Method for manufacturing a special item and special item

Abstract

To provide a fitting with excellent shape retention, weather resistance, and watertightness, and a method for efficiently manufacturing such fittings. [Solution] The present invention provides a method for manufacturing a fitting that is waterproofed at an outer corner or inner corner, comprising the steps of: joining a rigid polyvinyl chloride resin substrate and a flexible polyvinyl chloride resin sheet having a higher plasticizer content than the rigid polyvinyl chloride resin substrate to form a composite board; and molding the composite board into a predetermined shape by differential pressure molding to obtain a fitting.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a fitting and a fitting.

Background Art

[0002] In recent years, with the increasing demand for high durability of buildings, a sheet waterproof structure in which a resin sheet is laid has been adopted in the structures such as the roofs and verandas of buildings.

[0003] In this sheet waterproof structure, for example, at the boundary between the floor part of the roof and the wall part provided along the outer edge of the floor part, that is, at the outside corner part or the inside corner part, a seam of the resin sheet occurs. At the seam, in order to suppress the deterioration of the waterproof property of the sheet waterproof structure, a fitting that is pre-formed according to the shape of the outside corner part or the inside corner part is used.

[0004] Patent Document 1 discloses a method for manufacturing a fitting, in which a steel plate formed into a predetermined shape is dipped in a vinyl chloride resin paste, the vinyl chloride resin paste is coated on the entire surface with a thickness of 1.0 mm, and then the paste is gelled to form a film.

[0005] Patent Document 2 discloses a waterproof tool used in a region including a joint where a waterproof treatment is applied to a structure of civil engineering, which is a waterproof tool composed of an integrally formed product of a thermoplastic resin sheet piece formed by a powder slashing method.

Prior Art Documents

Patent Documents

[0006]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0007] The method described in Patent Document 1 cannot form a coating of sufficient thickness. Therefore, there are concerns about the occurrence of cracks and pinholes in the coating, and the resulting decrease in watertightness. In addition, since coatings formed using paste contain a large amount of plasticizer, a decrease in weather resistance due to the aging of the plasticizer is also a problem.

[0008] On the other hand, the waterproofing device described in Patent Document 2 is composed only of molded single-layer resin sheet pieces, and therefore does not have sufficient shape retention or weather resistance.

[0009] The object of the present invention is to provide a fitting that is excellent in shape retention, weather resistance, and watertightness, and a method for efficiently manufacturing such fittings. [Means for solving the problem]

[0010] These objectives are achieved by the present invention as described in (1) to (6) below. (1) A method for manufacturing a fitting that applies waterproofing treatment to an external or internal corner, A process of joining a rigid polyvinyl chloride resin substrate and a flexible polyvinyl chloride resin sheet having a higher plasticizer content than the rigid polyvinyl chloride resin substrate to form a composite board, The process involves forming the composite board into a predetermined shape using a differential pressure molding method to obtain a special part, A method for manufacturing a special-purpose item, characterized by having the following features.

[0011] (2) The method for manufacturing the special-purpose item as described in (1) above, wherein the differential pressure forming method is a vacuum forming method, a pressure forming method, or a vacuum pressure forming method.

[0012] (3) The method for manufacturing the component described in (1) or (2) above, wherein the composite board is obtained by co-extruding or laminating the rigid polyvinyl chloride resin substrate and the flexible polyvinyl chloride resin sheet.

[0013] (4) The composite board is the method for manufacturing the article according to the above (1) or (2), in which the rigid vinyl chloride resin substrate and the soft vinyl chloride resin sheet are adhered via an adhesive.

[0014] (5) The plate thickness of the rigid vinyl chloride resin substrate is 0.5 mm or more and 6.0 mm or less, The sheet thickness of the soft vinyl chloride resin sheet is 0.3 mm or more and 5.0 mm or less, and it is the method for manufacturing the article according to any one of the above (1) to (4).

[0015] (6) An article that performs waterproof treatment on the protruding corner or the recessed corner, characterized in that it is composed of a molded body of a composite board in which a rigid vinyl chloride resin substrate and a soft vinyl chloride resin sheet having a higher plasticizer content than the rigid vinyl chloride resin substrate are joined.

Advantages of the Invention

[0016] According to the present invention, an article excellent in shape retention, weather resistance, and water stopping property can be obtained. Also, according to the present invention, the above article can be efficiently manufactured.

Brief Description of the Drawings

[0017] [Figure 1] It is a partial cross-sectional perspective view showing an example of a building in which the article according to the embodiment is constructed. [Figure 2] It is a cross-sectional view taken along line A-A of the article shown in FIG. 1. [Figure 3] It is a process diagram for explaining the manufacturing method of the article according to the embodiment. [Figure 4] It is a cross-sectional view for explaining the manufacturing method of the article shown in FIG. 3. [Figure 5] It is a cross-sectional view for explaining the manufacturing method of the article shown in FIG. 3.

