Sanitary basin molding and method for manufacturing such a sanitary basin molding

Abstract

Sanitary basin molding (1), such as a kitchen sink, a washbasin or a shower tray, with a base body (10) having the shape of the sanitary basin molding (1) and providing the mechanical stability of the sanitary basin molding (1), wherein a cover layer (20) is arranged on the visible side of the sanitary basin molding (1) at least on a surface area above the base body (10), which has a fiber fabric (24) impregnated with a hardened binder, characterized in that the fiber fabric (24) is arranged eccentrically within the cover layer (20) with respect to the thickness of the cover layer (20), and that the cover layer (20) has a water-repellent layer (28) on the visible side of the sanitary basin molding (1).

Description

[0001] The invention relates to a sanitary basin component, such as a kitchen sink, a washbasin or a shower tray, as well as a method for manufacturing such a sanitary basin molding.

[0002] A basin molded part is known from DE 10 2004 055 365 A1. A related manufacturing process using a molded part suitable, for example, for kitchen sinks is known from EP 0 361 101 B1. Basin molded parts manufactured in this way exhibit high optical quality and very good performance characteristics, in particular high abrasion resistance and high long-term stability of their optical appearance.

[0003] Particularly large-volume and / or three-dimensionally extending basin components that deviate from a flat shape, such as a kitchen sink, can have a mass of, for example, more than 10 kg, especially if they are made of a composite material containing a polymerized, cured binder and embedded fillers, as described, for example, in EP 0 361 101 B1. Therefore, precautions must be taken to prevent breakage, especially during transport and installation of the basin components, which requires considerable effort and complicates handling.

[0004] Furthermore, while the surface of the manufactured sanitary basin components is of exceptionally high quality, they are subjected to considerable stress over years or even decades of use, not only mechanically, for example through abrasion, scratches, or impacts, but also through hot / cold stresses, such as from hot dishwater or from cookware left on the counter. Particularly with sanitary basin components made from composite materials, it is essential to prevent stress cracks from forming on the surface. This can only be guaranteed through the use of high-quality resins and a sophisticated manufacturing process.

[0005] A sanitary basin component with the features of the preamble is known from AT 327 568 B1. There, a method for manufacturing a composite body such as a bathtub or a washbasin is described, in which a preform, determining the basic shape of the final product and preferably its visible side, is produced from a thermoplastic film and coated on one side with a durable, glass-fiber-reinforced plastic using a binder. After coating, this coating hardens. A thermoplastic preform is shown, the outer surface of which forms a surface of the finished body, and the other surface of which is exposed to a solvent for this thermoplastic before or during the application of a layer of durable, glass-fiber-reinforced plastic.This allows the final product, after the durable plastic has cured, to have a transition zone containing the thermoplastic, fiberglass, and the durable plastic itself. Further layers of the same or a different curable resin, with or without fiberglass, can then be applied to this layer.

[0006] DE 3 712 959 C2 discloses a method for manufacturing a sanitary article, or a sanitary article manufactured accordingly. This article consists of two fiber assemblies of different structures lying directly adjacent to one another. The fiber assemblies with the looser structure are immediately adjacent to the tensile surface of the molded part. The two fiber assemblies are loosely placed side by side in a mold, such that the loose fiber assemblies face the tensile surface. The liquid material is then introduced into the mold under pressure, so that the molded part is formed. The two fiber layers form the underside of the molded part.

[0007] US 2005 / 0080184 A1 also deals with a molded item. This publication focuses primarily on a binder composition, which is characterized by having a hydrophobic monomer component comprising at least one organoxyloxane functionalized with an unsaturated group. This binder composition is advantageous with regard to cleaning properties.

[0008] The invention is therefore based on the objective of providing a sanitary basin molding and an associated manufacturing method by which the performance characteristics of the sanitary basin moldings are further improved, and which in particular provide a particularly appealing surface appearance.

