Manufacturing method of special-purpose items

Abstract

To provide a method for manufacturing a fitting that comprises a metal molded plate and a resin sheet of sufficient thickness, and that exhibits excellent shape retention, weather resistance, and watertightness. [Solution] The present invention provides a method for manufacturing a fitting that is waterproofed at an outer corner or an inner corner, and comprises the steps of: preparing a metal molded plate having a first main surface and a second main surface having a front-back relationship with each other, and a vacuum hole connecting the first main surface and the second main surface, and being molded into a predetermined shape; applying a primer to the first main surface to obtain a primer coating; attaching the metal molded plate to a differential pressure molding machine; and operating the differential pressure molding machine and pressing a resin sheet against the first main surface to mold the resin sheet and adhere the resin sheet to the first main surface.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing 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 on 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 decrease in the water stopping 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 construction civil engineering, the waterproof tool being 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 solely of molded resin sheet pieces, and therefore lacks sufficient shape retention and weather resistance.

[0009] The object of the present invention is to provide a method for manufacturing a fitting that comprises a metal molded plate and a resin sheet of sufficient thickness, and which has excellent shape retention, weather resistance, and watertightness. [Means for solving the problem]

[0010] These objectives are achieved by the present invention as described in (1) to (5) below. (1) A method for manufacturing a fitting that applies waterproofing treatment to an external or internal corner, A step of preparing a metal molded plate having a first main surface and a second main surface that are in a front-back relationship with each other, and a vacuum hole connecting the first main surface and the second main surface, and which is formed into a predetermined shape, The process involves applying a primer to the first main surface to obtain a primer coating, The process of attaching the aforementioned metal molded plate to a differential pressure molding machine, The steps include operating the differential pressure molding machine and pressing the resin sheet against the first main surface to mold the resin sheet and adhere the resin sheet to the first main surface, A method for manufacturing a special-purpose item, characterized by having the following features.

[0011] (2) The method for manufacturing a special-purpose item as described in (1) above, wherein the differential pressure molding machine is a vacuum molding machine that operates to reduce the pressure on the second main surface side.

[0012] (3) The method for manufacturing an article according to the above (1), wherein the differential pressure forming machine is a vacuum pressure forming machine that operates to pressurize the first main surface side and depressurize the second main surface side.

[0013] (4) The method for manufacturing an article according to any one of the above (1) to (3), wherein the metal forming plate and the resin sheet are pressed against each other in a heated state.

[0014] (5) The method for manufacturing an article according to any one of the above (1) to (4), wherein the constituent material of the resin sheet is a vinyl chloride-based resin.

Effect of the Invention

[0015] According to the present invention, an article having a metal forming plate and a resin sheet with a sufficient sheet thickness can be manufactured, and the article is excellent in shape retention, weather resistance, and water stoppage.

Brief Description of the Drawings

[0016] [Figure 1] It is a partial cross-sectional perspective view showing an example of a building in which a waterproof treatment using an article is applied. [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 method for manufacturing an article according to an embodiment. [Figure 4] It is a cross-sectional view for explaining the method for manufacturing an article shown in FIG. 3. [Figure 5] It is a cross-sectional view for explaining the method for manufacturing an article shown in FIG. 3.

Mode for Carrying Out the Invention

[0017] Hereinafter, the method for manufacturing an article of the present invention will be described in detail based on preferred embodiments shown in the accompanying drawings.

[0018] [[ID=?]] 1. Article First, an example of an article manufactured by the method for manufacturing an article of the present invention will be described.

[0019] It seems there might be a small issue with the tag "ID=?" in the original text. It's likely a typo, but I've translated it as is. If you can confirm the correct tag, that would be great for a more accurate translation. Figure 1 is a partial cross-sectional perspective view showing an example of a building 2 in which waterproofing treatment using fitting 1 has been applied. Figure 2 is a cross-sectional view of fitting 1 shown in Figure 1 along line AA.

