JPH11210039A - Thermoplastic resin waterproof pan - Google Patents

Abstract

PROBLEM TO BE SOLVED: To increase the strength and the surface performance by forming the base material of a box-shaped waterproof pan of a thermoplastic resin and providing rib-shaped reinforcing bodies on the rear face of a floor member. SOLUTION: A thermoplastic resin such as polypropylne, polyethylene terephthalate, etc., is used as a base material and rib-shaped reinforcing bodies 7 are integrally formed at the rear face of a floor plate 8, and further, vertical walls 6 are formed at a part or the whole of the outer edge of the floor plate 8 to constitute a waterproof pan. When a higher surface hardness is required to the waterproof pan, a thermosetting resin hard coat layer, a metallic sheet or a film, a ceramic or tile layer, etc., are provided on the surface of the waterproof pan to laminate a surface layer having a higher hardness than the thermoplastic resin as the base material. When imparting a higher rigidity and a shock- resistance to the waterproof pan, long fiber reinforcing resin pellets in which reinforcing fiber such as glass fiber or the like is filled, are used for the base material. In this way, the strength and the surface performance can be improved.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a waterproof pan made of thermoplastic resin.

[0002]

2. Description of the Related Art Conventionally, places where hot water is used in a wide range of fields such as construction fields such as bathrooms and verandas, home electric appliances fields such as washing machines and dish dryers, agricultural fields such as crop cultivation, and automobile fields. Waterproof pans are widely used to prevent water leakage. For example, in a well-known unit-structured bathroom, a waterproof pan is installed under a part called a washing place and under a bathtub, and plays a role of collecting hot water overflowing from the washing place and the bathtub to a drain outlet.

Such a waterproof pan is disclosed in, for example,
As shown in JP-A-90573 and JP-A-8-336849, it generally consisted of a thermosetting resin.

[0004] However, the waterproof pan made of such a thermosetting resin has the feature of being excellent in strength and surface performance, but has a long molding cycle in the production thereof,
In addition, there is a problem that the cost is increased due to a poor working environment, and a serious problem of industrial waste treatment is occurring because the material cannot be recycled.

[0005]

SUMMARY OF THE INVENTION
The present inventors have studied waterproof pans which are excellent in strength and surface performance, are easily manufactured industrially, and are recyclable, and as a result, have reached the present invention.

[0006]

That is, the present invention relates to a box-shaped waterproof pan having a water collecting structure in which a part or the entire periphery of an outer edge forms a vertical wall, and a floor plate portion is inclined. An object of the present invention is to provide a waterproof pan made of a thermoplastic resin, wherein the waterproof pan is made of a thermoplastic resin and has a rib-like reinforcing member provided on the back surface of the floorboard.

[0007]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below. The waterproof pan in the present invention is not particularly limited in its use as long as it is for preventing water leakage or receiving water in a place where hot and cold water is used, and the above-described bathroom, a building field such as a veranda, a washing machine, It is applied to a wide range of fields such as household appliances such as tableware dryers, agricultural fields such as crop cultivation, and even automobile fields, and in some cases, is not limited to only when the target liquid is hot water, It may be widely used for preventing liquid leakage or receiving liquid.

The thermoplastic resin waterproof pan of the present invention has a basic shape in which a part or the entire periphery of the outer edge forms a vertical wall, and a floor plate portion is inclined to have a water collecting function. The shape of the waterproof pan is appropriately determined according to each application scene, but is typically a rectangular box-like shape as shown in FIG. 1 which is often applied as a bathroom waterproof pan.

Hereinafter, the present invention will be described with reference to a waterproof pan mainly applied to a bathroom as exemplified in FIG.
This waterproof pan comprises a floor plate portion (8) and a vertical wall (6) formed on a part or all of the outer edge of the floor plate portion.
In this example, three sides of the square floor plate portion and its periphery are vertical walls, and one side is open.
The outer peripheral vertical wall (6) serves as a weir to prevent hot water on the waterproof pan from leaking around, and its height varies depending on the purpose of use.
It is about 0 mm.

Further, in a bathroom application, depending on the structure of the bathroom, a horizontal plane (1) for setting a bathroom wall panel may be used.
0) in the middle of the outer edge, and the outer edge may be composed of two steps. The lower end of the bathroom wall panel is placed on this horizontal surface to fill the gap between the waterproof pan and the wall panel, We do not leak out of the bathroom.