Modes for Carrying Out the Invention

[0018] Hereinafter, the manufacturing method of the device of the present invention and the device will be described in detail based on the preferred embodiments shown in the accompanying drawings.

[0019] 1. Device First, the device according to the embodiment will be described.

[0020] FIG. 1 is a partial cross-sectional perspective view showing an example of a building 2 in which a device 1 according to the embodiment is installed. FIG. 2 is a cross-sectional view taken along line A-A of the device 1 shown in FIG. 1.

[0021] As shown in FIG. 1, the device 1 is a material for waterproofing the outer corner portion 21 and the inner corner portion 22. In this specification, the outer corner portion 21 refers to a portion where two surfaces intersect in a concave shape. Also, in this specification, the inner corner portion 22 refers to a portion where two surfaces intersect in a convex shape. The shapes of the outer corner portion 21 and the inner corner portion 22 vary depending on the building 2. Therefore, the device 1 may be formed into a general-purpose shape so as to be applicable to various buildings 2, or may be formed into a shape specific to the different outer corner portions 21 and inner corner portions 22 for each building 2. Further, the device 1 is joined to the end of a waterproof sheet (not shown) as necessary. Thereby, continuous waterproofing treatment can be performed over a wide range.

[0022] The portion of the building 2 where the waterproofing treatment is performed is not particularly limited. In FIG. 1, an example of performing waterproofing treatment on the roof of the building 2 is illustrated. The building 2 shown in FIG. 1 has a floor portion 2A and a parapet 2B that constitute the roof. Examples of portions other than the roof include, for example, a roof, a veranda, a balcony, around a window, an outer wall, etc. Note that the outer corner portion 21 and the inner corner portion 22 include, for example, the irregularities associated with the drain 23 and the drain gutter 24 shown in FIG. 1.

[0023] As shown in FIG. 2, the device 1 has one surface 112 and the other surface 114 that are in a front-back relationship with each other, and includes a rigid PVC substrate 11 (rigid vinyl chloride resin substrate) formed into a predetermined shape, and a soft PVC sheet 12 (soft vinyl chloride resin sheet) laminated on one surface 112 of the rigid PVC substrate 11.

[0024] The rigid PVC substrate 11 is composed of a rigid vinyl chloride resin composition. The rigid vinyl chloride resin composition is a resin composition in which the plasticizer content is less than 15 parts by mass per 100 parts by mass of vinyl chloride resin. By using a rigid PVC substrate 11 composed of such a rigid vinyl chloride resin composition, a fitting 1 can be obtained that has good shape retention and mechanical strength and can be subjected to a highly durable waterproof treatment.

[0025] The size of the rigid PVC substrate 11 is preferably set to a size that can cover multiple areas where conventional corner patches are attached. Corner patches are sheets that are attached to the corners of outer corners 21 and inner corners 22, and are molded into a predetermined shape. By using a large rigid PVC substrate 11 to cover multiple areas where corner patches are attached, waterproofing can be performed at once. This reduces the amount of work required for waterproofing compared to attaching multiple corner patches. In addition, while conventional methods create numerous joints between the corner patches and the waterproofing sheet, the number and area of ​​such joints can be reduced. This makes it possible to apply waterproofing with fewer steps and suppress the occurrence of water leakage due to poor adhesion at the joints.

[0026] The fitting 1 shown in Figure 1 is an example that covers both the outer corner 21 and the inner corner 22. With such a fitting 1, waterproofing treatment can be applied to both the outer corner 21 and the inner corner 22 at the same time. Note that the shape of the fitting 1 may be such that it is applied to only one of the outer corner 21 or the inner corner 22.

[0027] The thickness of the rigid PVC substrate 11 is not particularly limited, but is preferably 0.5 mm to 6.0 mm, more preferably 1.0 mm to 4.0 mm, and even more preferably 1.5 mm to 3.0 mm. This provides sufficient shape retention and mechanical strength to the component 1. It also suppresses the weight increase of the rigid PVC substrate 11, improving handling.

[0028] The flexible PVC sheet 12 is composed of a flexible vinyl chloride resin composition and covers one side 112 of the rigid PVC substrate 11. The flexible vinyl chloride resin composition is a resin composition in which the plasticizer content is 15 parts by mass or more, preferably 20 parts by mass or more and 100 parts by mass or less, per 100 parts by mass of vinyl chloride resin. By using a flexible PVC sheet 12 composed of such a flexible vinyl chloride resin composition, the surface of the fitting 1 is composed of a flexible vinyl chloride resin composition, so that when the fitting 1 is bonded to a waterproof sheet (not shown), for example, the fitting 1 can be made to have excellent adhesion to the waterproof sheet. As a result, the wind pressure resistance of the waterproof sheet after installation can be improved. The one side 112 is the side that faces upward when the fitting 1 is attached to the building 2.

