JP2000108122A - Manufacture of surface decorating sheet molding compound - Google Patents

Abstract

PROBLEM TO BE SOLVED: To give an externally beautiful surface decoration without developing flow of a pattern material at a compression molding even when a large sized pattern material is employed. SOLUTION: In this method, a surface mat 22 is placed on one film 12. A pattern material-containing thermosetting resin compound 31 is applied on the surface of the surface mat. Further, fiber reinforcing materials 43 are fallen on the compound 31. On the other film 14, a thermosetting resin compound 35 containing the pattern material or not is applied. Both the films 12 and 14 are laminated to each other by mating their surfaces coated with the resin compounds so as to infiltrate the compounds 31 and 35 in the fiber reinforcing materials 43.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION The present invention relates to a method for molding a thermosetting resin molded article having a decorative surface used for a house interior material, a house exterior material, a base material for a bathroom, a base material for a wash basin, and the like. The present invention relates to a method for manufacturing a sheet molding compound to be used.

[0002]

2. Description of the Related Art Interior and exterior materials for houses, base materials for bathrooms,
Alternatively, a curable resin molded product used as a wash basin base material or the like is patterned on the surface by coloring or the like (surface decoration).
By doing so, the appearance is improved.

[0003] As a method of decorating the surface of a thermosetting resin molded product, in the hand lay-up method of FRP, first, a transparent resin is applied to the surface of a molding die and gelled, and then a pulverized natural stone is placed thereon. A method of applying a resin mixed with a material giving a pattern (hereinafter referred to as a pattern material) to a molded product such as aluminum or aluminum flakes, and then laminating and curing a resin containing a reinforcing material such as glass fiber thereon, and curing the resin. It has been done. However, the hand lay-up method has low productivity and is not suitable for mass production.

Various methods have been proposed for decorating the surface in the FRP press method with good productivity. For example,
JP-A-63-4915 discloses a sheet molding compound (hereinafter, referred to as a "sheet molding compound") containing a pattern material for giving a stone pattern.
SMC), a glass mat and a normal SMC that does not contain a pattern material are sequentially laminated on a mold, and then compression-molded, so that the SMC resin that does not contain the pattern material flows into the surface to decorate the surface. Methods have been proposed to keep the pattern intact.

However, in recent years, in order to obtain a more natural grain pattern, there has been a demand for an SMC mixed with a mixture of various sizes of 0.2 to 5 mm as a pattern material. Is coming. If a large-sized pattern material is used, S
In the process of impregnating the fiber-reinforced material with the thermosetting resin compound containing the pattern material in the manufacturing process of the MC, the large-sized pattern material tends to remain on the surface without being impregnated into the fiber-reinforced material. That is, the surface layer is an SMC having a layer structure of a large amount of large-sized pattern material, and the middle is a layer structure of a compound-containing fiber reinforced material including small to medium-sized pattern material.

[0006]

SUMMARY OF THE INVENTION SM having the above layer structure
When compression molding is performed using C, a large-sized pattern material on the surface layer is flowed at the time of compression molding, and the portion where the large-sized pattern material exists and the small
The surface where the medium-sized pattern material is present is irregularly mixed with the surface, and the appearance is impaired. In particular, when molding a molded product having a curved surface portion, a large-sized pattern material does not remain on the curved surface portion, only small to medium-sized pattern materials are conspicuous, and an appearance such that the pattern is cut at that portion. This causes a problem that the appearance is extremely deteriorated.

The present invention has been made to solve such a problem, and an object of the present invention is to provide an SM which gives a beautiful appearance of a surface without causing a flow of the pattern material even if a large-sized pattern material is used.
An object of the present invention is to provide a method for producing C.

[0008]

Means for Solving the Problems SM for surface decoration of the present invention
The method of manufacturing C is to superimpose a surface mat on one film, apply a thermosetting resin compound containing a pattern material to the surface mat surface, drop a fiber reinforced material on the compound, and form a pattern on the other film. It is characterized in that a thermosetting resin compound containing or not containing a material is applied, the applied surfaces of both films are laminated together, and the fiber reinforced material is impregnated with the compound.

The film used in the present invention is a film generally used in the production of a conventionally known SMC, and usually a plastic film is used.