[0020] As shown in Figure 1, the fitting 1 is a material used to apply waterproofing treatment to the outer corners 21 and inner corners 22. In this specification, the outer corner 21 refers to a portion where two surfaces intersect in a concave manner. In this specification, the inner corner 22 refers to a portion where two surfaces intersect in a convex manner. The shape of the outer corners 21 and inner corners 22 varies depending on the building 2. For this reason, the fitting 1 may be molded into a general shape so that it can be applied to various buildings 2, but it may also be molded into a shape specific to the outer corners 21 and inner corners 22 that differ for each building 2. In addition, the fitting 1 can be joined to the edge of a waterproof sheet (not shown) as needed. This allows for continuous waterproofing treatment over a wide area.

[0021] The areas in building 2 to which waterproofing treatment is applied are not particularly limited. Figure 1 illustrates an example of waterproofing treatment being applied to the roof of building 2. The building 2 shown in Figure 1 has a floor section 2A and a parapet 2B that constitute the roof. Other areas besides the roof include, for example, the roof, veranda, balcony, window surrounds, and exterior walls. The outer corners 21 and inner corners 22 also include irregularities associated with, for example, the drain 23 and drainage channel 24 shown in Figure 1.

[0022] As shown in Figure 2, the accessory 1 comprises a metal molded plate 11 formed into a predetermined shape and a resin sheet 12 laminated on one side 112 of the metal molded plate 11.

[0023] The metal molded plate 11 is made of a metal material. This provides a fitting 1 that has good shape retention and mechanical strength, and can be used to apply a highly durable waterproofing treatment.

[0024] Preferably, the size of the metal molded plate 11 is set to a size that can cover multiple areas where conventional corner patches are attached. Corner patches are sheets attached to the corners of outer corners 21 and inner corners 22, and are molded into a predetermined shape. By using a large metal molded plate 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.

[0025] 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.

[0026] The metal molded sheet 11 has the aforementioned surface 112 and the other surface 114 which is the opposite surface. The surface 112 and the other surface 114 correspond to the first main surface and the second main surface of the metal molded sheet 11, which are in a front-back relationship with each other.

[0027] Examples of metal materials include various metal materials such as stainless steel, iron-based alloys such as steel, aluminum alloys, and copper alloys. Of these, iron-based alloys are preferably used, and stainless steel is more preferably used. This further enhances the mechanical strength and durability of the metal formed sheet 11.

[0028] Furthermore, the metal molded plate 11 may be treated with rust prevention treatment as needed. Examples of rust prevention treatments include zinc-aluminum-magnesium plating and zinc plating.

[0029] The thickness of the metal molded plate 11 is not particularly limited, but is preferably 0.1 mm to 2.0 mm, and more preferably 0.3 mm to 1.5 mm. This provides the fitting 1 with sufficient shape retention and mechanical strength. It also suppresses the weight increase of the metal molded plate 11, improving handling.

[0030] The metal molded plate 11 has a vacuum hole 116. The vacuum hole 116 is a through hole connecting one surface 112 and the other surface 114. By providing this vacuum hole 116, the resin sheet 12 can be tightly attached to one surface 112 of the metal molded plate 11 and molded. In other words, the resin sheet 12 can be formed by differential pressure molding of the resin raw material sheet using the metal molded plate 11 as a mold. Differential pressure molding is a method of molding a resin raw material sheet using a pressure difference, as will be described later. As a result, even if the metal molded plate 11 has a complex shape and is large in size, it is possible to realize a fitting 1 with a seamless resin sheet 12. In addition, during differential pressure molding, the vacuum hole 116 serves as a path for escaping air, so the adhesion of the raw material sheet is particularly enhanced, and small foreign matter and moisture can also be discharged through the vacuum hole 116. As a result, peeling of the resin sheet 12 due to foreign matter and rusting of the metal molded plate 11 due to moisture are suppressed, and a fitting 1 with excellent durability is obtained.

[0031] The inner diameter of the vacuum hole 116 is not particularly limited, but is preferably 2 mm or less, and more preferably 1 mm or less. This makes it less likely that the shape of the vacuum hole 116 will be reflected in the resin sheet 12. As a result, a fitting 1 with a good surface shape can be obtained.

[0032] The lower limit of the inner diameter of the vacuum hole 116 does not need to be specifically set, but considering the time required for depressurization, it is preferable that it be 0.2 mm or more, and more preferably 0.5 mm or more.

[0033] The number of vacuum holes 116 in the metal molded plate 11 may be one, but it is preferable to have multiple holes in order to reduce the pressure evenly.