In such a waterproof pan for a bathroom, the floor plate portion (8) inside the vertical wall (6) on the outer edge is a washing place in the bathroom or a portion for receiving hot water overflowing from the bathtub (tab pan).
However, the floor plate portion (8) is inclined so as to have a water collecting function of preventing hot water from collecting and collecting water to guide the water to a drain port. This inclination may be performed, for example, by inclining the central portion of the floor plate portion below the peripheral portion to collect hot water at the central portion of the floor plate portion, or making the central portion of the floor plate portion higher than the peripheral portion, May be guided to the peripheral portion of the floor plate portion, and the inclination angle in the longitudinal direction of each peripheral portion at that time may be appropriately changed and guided to a specific side. In the case of a waterproof pan in a bathroom, the inner surface of the vertical wall (6) often serves as a design surface, and a tile pattern or a stone-pattern pattern such as granite is applied as necessary. Is also good.

The back surface of the floor plate portion (8) that receives the hot and cold water of the waterproof pan is reinforced by a rib-like reinforcement (hereinafter simply referred to as a rib) (7) integrated with the back surface. The location and shape of the ribs (7) are appropriately selected according to the required strength. The ribs may be provided in only one direction, or the ribs (7) may be provided in a lattice shape by combining the ribs at right angles. Alternatively, the ribs may be provided so that the ribs intersect at a certain angle. Further, the rib (7) is not limited to a linear shape, and may be a zigzag shape or a curved shape such as a waveform, or may have a curved point at an intersection of the ribs. It may be appropriately selected depending on the shape and desired strength of the floorboard portion, such as having an appropriate curved point at a place.

[0013] In some cases, a rib may be arranged at a position corresponding to the design of the surface. This is because, in the case of a resin product, appearance defects called sink marks often occur on the surface on the ribs, and this is because the appearance defects are solved by arranging the ribs in a design portion where sink marks are not conspicuous.
For example, when a tile-shaped design is provided on the surface of the floorboard,
By arranging the ribs (7) in accordance with the joints of the tiles, it is possible to hide the presence of sink marks, and even if the shape is irregular, such as stone-stone, the ribs can be used by using the seams. By arranging, sink marks on the surface can be made inconspicuous.

The ribs (7) may be provided with as many intersections as possible so that the reinforcing effect can be easily obtained. In addition, a portion to which more load is applied, for example, a portion where a bathtub is placed, a portion where a person enters the bathtub, or a waterproof pan is provided. By increasing the number of ribs, the supporting portion for supporting the ribs can obtain a higher reinforcing effect. The rib spacing is appropriately determined according to the desired strength. For example, when the ribs (7) are provided in a lattice shape, the spacing is about 50 to 300 mm.

The thickness of the rib (7) is appropriately determined according to the shape of the product and the required strength, and is not particularly limited. In general, the thicker the rib, the stronger the reinforcing effect is obtained, but if it is too thick, it not only leads to an increase in product weight,
Usually, the thickness is limited to about 1 to 5 mm or about 1/3 to 2/3 of the thickness of the floor panel portion of the waterproof pan because the sink marks on the surface described above become large and conspicuous. Instead, it is determined appropriately according to each condition. It is preferable that the thickness of the rib is as uniform as possible in the length direction thereof, but the surface design is impaired or the strength is locally required due to sink marks, and in some cases, the rib thickness is partially reduced, or It can be thicker. It is preferable that the ribs have a so-called tapered shape in which the thickness of the ribs in the height direction is generally reduced toward the rib tip. The preferred thickness of the rib in this case means the thickness at the base of the rib.

The height of the rib (7) is appropriately determined according to the required strength, and is not particularly limited. In general, the higher the height of the rib, the higher the strength (rigidity) of the product tends to be. The height of the ribs is not necessarily required to be uniform, and is appropriately determined according to the inclination of the floor plate portion of the waterproof pan and the outer edge shape. In addition, when a drain pan, a water pipe, or the like is provided on the lower surface of the waterproof pan, for example, the installation state of the waterproof pan, the height of the rib is determined so as to avoid interference of the rib according to the structure. You.

The shape of the intersections (contacts) between the ribs or between the ribs and the floor plate is not particularly limited, but the connection is made in a gentle curved shape so that concentrated stress does not occur at the intersections (contacts). You can also. The effect of making the local sink on the integrated surface of the rib and the floor plate portion less visibly noticeable is obtained with a gentle curved shape.

