JP2000094556A - Resin molded article and its preparation - Google Patents

Abstract

PROBLEM TO BE SOLVED: To make adhesive force between a resin plate and a reinforcing layer good and to simplify the manufacturing process. SOLUTION: When a resin molded article consisting of an inner layer 1 prepd. by preforming of a resin plate and a reinforcing layer 3 by an FRP laminated through a primer layer 2 on its outside is prepd., the primer layer 2 is provided in advance on the outside of the resin plate being the inner layer 1 and after this resin plate provided with the primer layer 2 is molded into a required shape, the reinforcing layer 3 is laminated on the primer layer 2 and they are integrated.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a resin molded product used for a bathtub, a wash basin and the like, and a method for producing the same.

[0002]

2. Description of the Related Art Conventionally, as this kind of resin molded product, an inner layer formed by preforming a resin plate of acrylic or the like and a reinforcing layer made of FRP (Fiber Reinforced Plastic) laminated on the outer layer are generally widely used. ing. As a method of manufacturing this resin molded product, a pattern is formed on a transparent acrylic plate by printing or transfer, and then this is thermoformed into a desired shape.
Are known (Japanese Patent Publication No. 56-2725).
No. 9, JP-B-55-45696, etc.). Alternatively, a method of printing on a transparent acrylic plate or an acrylic film, laminating the two in a state where the printing is sandwiched, thermoforming the laminate to a desired shape, and then laminating FRP on the acrylic film side is also available. Known (6
No. 4-1289).

[0003]

In the former method among the manufacturing methods described in the prior art, since the primer layer is provided by coating, the process is complicated and the cost is high.
There is a problem that the stability of quality is lacking. In the latter method, when the acrylic film is laminated simultaneously with the painting of the acrylic plate, the production lot becomes large,
It becomes difficult to cope with many kinds. On the other hand, when laminating in a separate process from the painting of the acrylic plate, the process does not change compared with the above-mentioned primer coating specification, and there is not much merit. In any case, when an acrylic film is used, there are concerns about defects such as swelling due to air bite during lamination and whitening of the acrylic film.

[0004]

In order to solve the above problems, the present invention forms a primer layer in a state of a resin plate before preforming. By adopting such a configuration, the manufacturing process can be simplified, and the disadvantages caused by using a film for bonding can be avoided.

[0005]

BEST MODE FOR CARRYING OUT THE INVENTION The resin molded product of the present invention is a resin molded product comprising an inner layer formed by preforming a resin plate, and a reinforcing layer made of FRP laminated on the outside with a primer layer interposed therebetween. It has a structure in which a resin plate having a primer layer formed on the outside in advance is formed into a desired shape, and then a reinforcing layer is laminated.

FIG. 1 is a sectional view showing a bathtub as an example of a resin molded product according to the present invention. As shown in the figure, the bathtub has an inner layer 1 and a primer layer 2
And the reinforcing layer 3 laminated through the intermediary layer. And inner layer 1
When a decorative layer is provided between the inner layer 1 and the reinforcing layer 3, a transparent or translucent resin plate is used as the inner layer 1, and a pattern layer or a colored layer may be formed between the inner layer 1 and the primer layer 2. .

[0007] The method of manufacturing this resin molded product is as follows. First, as shown in FIG. 2A, a picture layer or a coloring layer is provided on the outside of the resin plate serving as the inner layer 1 as necessary,
After forming the primer layer 2 in advance, and then forming the resin plate provided with the primer layer 2 into a desired shape as shown in FIG. 2B, the primer layer 2 side is formed as shown in FIG. And a reinforcing layer 3 made of FRP is laminated and integrated.

[0008] As the resin plate, a material suitable for the application and purpose is used. For example, in the case of a bathtub, an acrylic resin is preferable. In particular, those obtained by adding a colorant as necessary to a monomer mixture of methyl methacrylate alone or an acrylic acid ester, adding a crosslinking agent as appropriate, and polymerizing in the presence of a polymerization initiator, are preferable. It is preferably manufactured by a plate making method, a casting polymerization method, or an extrusion plate making method, and has a plate thickness of 2 to 8 mm.

The resin plate is provided with a picture layer or a coloring layer as required. The method may be direct printing or transfer to a resin plate, but direct printing is preferred in view of the ease of providing a primer layer. Specific printing methods include a gravure offset method, a silk screen method, a flexographic method, an offset method, and the like. For example, a gravure offset method, an offset method, a flexo method, or the like is preferable when a design including a delicate gradation expression is applied, and a silk screen method is preferable when a pattern with a punch is applied.

The ink used for the pattern layer or the colored layer only needs to be in close contact with the resin plate and have flexibility and heat resistance enough to withstand vacuum forming. Acrylic resin or a resin obtained by using a mixed resin of acrylic and vinyl chloride-vinyl acetate copolymer as a binder can be used. Acrylic resins include poly (meth) acrylate, poly (meth) acrylate, poly (meth) acrylate, butyl (meth) acrylate, methyl (meth) acrylate and (meth) acrylate (Meth) such as butyl copolymer, ethyl (meth) acrylate / butyl (meth) acrylate, ethylene / methyl (meth) acrylate, styrene / methyl (meth) acrylate There is an acrylic resin made of a homopolymer or a copolymer containing an acrylate ester (however, here, (meth) acryl means acrylic or methacryl).

