Plumbing fixtures

Abstract

To provide a water-related component with superior aesthetics by suppressing or preventing the occurrence of a phenomenon where the area near the edge of a matte-finish counter top becomes exceptionally high gloss. [Solution] A plumbing fixture comprising at least a bowl or sink and a counter, wherein the surface of the plumbing fixture comprises the top surface of the counter (hereinafter simply referred to as the "top surface") and a surface other than the top surface (hereinafter referred to as the "visible surface"), and when the portion of the plumbing fixture defining the boundary between the top surface and the visible surface is defined as the ridge, the arithmetic mean roughness Ra of at least the region of the top surface adjacent to the ridge is 0.2 μm or more as defined in JIS B 0601:2013, and the 85-degree specular gloss as defined in JIS Z 8741:1997 is 45% or less.

Description

Technical Field

[0001] The present invention relates to a plumbing member, and more particularly to a plumbing member with reduced gloss unevenness on the surface and excellent aesthetics.

Background Art

[0002] Conventionally, as a plumbing member having a bowl or a sink and a counter such as a washstand or a washbasin, a gentle shape with a relatively large R dimension of a ridge line portion (corner portion) forming a boundary between the counter top surface and the bowl side surface or a ridge line portion forming a boundary between the counter top surface and the counter side surface (counter apron) has been used. In recent years, however, those with a small R dimension of these ridge line portions to form a sharp shape or those with a matte finish (non-glossy finish) on the surface of the plumbing member, particularly on the surface of the counter top surface, have become trendy.

[0003] For example, Japanese Patent Application Laid-Open No. 2001-218689 (Patent Document 1) describes that in a counter with a bowl in which a bowl portion and a counter portion are integrally formed of the same material, by finishing the surface of the counter portion to a low gloss, that is, to a matte finish, the weld line generated in the counter portion can be made unrecognizable visually.

[0004] Also, Japanese Patent Application Laid-Open No. 10-34692 (Patent Document 2) describes a problem that since the rib and boss portions formed in a molded product are thicker than other portions, a large dimensional shrinkage due to the polymerization shrinkage of the raw material resin occurs, and a recess defect called sink mark occurs in the rib and boss portions.

Prior Art Documents

Patent Documents

[0005]

Patent Document 1

Patent Document 2

Summary of the Invention

[0006] The inventors have now discovered a novel problem in which, when molding a bathroom fixture comprising a bowl or sink and a counter, reducing the radius (R) of the ridge to obtain a sharp shape results in the wall thickness near the ridge becoming thicker than other parts, leading to increased shrinkage. As a result, the way light reflects changes on the flat surface of the matte counter, causing the area near the ridge of the counter to become exceptionally glossy. This results in uneven gloss being visible when the entire counter surface, including the area near the ridge and the flat area outside of that area, impairs the aesthetic appearance of the bathroom fixture. The inventors have now discovered a novel configuration for a bathroom fixture that can suppress or prevent the occurrence of the phenomenon where the area near the ridge of a matte counter becomes exceptionally glossy. Specifically, they have found that by imparting a specific surface property to the area near the ridge of the matte counter, it is possible to suppress or prevent the occurrence of the phenomenon where that area becomes exceptionally glossy. The present invention is based on this finding.

[0007] Therefore, the present invention aims to provide a water-related component with superior aesthetics by suppressing or preventing the occurrence of the phenomenon in which the area near the edge of a matte-finish counter top surface becomes exceptionally high gloss. [Means for solving the problem]

[0008] Furthermore, the plumbing component according to the present invention is Equipped with a bowl or sink and a counter, When the surface of a plumbing fixture consists of the top surface of the counter (hereinafter simply referred to as the "top surface") and the surface other than the top surface (hereinafter referred to as the "visible surface"), and the part of the plumbing fixture that defines the boundary between the top surface and the visible surface is defined as the ridge line, The arithmetic mean roughness Ra of at least the area adjacent to the edge of the top surface is 0.2 μm or greater, as defined in JIS B 0601:2013, and the 85-degree specular gloss is 45% or less, as defined in JIS Z 8741:1997. It is characterized by the following: [Brief explanation of the drawing]