[0029] The sheet thickness of the flexible PVC sheet 12 is not particularly limited, but is preferably 0.3 mm to 5.0 mm, more preferably 0.5 mm to 3.0 mm, and even more preferably 0.7 mm to 2.0 mm. This ensures sufficient coverage of the flexible PVC sheet 12 over the rigid PVC substrate 11, and provides a flexible PVC sheet 12 with fewer pinholes and excellent weather resistance. Furthermore, it suppresses the increase in weight and overall thickness caused by the flexible PVC sheet 12 being too thick.

[0030] The sheet thickness of the flexible PVC sheet 12 may be greater than or equal to the thickness of the rigid PVC substrate 11, but is preferably set to less than the substrate thickness, more preferably to be 0.3 mm or more thinner than the substrate thickness, and even more preferably to be 0.5 mm or more thinner than the substrate thickness. This optimizes the balance between the thickness of the rigid PVC substrate 11 and the sheet thickness of the flexible PVC sheet 12. As a result, a fitting 1 is obtained that has excellent shape retention and excellent adhesion to the waterproof sheet.

[0031] Furthermore, while it is preferable that the flexible PVC sheet 12 covers the entire surface of the rigid PVC substrate 11, there may be areas that are not covered. Also, the thickness of the flexible PVC sheet 12 may be the same throughout, or it may vary in thickness in certain areas.

[0032] The vinyl chloride resin included in the rigid vinyl chloride resin composition and the flexible vinyl chloride resin composition is not particularly limited as long as it is a polymer containing vinyl chloride, i.e., oligomers, prepolymers, and polymers, but examples include monomeric polymers of vinyl chloride, copolymers of vinyl chloride and other monomers, and mixtures of two or more of these polymers.

[0033] In the case of copolymers, the proportion of vinyl chloride is preferably set to 50% by mass or more, more preferably 70% by mass or more. Examples of monomers copolymerized with vinyl chloride include olefins such as ethylene and propylene; halogenated olefins such as allyl chloride, vinylidene chloride, vinyl fluoride, and trifluoroethylene chloride; vinyl carboxylate esters such as vinyl acetate and vinyl propionate; vinyl ethers such as isobutyl vinyl ether and cetyl vinyl ether; allyl ethers such as allyl-3-chloro-2-oxypropyl ether and allyl glycidyl ether; unsaturated carboxylic acids such as acrylic acid, maleic acid, itaconic acid, 2-hydroxyethyl acrylate, methyl methacrylate, monomethyl maleate, diethyl maleate, and maleic anhydride, their esters, or acid anhydrides; unsaturated nitriles such as acrylonitrile and methacrylonitrile; acrylamides such as acrylamide, N-methylolacrylamide, acrylamide-2-methylpropanesulfonic acid, and (meth)acrylamidopropyltrimethylammonium chloride; and allylamines and their derivatives such as allylamine benzoate and diallyldimethylammonium chloride.

[0034] The average degree of polymerization of the vinyl chloride resin contained in the rigid vinyl chloride resin composition is preferably 500 to 1300, and more preferably 600 to 1100. This results in a rigid PVC substrate 11 with high rigidity and excellent shape retention.

[0035] The average degree of polymerization of the vinyl chloride resin contained in the flexible vinyl chloride resin composition is preferably 1000 to 1800, and more preferably 1300 to 1500. This results in a flexible PVC sheet 12 with low rigidity and excellent shape conformability.

[0036] The average degree of polymerization is calculated on a standard polystyrene basis using gel permeation chromatography (GPC).

[0037] Examples of plasticizers include phthalate ester plasticizers, phosphate ester plasticizers, adipic acid ester plasticizers, sebatic acid ester plasticizers, etc., and one or more of these are used as a mixture.

[0038] Examples of phthalate ester plasticizers include dimethyl phthalate (DMP), diethyl phthalate (DEP), dibutyl phthalate (DBP), dihexyl phthalate (DHP), di-2-ethylhexyl phthalate (DOP), diisodecyl phthalate (DIDP), butyl benzyl phthalate (BBP), diisononyl phthalate (DINP), and dinonyl phthalate (DNP).

[0039] Examples of phosphate ester plasticizers include tricresyl phosphate (TCP) and trixylylene phosphate (TXP).

[0040] Examples of adipic acid ester plasticizers include dioctyl adipate (DOA) and diisodecyl adipate (DIDA).

[0041] Examples of sebatic acid ester plasticizers include dibutyl sebacate (DBS) and dioctyl sebacate (DOS).