[0034] The resin sheet 12 contains a resin material and covers one surface 112 of the metal molded plate 11. This enhances the corrosion resistance of the metal molded plate 11 and modifies its surface. As a result, for example, when a waterproof sheet is placed over the fitting 1, the adhesion between the fitting 1 and the waterproof sheet can be easily increased, and the wind pressure resistance of the waterproof sheet after installation can be improved. The one surface 112 is the surface that faces upward when the fitting 1 is attached to the building 2. The resin sheet 12 may cover both the one surface 112 and the other surface 114 of the metal molded plate 11.

[0035] Examples of resin materials include various thermoplastic resins such as polyvinyl chloride (PVC), polyolefin resins, ethylene vinyl acetate copolymers, polyamide resins, and hot-melt resins, and one or more of these can be used in combination. Of these, polyvinyl chloride resins are preferred. Polyvinyl chloride resins have excellent solvent weldability, heat weldability, and weather resistance. Therefore, by using polyvinyl chloride resins, a fitting 1 with excellent bonding strength to the waterproof sheet and excellent weather resistance can be obtained.

[0036] The vinyl chloride resin is not particularly limited as long as it is a polymer containing vinyl chloride, i.e., an oligomer, prepolymer, or polymer. Examples include monomeric polymers of vinyl chloride, copolymers of vinyl chloride and other monomers, and mixtures of two or more of these polymers.

[0037] 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.

[0038] The average degree of polymerization of the vinyl chloride resin is preferably 1000 to 1800, and more preferably 1300 to 1500. This results in a resin sheet 12 with low rigidity and excellent shape conformability.

[0039] The average degree of polymerization is calculated on a standard polystyrene basis using gel permeation chromatography (GPC).

[0040] Examples of polyolefin resins include polyethylene and polypropylene.

[0041] Specific examples of polyethylene include high-density polyethylene (HDPE), low-density polyethylene (LDPE), linear low-density polyethylene (LLDPE), and mixtures of two or more of the above types of polyethylene.

[0042] Specific examples of polypropylene include isotactic polypropylene, syndiotactic polypropylene, atactic polypropylene, and mixtures of two or more of the above types of polypropylene.

[0043] The sheet thickness of the resin 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 metal molded plate 11, resulting in a resin sheet 12 with fewer pinholes and other defects. Furthermore, it prevents the resin sheet 12 from becoming too thick, thus suppressing increased weight and overall thickness.

[0044] The sheet thickness of the resin sheet 12 may be equal to or greater than the thickness of the metal molded plate 11, but is preferably set to be less than the plate thickness, more preferably set to be 0.3 mm or more thinner than the plate thickness, and even more preferably set to be 0.5 mm or more thinner than the plate thickness. This optimizes the balance between the thickness of the metal molded plate 11 and the sheet thickness of the resin sheet 12. As a result, a fitting 1 is obtained that has excellent shape retention and excellent adhesion to the waterproof sheet.

[0045] Furthermore, while it is preferable that the resin sheet 12 covers the entire surface of the metal molded plate 11, there may be areas that are not covered. Also, the thickness of the resin sheet 12 may be the same throughout, or it may vary in some areas. The resin sheet 12 may contain a plasticizer.

[0046] 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.

[0047] 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).

[0048] Examples of phosphate ester plasticizers include tricresyl phosphate (TCP) and trixylylene phosphate (TXP).

[0049] Examples of adipic acid ester plasticizers include dioctyl adipate (DOA) and diisodecyl adipate (DIDA).

[0050] Examples of sebatic acid ester plasticizers include dibutyl sebacate (DBS) and dioctyl sebacate (DOS).

[0051] The plasticizer content of the resin sheet 12 is preferably 15 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, per 100 parts by mass of vinyl chloride resin. This results in a resin sheet 12 with excellent shape conformability and adhesion to the waterproof sheet. As a result, the wind pressure resistance of the waterproof sheet after installation can be improved.

[0052] The resin sheet 12 may contain any additives. Examples of additives include saturated fatty acids, metal soaps, colorants, impact modifiers, perchlorate compounds, antioxidants, antifungal agents, flame retardants, antistatic agents, fillers, ultraviolet absorbers, light stabilizers, and foaming agents.

[0053] 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.

[0054] 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.

[0055] 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.