[0009] [Figure 1] This is a schematic perspective view showing an example of a bathroom product comprising a bathroom component and a cabinet according to the present invention. [Figure 2] This is a schematic perspective view showing an example of a plumbing component according to the present invention. In the figure, the gray area represents the plumbing component according to the present invention. [Figure 3] (a) A schematic side view of a plumbing product equipped with plumbing components according to the present invention. Figure 3a shows the top surface and the visible surfaces of the plumbing components: the front epson of the counter, the rear apron adjacent to the rear wall, and the left side apron. In Figure 3a, the dashed line represents the contour of the underside of the bowl. (b) A schematic cross-sectional view of the circled portion in Figure 3a. [Figure 4] Figure 3a is a schematic cross-sectional view of the circled area, illustrating the relationship between the counter thickness and the rounding radius of the edges (front and back sides). [Figure 5] This is a schematic diagram of a patterned prepreg sheet viewed from above. [Figure 6] This is a schematic cross-sectional view of an example of the configuration of the decorative part in the present invention. [Figure 7] This diagram illustrates a method for integrally manufacturing a plumbing fixture, comprising a bowl and a counter with a decorative top surface, by press molding. It also illustrates the molding die used in this method. [Modes for carrying out the invention]

[0010] Water-related component according to the present invention The basic configuration of the plumbing member according to the present invention will be described with reference to FIGS. 1 and 2. In the aspect shown in FIG. 1, the plumbing member 1 includes a bowl 11 and a counter 12. Note that FIG. 1 is for explaining the plumbing member 1 in accordance with the scene where it is actually used, and shows an aspect in which a plumbing product including the plumbing member 1 and a cabinet is installed on the floor, and the left side surface and the rear side surface of the plumbing member 1 are installed in contact with walls (lateral wall and rear wall).

[0011] Top surface, visible surface, The plumbing member according to the present invention refers to the portion colored gray in the aspect shown in FIG. 2. In the aspect shown in FIG. 2, the surface of the plumbing member 1 consists of the top surface of the counter (hereinafter simply referred to as the "top surface") and the surfaces other than the top surface (hereinafter referred to as the "visible surface"). In the aspect shown in FIG. 2, the visible surface includes the front apron of the counter, the rear apron (not shown) in contact with the rear wall, the right lateral apron, and the left lateral apron (not shown) in contact with the lateral wall, that is, the surfaces of all four sides of the counter. Further, the visible surface includes all the surfaces of the bowl (side surface, bottom surface of the bowl, surface where the faucet is installed).

[0012] Ridge section In the present invention, the portion of the plumbing member that defines the boundary between the top surface and the visible surface is defined as the "ridge line portion". The ridge line portion includes the portion indicated as "ridge line portion (angle r)" in FIG. 2. Even if not explicitly shown in FIG. 2, the portions facing each of the portions indicated as "ridge line portion (angle r)" are also ridge line portions. The description of "bowl side surface (4 surfaces)" in FIG. 2 represents that in the aspect shown in the same figure, there are 4 visible surfaces of the bowl that are connected to the top surface via the ridge line portion among the visible surfaces of the bowl.

[0013] The area adjacent to the ridge of the top surface In the present invention, the "region adjacent to the ridge line portion on the top surface" is a region of the top surface and is a region adjacent to the ridge line portion. The region adjacent to the ridge line portion on the top surface will be described while referring to FIG. 3. FIG. 3a is a schematic side view of a plumbing product including a plumbing member according to the present invention. In FIG. 3a, a front apron of a counter, a rear apron contacting a rear wall, and a left side apron are shown. In FIG. 3a, a broken line represents a lower contour of a bowl. FIG. 3b is a schematic cross-sectional view of a portion surrounded by a circle in FIG. 3a. In the aspect shown in FIG. 3b, the region adjacent to the ridge line portion on the top surface may be, for example, a region between a starting point and an ending point when starting from a boundary between the ridge line portion 1 and the top surface and a boundary between the ridge line portion 2 and the top surface, and ending at a point 0 mm to 10 mm away from the ridge line portion 2 and the ridge line portion 1 in the direction of the ridge line portion 2 and the ridge line portion 1 respectively.

