JPH0618706B2 - Molding method for resin bath - Google Patents

Description

TECHNICAL FIELD The present invention relates to a method for molding a resin bath.

(Prior Art) As one type of resin bath, there is a resin bath having a laminated structure composed of a gel coat layer on the surface, a first FRP layer following it, a resin concrete layer thereunder, and a second FRP layer on the back side. As a method, a gel coat layer and a first FRP layer are formed on a molding surface of a convex mold (first molding mold), while a second FRP layer is formed on a molding surface of a concave mold (second molding mold), and A method is practiced in which both molding dies are matched with each other, and a resin concrete layer is sandwiched between the first FRP layer and the second FRP layer to be solidified, and thus the plurality of layers are integrally laminated and molded. .

By the way, in this kind of resin bath, there is a problem that the resin molded body is apt to be deformed such as warp due to the large shrinkage of the resin concrete layer. If such deformation occurs, the appearance of the bathtub itself will be impaired, the fit will not be good when it is installed, and a gap will be created in the assembly part when the members such as the apron are assembled. The external appearance after attachment or construction will be impaired.

Further, due to such deformation, a step of correcting the deformation after molding the bathtub is necessary, and even if such correction is performed, the deformation occurs again while the bathtub is in use. It causes trouble.

This deformation is particularly large in the handrail part on the upper edge of the bathtub body,
Therefore, conventionally, after the bath is formed, a reinforcing rib is attached to the lower surface of the handrail portion to suppress such deformation.

However, at the stage of mounting such reinforcing ribs, the bathtub has already been deformed, and therefore the rib mounting cannot sufficiently prevent this deformation.
Since this rib is attached manually, the dimensional accuracy of the rib shape and attachment position is poor, and in addition, additional man-hours are required to attach the rib, increasing the number of bath manufacturing processes. There was a problem.

(Means for Solving the Problem) The present invention has been made to solve such a problem, and the gist thereof is to provide a first molding die on the molding surface of the first molding die arranged on the surface side of the bathtub. While forming the FRP layer of the second F on the molding surface of the second molding die arranged on the back surface side of the bathtub.
An RP layer is formed, and both molding dies are combined in such a manner that an intermediate layer such as a resin concrete layer is sandwiched between these FRP layers to form a resin bath having a laminated structure including a first FRP layer, an intermediate layer and a second FRP layer. In the method described above, a recess for forming a reinforcing rib provided on the lower surface of the handrail portion at the upper edge of the bathtub body is provided in advance in the second mold, and the second FRP layer is formed when the second FRP layer is formed. This is to form the reinforcing rib integrally with the FRP layer.

(Operation and Effect of the Invention) As described above, according to the present invention, the reinforcing ribs are integrally formed at the same time when the second FRP layer is formed, and the bath is formed under the function of preventing the deformation of the reinforcing ribs. Therefore, unlike the case where the reinforcing ribs are separately attached after forming the bathtub, it is possible to effectively prevent the deformation of the bathtub, especially the handrail portion. If the deformation of the handrail part of the bathtub can be prevented, the appearance of the bathtub itself will be improved, and the assembled state when the apron or the like is installed or the bathtub installed in the site, the appearance of the installed state, and the fit will also improve. However, the step of correcting deformation such as warpage after forming the bathtub can be omitted, and the problem that the handrail portion of the bathtub is deformed during use of the bathtub can be solved.

In addition, since the present invention forms the reinforcing ribs at the same time as forming the bath, unlike the case where the reinforcing ribs are attached after forming the bath, a separate step for attaching the ribs is not required, which reduces the number of manufacturing steps of the bath. In addition to the decrease, the effect of improving the accuracy of the rib shape, the mounting position, etc. is produced.

(Example) Next, the Example of this invention is described in detail based on drawing.

2 and 3, reference numeral 10 denotes an example of the resin bathtub, which includes the bathtub body 12 and the handrail portion 1 at the upper edge thereof.
4 and the reinforcing ribs 16 are formed at four corners on the lower surface side of the handrail portion 14.

As shown in FIG. 4, this bathtub 10 has a transparent gel coat layer 18 on the surface and a first FRP layer 20 on the lower side thereof.
, The second FRP layer 24 on the back side, and these two FRP layers 2
It has a laminated structure having a resin concrete layer 22 between 0 and 24, and the reinforcing rib 16 is formed integrally with the second FRP layer 24 on the back side thereof.

