JP4862489B2 - Manufacturing method of waterproof pan - Google Patents

Description

  The present invention relates to a method for producing a waterproof pan used in a bathroom, a washroom, a washing machine storage, and the like.

  Conventionally, as a technique for molding fiber reinforced plastic (FRP), there are a hand lay-up (HLU) molding method and a resin transfer molding (RTM) molding method (Patent Document 1). Moreover, the manufacturing method of waterproof pans, such as a bathroom, has already been proposed (refer patent document 2).

  By the way, when manufacturing waterproof pans for bathrooms or the like by FRP, they are stacked and molded by impregnating fibers with resin or the like manually by an operator by the HLU molding method.

  Since a large load is applied to such a waterproof pan, a metal (iron) frame is inserted, and nuts, bolts, etc. are installed to place and fix the waterproof pan on the bathroom flooring. The members were fixed by welding to a metal frame, but there was a problem that the welding work was time consuming and costly.

On the other hand, the present applicant has developed a technique for forming a waterproof pan by the RTM molding method. According to this RTM molding method, there is an advantage that there is no variation in quality due to the operator and that the manufacturing operation is significantly more efficient than the HLU molding method. Further, it is only necessary to provide a reinforcing material such as a wooden material in the preform member, and there is an advantage that a metal frame as in the HLU molding method becomes unnecessary.
JP 2006-70684 A JP-A-8-312170

  However, when the waterproof pan is molded by the RTM molding method, it is necessary to attach the waterproof pan fixing bracket to the reinforcing material of the waterproof pan that has been molded by post-processing. There was a problem that the efficiency of the waterproof pan manufacturing work was hindered.

The present invention has been made to solve the above problems, as unnecessary trouble of attaching a post processing waterproof pan fixing clasp, a manufacturing method of a waterproof pan so efficiency can be improved waterproof pan manufacturing operations It is intended to provide.

  In order to solve the above-mentioned problem, the present invention applies a first resin to a lower mold for molding, and places a preform member on which a waterproof pan fixing metal fitting is previously attached to a reinforcing material on the first resin. Then, after placing the upper mold on the preform member and clamping the upper and lower molds, the second resin is press-fitted between the preform member and the upper mold, so that the waterproof pan is placed on the second resin layer. The present invention provides a method for producing a waterproof pan, wherein the fixing metal fitting is insert-molded.

  As in claim 2, the first FRP layer is formed on the lower mold for the preform, the reinforcing material is placed on the first FRP layer, and the waterproof pan fixing metal fitting is attached to the reinforcing material for reinforcement. It is preferable to include a manufacturing process of a preform member in which a second FRP layer is formed on the material to insert-mold a waterproof pan fixing metal fitting into the second FRP layer.

  It is preferable to attach the waterproof pan fixing metal fitting in advance to the reinforcing material by fitting the waterproof bread fixing metal fitting into the recess formed in the reinforcing material.

  According to a fourth aspect of the present invention, the waterproof pan fixing bracket can be attached in advance to the reinforcing member by fixing the waterproof pan fixing bracket to the reinforcing member with a screw, a nail, or an adhesive.

  As in claim 5, the reinforcing material is preferably wooden.

  Preferably, the waterproof pan fixing bracket is a nut, and the screw hole of the nut is preferably closed with a removable cap.

According to the present invention, a waterproof pan fixing metal fitting premounted on the reinforcement pre-form member, it is so arranged that the insert molded second resin layer, the reinforcement of the waterproof pan molding is completed, waterproof pan This eliminates the need to attach the fixing bracket by post-processing, thereby improving the efficiency of the waterproof pan manufacturing work.

  In addition, since the waterproof pan fixing metal fitting previously attached to the reinforcing material is insert-molded in the second resin layer, the second resin layer is used in comparison with the case where the waterproof bread fixing metal fitting is attached to the reinforcing material by post-processing. The attachment of the waterproof pan fixing metal fitting is more reinforced.