[0014] Surface texture In the present invention, the arithmetic mean roughness Ra defined in JIS B 0601:2013 of at least the region adjacent to the ridge line portion on the top surface is 0.2 μm or more, and the 85-degree specular gloss defined in JIS Z 8741:1997 is 45% or less. Thereby, even if the above region becomes relatively highly glossy with respect to the entire top surface, it is possible to obtain an appearance in which the high gloss is not noticeable and gloss unevenness is hardly visually recognized when observing the entire top surface. Ra is preferably 0.2 μm or more and 0.6 μm or less. By setting the upper limit to 0.6 μm, the cleaning property of the surface is not sacrificed, that is, good cleaning property of the surface can also be ensured. The lower limit of Ra is more preferably 0.22 μm. The upper limit of Ra is more preferably 0.53 μm. The 85-degree specular gloss is preferably 28% or more and 45% or less. By setting the lower limit to 28%, similarly, the cleaning property of the surface is not sacrificed, that is, good cleaning property of the surface can also be ensured. The lower limit of the 85-degree specular gloss is more preferably 31%. Means for controlling Ra and the 85-degree specular gloss of the region adjacent to the ridge line portion on the top surface within the above ranges will be described later.

[0015] Region other than the region adjacent to the ridge line portion on the top surface In the present invention, the surface property of the region other than the region adjacent to the ridge line portion on the top surface (hereinafter, also referred to as "other region") is preferably matte, that is, low gloss. For example, the Ra of the region other than the region adjacent to the ridge line portion on the top surface is preferably 0.2 μm or more and 0.6 μm or less. Also, the 85-degree specular glossiness is preferably 45% or less. Further, the difference (the former - the latter) between the Ra of the region adjacent to the ridge line portion on the top surface and the Ra of the other region is preferably within the range from a value greater than -0.37 μm to +0.17 μm, more preferably within the range of -0.3 μm to +0.17 μm, and even more preferably within the range of -0.22 μm to +0.17 μm. Also, the difference (the former - the latter) between the 85-degree specular glossiness of the region adjacent to the ridge line portion on the top surface and the 85-degree specular glossiness of the other region is preferably within the range from a value greater than -9.7% to +9.0%, more preferably within the range of -9.0% to +9.0%, and even more preferably within the range of -3.7% to +8.4%.

[0016] Relationship between counter thickness and edge rounding radius In the present invention, when the rounding radius on the front surface side of an (arbitrary) ridge line portion is R1 [mm], the rounding radius on the back surface side of the ridge line portion is R2 [mm], and the thickness of the counter is T1 [mm], the following formula (1): R1 < R2 + T1 Formula (1) It is preferable that the relationship represented by this holds. For example, as shown in FIGS. 3b and 4, when the rounding radius on the front surface side of the ridge line portion 1 on the bowl side is R3 [mm], the rounding radius on the back surface side of the ridge line portion is R4 [mm], and the thickness of the counter is T1 [mm], the following formula (1-1): R3 < R4 + T1 Formula (1-1) It is preferable that the relationship represented by this holds. Similarly, when the rounding radius on the front surface side of the ridge line portion 2 on the apron side is R5 [mm], the rounding radius on the back surface side of the ridge line portion is R6 [mm], and the thickness of the counter is T1 [mm], the following formula (1-2): R5 < R6 + T1 Formula (1-2) It is preferable that the relationship represented by this holds.

[0017] The above embodiment will be explained with reference to Figures 3b and 4. Note that the part shown in Figure 4 is the same as the part shown in Figure 3b, and is a schematic cross-sectional view of the part circled in Figure 3a. When forming the plumbing components according to the present invention, if the rounding radius R1 of the ridge portion 1 is reduced to obtain a sharp shape, that is, if the angle r1 formed between the top surface and the visible surface (the surface of the bowl side) connected to the top surface via the ridge portion 1 is reduced, the thickness of the portion of the counter adjacent to the ridge portion 1 becomes thicker than the film thickness (T1) of other portions (for example, the portion between the ridge portion 1 and the ridge portion 2 of the counter, or the adjacent portion), and sink marks (shrinkage) become larger. The same applies to the ridge portion 2. For this reason, the area of ​​the top surface adjacent to the ridge portion is susceptible to the effects of shrinkage in the thicker portion, and is an area where a matte finish is likely to change to a high gloss. On the other hand, the area of ​​the top surface other than the area adjacent to the ridge portion, in other words, the area of ​​the counter top surface where the thickness is T1, is less affected by shrinkage in the thicker portion and is an area where a low gloss is easily maintained.