As described above, the basic shape of the waterproof pan according to the present invention has a structure in which a part of the outer edge or the entire periphery forms a vertical wall, and the floor plate portion is inclined to have a water collecting function. As a resin material serving as a base material of such a waterproof pan, a thermoplastic resin (4) having excellent recyclability is used.
Examples of such thermoplastic resins include polyolefin resins such as polypropylene and polyethylene, polyethylene terephthalate (PET), acrylonitrile styrene copolymer (AS resin), acrylonitrile butadiene styrene terpolymer (ABS resin), and polystyrene. (PS resin), polycarbonate (PC resin), polyamide or the like, or a polymer alloy composed of these. By filling such a thermoplastic resin with fillers, fibers, and the like, the flexural modulus of the base material can be improved. In particular, the use of a reinforcing fiber such as a glass fiber or a carbon fiber as a filler is effective for improving the physical properties. In particular, a glass fiber which is easy in cost and has a large effect of improving the flexural modulus is preferably used.

Since the base material of the waterproof pan is required to have properties such as warm water resistance and chemical resistance, the resin material used as the base material has a relatively low water absorption among the thermoplastic resins described above. Polypropylene excellent in chemical resistance is particularly preferably used. Since this polypropylene has excellent thermal stability, it can be said that it is a resin material suitable for reuse by recycling.

The resin material used as the base material of the waterproof pan is preferably a resin material filled with reinforcing fibers as described above. However, the waterproof pan requires high rigidity and impact resistance. It is particularly desirable to use long fiber reinforced resin pellets. In general, in the case of a fiber-reinforced thermoplastic resin material, when the fiber length of the filled reinforcing fiber is short, it is possible to obtain excellent product physical properties having a high flexural modulus, but the impact resistance is low. It is not always sufficient, and it is effective to use long fiber reinforced resin pellets satisfying rigidity and impact resistance as a raw material in this regard. Molded products made of long fiber reinforced resin pellets
Reinforcing fibers of a length approximately equal to the pellet length are present in the compact, and these long fibers contribute to the improvement of impact resistance.

Such a long fiber reinforced resin pellet is obtained by impregnating continuous reinforcing fibers, for example, glass fibers with a molten thermoplastic resin, and cutting the resin into a predetermined length, usually about 3 to 25 mm. It is. The length of the long fiber reinforced resin pellet used for the waterproof pan is preferably about 6 to 12 mm in consideration of impact resistance and formability.
The amount of reinforcing fibers contained in the resin material is appropriately selected depending on the type of thermoplastic resin to be used, product shape, required strength, performance, and the like. % By weight.

Such a waterproof pan made of a thermoplastic resin whose back surface is reinforced with a rib (7) can obtain surface performance and rigidity comparable to those of a waterproof pan made of a thermosetting resin. The rigidity required of the thermoplastic resin waterproof pan depends on the state of support with the floor on which it is placed, but is 10% in terms of the average value of the floor plate.
A cm width of about 1.5 × 10 ⁵ kgf · cm ² or more is required, and such rigidity can be satisfied by selecting the resin material as the base material and adjusting the ribs.

Such a waterproof pan made of a thermoplastic resin whose back surface is reinforced with a rib (7) can obtain surface performance and rigidity comparable to those of a waterproof pan made of a thermosetting resin. The rigidity required of the thermoplastic resin waterproof pan depends on the state of support with the floor on which it is placed, but is 10% in terms of the average value of the floor plate.
A cm width of about 1.5 × 10 ⁵ kgf · cm ² or more is required, and such rigidity can be satisfied by selecting the resin material as the base material and adjusting the ribs.

When a higher surface hardness is required for the waterproof pan based on the thermoplastic resin of the present invention,
By laminating the surface layer (9) having a higher hardness than the thermoplastic resin material as the base material on the surface of the waterproof pan, the surface hardness is improved and the scratch resistance of the surface of the waterproof pan can be improved. As a material having a higher hardness than the thermoplastic resin material of the base material for forming the surface layer, the hardening of the thermosetting resin may be used.
Examples include a coating layer, a metal sheet or film, or a ceramic or tile. Even when it is a sheet or film made of a thermoplastic resin, it can be used in combination with a base resin. For example, when the base resin is glass fiber reinforced polypropylene, an acrylic resin sheet can be used as the surface layer material having a higher hardness.

When a sheet material is bonded as the surface layer (9), the design can be improved by printing various patterns on the sheet material in advance. In addition, by attaching an uneven pattern or the like to such a sheet material,
Higher designability can be obtained.

The base resin and the surface layer may be previously subjected to antibacterial and antifungal treatments. As a bactericidal / antifungal material, a general material such as silver can be used.

The waterproof pan of the present invention can be easily manufactured by a molding technique of a thermoplastic resin, for example, a general molding method such as injection molding, compression molding and injection compression molding. However, in the case of thermoforming from a sheet material such as vacuum forming or compressed air forming, the integral molding of the reinforcing ribs is not sufficient, and this is not a preferable method.