[0009] The problem is solved by the sanitary basin molding component defined in claim 1 and by the manufacturing method defined in the dependent claim. Further embodiments of the invention are defined in the dependent claims.

[0010] In one embodiment, the invention relates to a sanitary basin component such as a kitchen sink, a washbasin or a shower tray, comprising a base body having the shape of the sanitary basin component and providing the mechanical stability of the sanitary basin component, wherein on the visible side, which in the application forms the usable surface of the sanitary basin component, a cover layer is arranged at least on a surface area above the base body, which has a fibrous fabric impregnated with a hardened binder.

[0011] The base body can, for example, be made of a composite material comprising a polymerized, cured binder and embedded fillers, as described in EP 0 361 101 B1 or DE 10 2004 055 365 A1. In particular, the base body can already be a basin molding that constitutes a marketable product even without the top layer according to the invention. Alternatively, compared to a marketable basin molding, the base body can also have a slightly reduced thickness and / or a lower surface quality on the visible side, which in the sanitary basin molding according to the invention is formed by the additionally applied top layer.

[0012] The composite material of the base body can, for example, consist of a cured resin, in particular an acrylic resin, with embedded, preferably particulate, inorganic fillers, such as sand or quartz. The filler content is preferably between 55 and 85 wt.%, in particular between 60 and 80 wt.%, and preferably between 65 and 75 wt.%, in each case based on the total mass of the base body. The size of the filler particles can be selected, for example, as described in EP 0 361 101 B1 or DE 10 2004 055 365 A1.

[0013] In one embodiment, the surface layer is applied across the entire visible surface of the sanitary basin molding, covering the base body. The surface layer can also be applied laterally to the edges of the sanitary basin molding, so that after installation, the entire visible surface of the sanitary basin molding is formed by the surface layer.

[0014] In one embodiment, the top layer has a thickness of less than 35%, particularly less than 30%, and preferably less than 25% of the thickness of the base body. For example, the base body may have a thickness of 10 mm, while the top layer has a thickness of only 1.5 mm. Despite the relatively small percentage thickness of the top layer, the fibers arranged within it, which are particularly woven and preferably perpendicular to each other, ensure stabilization of the top layer, which is arranged above the fiber woven structure and consists, for example, of a resin, particularly against stress cracks due to hot / cold loads. The top layer may, for example, be formed from a preferably highly transparent, or alternatively colored, polyester resin, or alternatively from an epoxy resin, preferably with a water-repellent surface layer.

[0015] The fiber fabric arranged in the top layer stabilizes the surface layer above it, thus ensuring high stability of the surface of the sanitary basin molding formed by the top layer, particularly against stress cracks caused by hot / cold exposure. In one embodiment, compressive stresses prevail in the top layer, especially in the top layer, at room temperature, reliably preventing the occurrence of stress cracks.

[0016] While the rigidity of the sanitary basin molding is already provided by the base body, the top layer allows for additional surface stabilization and also increases impact resistance in the event of impacts, for example from falling kitchen utensils. Furthermore, the application of a top layer to the base body offers additional design options for the visual appearance of the sanitary basin molding, and the use of a fiber fabric impregnated with a hardened binder ensures that the resulting appearance meets even the highest aesthetic standards over the long term.

[0017] According to the invention, the fiber fabric is arranged eccentrically within the cover layer with respect to the thickness of the cover layer and, for example, offset towards the base body. Thus, the fiber fabric can be arranged on or near a surface of the cover layer facing the base body. A comparatively thin layer of the cured binder with which the fiber fabric is impregnated can be arranged between the fiber fabric and the surface of the base body, for example, with a thickness of less than 0.3 mm, in particular less than 0.2 mm, and preferably less than 0.1 mm. Such a sandwich structure further improves the resistance of the surface of the sanitary basin molding to hot / cold stresses. Alternatively, the fiber fabric can also be arranged offset from the center of the cover layer towards the surface of the sanitary basin molding.