[0018] In other words, even when the thickness of the counter and the rounding radius of the edge satisfy formula (1-1) or formula (1-2) above, which is inherently prone to gloss unevenness, the present invention features a characteristic in which at least the area adjacent to the edge of the top surface has a specific Ra and 85-degree specular gloss, thereby suppressing or preventing the occurrence of high gloss in that area, and consequently reducing or eliminating the visibility of gloss unevenness when the top surface is observed as a whole. In other words, even when the angle (r1, r2) between the top surface and the visible surface connected to the top surface via the edge, i.e., the rounding radius of the edge (R3, R5), is small, and the area adjacent to the edge is prone to high gloss, the fact that at least the area adjacent to the edge of the top surface has a specific Ra and 85-degree specular gloss suppresses or prevents the occurrence of high gloss, and consequently reduces or eliminates the visibility of gloss unevenness when the top surface is observed as a whole. Furthermore, an embodiment in which the thickness of the counter and the rounding radius of the edge satisfy equation (1-1) or equation (1-2) above is one embodiment in which the effects of the present invention are maximized. In equation (1-1), for example, a combination of T1=5.5, R3=2, and R4=3 can be given. The explanation above, which applies to ridge sections 1 and 2, naturally also applies to any ridge section in the present invention.

[0019] In the present invention, it is preferable that the rounding radius on the surface side of the ridge portion is 5 mm or less. This suppresses or prevents the occurrence of the phenomenon in which the area adjacent to the ridge portion of the top surface becomes highly glossy, and consequently reduces or eliminates the visibility of gloss unevenness when the top surface is observed as a whole, thereby efficiently demonstrating the effects of the present invention.

[0020] Components of plumbing fixtures In the present invention, it is preferable that the main component of the plumbing component is resin. It is preferable that the resin includes a thermosetting resin. As the thermosetting resin, unsaturated polyester resin and the like can be used. It is even more preferable that the resin further includes fiber-reinforced plastic (FRP). This makes it possible to obtain a plumbing component with excellent strength. In the present invention, when the "main component" of the plumbing component is resin, it means that the resin matrix constituting the plumbing component may also contain components other than resin, such as fillers.

[0021] Decorative part In the present invention, the plumbing fixture may have a decorative portion on the top surface of the counter. This allows for the application of patterns, colors, or combinations thereof to the top surface of the counter, thereby providing the plumbing fixture with a wide variety of designs.

[0022] Purpose The plumbing components according to the present invention are preferably used for bathroom or kitchen applications. According to a more preferred embodiment of the present invention, the plumbing components are plumbing components comprising a bowl and a washbasin counter, for example, a washbasin counter with a bowl, or plumbing components comprising a sink and a kitchen counter, for example, a kitchen counter with a sink.

[0023] Bathroom and kitchen products In another aspect of the present invention, a plumbing product is provided comprising a plumbing component according to the present invention and a support member for supporting the plumbing component. Examples of the support member include a (storage) cabinet. In the present invention, the plumbing product may further include, for example, a faucet, a mirror, etc.

[0024] Manufacturing method for plumbing components The plumbing components according to the present invention can be manufactured, for example, by the following method. Here, we will describe an example of manufacturing a counter with a bowl by integrally molding the bowl and counter using the same press-molding material.

[0025] Starting up the press molding machine Start the press molding machine. The operation of the press molding machine will be explained as needed in the descriptions of each manufacturing process described later.

[0026] Preparation of materials and molds (dies) <Material> For example, the following press-formed materials can be used to manufacture a counter with a bowl. (Press-formed material) As press molding materials, sheet molding compounds (SMC), thick molding compounds (TMC), and bulk molding compounds (BMC), which are composed of thermosetting resins such as unsaturated polyester resin and fillers, can be used. It is preferable to further use fiber-reinforced plastic (FRP) molding materials as press molding materials.

