waterproof pan has a high-grade appearance with a marbled marble tone, and the BMC completely fills the ribs on the bottom surface of the waterproof pan through the holes in the FRP plate. Was firmly integrated with the bottom surface of the waterproof pan, and had no defects such as chipping of ribs or breakage of the FRP plate.

[Comparative Example 1]
WA580-100 was coated and impregnated with Dicklight UE-3505 from both sides and cured to have a glass content of 65%, a hole area ratio in the thickness direction of 6 area%, a weight of 750 g / m ² , and a thickness of about 0 A 8 mm FRP plate was produced. The holes of the FRP plate were square and opened at regular intervals in a lattice shape, but the surface did not have a resin layer on both sides, and the texture pattern unevenness of the fiber reinforcement was remarkable.
A waterproof pan was formed in the same manner as in Example 1 except that the above FRP plate was used. The resulting waterproof pan has a high-grade appearance with a stone-patterned marble tone, and the BMC completely fills the ribs on the bottom surface of the waterproof pan through the holes in the FRP plate. The FRP plate on the bottom bottom surface was damaged so as to be torn.

[Comparative Example 2]
WA580-100 was coated and impregnated with Dicklight UE-3505 from both sides and cured to produce an FRP plate having a glass content of 40%, a weight of 1220 g / m ² , and a thickness of about 0.8 mm. Such an FRP plate had a resin layer on both surfaces and had almost no holes in the thickness direction.
A waterproof pan was formed in the same manner as in Example 1 except that the FRP plate was used. The resulting waterproof pan had a stone-like marble-like high-grade appearance, and the FRP plate was not damaged, but the BMC was insufficiently filled in the ribs on the bottom surface of the waterproof pan and the ribs There was a defect of chipping, and a blister considered to be due to poor adhesion occurred between the FRP plate and the BMC on the bottom surface of the bottom surface of the waterproof pan.

[Comparative Example 3]
Using only W-2198, a stone-patterned marble-like waterproof pan having a bottom plate thickness of 6 mm was formed in the same manner as in Example 1.
The resulting waterproof pan has a high-grade appearance with a marbled marble tone, and BMC is completely filled in the ribs on the bottom of the bottom of the waterproof pan. It was very inconvenient.

[Comparative Example 4]
A waterproof pan having a bottom plate thickness of 4 mm was molded in the same manner as in Example 1 using only Dickmat 2562 [general SMC for waterproof pan molding, manufactured by Dainippon Ink and Chemicals, Inc.].
The waterproof pan thus obtained had a gray single color appearance with poor luxury.
Table 1 shows a performance comparison of the waterproof pan formed in Example 1 and Comparative Examples 1, 2, 3 and 4.

*1 防水パンの製品面側から１１２ｇの重さの鋼球を２００ｃｍの高さで自然 落下させ、製品の割れなどの損傷について目視で判定。
実施例１によれば、従来使用されているＳＭＣ製の防水パンと同等以上の強度と軽量性を確保し、且つ高級な大理石質感を有する防水パンを得ることができた。

* 1 A 112 g-weight steel ball is dropped naturally from the product surface side of the waterproof pan at a height of 200 cm, and the product is visually checked for damage such as cracks.
According to Example 1, it was possible to obtain a waterproof pan having a high-grade marble texture while ensuring a strength and lightness equal to or higher than those of conventionally used SMC waterproof pans.

Claims (1)

An artificial marble waterproof pan provided with ribs on the back surface of the bottom surface obtained by press molding, wherein the back surface of the bottom surface is made of woven continuous fibers with holes in a lattice shape and has a resin on one side in contact with the molding material A sheet-like fiber having a resin layer having a thickness of 30 to 300 μm , wherein the sheet-like reinforcement material is integrally formed with a sheet-like reinforcing material having a layer, and a plurality of holes are opened in a lattice shape in the thickness direction. An artificial marble waterproof pan characterized by being a reinforced plastic plate.