[0042] The plasticizer content of the rigid PVC substrate 11 and the plasticizer content of the flexible PVC sheet 12 are within the aforementioned ranges per 100 parts by mass of vinyl chloride resin, but the difference between the two is preferably 10 parts by mass or more, more preferably 20 parts by mass or more and 100 parts by mass or less, and even more preferably 40 parts by mass or more and 100 parts by mass or less. This makes it possible to obtain a fitting 1 that more highly balances the shape retention of the rigid PVC substrate 11 with the shape conformability and adhesion to the waterproof sheet of the flexible PVC sheet 12.

[0043] The rigid polyvinyl chloride resin composition and the flexible polyvinyl chloride resin composition may contain any additives. Examples of additives include saturated fatty acids, metal soaps, colorants, impact resistance modifiers, perchlorate compounds, antioxidants, antifungal agents, flame retardants, antistatic agents, fillers, ultraviolet absorbers, light stabilizers, and foaming agents.

[0044] The amount of each additive added is preferably 50 parts by mass or less, and more preferably 30 parts by mass or less, per 100 parts by mass of vinyl chloride resin.

[0045] 2. Manufacturing method of the special item Next, a method for manufacturing the component according to the embodiment will be described. In the following description, the method for manufacturing the component 1 shown in Figure 2 will be used as an example.

[0046] Figure 3 is a process diagram illustrating the manufacturing method of the gimmick according to the embodiment. Figures 4 and 5 are cross-sectional views illustrating the manufacturing method of the gimmick shown in Figure 3, respectively.

[0047] The manufacturing method for the special-purpose item shown in Figure 3 comprises a composite board forming step S102 and a molding step S104.

[0048] 2.1. Composite board forming process In the composite board formation process S102, first, a rigid PVC substrate 11 and a flexible PVC sheet 12 are joined together to form the composite board 10 shown in Figure 4(a).

[0049] Examples of methods for manufacturing the rigid PVC substrate 11 include extrusion, pressing, and continuous pressing.

[0050] Examples of methods for manufacturing the flexible PVC sheet 12 include calendering and T-die extrusion.

[0051] Methods for joining the rigid PVC substrate 11 and the flexible PVC sheet 12 include, for example, co-extrusion (multilayer extrusion), lamination (heat welding), solvent welding, and adhesive bonding. Of these, co-extrusion and lamination methods allow for the integration of the interface between the rigid PVC substrate 11 and the flexible PVC sheet 12, enabling particularly strong bonding. On the other hand, adhesive bonding allows for bonding of components that cannot be bonded by welding. Furthermore, by using a method that joins pre-formed sheet components, a composite board 10 can be obtained that includes a flexible PVC sheet 12 with good coverage and pinhole resistance.

[0052] Furthermore, a primer may be applied to the bonding interface between the rigid PVC substrate 11 and the flexible PVC sheet 12. The primer may be applied to bonding by co-extrusion, welding, or adhesive bonding.

[0053] The primer is not particularly limited as long as it has the function of improving the adhesion between the rigid PVC substrate 11 and the flexible PVC sheet 12. The primer is, for example, a liquid composition containing a resin, a curing agent, and a solvent.

[0054] Examples of resins that can be included in the primer include polyester resins, alkyd resins, epoxy resins, acrylic resins, fluororesins, and vinyl chloride resins. The resin included in the primer may also be one or a mixture of two or more of these resins.

[0055] Examples of polyester resins include oil-free polyester resins, urethane-modified polyester resins, epoxy-modified polyester resins, and acrylic-modified polyester resins.

[0056] Alkyd resins are resins obtained by modifying polyester resins with fatty acids. Examples of alkyd resins include phenol-modified alkyd resins, epoxy-modified alkyd resins, and oil-modified alkyd resins.

[0057] Examples of epoxy resins include bisphenol-type epoxy resins and novolac-type epoxy resins. Modified epoxy resins are also obtained by reacting the epoxy groups or hydroxyl groups in these epoxy resins with various modifying agents.

[0058] The curing agent is not particularly limited as long as it can react with the above-mentioned resin to cause curing, but examples include amino compounds and blocked polyisocyanate compounds.

[0059] Examples of amino compounds include methylolated amino resins obtained by the reaction of amino components such as melamine, urea, benzoguanamine, acetogranamine, sterognamin, spiloganamine, and dicyandiamide with aldehydes. Examples of aldehydes used in the above reaction include formaldehyde, paraformaldehyde, acetaldehyde, and benzaldehyde. Alternatively, the above methylolated amino resin may be etherified with a suitable alcohol. Examples of alcohols used for etherification include methyl alcohol, ethyl alcohol, n-propyl alcohol, isopropyl alcohol, n-butyl alcohol, isobutyl alcohol, 2-ethylbutanol, and 2-ethylhexanol.