[0056] The manufacturing method for the accessory shown in Figure 3 comprises a preparation step S100, a primer application step S102, an installation step S104, and a molding step S106.

[0057] 2.1. Preparation process In preparation step S100, first, the metal molded plate 11 and the resin sheet 12 are prepared.

[0058] The metal molded sheet 11 is manufactured by shaping a metal sheet into a predetermined shape. Furthermore, a vacuum hole 116 is formed connecting one surface 112 (first main surface) and the other surface 114 (second main surface) of the molded metal sheet. This results in the metal molded sheet 11.

[0059] Examples of methods for manufacturing the resin sheet 12 include calendering and T-die extrusion.

[0060] 2.2. Primer application process In the primer application step S102, a primer is applied to one side 112 of the metal molded plate 11. This results in a primer coating (not shown).

[0061] The primer modifies one surface 112 of the metal molded plate 11, improving the weldability when welding the interface between the metal molded plate 11 and the resin sheet 12. Furthermore, when using an adhesive to bond the metal molded plate 11 and the resin sheet 12, the primer improves the adhesion of the adhesive to one surface 112.

[0062] Furthermore, the metal molded plate 11 after the primer coating is formed, or the metal molded plate 11 before the primer coating is formed, may be preheated. This particularly enhances the weldability and adhesion of the resin sheet 12 to the primer coating. Figure 4(a) illustrates an example of preheating the metal molded plate 11 by generating hot air 55 from a hot air generator 54. The preheating method is not particularly limited, and the heating method described later may be used.

[0063] The preheating temperature of the metal molded plate 11 is set appropriately according to the constituent material (resin material) of the resin sheet 12. Specifically, it is preferable to set the preheating temperature to be above the melting temperature of the resin material. This allows the resin sheet 12 to be efficiently molded when the preheated metal molded plate 11 is subjected to the molding process S106.

[0064] The preheating temperature is preferably 200°C to 500°C, and more preferably 230°C to 350°C. By subjecting the metal molding plate 11 heated to such a preheating temperature to the molding process S106, the resin sheet 12 can be molded more efficiently.

[0065] Furthermore, if the preheating temperature falls below the lower limit, the temperature of the metal molded sheet 11 may decrease if time is required between preheating and the molding process S106. On the other hand, if the preheating temperature exceeds the upper limit, the metal molded sheet 11 may become more susceptible to oxidation.

[0066] Furthermore, the order of the primer application step S102 and the mounting step S104, which will be described later, may be reversed from that of this embodiment. In other words, the primer may be applied after the metal molded plate 11 has been mounted to the differential pressure molding machine.

[0067] The primer is not particularly limited as long as it has the function of improving the weldability and adhesion of the resin sheet 12 to one surface 112 of the metal molded plate 11. The primer is, for example, a liquid composition containing a resin, a curing agent, and a solvent.

[0068] 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.

[0069] Examples of polyester resins include oil-free polyester resins, urethane-modified polyester resins, epoxy-modified polyester resins, and acrylic-modified polyester resins.

[0070] 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.

[0071] Examples of epoxy resins include bisphenol-type epoxy resins and novolac-type epoxy resins. Modified epoxy resins are also produced by reacting the epoxy groups or hydroxyl groups in these epoxy resins with various modifying agents.

[0072] 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.

[0073] 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.

[0074] 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.

[0075] Examples of blocking agents include phenol-based blocking agents, alcohol-based blocking agents, oxime-based blocking agents, and activated methylene-based blocking agents.

[0076] 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 weldability and adhesion to the resin sheet 12.

[0077] 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.

[0078] Specific examples of solvents include xylene, toluene, propylene glycol methyl ether acetate, methanol, isopropyl alcohol, and ethylene glycol monopropyl ether.

[0079] 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.

[0080] 2.3. Installation Process In the installation process S104, the metal molded plate 11 is first attached to the differential pressure molding machine.

[0081] Examples of differential pressure molding machines include vacuum molding machines and vacuum pressure molding machines. These molding machines can accurately mold resin sheets 12 by utilizing a large pressure difference.

[0082] 2.3.1. Vacuum forming method The vacuum forming machine 5 shown in Figures 4(b) and 5(a) comprises a frame 51, an exhaust pump 52, and a heating unit 53. The vacuum forming method involves setting a metal forming plate 11 in the vacuum forming machine 5 and forming a resin sheet 12 using the pressure difference generated by vacuuming.