[0018] In one embodiment, the thickness of the fiber fabric is less than 20%, particularly less than 15%, and preferably less than 10% of the thickness of the base body. The thickness of the fiber fabric can be less than 60%, particularly less than 50%, and preferably less than 40% of the thickness of the cover layer. In one embodiment, for example, the thickness of the fiber fabric is between 0.3 and 0.7 mm, whereas the total thickness of the cover layer is more than 1 mm and less than 2 mm. The thickness of the base body can be more than 7 mm and less than 14 mm, particularly more than 8 mm and less than 12 mm. The comparatively small thickness of the fiber fabric is sufficient to withstand the stresses occurring, particularly laterally with respect to the surface, in the event of hot / cold loading.

[0019] According to the invention, the surface layer on the visible side of the sanitary basin molding has a water-repellent layer, for example a thin surface layer made of a polyester resin. This ensures that water penetration into the surface layer is permanently prevented.

[0020] The glass transition temperature and preferably also the Martens temperature of the top layer can be comparatively low with respect to the underlying base material, for example only higher than 80°C.

[0021] In one embodiment, the fiber fabric of the top layer contains carbon fibers; in particular, the fiber fabric consists entirely of carbon fibers. Fiber bundles or so-called rovings can be woven into a fiber fabric, with the warp and weft fiber rovings forming an angle of essentially 90°. For sanitary fittings, a twill weave has proven particularly advantageous.

[0022] Preferably, the warp and weft thread rovings run parallel or transversely to the longitudinal direction of the sanitary basin molding. Investigations have shown that the resistance to stress cracking is particularly high in such a fiber fabric.

[0023] In one embodiment, the basis weight of the fiber fabric is more than 50 g / m² and less than 400 g / m², in particular more than 80 g / m² and less than 350 g / m², and preferably more than 100 g / m² and less than 300 g / m². The rovings preferably have a width of more than 0.5 mm and less than 5 mm, in particular more than 0.7 mm and less than 3.5 mm, and preferably more than 1.0 mm and less than 2.0 mm. In one embodiment, the fiber fabric is a spread-tow fabric, either in twill or plain weave. In this case, the width of the fiber strand in the warp and / or weft is more than 5 mm and less than 15 mm, in particular more than 6 mm and less than 12 mm.

[0024] The invention also relates to a method for manufacturing a sanitary basin molded part, such as a kitchen sink, a washbasin or a shower tray, with a base body having the shape of the sanitary basin molded part and providing the mechanical stability of the sanitary basin molded part, wherein a cover layer is arranged on the visible side of the sanitary basin molded part over the base body, and the cover layer comprises a fibrous fabric impregnated with a hardened binder.

[0025] The base body can be made from a composite material comprising a polymerized binder and embedded fillers, as described above. In one embodiment, the base body and the cover layer are manufactured separately. The cover layer, in the form of a cover shell, can then be firmly and permanently bonded to the base body by applying the cover layer to the surface of the base body corresponding to the visible side of the sanitary basin component and bonding it to the base body. For example, the bond can be made using an epoxy adhesive, in particular a two-component epoxy adhesive.

[0026] The top layer can be subjected to compressive stress either during its production or when it is applied to the base body. This can be achieved, for example, by applying a temperature higher than room temperature either during production or when bonding the top layer to the base body, so that during subsequent cooling, the top layer is subjected to compressive stress due to the different coefficients of thermal expansion of the top layer and the base body.

[0027] This is particularly true when using carbon fibers for the surface layer, since carbon fibers exhibit a negative coefficient of thermal expansion in certain areas. This means that the carbon fibers lengthen upon cooling, while the binder with which the carbon fibers are impregnated tends to shrink. The same applies to the base material, which also shrinks upon cooling. Therefore, especially when carbon fibers are used for the fiber fabric, compressive stresses are introduced into the surface layer, particularly into the resin layer above the fiber fabric, during the manufacturing process of the sanitary basin molding. These stresses reliably prevent the occurrence of stress cracks during subsequent use.