[0060] Blocked polyisocyanate compounds are compounds obtained by blocking the isocyanate group of an isocyanate compound with a blocking agent. Examples of blocked polyisocyanate compounds include aliphatic diisocyanates such as hexamethylene diisocyanate and trimethylhexamethylene diisocyanate; cyclic aliphatic diisocyanates such as hydrogenated xylylene diisocyanate and isophorone diisocyanate; aromatic diisocyanates such as tolylene diisocyanate and 4,4'-diphenylmethane diisocyanate; adducts of these organic diisocyanates with polyhydric alcohols, low molecular weight polyester resins, or water, cyclized polymers of the above organic diisocyanates, and isocyanate biuret compounds.

[0061] Examples of blocking agents include phenol-based blocking agents, alcohol-based blocking agents, oxime-based blocking agents, and activated methylene-based blocking agents.

[0062] The mixing ratio of resin to curing agent in the primer is not particularly limited, but preferably, the resin content is 55 to 95 parts by mass and the curing agent content is 5 to 45 parts by mass. This results in a primer coating film with excellent adhesion between the rigid PVC substrate 11 and the flexible PVC sheet 12.

[0063] The solvent can be any substance capable of dissolving or dispersing the resin or curing agent, and is not particularly limited, but examples include aliphatic hydrocarbons, aromatic hydrocarbons, alcohols, ethers, esters, and alcohol ethers.

[0064] Specific examples of solvents include xylene, toluene, propylene glycol methyl ether acetate, methanol, isopropyl alcohol, and ethylene glycol monopropyl ether.

[0065] Furthermore, the primer may contain any additives. Examples of additives include coupling agents, curing accelerators, viscosity modifiers, plasticizers, leveling agents, defoaming agents, anti-sedimentation agents, colorants, stabilizers, rust inhibitors, mold inhibitors, fluorescent agents, UV absorbers, antioxidants, and fillers.

[0066] 2.2. Molding process In molding step S104, the composite plate 10 is molded into a predetermined shape using a differential pressure molding method. This yields the special piece 1.

[0067] Examples of differential pressure forming methods include vacuum forming, pressure forming, or vacuum pressure forming. These forming methods allow for the precise molding of composite panels 10 by utilizing large pressure differences.

[0068] 2.2.1. Vacuum forming method Vacuum forming is a molding method that uses the pressure difference created by reducing the pressure inside a mold with vacuum holes to make the object to be molded adhere tightly to the mold.

[0069] Specifically, first, the composite board 10 is heated. When heated, the composite board 10 softens and becomes plastic, thus improving its moldability.

[0070] The heating temperature of the composite board 10 is set appropriately according to the rigid polyvinyl chloride resin composition, the flexible polyvinyl chloride resin composition, the thickness of the composite board 10, etc., but is preferably 130°C to 175°C, and more preferably 140°C to 170°C. This enables molding with high dimensional accuracy.

[0071] The method for heating the composite panel 10 is not particularly limited, but one example is to hold the composite panel 10 horizontally and heat it with an upper heater 53 and a lower heater 54, respectively. In this method, the amount of heat generated by the upper heater 53 and the lower heater 54 can be adjusted individually. Therefore, the heating temperature of the rigid PVC substrate 11 and the heating temperature of the flexible PVC sheet 12 can be made different and optimized for each.

[0072] The heating temperature of the rigid PVC substrate 11 is not particularly limited, but as an example, it is preferably set 3°C ​​to 30°C higher, and more preferably 5°C to 15°C higher, than the heating temperature of the flexible PVC sheet 12. This allows both the rigid PVC substrate 11 and the flexible PVC sheet 12 to maintain good moldability. By reducing the temperature, it is possible to suppress the occurrence of molding defects due to insufficient heating of the rigid PVC substrate 11 or molding defects due to overheating of the flexible PVC sheet 12.

[0073] Next, as shown in Figure 4(b), a mold 52 having a vacuum hole 51 and a pressure reducing box 50 hermetically connected to the mold 52 are prepared. The space V defined by the surface 524 of the mold 52 opposite to the molding surface 522 and the pressure reducing box 50 is depressurized by an exhaust pump 56.

[0074] Next, the heated composite panel 10 is pressed against the molding surface 522 of the mold 52, as shown in Figure 5(a). Then, the space V is depressurized by the exhaust pump 56. This causes the air between the molding surface 522 and the composite panel 10 to be discharged through the vacuum holes 51. As a result, the composite panel 10 adheres tightly to the molding surface 522 of the mold 52 due to the pressure difference, and the composite panel 10 is molded into a predetermined shape. Subsequently, the composite panel 10 is cooled. This fixes the molded shape.