Next, an example of the production of the waterproof pan of the present invention using glass fiber reinforced polypropylene (long fiber reinforced resin pellets) as the thermoplastic resin constituting the substrate will be described. FIG. 2 shows a pair of male and female molds, and one of the male and female molds is attached to a press device (not shown) so that the mold can be opened and closed. In the figure, female type (2)
Is fixed, and the male mold (1) is movable.
Each mold has a cavity surface, and the cavity surface of one mold (male mold in this figure) becomes a design surface, and the other mold (female mold in this figure) becomes a back surface. A desired concave and convex pattern is processed on the cavity surface on the design surface side, and the cavity surface on the back surface has a shape in which a rib for reinforcement can be formed.

In the cavity surface of the female mold (2), a molten resin supply port (3) for supplying molten resin into the cavity.
Is opened, and the molten resin supply port (3) is connected to an injection machine (not shown) outside the mold via a molten resin passage in the mold,
The thermoplastic resin (4) melted by the injection machine can be supplied into the cavity.

Using such a mold, the male mold is lowered and clamped until a predetermined cavity clearance exists between the two molds, and the molten resin (4) is supplied between the two cavity surfaces. (FIG. 3) At this time, the mold clamping operation may be temporarily stopped, or the mold clamping operation and the supply of the molten resin may be performed in parallel. The amount of resin to be supplied is determined in advance according to the volume of the final product. When supplying the molten resin by temporarily stopping the mold clamping operation, the mold clamping is restarted immediately before or almost simultaneously with the completion of the supply of the molten resin. The mold clamping is continued until the molten resin is completely filled in the cavity, and the pressure is maintained at a predetermined pressure while the molten resin is filled in the cavity. (FIG. 4)

This pressure-holding state is maintained until the molten resin in the cavity cools and solidifies. After cooling is completed, both molds are opened to take out the solidified compact (FIG. 5), as shown in FIG. You can get a waterproof pan. After the supply of the molten resin is completed, the molten resin is stored in the injection machine and prepared for the next production, whereby the desired waterproof pan can be produced in a short molding cycle.

Prior to the supply of the molten resin, a material serving as a surface layer, for example, a resin sheet is fixed to the mold cavity surface on the design surface side (FIG. 6), and otherwise the same method as described above is used. By performing the supply of the molten resin, the mold clamping, and the cooling operation, the waterproof pan having the surface layer (9) can be easily manufactured.

[0033]

The waterproof pan of the present invention has excellent features such as excellent strength and surface performance, and is easily manufactured industrially and can be recycled.

[Brief description of the drawings]

FIG. 1 is a perspective view showing an example of a waterproof pan according to the present invention.

FIG. 2 is a schematic cross-sectional view of an example of a mold used for manufacturing the waterproof pan of the present invention.

FIG. 3 is a schematic sectional view of a mold showing a manufacturing process of the waterproof pan of the present invention.

FIG. 4 is a schematic cross-sectional view of a mold showing a manufacturing process of the waterproof pan of the present invention.

FIG. 5 is a schematic cross-sectional view of a mold showing a manufacturing process of the waterproof pan of the present invention.

FIG. 6 is a schematic cross-sectional view of a mold showing a manufacturing process of the waterproof pan of the present invention.

FIG. 7 is a schematic cross-sectional view of a mold showing a manufacturing process of the waterproof pan of the present invention.

[Explanation of symbols]

 1: Male mold 2: Female mold 3: Molten resin supply port 4: Molten thermoplastic resin 5: Waterproof pan base material 6: Waterproof pan vertical wall 7: Rib 9: Surface layer 10: Horizontal plane

Claims (4)

[Claims] 1. A box-shaped waterproof pan having a water collecting structure in which a part or the entire periphery of an outer edge forms a vertical wall and a floor plate portion is inclined, wherein a base material is made of a thermoplastic resin, and a rib is provided on a back surface of the floor plate. A waterproof pan made of a thermoplastic resin, characterized in that it is provided with a reinforcing member. 2. The thermoplastic resin waterproof pan according to claim 1, wherein a surface layer having a higher hardness than the substrate is laminated on at least a part of the surface of the substrate. 3. The waterproof pan made of thermoplastic resin according to claim 1, wherein the base material is a thermoplastic resin containing reinforcing fibers, and the base material is formed from long fiber reinforced thermoplastic resin pellets. 4. The thermoplastic resin waterproof pan according to claim 1, wherein the substrate and / or the surface layer are subjected to antibacterial and antifungal treatments.