  According to the second aspect of the present invention, the waterproof pan fixing metal fitting attached to the reinforcing material is insert-molded into the second FRP layer in the manufacturing process of the preform member. There is no risk of the waterproof pan fixing bracket falling off the material.

  According to the third aspect, the waterproof pan fixing bracket can be attached to the reinforcing member in advance simply by fitting the waterproof pan fixing bracket into the recess of the reinforcing member. Since the waterproof pan fixing bracket does not move due to the pressure input of the resin No. 2, it is possible to prevent misalignment.

  According to the fourth aspect, the waterproof pan fixing metal fitting can be easily attached to the reinforcing material in advance using a general-purpose screw, nail, or adhesive without processing the concave portion or the like in the reinforcing material.

  According to claim 5, the wooden reinforcing material is lighter and less expensive than a metal frame, is easy to process the recesses, etc., and the waterproof pan fixing bracket is made of wood screws, nails, adhesives Any of these can be directly fixed.

  According to the sixth aspect, the material of the second resin layer or the FRP layer can be prevented from entering the screw hole of the nut.

  Hereinafter, the best mode for carrying out the present invention will be described in detail with reference to the drawings.

  As shown in FIG. 7, for example, a waterproof pan 1 in a bathroom is arranged on a flooring 5 in a bathroom, and is divided into a washing place 2 and a place 3 for a bathtub 4. On the lower surface of the waterproof pan 1, as will be described later, a nut (waterproof pan fixing bracket) 30 is attached to a square member (reinforcing material) 22 of a preform member (reinforcing material) 19. The waterproof pan 1 is fixed to the floor material 5 by screwing bolts 31 from below the material 5.

  FIGS. 1A, 1 </ b> B, and 2 </ b> C are process diagrams for manufacturing a preform member 19 that is insert-molded into the waterproof pan 1.

  As shown in FIG. 1A, the mixture of the glass fiber bundle and the binder is applied to the upper surface (surface) of the preform lower mold 11 on the base 9 by a spray 10 with a predetermined thickness (for example, about 3 to 3). 4 mm) to form a first FRP layer 20 (see FIG. 6B). In this case, in order to make the first FRP layer 20 follow the upper surface of the lower mold 11 for preform, suction is performed until the step of FIG. 1C is completed (see arrow a).

  Next, as in the step of FIG. 1B, a reinforcing plywood (reinforcing material) 21 having a predetermined thickness (for example, 8.5 mm) is placed on the first washing layer 2 side (left side in the figure) on the first FRP layer 20. While placing each on the bathtub storage 3 side (right side in the figure), a reinforcing square member (reinforcing material) 22 having a predetermined dimension (for example, 40 × 40 mm square) is placed at a predetermined position on each plywood 21. A plurality of nuts (waterproof pan fixing metal fittings) 30 (four in this example, see FIG. 2C) are attached to the square members 22 at appropriate positions. The plywood 21 and the square member 22 are made of wood.

  Specifically, as shown in FIG. 6 (a), the square member 22 is formed with a recess 22a straddling the upper surface and both side surfaces, and by inserting the recess 30a of the nut 30 into the recess 22a from above, A nut 30 can be attached to the square member 22 in advance.

  By attaching the cap 32 to the upper surface of the nut 30, the screw hole 30 b of the nut 30 is closed with the cap 32.

  Then, as in the step of FIG. 1C, the mixture of the glass fiber bundle and the binder is layered with a predetermined thickness (for example, about 1 to 3 mm) by the spray 10 from the placed plywood 21 and the square member 22. The second FRP layer 23 (see FIG. 6B) is formed by spraying.

  Thereafter, as shown in FIG. 2A, the preform upper mold 12 is disposed on the second FRP layer 23, the upper and lower molds are clamped, and then the upper and lower molds are moved to a predetermined temperature (for example, about 60 ° C.). ) In a drying oven for a predetermined time (for example, about 45 minutes).

  After a predetermined time has elapsed, the upper and lower molds are taken out of the drying furnace, the upper and lower molds are unclamped, and the completed preform member 19 is removed as shown in FIGS.