[0075] Next, the molded composite panel 10 is removed from the mold 52. Then, trimming is performed as needed. This yields the component 1 shown in Figure 5(b).

[0076] In addition, the part of the composite board 10 that comes into contact with the mold 52 may be a soft PVC sheet 12, but preferably a hard PVC substrate 11 is used. This further improves moldability and release properties.

[0077] Furthermore, the mold 52 may be heated. This promotes the plasticization of the composite board 10 and particularly enhances its moldability. The method of heating the mold 52 is not particularly limited. For example, it can be heated by a heating unit 55 arranged in the space V shown in Figure 5(a). Note that the arrangement and shape of the heating unit 55 are not limited to those shown.

[0078] 2.2.2. Pressure forming method Compression forming is a molding method in which the object to be molded is pressed against a mold having air holes using the pressure of compressed air.

[0079] Specifically, first, the composite panel 10 is heated. The heating method is the same as in the vacuum forming method. Next, the heated composite panel 10 is placed in a compressed air box (not shown). Compressed air is then supplied into the compressed air box. In addition, if necessary, air from the molding surface side of the molding die is discharged through the air holes in the molding die. As a result, the composite panel 10 adheres tightly to the molding surface of the molding die due to the pressure difference, and the composite panel 10 is formed into a predetermined shape. Subsequently, the composite panel 10 is cooled. This fixes the molded shape.

[0080] Next, the molded composite panel 10 is removed from the mold. Then, trimming is performed as needed. This yields the component piece 1. At this time, the pressure inside the compressed air box may be reduced if necessary.

[0081] 2.2.3. Vacuum pressure forming method Vacuum pressure forming is a molding method that combines vacuum forming and pressure forming, and is also called TOM forming. In vacuum pressure forming, the workpiece is sandwiched between a mold and a pressure box, and the pressure difference created by reduced pressure and the supply of compressed air is used to make the workpiece adhere tightly to the mold.

[0082] Specifically, first, the composite panel 10 is placed in a vacuum box (not shown). Then, the composite panel 10 is sandwiched between the vacuum box and a compressed air box (not shown). Next, the pressure inside the vacuum box and the compressed air box are reduced. Next, the composite panel 10 is heated. The heating method is the same as in the vacuum forming method. Next, the compressed air box is opened to the atmosphere, and compressed air is supplied into the compressed air box. As a result, the composite panel 10 adheres tightly to the molding surface of the mold due to the pressure difference, and the composite panel 10 is formed into a predetermined shape. Subsequently, the composite panel 10 is cooled. This fixes the molded shape.

[0083] Next, the molded composite panel 10 is removed from the mold. Then, trimming is performed as needed. This results in the special piece 1.

[0084] 3. Effects achieved by the above embodiment The method for manufacturing a fitting according to the above embodiment is a method for manufacturing a fitting 1 to which a waterproof treatment is applied to the outer corner 21 or inner corner 22, and comprises a composite panel forming step S102 and a molding step S104. In the composite panel forming step S102, a rigid PVC substrate 11 (rigid polyvinyl chloride resin substrate) and a flexible PVC sheet 12 (flexible polyvinyl chloride resin sheet) having a higher plasticizer content than the rigid PVC substrate 11 are joined to form a composite panel 10. In the molding step S104, the composite panel 10 is molded into a predetermined shape by differential pressure molding to obtain the fitting 1.

[0085] With this configuration, since a rigid PVC substrate 11 and a flexible PVC sheet 12 are used in combination, it is possible to manufacture a fitting 1 with excellent shape retention, weather resistance, and watertightness. Furthermore, by using a method of joining pre-formed sheet-shaped components, a fitting 1 can be obtained that includes a flexible PVC sheet 12 with good covering properties and pinhole resistance.

[0086] In the manufacturing method of the accessory according to the above embodiment, the differential pressure molding method is a vacuum molding method, a pressure molding method, or a vacuum pressure molding method. With this configuration, the composite panel 10 can be molded with high precision by utilizing a large pressure difference.

[0087] In the manufacturing method of the accessory according to the above embodiment, the composite board 10 is formed by co-extruding or laminating a rigid PVC substrate 11 (rigid polyvinyl chloride resin substrate) and a flexible PVC sheet 12 (flexible polyvinyl chloride resin sheet).

[0088] With this configuration, the interface between the rigid PVC substrate 11 and the flexible PVC sheet 12 can be integrated, enabling a particularly strong bond.

[0089] In the manufacturing method of the accessory according to the above embodiment, the composite board 10 is formed by bonding a rigid PVC substrate 11 (rigid polyvinyl chloride resin substrate) and a flexible PVC sheet 12 (flexible polyvinyl chloride resin sheet) together with an adhesive. This configuration allows for bonding components that cannot be bonded together using welding methods.