[0028] In one method, the base body is produced by molding a mold part, particularly using casting molds. This allows for the production of base bodies, especially those made from composite materials, with high material homogeneity and thus good mechanical properties.

[0029] In one embodiment, the fiber fabric can be embedded in the visible surface of the sanitary basin molding. The top layer can also be pre-embedded in the molding as a semi-finished product, known as a prepreg. Alternatively, the fiber fabric impregnated with the binder can be in the form of a prepreg and bonded to the already manufactured base body within a molding by heating the molding until the prepreg has cured and, if desired, is already bonded to the base body. A molding identical in shape to the one used to manufacture the base body can be used for curing the prepreg.

[0030] Further advantages, features, and details of the invention will become apparent from the dependent claims and the following description, in which an exemplary embodiment is described in detail with reference to the drawings. The features mentioned in the claims and in the description can be essential to the invention individually or in any combination. Fig. Figure 1 shows a section through an embodiment of a sanitary basin molding according to the invention in the direction of its longitudinal axis, Fig. Figure 2 shows an enlarged view of a section of the sanitary basin molding of the Fig. 1 in the area of ​​the draining surface, and Fig. Figure 3 shows a top view of the surface of the sanitary basin molding.

[0031] The Fig. Figure 1 shows a section through an embodiment of a sanitary basin molding 1 according to the invention in the direction of its longitudinal axis. In the embodiment, it is a kitchen sink with a basin 2 and a draining area 4. Fig. Figure 2 shows an enlarged view of a section of the sanitary basin molding 1 in the area of ​​the draining surface 4.

[0032] The sanitary basin molding 1 has a base body 10 that fully defines the shape of the sanitary basin molding 1 and provides mechanical stability. In the exemplary embodiment, this base body is made of a composite material. The composite material consists of a cured acrylic resin with embedded particulate fillers made of SiO2. The proportion of the SiO2 filler is more than 65% and less than 75% by weight, based on the total mass of the base body, which in the exemplary embodiment is 8 kg. The thickness 12 of the base body 10 is 10 mm.

[0033] On the surface 30 forming the visible side of the sanitary basin molding 1, a cover layer 20 is arranged over the base body 10. This cover layer comprises a fiber fabric 24 impregnated with a cured binder 22. The fiber fabric 24 is arranged on or near the surface of the cover layer 20 facing the base body 10, with a thin layer of the binder 22 running between the fiber fabric 24 and the base body 10. This ensures that the cover layer 20 also has a surface closed by the binder 22 on its surface facing the base body 10. This ensures that any stabilizing effect emanating from the fiber fabric 24 is completely transferred into the cover layer 20 via the binder 22. The fiber fabric 24 is made of carbon fibers. The weave is twill.

[0034] In this embodiment, the basis weight is greater than 100 g / m² and less than 250 g / m². The binder is an epoxy resin. The Martens temperature is higher than 80 °C.

[0035] Above the fiber fabric 24, the cover layer 20 has a top layer 26 in the direction of the surface 30 of the sanitary basin molding 1. This top layer can also consist of a cured polymerized resin, for example, an epoxy resin or a polyester resin. The surface of the cover layer 20 has a water-repellent layer 28, which forms the surface 30 of the cover layer 20 and thus also of the sanitary basin molding 1. If suitable resins are used for the top layer 26, for example, polyester resin, the water-repellent layer 28 can be omitted. In one embodiment, the cover layer 20 has a fiber fabric 24 impregnated with epoxy resin and a top layer 26 made of polyester resin.

[0036] In the exemplary embodiment, the thickness of the top layer 20 is approximately 1.5 mm, wherein the proportion 32 of the top layer 26 to the thickness of the top layer 20 is approximately 1 mm and the proportion 34 of the fiber fabric 24 impregnated with the binder to the thickness of the top layer 20 is approximately 0.5 mm.