[0027] In this example, if a decorative section is provided on the top surface of the counter, a prepreg sheet with the following pattern can be used as the material for the decorative section. (Patterned prepreg sheet) • Patterned prepreg sheets can be made by applying a desired pattern to a base fabric of a predetermined thickness (e.g., 0.1-0.3 mm), and then impregnating it with a transparent thermosetting resin mixed with a filler. As the base fabric, for example, pulp nonwoven paper or PET nonwoven fabric can be used. A mixture of pulp and PET may also be used. As a method for applying a pattern to the base fabric, known methods such as inkjet printing and gravure printing can be used. • As the thermosetting resin (impregnation resin) used to impregnate the patterned base fabric, highly transparent thermosetting resins such as DAP resin and epoxy resin can be used. The amount of resin impregnated into the base fabric can be adjusted as appropriate within the range in which the desired decorative area can be obtained, for example, 50-90 g / m². 2 Preferably 65 g / m² 2 Such a degree is preferable from the viewpoint of easily imparting a specific Ra and 85-degree specular gloss. The thickness of the patterned prepreg sheet is preferably, for example, 0.12 mm or more and 0.4 mm or less. In this example, the patterned prepreg sheet can be molded into a shape with an opening in the portion corresponding to the bowl without the decorative portion, so that it is provided only on the top surface of the counter where the decorative portion is to be placed. A schematic diagram of the prepreg sheet molded in this way, viewed from above, is shown in Figure 5. Figure 6 also shows a schematic cross-sectional view of an example of the configuration of the decorative part in the present invention.

[0028] <Mold> The mold for forming plumbing components according to the present invention preferably consists of a pair of upper and lower molds, as shown in Figure 7a, for example, with a molding cavity (molding space) between the front molding surface of the lower mold and the back molding surface of the upper mold.

[0029] <Forming method> The molding method will be explained with reference to Figure 7. When manufacturing a counter with a bowl using the aforementioned press-formed material, the press-formed material of the desired thickness is placed on the front molding surface of the lower die. The amount of press-formed material to be placed can be adjusted as appropriate within the range in which the desired molded body can be obtained, for example, 50 to 90 g / m². 2 Preferably 65 g / m² 2 Such a degree is preferable from the viewpoint of easily imparting a specific Ra and 85-degree specular gloss. On the other hand, when manufacturing a bowl-shaped counter (with decorative portion) using the prepreg sheet and the press-molded material, as described above, a prepreg sheet having an area or shape corresponding to the decorative portion, as shown in Figure 7a, is formed in advance. Next, as shown in Figure 7a, the formed prepreg sheet is placed on a predetermined front-side molding surface of the lower die with the decorative portion facing outwards. When placing the sheet, the prepreg sheet may be fixed to a jig, and then the jig may be set on the lower die. Alternatively, the mold may be preheated before placing the sheet. This allows the placed prepreg sheet to be attached (transferred) along the front-side molding surface. Next, the jig is removed from the mold. Then, the prepreg sheet may be smoothed out or otherwise processed. Finally, a press-molded material of the desired thickness is placed on top of the prepreg sheet.

[0030] Press molding Subsequently, as shown in Figure 7b, the upper and lower molds are clamped together, and a predetermined mold temperature (e.g., 125°C for the upper mold, 145°C for the lower mold) and a predetermined pressure (e.g., 8 MPa) are applied. In the case of manufacturing a counter with a bowl, the resin contained in the press-molded material softens and fills the molding cavity (molding space) following the shape of the front molding surface, and hardens after a predetermined time (e.g., 6 minutes). In the case of manufacturing a counter with a bowl (with decorative parts), the transparent resin of the prepreg sheet softens and fills the molding cavity together with the press-molded material following the shape of the front molding surface, and hardens after a predetermined time (e.g., 6 minutes).