[0083] A metal molded plate 11 is attached to the frame 51, as shown in Figure 4(b). The connection between the two is preferably airtight. This allows the exhaust pump 52 to depressurize the space on the other side 114 of the metal molded plate 11.

[0084] The heating unit 53 heats the metal molded plate 11. Examples of heating methods using the heating unit 53 include dielectric heating, induction heating, electrical heating, resistance heating, and flame heating. Two or more of these methods may be used in combination. The arrangement and shape of the heating unit 53 are not limited to those shown in the illustration.

[0085] Dielectric heating is a heating method that heats an object by irradiating it with electromagnetic waves, causing the molecules within the object to vibrate. For example, microwaves are used as electromagnetic waves. While dielectric heating using microwaves is typically applied to dielectric materials, it can also be applied to plate-shaped members such as the metal molded plate 11, even if they are made of metallic materials. Dielectric heating allows the object to be heated without direct contact between the heat source and the object. Therefore, the metal molded plate 11 can be heated uniformly.

[0086] Induction heating is a heating method in which an object to be heated is placed in an alternating magnetic field, and eddy currents are generated in the object to be heated to heat it. The alternating magnetic field can be generated, for example, using a solenoid-shaped coil. Alternatively, eddy currents may be generated in the metal molded plate 11 to heat it, or eddy currents may be generated in an object to be heated adjacent to the metal molded plate 11, and the metal molded plate 11 may be heated by heat transfer from the object to be heated.

[0087] The electric heating method is a heating method that generates heat by passing an electric current through the metal molded plate 11. By attaching electrodes to the metal molded plate 11, the metal molded plate 11 can be heated in a short time, thus shortening the film deposition time. Furthermore, since only the metal molded plate 11 can be heated, highly accurate temperature control is possible in a short time.

[0088] Resistance heating methods include a self-heating method in which a resistance heating element is incorporated into the metal molded plate 11 and current is passed through the resistance heating element to heat the metal molded plate 11 itself, and an indirect heating method in which the metal molded plate 11 is heated by radiant heat and thermal convection from a resistance heating element located away from the metal molded plate 11. In the self-heating method, the metal molded plate 11 is heated directly, so highly accurate temperature control is possible in a short time. In the indirect heating method, the metal molded plate 11 is heated indirectly without contact, so the metal molded plate 11 can be easily heated without incorporating a resistance heating element into the metal molded plate 11 or passing current through it.

[0089] The flame heating method involves applying a flame to the other surface 114 of the metal molded plate 11 to heat it. This allows the metal molded plate 11 to be heated easily.

[0090] By heating the metal molded plate 11 attached to the vacuum forming machine 5, the adhesion between the metal molded plate 11 and the resin sheet 12 can be improved.

[0091] 2.3.2. Vacuum pressure forming method The vacuum pressure forming method involves setting a metal forming plate 11 in a vacuum pressure forming machine (not shown) and forming a resin sheet 12 using the pressure difference generated by the supply of compressed air.

[0092] Specifically, the metal molded plate 11 is attached to a vacuum pressure forming machine, and the resin sheet 12 is set in a pressure box located opposite the metal molded plate 11. In the molding process S106, which will be described later, when compressed air is supplied into the pressure box, one side 112 (first main surface) of the metal molded plate 11 is pressurized. Also, when air is discharged through the vacuum holes 116 of the metal molded plate 11, the other side 114 (second main surface) of the metal molded plate 11 is depressurized. The resin sheet 12 is molded into a predetermined shape according to the pressure difference formed in this way.

[0093] Next, the metal forming plate 11 attached to the vacuum pressure forming machine is heated. The heating method is the same as in the vacuum forming method.

[0094] The metal forming plate 11 may be preheated before being attached to the vacuum pressure forming machine.

[0095] 2.4. Molding process In molding step S106, first, a resin sheet 12 is placed on top of a primer coating film (not shown) that has been formed on one surface 112 of the metal molded plate 11, as shown in Figure 5(a).

[0096] The resin sheet 12 may be preheated. Heating softens and plasticizes the resin sheet 12, improving its moldability. Alternatively, the resin sheet 12 may be heated after being laminated onto the primer coating.