[0037] The Fig.Figure 3 shows a top view of the surface 30 of the sanitary basin molding 1. In one embodiment, the cover layer 26 and preferably also the binder 22 with which the fiber fabric 24 is impregnated are transparent or at least translucent, so that the orientation of the fiber fabric 24 is visible on the surface 30. Particularly when carbon fibers are used for the fiber fabric 24, aesthetically pleasing light reflections and a 3D effect occur due to the non-planar orientation of the warp rovings 36 and the weft rovings 38 within the fiber fabric 24, especially when using a twill weave for the fiber fabric 24. This effect is further enhanced by the thickness 32 of the cover layer 26 and its refractive index.

[0038] The asymmetrical arrangement of the fiber fabric 24 with respect to the thickness of the top layer 20 also leads to the occurrence of compressive stresses, especially on the surface 30, which effectively counteracts the formation of stress cracks.

Claims

[1] Sanitary basin fitting (1), such as a kitchen sink, a washbasin or a shower tray, comprising a base body (10) having the shape of the sanitary basin fitting (1) and providing the mechanical stability of the sanitary basin fitting (1), wherein on the visible side of the sanitary basin fitting (1) at least on a surface area above the base body (10) a cover layer (20) is arranged which has a fibrous fabric (24) impregnated with a cured binder, characterized by , that the fiber fabric (24) is arranged off-center within the cover layer (20) with respect to the thickness of the cover layer (20), and that the cover layer (20) has a water-repellent layer (28) on the visible side of the sanitary basin molding (1). [2] Sanitary basin molding (1) according to claim 1, characterized by, that the base body (10) is made from a composite material comprising a polymerized cured binder and fillers embedded therein. [3] Sanitary basin molding (1) according to one of the preceding claims, characterized by , that the cover layer (20) is arranged over the entire surface of the base body (10) on the visible side of the sanitary basin molding (1). [4] Sanitary basin molding (1) according to one of the preceding claims, characterized by that the top layer (20) has a thickness that is less than 35%, in particular less than 30% and preferably less than 25% of the thickness (12) of the base body (10). [5] Sanitary basin molding (1) according to one of the preceding claims, characterized by , that the thickness (34) of the fibrous fabric (24) is less than 20%, in particular less than 15% and preferably less than 10% of the thickness (12) of the base body (10). [6] Sanitary basin molding (1) according to one of the preceding claims, characterized by , that the fibrous fabric (24) of the cover layer (20) has carbon fibers, in particular that the fibrous fabric (24) consists of carbon fibers. [7] Method for manufacturing a sanitary basin component (1), such as a kitchen sink, a washbasin or a shower tray, comprising a base body (10) having the shape of the sanitary basin component (1) and providing the mechanical stability of the sanitary basin component (1), wherein a cover layer (20) is arranged on the visible side of the sanitary basin component (1) at least on a surface area above the base body (10), and the cover layer (20) comprises a fibrous fabric (24) impregnated with a cured binder, and wherein the base body (10) and the cover layer (20) are manufactured separately and then joined together by applying the cover layer (20) to the surface of the base body (10) corresponding to the visible side of the sanitary basin component (1) and bonding it to the base body (10),wherein a cover layer (20) is used with a fiber fabric (24) arranged off-center with respect to the thickness of the cover layer (20) and a water-repellent layer (28) is applied to the cover layer (20) on the visible side of the sanitary basin molding (1). [8] Method according to claim 7, characterized by , that the top layer (20) in the form of an uncured semi-finished product, in particular in the form of a prepreg, is applied to the surface of the base body and bonded to it, and that the top layer (20) is also cured in the process. [9] Method according to claim 7 or 8, characterized by , that the base body (10) is produced by molding a mold part, in particular by casting molds.

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