[0031] As described above, according to one aspect of the present invention, a method for manufacturing a plumbing component according to the present invention, A process of filling a molding cavity with a resin-containing material, A process of forming plumbing components by heating and pressurizing a resin-containing material. A method is provided that includes the following: This method allows for the desired surface properties to be imparted to the water-related components while they are being molded by a mold, resulting in a lower cost compared to methods that impart the desired surface properties to the molded product's surface through post-processing after molding.

[0032] Furthermore, according to one aspect of the present invention, there is a method for manufacturing a bathroom fixture comprising a bowl and a counter with a decorative part on its top surface, (a) A step of placing a patterned prepreg sheet containing a thermosetting resin on a predetermined area of ​​the surface forming surface of a mold for forming a decorative part, (b) A step of filling the molding cavity on which the prepreg sheet is placed with a resin-containing material, (c) A step of integrally heating and pressurizing the material including the prepreg sheet and the resin to form a water-related component. A method is provided that includes the following: This method allows for the application of patterns, colors, or combinations thereof to the countertop surface, resulting in aesthetically pleasing bathroom fixtures.

[0033] Furthermore, according to one aspect of the present invention, the method described above, The process includes, prior to step (a), heating the mold, The process after step (a) includes a step of attaching the placed prepreg sheet along the area, and then In place of step (b), (b') a step of filling the molded cavity to which the prepreg sheet is attached with a resin-containing material, (c) A step of integrally heating and pressurizing the material including the prepreg sheet and the resin to form a water-related component. A method is provided that includes the following: This method allows for the application of patterns, colors, or combinations thereof to the countertop surface, resulting in a water-resistant component with superior aesthetics due to the suppression of uneven gloss on the countertop surface, as well as excellent strength.

[0034] Demoulding, post-processing After curing is complete, the resulting molded body is removed from the mold. Subsequently, it is preferable to perform post-processing such as straightening, deburring, and chamfering.

[0035] In the present invention, when manufacturing a counter with a bowl, at least the portion corresponding to the top surface of the front molding surface of the lower die may be processed to a matte finish (low gloss finish), and the arithmetic surface roughness Ra (JIS B 0601:2013) of the front molding surface may be 0.2 μm or more, and the 85-degree specular gloss (JIS Z 8741:1997) may be 45% or less. For example, the matte finish can be achieved by polishing using sandpaper, grinding wheels, buffs, etc., containing abrasives of about #120 to #200. Blasting using the above-mentioned abrasives may also be performed. If the properties (Ra and 85-degree specular gloss) of the matte-finished surface of the lower mold are 100% transferred to the molded product by molding, then the properties of the top surface will be identical to those of the matte-finished surface of the upper mold. In this example, both the top surface and the visible surface of the molded product are made of unsaturated polyester resin or the like, which was included in the press-molded material.

[0036] In the present invention, when manufacturing a counter with a bowl (with a decorative portion), at least the portion of the front molding surface of the lower mold corresponding to the decorative portion may be processed to a matte finish (low gloss finish), and the arithmetic surface roughness Ra (JIS B 0601:2013) of the front molding surface may be 0.2 μm or more, and the 85-degree specular gloss (JIS Z 8741:1997) may be 45% or less. The matte finish processing is carried out in the same manner as when manufacturing a counter with a bowl. If the properties (Ra and 85-degree specular gloss) of the matte-finished surface of the lower mold are 100% transferred to the molded product by molding, the properties of the decorative surface will be the same as those of the matte-finished surface of the upper mold. In this example, the decorative surface of the molded product is made of DAP resin impregnated in the prepreg sheet, while the undecorated surface of the bowl (including the sides, bottom, and the surface where the faucet is installed) is made of unsaturated polyester resin contained in the press-molded material.

[0037] Alternatively, instead of applying a matte finish to the mold as described above, the molded product may be post-processed to achieve a Ra of 0.2 μm or more and an 85-degree specular gloss of 45% or less in the area adjacent to the ridge of the top surface or decorative surface of the molded product. [Examples]

[0038] The present invention will be described in more detail by the following embodiments, but the present invention is not limited to these embodiments. In the following, an example will be described in which a counter with a bowl is manufactured by integrally molding a bowl and a counter with a decorative part on its top surface.