As the surface mat used in the present invention, for example, a mat or woven fabric made of a heat-resistant material such as polyester fiber or glass fiber can be used. When using a glass fiber surface mat, the basis weight is 5
If it is less than 0 g / cm ² , the effect of preventing the flow of the pattern material during compression molding is small, and if it exceeds 200 g / cm ² , the transparency of the surface of the obtained molded article is reduced, the pattern material becomes less noticeable, and the resin from the compound A weight per unit area of 50 to 200 g / cm ² is preferable since impregnation becomes insufficient and the surface appearance deteriorates.

When a polyester fiber surface mat is used, if the thickness is less than 0.1 mm, it is easy to cut during SMC production, and it is also easy to cut during compression molding, preventing the flow of the pattern material. When the thickness exceeds 0.3 mm, the transparency of the surface of the obtained molded product is reduced, and the surface does not have a deep feeling. Therefore, a thickness of 0.1 to 0.3 mm is preferable. Also, the tensile strength needs to be 8 kg / cm ² or more.

The pattern material used in the present invention is preferably a material that does not decompose or deteriorate by heat or pressure during press molding.
The shape is preferably a flaky shape rather than a granular shape. Examples of the flaky pattern material include colored mica and colored aluminum foil in the case of inorganic materials, and cut products of colored films such as polyethylene, PVC, polyamide, polycarbonate, and PET in the case of organic materials. Especially, an organic type is preferable.

When the size of the pattern material is less than 0.1 mm, the pattern of the molded article obtained is not conspicuous, and when it exceeds 2.5 mm, the dispersion in the compound becomes poor, and the pattern material is separated from the cured resin even after molding. The thickness is preferably from 0.1 mm to 2.5 mm because the resulting pattern becomes poor in transparency. 0.2 mm to 2. Rather than using only a single size.
It is more preferable to use a mixture of several different sizes in the range of 0 mm.

As the thermosetting resin used in the compound of the present invention, a thermosetting resin used in the preparation of a conventionally known SMC can be used. For example, unsaturated polyester resin, epoxy acrylate resin, urethane acrylate resin and the like can be used. Is mentioned. This thermosetting resin, in addition to the pattern material, if necessary, a coloring agent, a low shrinkage agent, a filler,
A curing agent, a release agent and the like are added and mixed to form a compound.

In order to improve the transparency of the surface of the obtained molded article and to express a sense of depth in the pattern, it is preferable to use a resin, a filler or the like having a refractive index close to that of glass. In particular, it is preferable to use a filler having a refractive index close to that of glass, and glass powder and aluminum hydroxide are suitable.

In the present invention, the compound containing the pattern material is applied to the surface mat surface obtained by superposing the surface mat on one film, and the compound containing or not containing the pattern material is applied to the other film. Is done. This coating is performed using a conventionally known SMC manufacturing apparatus,
Usually done by a doctor blade.

If the thickness of the compound applied to the surface mat surface is less than 1.5 mm, clogging of a large-sized pattern material under the doctor blade occurs.
The pattern material of the coating layer becomes uneven or this clogging causes
A coating thickness of 1.5 mm or more is preferable because the film or surface mat is likely to be damaged or cut.

As the compound applied to the other film, the same compound as applied to the surface mat surface may be used, but the type and amount of the filler, the type of the pattern material,
You may use the compound which changed the size and the amount, or the compound which does not mix | blend a pattern material.

The fiber reinforcing material used in the present invention includes:
For example, glass fibers, carbon fibers, organic fibers such as vinylon, polyester and the like can be mentioned, and glass fibers are preferable in terms of strength, price and the like.

The reinforcing fibers are preferably dropped and dispersed from above the compound applied to the surface mat surface, as is conventionally known in the SMC production. When glass fiber is used, the amount to be dispersed and dispersed is 400 g.
If it is less than / cm ² , the compound of the SMC used for the back layer at the time of compression molding tends to flow into the surface, and the surface of the obtained molded product tends to have a mottled pattern, and 1000 g / cm 2
^If it exceeds ² , a part of the glass fiber is not sufficiently impregnated with the compound, and it becomes difficult to remove air during compression molding, which tends to cause blistering and whitening of the molded product.
0-1000 g / cm < ² > is preferable.

The surface of the compound in which the reinforcing fibers are dropped and dispersed and the surface of the compound applied to the other film are laminated together, and the laminated product is impregnated with an impregnated roll or impregnated material in the usual manner for SMC production. After passing through a belt, the reinforcing fibers are impregnated with the compound and wound up, and are subjected to a predetermined thickening step to form SMC.