[0097] Next, the vacuum forming machine 5 or a vacuum pressure forming machine (not shown) is activated. Then, the pressure is reduced on the other side 114 of the metal forming plate 11. As a result, the air between the metal forming plate 11 and the resin sheet 12 is discharged through the vacuum holes 116, so that the resin sheet 12 can be pressed tightly against one side 112 and formed as shown in Figure 5(a). With this method, the resin sheet 12 can be formed without using a mold, so a resin film with sufficient thickness can be easily formed at low cost.

[0098] Next, the molded resin sheet 12 is cooled. This fixes the molded shape and adheres the resin sheet 12 to the metal molded plate 11.

[0099] Next, the metal molded plate 11 is separated from the frame 51. Then, if necessary, the resin sheet 12 is trimmed. This yields the fitting 1 shown in Figure 5(b). In this way, by using a method of bonding a pre-formed sheet-shaped component, a fitting 1 is obtained that has a resin sheet 12 with good coverage and pinhole resistance.

[0100] In molding step S106, it is preferable to heat the metal molded plate 11 with the heating unit 53. This allows the temperature of the metal molded plate 11 to be maintained during molding step S106, even if the heat capacity of the metal molded plate 11 is small. As a result, the moldability and adhesion of the resin sheet 12 can be further improved.

[0101] The heating temperature of the metal molded plate 11 is set appropriately according to the melting temperature of the resin sheet 12, but as an example, it is preferably 200°C to 500°C, and more preferably 230°C to 350°C. By heating the metal molded plate 11 at such a temperature, the moldability and adhesion of the resin sheet 12 can be further improved.

[0102] Furthermore, if the heating temperature falls below the lower limit, the moldability and adhesiveness of the resin sheet 12 may not be sufficiently improved. On the other hand, if the heating temperature exceeds the upper limit, the metal molded plate 11 may become prone to oxidation, or the resin sheet 12 may undergo thermal deformation.

[0103] 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 an outer corner 21 or an inner corner 22, and comprises a preparation step S100, a primer application step S102, an installation step S104, and a molding step S106. In the preparation step S100, a metal molded plate 11 is prepared which has one surface 112 (first main surface) and the other surface 114 (second main surface) that are in a front-back relationship with each other, and a vacuum hole 116 connecting the one surface 112 and the other surface 114, and which is molded into a predetermined shape. In the primer application step S102, a primer is applied to one surface 112 to obtain a primer coating film. In the installation step S104, the metal molded plate 11 is attached to a differential pressure molding machine. In molding step S106, the differential pressure molding machine is activated to press the resin sheet 12 against one surface 112, thereby molding the resin sheet 12 and bonding it to the other surface 112.

[0104] With this configuration, a fitting 1 can be manufactured that comprises a metal molded plate 11 and a resin sheet 12 of sufficient thickness, and has excellent shape retention, weather resistance, and watertightness. Furthermore, by using a method of bonding pre-formed sheet-shaped components, a fitting 1 can be obtained that has a resin sheet 12 with good covering properties and pinhole resistance. Moreover, with this method, the resin sheet 12 can be molded without using a mold, so a resin film with sufficient thickness can be easily formed at low cost.

[0105] In the manufacturing method of the special-purpose piece according to the above embodiment, the differential pressure molding machine may be a vacuum molding machine that operates to reduce the pressure on the other side, the 114 (second main surface).

[0106] With this configuration, the resin sheet 12 can be molded with high precision by utilizing a large pressure difference.

[0107] In the manufacturing method of the special-purpose product according to the above embodiment, the differential pressure molding machine may be a vacuum pressure molding machine that operates to pressurize one side 112 (first main surface) and depressurize the other side 114 (second main surface).

[0108] With this configuration, the resin sheet 12 can be molded with high precision by utilizing a large pressure difference.

[0109] In the manufacturing method of the accessory according to the above embodiment, the metal molded plate 11 may be heated, and one surface 112 (first main surface) of the metal molded plate 11 and the resin sheet 12 may be pressed against each other.

[0110] With this configuration, even if the heat capacity of the metal molded plate 11 is small, the temperature of the metal molded plate 11 can be maintained during the molding process S106. As a result, the moldability and adhesion of the resin sheet 12 can be further improved.