  FIGS. 3A, 3B, 3C and 4A, 4B, and 4C are process diagrams for manufacturing the waterproof pan 1 in which the preform member 19 is insert-molded.

  As shown in FIG. 3A, the gel coat [first resin (iso-based resin)] is applied to the upper surface (surface) of the molding lower mold 14 by a spray 13 to a predetermined thickness (for example, about 0.3 to 0). 0.5 mm) to form a first exterior resin layer 24 (see FIG. 6B).

  As in the step of FIG. 3B, the lower mold 14 is placed in a drying furnace at a predetermined temperature (for example, about 70 ° C.) for a predetermined time (for example, about 10 minutes), and the first resin layer 24 is cured.

  As in the step of FIG. 3C, the lower mold 14 is removed from the drying furnace, and the preform member 19 is placed on the cured first resin layer 24.

  As shown in FIG. 4 (a), after the upper mold 15 is placed on the preform member 19 and the upper and lower molds are clamped, the outer peripheral flange portion of the upper and lower molds are provided to prevent resin leakage. Suction is performed at a predetermined pressure (for example, about −0.08 MPa) (see arrow b). Further, in order to assist the flow of the resin, the inside of the upper and lower molds is sucked at a predetermined pressure (for example, about −0.04 MPa) (see arrow c).

  As in the step of FIG. 4B, a blend of unsaturated polyester resin [second resin (iso-based resin)] and filler (for example, calcium carbonate 0 to 100 phr) is predetermined from tank 16 together with a curing agent. A second exterior having a predetermined thickness (for example, about 0.3 to 0.5 mm) is press-fitted into the gap between the preform member 19 and the molding upper mold 15 with pressure (for example, 0.3 to 0.5 MPa). The resin layer 25 is formed [see FIG. 6B].

  As shown in FIG. 4C, after leaving each resin to stand at room temperature for a predetermined time (for example, about 60 to 90 minutes), the finished waterproof pan 1 is removed from the upper and lower molds as shown in FIG. Then, the cap 32 on the upper surface of the nut 30 is removed.

  As a result, the preform member 19 is coated (coated) with the first exterior resin layer 24 and the second exterior resin layer 25.

In the manufacturing process (method) of the waterproof pan 1 as described above, when forming the waterproof pan 1 which is an FRP molded product, the nut 30 previously attached to the square member 22 of the preform member 19 is used as the second FRP layer. 23, the second resin layer 25 is insert-molded, so that it is no longer necessary to attach the nut 30 by post-processing to the square member 22 of the preform member 19 of the waterproof pan 1 that has been molded. Work efficiency can be improved.

  Further, since the nut 30 attached to the square member 22 is insert-molded in the second FRP layer 23 in the manufacturing process of the preform member 19, the nut 30 is removed from the square member 22 during the handling operation of the preform member 19. There is no risk of dropping off. It should be noted that the insert mold of the nut 30 by the second FRP layer 23 is sufficient to prevent the nut 30 from falling off, and need not be complete. In the manufacturing process of the preform member 19, the second FRP layer 23 is prevented from adhering by sticking an adhesive tape or the like on the nut attachment portion of the square member 22, and in the process of FIG. When the preform member 19 is placed on 24, the adhesive tape or the like is peeled off and the nut 30 is attached to the square member 22, and when the second resin layer 25 is formed in the subsequent step of FIG. It is also possible to insert-mold the nut 30 directly on the second resin layer 25.

  Furthermore, since the nut 30 previously attached to the square member 22 is insert-molded into the second resin layer 25 together with the second FRP layer 23, the second resin is compared with the case where the nut 30 is attached to the square member 22 by post-processing. The mounting of the nut 30 is reinforced more strongly by the layer 25.