[0090] In the manufacturing method of the accessory according to the above embodiment, the thickness of the rigid PVC substrate 11 (rigid polyvinyl chloride resin substrate) is 0.5 mm or more and 6.0 mm or less, and the thickness of the flexible PVC sheet 12 (flexible polyvinyl chloride resin sheet) is 0.3 mm or more and 5.0 mm or less.

[0091] This configuration provides the component 1 with sufficient shape retention and mechanical strength. It also suppresses the weight increase of the rigid PVC substrate 11, improving handling. Furthermore, it ensures sufficient coverage of the rigid PVC substrate 11 by the flexible PVC sheet 12, and provides a flexible PVC sheet 12 with fewer pinholes and excellent weather resistance. In addition, it suppresses the weight increase and overall thickness increase caused by the flexible PVC sheet 12 being too thick.

[0092] The fitting piece 1 according to the above embodiment is a fitting piece 1 to which a waterproof treatment is applied to the outer corner portion 21 or the inner corner portion 22, and is composed of a molded composite board 10 which is made by joining together a rigid PVC substrate 11 (rigid polyvinyl chloride resin substrate) and a flexible PVC sheet 12 (flexible polyvinyl chloride resin sheet) which has a higher plasticizer content than the rigid PVC substrate 11.

[0093] With this configuration, since a rigid PVC substrate 11 and a flexible PVC sheet 12 are used in combination, a fitting 1 with excellent shape retention, weather resistance, and watertightness can be obtained.

[0094] The manufacturing method and the present invention of the special feature have been described above, but the present invention is not limited to these.

[0095] For example, the method for manufacturing the special feature of the present invention may be modified from the above embodiment by adding any additional steps for any purpose.

[0096] Furthermore, the component of the present invention may be one in which each part of the above embodiment is replaced with any component having a similar function, or in which any component is added to the above embodiment. [Examples]

[0097] Next, specific embodiments of the present invention will be described. However, the present invention is not limited in any way to these embodiments.

[0098] 4. Production of special features Each sample No. was manufactured according to the manufacturing conditions shown in Table 1 or Table 2. The shape of the component was as shown in Figure 2.

[0099] The flexible PVC sheet is a sheet made of a resin composition containing plasticizers in the amounts shown in Tables 1 and 2, per 100 parts by mass of polyvinyl chloride resin.

[0100] Furthermore, the rigid PVC substrate is a substrate composed of a resin composition containing a plasticizer in the amounts shown in Tables 1 and 2, per 100 parts by mass of vinyl chloride resin.

[0101] Furthermore, Tables 1 and 2 show the sheet thickness of the flexible PVC sheet, the board thickness of the rigid PVC substrate, the bonding method of the composite board, the type of molding method, the heating temperature of the flexible PVC sheet, the heating temperature of the rigid PVC substrate, and the difference between the heating temperatures of the flexible PVC sheet and the rigid PVC substrate, respectively.

[0102] Furthermore, the component in sample No. 12 is made by vacuum forming only a rigid PVC substrate instead of a composite panel.

[0103] Furthermore, the component in sample No. 13 uses a stainless steel metal molded plate instead of a rigid PVC substrate, and a flexible PVC sheet is bonded to it with adhesive.

[0104] Furthermore, the special part of sample No. 14 is formed by creating a PVC film with the configuration shown in Table 2 on the surface of a rigid PVC substrate using a dipping method, and then vacuum forming it.

[0105] In Tables 1 and 2, methods for manufacturing the special features of each sample number that correspond to the present invention are labeled as "Examples," while those that do not correspond to the present invention are labeled as "Comparative Examples."

[0106] 5. Evaluation of the special features The following evaluations were performed on the components of each example and each comparative example.

[0107] 5.1. Shape retention Test specimens measuring 100 mm in length and 25 mm in width were cut from the components of each example and comparative example.

[0108] Next, the main surface of the test specimen was made horizontal, and the other end of the specimen was fixed so that one end along its length was suspended in the air. The length of the fixed portion was 20 mm.

[0109] Next, the amount by which one end sagged under its own weight was measured. The shape retention of the test specimen was then evaluated by comparing the measurement results against the following evaluation criteria. The evaluation results are shown in Tables 1 and 2.

[0110] A: The amount of sagging is equal to or less than the standard value. B: The amount of sagging exceeds the standard value.

[0111] The reference value is based on measurements taken from a test specimen cut from sample No. 13 (a test specimen using steel plate instead of a rigid PVC substrate).

[0112] 5.2. Peel Strength From the components of each example and comparative example, component pieces measuring 200 mm in length and 25 mm in width were cut out.

[0113] Next, from the cut-out pieces of material, a waterproof sheet made of polyvinyl chloride resin was attached to a soft PVC sheet. This obtained a test specimen. The waterproof sheet piece was 200 mm long, 25 mm wide, and 1.5 mm thick. The attachment length was 100 mm, and the attachment method was solvent welding.