[0039] Manufacturing of plumbing components <Material> To manufacture the plumbing components, the following press-formed materials and the following patterned prepreg sheets were used. (Press-formed material) Sheet molding compound (SMC) (product name: Polymar® Matt, manufactured by Japan Composite Co., Ltd.) or thick molding compound (TMC) (product name: Polymar® Matt™, manufactured by Japan Composite Co., Ltd.) were used as the press molding material. (Patterned prepreg sheet) The prepreg sheets with decorative patterns were prepared by applying the desired pattern to a pulp nonwoven fabric base with a thickness of 0.1 to 0.3 mm using inkjet printing, and then impregnating it with a mixture of DAP resin and filler in the amounts shown in Table 1. The resulting prepreg sheets had a thickness of 0.2 to 0.4 mm. Furthermore, the patterned prepreg sheets were molded into a shape with an opening corresponding to the bowl without the decorative part, as shown in Figure 5, so that they could be applied only to the top surface of the counter where the decorative part was to be placed.

[0040] <Molding machine, mold> As the molding machine, we used either the Kawasaki Oil Industries Co., Ltd. FMP1-1100S or the Kojima Iron Works straight-side frame type. The molding die consisted of a pair of upper and lower dies, as shown in Figure 6a, with a molding cavity between the front molding surface of the lower die and the back molding surface of the upper die. The front molding surface of the lower die was polished (matted) by sandblasting (#200~220) to achieve a lower die molding surface with an Ra of 0.3~0.7 μm and an 85-degree specular gloss of 20~33%. Since it was difficult to directly measure the Ra and 85-degree specular gloss of the polished lower die surface, the Ra and 85-degree specular gloss of a textured molded sample with the same finish were measured and considered to be the Ra and 85-degree specular gloss of the matted lower die surface.

[0041] <Forming method> The prepreg sheet described above was placed on the designated front molding surface of the lower die with the decorative portion facing outwards. During placement, the prepreg sheet was secured to a jig, and then the jig was set in the lower die. Prior to placement, the molds were preheated to 125°C for the upper die and 145°C for the lower die. In this manner, the placed prepreg sheet was attached (transferred) along the front molding surface. Next, the jig was removed from the mold. Then, the wrinkles in the prepreg sheet were smoothed out. Finally, a press-molded material of the desired weight was placed on top of the prepreg sheet.

[0042] Press molding Subsequently, as shown in Figure 7b, the upper and lower molds were clamped together, and mold temperatures (upper mold 125°C, lower mold 145°C) and pressure (approximately 8 MPa) were applied. After about 6 minutes, a counter with a bowl was obtained, in which the bowl and the counter with a decorative top surface were integrally molded.

[0043] Demoulding, post-processing The resulting molded bodies were removed from the mold and subjected to post-processing such as straightening, deburring, and chamfering. This yielded samples 1-14 of the bowl-type counter. The following evaluations were performed on the parts of each sample shown in Figure 4.

[0044] evaluation Measurement of the rounding radius of the ridge line For each sample, the rounding radius R3 on the front side and R4 on the back side of the ridge connecting the top surface and the visible surface (bowl side) were measured, as well as the rounding radius R5 on the front side and R6 on the back side of the ridge connecting the top surface and the visible surface (front apron side), and the thickness T1 of the top surface was also measured. The results are shown in Table 1.

[0045] Measurement of arithmetic surface roughness Ra and 85-degree specular gloss. For each sample, the arithmetic surface roughness Ra (JIS B 0601:2013) and 85-degree specular gloss (JIS Z 8741:1997) were measured at measurement points A, B, and C in the area shown in Figure 4. Measurement point A refers to the area within 1 cm of the boundary between the top surface and the visible surface (bowl side) and the ridge line 1 connecting the top surface and the visible surface (bowl side), toward the visible surface (front apron side). Measurement point C refers to the area within 1 cm of the boundary between the top surface and the ridge line 2 connecting the top surface and the visible surface (front apron side), toward the visible surface (bowl side). Measurement point B refers to the area intermediate between measurement point A and measurement point C. The measurement results are shown in Table 1. As previously explained, measurement points A and C are areas that are easily affected by shrinkage of the thickness of the ridge area, and the matte finish is likely to change to a high gloss. On the other hand, measurement point B is less affected by such factors and is an area that is likely to maintain a low gloss. Although there is some variation in the measurement results, it was confirmed that the results at measurement points A and C tend to have a lower Ra and higher 80-degree specular gloss compared to the results at measurement point B.