[0111] In the method for manufacturing the accessory according to the above embodiment, the constituent material of the resin sheet 12 is preferably a vinyl chloride resin.

[0112] With this configuration, a fitting 1 with excellent bonding strength to the waterproof sheet and weather resistance can be obtained.

[0113] The method for manufacturing the special feature of the present invention has been described above, but the present invention is not limited to these.

[0114] 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. [Examples]

[0115] Next, specific embodiments of the present invention will be described. However, the present invention is not limited in any way to these embodiments.

[0116] 4. Production of special effects 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.

[0117] The resin sheet is 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 (PVC).

[0118] Tables 1 and 2 also show the sheet thickness of the resin sheet, the constituent materials of the metal molded plate, the plate thickness of the metal molded plate, the type of differential pressure molding method, the presence or absence of primer, and the heating temperature of the resin sheet, respectively. Furthermore, "SUS" in Tables 1 and 2 refers to stainless steel SUS304. Furthermore, the component in sample No. 10 is made solely from a resin sheet that has been vacuum-formed.

[0119] Furthermore, the component in sample No. 11 is made by bonding a resin sheet to a metal molded plate with adhesive. A primer was applied to the bonding surface of the metal molded plate.

[0120] Furthermore, the accessory part of sample No. 12 is formed by creating a PVC film with the configuration shown in Table 2 on the surface of a metal molded plate using a dipping method.

[0121] 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."

[0122] 5. Evaluation of the special features The following evaluations were performed on the components of each example and each comparative example.

[0123] 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.

[0124] 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.

[0125] 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.

[0126] A: The amount of sagging is below the standard value. B: The amount of sagging is below the standard value.

[0127] Note that the reference value is the measurement value for a test specimen (a test specimen from which the metal molded body has been omitted) cut from the special piece of sample No. 10.

[0128] 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.

[0129] 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.

[0130] 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.

[0131] Next, the measurement results were evaluated against the following evaluation criteria. The evaluation results are shown in Tables 1 and 2.

[0132] 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]

[0133] 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. 2 The 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

[0134] 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.

[0135] 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%)

[0136] [Table 1]

[0137] [Table 2]

[0138] Based on the evaluation results shown in Tables 1 and 2, the following can be observed. • In each embodiment, the fittings were found to have good shape retention because they contained a metal molded plate. • 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.

[0139] From the above, it has been confirmed that the present invention makes it possible to manufacture a fitting that is excellent in shape retention, weather resistance, and watertightness, comprising a metal molded plate and a resin sheet of sufficient thickness. [Explanation of Symbols]

[0140] 1. Special Features 2 buildings 2A Floor part 2B Parapet 5 Vacuum forming machine 11 Metal forming plate 12 Resin Sheets 21 Corner section 22 Inside corner 23 Drain 24 Drainage 51 frames 52 Exhaust pump 53 Heating section 54 Hot air generator 55 Hot air 112 One side 114 The other side 116 Vacuum hole S100 Preparation process S102 Primer application process S104 Installation Process S106 Molding process

Claims

1. A method for manufacturing a fitting that applies waterproofing treatment to an external or internal corner, A step of preparing a metal molded plate having a first main surface and a second main surface that are in a front-back relationship with each other, and a vacuum hole connecting the first main surface and the second main surface, and which is formed into a predetermined shape, The process involves applying a primer to the first main surface to obtain a primer coating, The process of attaching the aforementioned metal molded plate to a differential pressure molding machine, The steps include operating the differential pressure molding machine and pressing the resin sheet against the first main surface to mold the resin sheet and adhere the resin sheet to the first main surface, 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 machine is a vacuum molding machine that operates to reduce the pressure on the second main surface side.

3. The method for manufacturing a special-purpose item according to claim 1, wherein the differential pressure molding machine is a vacuum pressure molding machine that operates to pressurize the first main surface and depressurize the second main surface.

4. A method for manufacturing a decorative piece according to any one of claims 1 to 3, wherein the first main surface and the resin sheet are pressed against each other while the metal molded plate is heated.

5. The method for manufacturing a decorative piece according to any one of claims 1 to 3, wherein the constituent material of the resin sheet is a vinyl chloride resin.

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