The reinforcing rib 16 has a form in which a wood piece 26 as a reinforcing member is embedded inside the FRP material.

The bathtub 10 of this example can be molded as follows.

That is, as shown in FIG. 5, first, the gel coat layer 18 and the first FRP layer 20 are laminated on the molding surface 30 of the convex mold (first molding mold) 28 as the bath molding mold. Along with this, the second FRP layer 24 is molded on the molding surface 34 of the concave mold (second molding mold) 32. At the same time, the reinforcing rib 16 is integrally formed. The method of forming the reinforcing rib 16 at that time is specifically shown in FIG. As shown in the figure, in this example, the glass mat 36 is placed on the molding surface 34 of the concave mold 32, and a part of the glass mat 36 is buried in a rib molding recess 38 formed in the concave mold 32 in advance, and then the recess 38 is formed. A wood piece 26 as a reinforcing member is inserted therein, and a glass mat 42 is further covered from above to impregnate the glass mat 42 with a liquid resin and cure the resin. By this, the second F
The RP layer 24 and the reinforcing rib 16 are integrally molded at the same time.

As described above, the gel coat layer 18 and the first FRP layer 20 are provided on the convex mold 28 side, and the second FRP layer 2 is provided on the concave mold 32 side.
After molding 4 respectively, these molds 28 and 32 are then closed and molded so as to sandwich the resin concrete layer 22 between the first FRP layer 20 and the second FRP layer 24. The molding of the resin concrete layer 22 may be performed by pouring the constituent material of the resin concrete layer 22 into a gap formed between the first FRP layer 20 and the second FRP layer 24 during mold matching and solidifying the material. Good and
In addition, the constituent material of the resin concrete layer 22 is poured in advance on the second FRP layer 24 on the molding surface of the concave mold 32, and then the convex mold 28 and the concave mold 32 are combined to form the first FRP layer 20. The constituent material may be sandwiched between the second FRP layer 24 and the second FRP layer 24 to be solidified and molded.

As described above, according to the method of this example, the reinforcing rib 16 can be formed at the same time when the bathtub 10 is formed. That is, the reinforcing ribs 16 can be formed before the bathtub handrail portion 14 is deformed such as warped, and the deformation of the handrail portion 14 can be effectively prevented.

Although the embodiments of the present invention have been described in detail above, the present invention can be carried out in other modes.

For example, the form of the above-mentioned reinforcing rib is merely an example of the present invention, and in the present invention, it is possible to make various other forms, and as the insert material of the reinforcing rib, a material other than the above wood chips is used. It is also possible to do so. Further, the present invention can be applied to a bathtub having a laminated structure other than the above examples, and the present invention is carried out in a mode in which various modifications are made based on the knowledge of those skilled in the art without departing from the spirit of the present invention. It is possible.

[Brief description of drawings]

FIG. 1 is an explanatory view of a method of forming a reinforcing rib in an embodiment method of the present invention, FIG. 2 is a perspective view of a bath formed by the same method, and FIG. 3 is a periphery of the reinforcing rib in FIG. FIG. 4 is an enlarged cross-sectional view of a main part of the portion, FIG. 4 is a cross-sectional view of the reinforcing rib of FIG.
FIG. 5 is an explanatory view of the molding method according to the embodiment. 10: Resin bath, 14: Handrail part 16: Reinforcing ribs, 20: First FRP layer 22: Resin concrete layer 24: Second FRP layer, 28: Convex mold 30, 34: Molded surface, 32: Recessed form 38: Recessed part

Claims (1)

[Claims] 1. A first FRP layer is formed on the molding surface of a first molding die arranged on the front surface side of a bathtub, while a first FRP layer is formed on the molding surface of a second molding die arranged on the rear surface side of the bathtub. The first FR is formed by forming two FRP layers, and placing both molding dies in a state where an intermediate layer such as a resin concrete layer is sandwiched between the two FRP layers.
In a method for molding a resin bath having a laminated structure including a P layer, an intermediate layer, and a second FRP layer, a recess for forming a reinforcing rib provided on the lower surface of the handrail portion at the upper edge of the bath body is provided with the second molding die. In advance,
A method for molding a resin bath, wherein the reinforcing ribs are molded integrally with the second FRP layer when the second FRP layer is molded.