[0046] Appearance determination For the visual evaluation, each sample was placed with its top surface approximately 80 cm from the floor. The evaluator stood in front of the sample and varied their eye level from a position close to the top surface (adjusted by bending forward) to a standing position (eye level: approximately 90-150 cm from the floor). The evaluation criteria were as follows: if no glare was perceived or gloss unevenness (gloss difference) was not noticeable upon visual inspection of each measurement point, it was judged as "acceptable." Conversely, if glare was perceived or gloss unevenness was noticeable, it was judged as "unacceptable." The evaluation results are shown in Table 1.

[0047] According to the visual inspection results, it was confirmed that a "passable" rating was given when the Ra value at all measurement points A, B, and C was within the range of 0.2 to 0.6 μm, and the 85-degree specular gloss was 45% or less.

[0048] Based on the above measurement and evaluation results, it was confirmed that if the arithmetic mean roughness Ra of at least the area adjacent to the edge of the surface is 0.2 μm or more, and the 85-degree specular gloss is 45% or less, a counter with a bowl that has a good appearance with no noticeable unevenness in gloss can be obtained. Furthermore, it was confirmed that if the arithmetic mean roughness Ra of the area adjacent to the edge of the top surface and the area other than that area is 0.2 μm or more, and the 85-degree specular gloss is 45% or less, a counter with a bowl that has a good appearance with no noticeable unevenness in gloss can be obtained.

[0049] [Table 1]

Claims

1. A plumbing component comprising at least a bowl or sink and a counter, When the surface of a plumbing fixture consists of the top surface of the counter (hereinafter simply referred to as the "top surface") and the surface other than the top surface (hereinafter referred to as the "visible surface"), and the part of the plumbing fixture that defines the boundary between the top surface and the visible surface is defined as the ridge line, A plumbing component in which the arithmetic mean roughness Ra of at least the area adjacent to the ridge of the top surface is 0.2 μm or more as defined in JIS B 0601:2013, and the 85-degree specular gloss as defined in JIS Z 8741:1997 is 45% or less.

2. When the rounding radius on the surface side of the ridge is R1 [mm], the rounding radius on the back side of the ridge is R2 [mm], and the thickness of the counter is T1 [mm], then the following formula (1): R1<R2+T1 Formula (1) The relationship represented by the following holds true for the plumbing unit according to claim 1.

3. The plumbing component according to claim 1, wherein the main component is resin.

4. The plumbing component according to claim 3, wherein the resin is a thermosetting resin.

5. The plumbing component according to claim 1, which is a washbasin counter with a bowl or a kitchen counter with a sink.

6. The plumbing component according to claim 1, wherein a decorative part is provided on the top surface.

7. A plumbing product comprising a plumbing component as described in claim 1 and a support member for supporting the plumbing component.

8. A method for manufacturing a plumbing component as described in claim 1, A process of filling a molding cavity with a resin-containing material, A process of forming plumbing components by heating and pressurizing a resin-containing material. A method characterized by including the following.

9. A method for manufacturing a plumbing component according to claim 6, (a) A step of placing a patterned prepreg sheet containing a thermosetting resin on a predetermined area of ​​the surface forming surface of a mold for forming a decorative part, (b) A step of filling the molding cavity on which the prepreg sheet is placed with a resin-containing material, (c) A step of integrally heating and pressurizing the material containing the prepreg sheet and the resin to form a water-related component. A method characterized by including the following.

10. The method according to claim 9, The process includes, before step (a), a step of heating the mold, The process after step (a) includes a step of attaching the placed prepreg sheet along the area, and thereafter In place of step (b), (b') a step of filling the molded cavity to which the prepreg sheet is attached with a resin-containing material, (c) A step of integrally heating and pressurizing the material containing the prepreg sheet and the resin to form a water-related component. A method characterized by including the following.

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