  Further, since the nut 30 can be attached to the square member 22 simply by fitting the nut 30 into the recess 22a of the square member 22, the attaching operation can be performed easily and quickly, and the insert of the nut 30 by the second FRP layer 23 is possible. Even if the mold is incomplete, the nut 30 does not move due to the pressure input of the second resin (see arrows d and e in FIG. 6A), so that it is possible to prevent displacement.

  Further, the wooden square member 22 and the plywood 21 are lighter and less expensive than the metal frame, and the processing of the concave portion 22a and the like is easy, and the nut 30 can be directly attached by any of wood screws, nails and adhesives. It can be fixed to.

  Further, since the screw hole 30b of the nut 30 is closed by the removable cap 32, the spraying material of the second FRP layer 23 and the second resin layer 25 cannot enter the screw hole 30b of the nut 30 in advance. Will be able to prevent.

  In the above embodiment, the nut 30 is attached to the square member 22 in advance by fitting the concave portion 30a of the nut 30 into the concave portion 22a of the square member 22 from above. The nut 30 can be attached to the square member 22 in advance by fixing with an adhesive. In this case, the nut 30 can be easily attached to the square member 22 in advance using a general-purpose screw, nail, or adhesive without processing the recess 22a or the like in the square member 22.

  In the embodiment, the nut 30 is illustrated as the waterproof pan fixing metal fitting, but a bolt or the like may be used instead of the nut 30.

(A)-(c) is process drawing which manufactures the preform member insert-molded in the waterproofing pan which concerns on embodiment of this invention. (A) is process drawing which manufactures the preform member insert-molded in the waterproofing pan which concerns on embodiment of this invention, (b) is sectional drawing of the completed preform member, (c) is the completed preform. It is a perspective view of a reforming member. (A)-(c) is process drawing which manufactures the waterproofing bread which insert-molded the preform member. (A)-(c) is process drawing which manufactures the waterproofing bread which insert-molded the preform member. It is a perspective view of the completed waterproofing pan. (A) is a perspective view of a square bar and a nut, (b) is principal part sectional drawing of a waterproof pan. It is sectional drawing of the waterproofing pan which concerns on embodiment of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Waterproofing pan 11 Preform lower mold 12 Preform upper mold 14 Molding lower mold 15 Molding upper mold 19 Preform member 20 First FRP layer 21 Plywood (reinforcing material)
22 Square material (reinforcing material)
22a Concave portion 23 Second FRP layer 24 First resin layer 25 Second resin layer 30 Nut (waterproof pan fixing bracket)
30a Recess 30b Screw hole 32 Cap

Claims (6)

  First resin is applied to the lower mold for molding, a preform member with a waterproof pan fixing bracket attached in advance to the reinforcing material is placed on the first resin, and the upper mold is placed on the preform member Then, after clamping the upper and lower molds, the second resin is press-fitted between the preform member and the upper mold to insert-mold the waterproof pan fixing metal fitting into the second resin layer. A method of manufacturing a waterproof pan.   The first FRP layer is formed on the preform lower mold, the reinforcing material is placed on the first FRP layer, the waterproof pan fixing metal fitting is attached to the reinforcing material, and the second material is placed on the reinforcing material. The method for manufacturing a waterproof pan according to claim 1, further comprising a preform member manufacturing step in which an FRP layer is formed to insert-mold a waterproof pan fixing metal fitting into the second FRP layer.   The waterproof pan manufacturing method according to claim 1 or 2, wherein the waterproof pan fixing metal fitting is attached in advance to the reinforcing material by fitting the waterproof bread fixing metal fitting into the recess formed in the reinforcing material. .   The waterproof pan according to claim 1 or 2, wherein the waterproof pan fixing bracket is attached to the reinforcing member in advance by fixing the waterproof pan fixing bracket to the reinforcing member with a screw, a nail, or an adhesive. Manufacturing method.   The method for manufacturing a waterproof pan according to any one of claims 1 to 4, wherein the reinforcing material is wooden.   The waterproof pan manufacturing method according to any one of claims 1 to 5, wherein the waterproof pan fixing metal fitting is a nut, and a screw hole of the nut is closed by a detachable cap.

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