[0114] Next, a 180° peel strength test was conducted in which the waterproof sheet piece was pulled in a direction where the angle of the waterproof sheet piece to the special-purpose piece was 180°, and the tensile load was measured. The load at which peeling occurred was measured and defined as the "180° peel strength." The measurement temperature was 20°C, and the peeling speed was 200 mm / min.

[0115] Next, the measurement results were evaluated against the following evaluation criteria. The evaluation results are shown in Tables 1 and 2.

[0116] A: The 180° peel strength is 200 [N / 25m] or higher. B: The 180° peel strength is 150 [N / 25m] or more and less than 200 [N / 25m]. C: 180° peel strength is less than 150 [N / 25m]

[0117] 5.3. Weather resistance (gloss retention rate under UV irradiation) The 60° reflectance was measured on the surface of the trim pieces of each example and comparative example using a gloss tester. The measurement result is referred to as "pre-test gloss." Next, the trim pieces were subjected to a test at a wavelength of 365 nm and an illuminance of 150 mW / cm². 2The surface of the component was continuously irradiated with ultraviolet light for 100 hours. Next, the 60° reflectance of the surface of the component after ultraviolet irradiation was measured again using a gloss tester. The measurement result is referred to as "post-test gloss." Next, the gloss retention rate was calculated using the following formula. Gloss retention rate (%) = {(Gloss after test) / (Gloss before test)} × 100

[0118] Next, the weather resistance of the trim pieces was evaluated by comparing the calculated gloss retention rate against the following evaluation criteria. The evaluation results are shown in Tables 1 and 2.

[0119] A: Particularly high weather resistance (gloss retention rate of 60% or more) B: Moderately high weather resistance (gloss retention rate of 30% or more but less than 60%) C: Low weather resistance (gloss retention rate less than 30%)

[0120] [Table 1]

[0121] [Table 2]

[0122] Based on the evaluation results shown in Tables 1 and 2, the following can be observed. • In each example, the shape retention of the components was found to be excellent. • In each example, the trim pieces exhibited better peel strength compared to the comparative examples. Based on this, it is considered possible to realize trim pieces with excellent watertightness and wind pressure resistance. • In each example, the gloss retention rate after UV irradiation was high for the decorative elements. This is thought to be due to the minimal degradation of the resin film upon UV irradiation.

[0123] From the above, it has been confirmed that it is possible to manufacture fittings with excellent shape retention, weather resistance, and water-sealing properties. [Explanation of Symbols]

[0124] 1. Special Features 2 buildings 2A Floor 2B Parapet 10 Composite board 11. Rigid PVC substrate 12. Soft PVC Sheet 21 Corner section 22 Inside corner 23 Drain 24 Drainage 50 Decompression Box 51 Vacuum hole 52 Molding mold 53 Heater 54 Heater 55 Heating section 56 Exhaust pump 112 One side 114 The other side 522 Molding surface 524 sides S102 Composite board forming process S104 Molding process V space

Claims

1. A method for manufacturing a fitting that applies waterproofing treatment to an external or internal corner, A process of joining a rigid polyvinyl chloride resin substrate and a flexible polyvinyl chloride resin sheet having a higher plasticizer content than the rigid polyvinyl chloride resin substrate to form a composite board, The process involves forming the composite board into a predetermined shape using a differential pressure molding method to obtain a special-purpose part, A method for manufacturing a special-purpose item, characterized by having the following features.

2. The method for manufacturing a special-purpose item according to claim 1, wherein the differential pressure molding method is a vacuum molding method, a pressure molding method, or a vacuum pressure molding method.

3. The method for manufacturing a component according to claim 1 or 2, wherein the composite board is obtained by co-extruding or laminating the rigid polyvinyl chloride resin substrate and the flexible polyvinyl chloride resin sheet.

4. The method for manufacturing a component according to claim 1 or 2, wherein the composite board is formed by bonding the rigid polyvinyl chloride resin substrate and the flexible polyvinyl chloride resin sheet together via an adhesive.

5. The thickness of the rigid polyvinyl chloride resin substrate is 0.5 mm or more and 6.0 mm or less. The method for manufacturing a special-purpose item according to claim 1 or 2, wherein the sheet thickness of the flexible polyvinyl chloride resin sheet is 0.3 mm or more and 5.0 mm or less.

6. A fitting used to apply waterproofing treatment to an outer corner or inner corner, A special feature characterized by being composed of a molded composite board formed by joining a rigid polyvinyl chloride resin substrate and a flexible polyvinyl chloride resin sheet having a higher plasticizer content than the rigid polyvinyl chloride resin substrate.

Images