The primer is a resin plate to be used and FRP
An appropriate resin is selected from acrylic resins, unsaturated polyester resins, vinyl ester resins, urethane resins, epoxy resins, and the like, depending on the material used. The primer used is colored if necessary. When a pattern or a colored layer is provided on the resin plate, it is efficient to apply the primer layer by a printing technique.

In forming the primer layer on the outside of the resin plate, it is preferable to increase the amount of the primer applied to a portion having a large elongation at the time of preforming compared to other portions. Further, if a protective film is laminated on the primer-coated surface, handling of the resin plate after forming the primer layer becomes easy.

The preforming is usually performed using a vacuum forming apparatus. Then, the resin plate having the primer layer formed outside is formed into a deep drawing shape. In this case, molding is performed under the condition that the primer applied to the resin plate is not completely cured. After molding into a desired shape by preliminary molding, the FRP is backed up and integrated on the primer layer side of the molded article to produce the resin molded article of the present invention.

[0014]

(Example 1) A thickness of 5 mm and a size of 900
× 1800mm acrylic plate (“PX-
200 ") was subjected to pattern printing by a gravure offset method. A vinyl chloride-based system (“LTC30” manufactured by The Inktec) was used as the pattern ink. Then, a primer was applied by in-line silk screen printing so as to cover the entire printing surface. Here, a vinyl ester-based primer colored to a desired color ("Lipoxy Y" manufactured by Showa Kogaku Kogyo)
8002 ”) and was applied in a thickness of 0.3 mm.

Subsequently, the acrylic layer was set in a vacuum forming apparatus with the primer layer facing the mold side, and was formed into a bathtub shape having an opening of about 700 × 1300 mm and a depth of about 450 mm by evacuation. At this time, conditions were set so that the primer was not completely cured. When the molded product was released from the mold after cooling, a highly designed molded product having a thickness of 0.8 mm or more was obtained.

On the molded product obtained in this way, a 450 g / m ² chopped strand mat (“CM455” manufactured by Asahi Fiberglass Co., Ltd.)
FA ") and an iso-unsaturated polyester resin (" Ester R289 "manufactured by Mitsui Toatsu Chemicals Co., Ltd.) to polymerize and cure the 2.0 mm thick FRP layers for both the first and second layers by spraying. A reinforcing layer was formed. Thus, a bathtub as a resin molded product was manufactured. The resulting bathtub had excellent interlayer adhesion.

(Example 2) The same acrylic plate as in Example 1 was subjected to the same pattern printing, and the same colored primer as in Example 1 was applied in-line by screen printing to cover the entire printing surface. Further, the same colored primer was used to apply a pattern by in-line screen printing to a portion having a particularly large elongation at the time of molding. Subsequently, when a molded product was manufactured by providing a reinforcing layer in the same manner as in Example 1, a bathtub having more excellent interlayer adhesion at the corners than that obtained in Example 1 was obtained.

(Example 3) The same acrylic plate as in Example 1 was subjected to the same pattern printing, and the same colored primer as in Example 1 was applied so as to cover the entire printing surface by in-line screen printing. Then, a protective film was laminated on the primer-coated surface, and the acrylic plate was preformed in the same manner as in Example 1 with the protective film attached. Thereafter, the protective film was peeled off from the primer layer, and a reinforcing layer was provided in the same manner as in Example 1 to produce a molded article. The handling of the resin plate after the formation of the primer layer was easier than in the case of Example 1.

[0019]

As described above, in the resin molded article of the present invention, a resin plate having a primer layer formed on the outside in advance is formed into a desired shape, and a reinforcing layer is laminated and integrated through the primer layer. As a result, the adhesion between the resin plate and the reinforcing layer can be improved, and the manufacturing process can be simplified as compared with the conventional case.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view showing a bathtub as an example of a resin molded product according to the present invention.

FIG. 2 is a process chart showing a manufacturing procedure of the resin molded product shown in FIG.

[Explanation of symbols]

 1 inner layer 2 primer layer 3 reinforcing layer

 ──────────────────────────────────────────────────の Continued on the front page F-term (reference) 4F100 AG00 AK01A AK15 AK15J AK21 AK22 AK22J AK25 AK44 AL01 AR00B AR00D BA03 BA04 BA05 BA07 BA10A BA10C DG03 DH02C EH012 EH461 EH612 EJ241 EJ391 J02H01J02H

Claims (4)

[Claims] 1. A resin molded product comprising an inner layer formed by preforming a resin plate and a reinforcing layer made of FRP laminated on the outer side with a primer layer interposed therebetween, the resin plate having a primer layer formed on the outer side in advance. Formed into a desired shape and laminated with a reinforcing layer. 2. The resin molded article according to claim 1, wherein a transparent or translucent resin plate is used as the inner layer, and a picture layer or a colored layer is formed between the inner layer and the primer layer. 3. A method for producing a resin molded product comprising an inner layer formed by preforming a resin plate and a reinforcing layer formed by FRP laminated on the outer side of the resin plate via a primer layer, wherein the outer layer of the resin plate serving as the inner layer is formed. A method for producing a resin molded product, comprising: providing a primer layer in advance, forming a resin plate provided with the primer layer into a desired shape, and then laminating and integrating a reinforcing layer on the primer layer side. 4. The resin molded article according to claim 1, wherein, when forming the primer layer on the outer side of the resin plate, a portion where the elongation is large during molding is applied with a larger amount of the primer than at other portions. Production method.