As an apparatus used for compression molding using the SMC obtained by the production method of the present invention, a press machine conventionally used for compression molding of FRP can be used as it is. As the mold, an upper and lower mold is preferable, and usually,
The upper mold is a movable mold and the lower mold is a fixed mold.

As an example of a method for producing a molded article using the SMC obtained by the production method of the present invention, the above mold is heated to 80 to 180 ° C.
The SMC obtained by the method of the present invention is placed so that the surface of the obtained molded article is on the side on which the surface mat is arranged, and if necessary, the normal SMC containing no pattern material is stacked, and the mold is formed. To 30 kg at a pressure of 10 to 120 kg / cm ^2.
After compression molding for seconds to 20 minutes, the mold is opened and the molded product is taken out.

[0024]

According to the method of manufacturing the surface decoration SMC of the present invention, a surface mat is superimposed on one film, a thermosetting resin compound containing a pattern material is applied to the surface mat surface, and a fiber reinforced material is further applied thereon. Drop the material, apply the thermosetting resin compound containing or not containing the pattern material to the other film, and laminate the applied surfaces of both films together, so that the fiber reinforced material is impregnated with the compound, The surface mat layer on the surface is not impregnated with the pattern material, only the compound is impregnated, and the intermediate fiber reinforcement layer is impregnated only with the compound with the small size pattern material,
The SMC has a compound layer including a large-sized pattern material formed between the intermediate layer and the surface layer. Therefore, when the SMC is compression-molded, the flow of the pattern material does not occur even if a large-sized pattern material is used, and the resulting molded article is given a beautiful surface decoration.

[0025]

DESCRIPTION OF THE PREFERRED EMBODIMENTS One embodiment of the present invention will be described below with reference to the drawings. FIG. 1 is a schematic explanatory view showing the steps of the method for manufacturing a surface decoration SMC of the present invention.
The present embodiment is directed to a surface-decorated SM for a kitchen counter.
It is an example of C.

(Embodiment) A glass surface mat 22 with a basis weight of 150 g / cm ² fed from a surface mat feeder 21 is superimposed on a film 12 fed from a film feeder 11, and the surface of the glass surface mat 22 is placed on the surface. The thermosetting resin compound 31 was applied by a doctor blade 32. In this embodiment, as the thermosetting resin compound 31, based on 100 parts by weight of the unsaturated polyester resin, 1 part by weight of a tertiary butyl peroxybenzoate (TBPB), 120 parts by weight of aluminum hydroxide having an average particle diameter of 12 μm, Each 1 part by weight of a colored PET film pattern material cut to a cut length of 0.5 mm and 2 mm, 7 parts by weight of a beige color pigment, and various other compounds such as a thickener (magnesia) in the usual manner for normal SMC production The ingredients were mixed and kneaded. The coating thickness of the compound was 2.5 mm.

A glass roving 41 continuously supplied from a supply device (not shown) provided above is cut into a cutter 4.
The glass fiber 43 was cut into pieces having a length of 1 inch, and was uniformly sprayed at a rate of 700 g / cm ^{2 on} the coated surface.

The other film 14 is fed from a film feeder 13 and has a doctor blade 3 on its upper surface.
6, a thermosetting resin compound 35 was applied to a thickness of 1.5 mm. As the thermosetting resin compound 35, 100 parts by weight of the unsaturated polyester resin is
1 part by weight of BPB, calcium carbonate 1 having an average particle size of 10 μm
50 parts by weight, 7 parts by weight of beige pigment, and ordinary S
A mixture obtained by mixing and kneading various thickeners (magnesia) and other compounding agents in the usual manner for MC production was used.

The surface on which the glass fibers 43 are scattered and the other application surface are laminated and advanced between the position regulating rolls 6, 6, and are advanced by the impregnated belt 7 including the mesh belt 71 and the belt driving roll 72. The glass fibers 43 are sufficiently impregnated with the two compounds 31 and 35, wound up by a winder (not shown) on the right side, and heated at 40 ° C. in an aging room.
After aging for a time, SMC for surface decoration was obtained.

The molding die has a long side of 1600 mm and a short side of 400 mm.
A mold for obtaining a rectangular molded product having a length of 30 mm and a sleeve length of 30 mm (decoration surface formed by a lower die) was used.

145 ° C. for lower mold and 125 ° C. for upper mold
To the lower mold and the above surface decoration SMC (charge rate 9
0%) and then a normal SMC without pattern material (charge rate 80%) is charged and the final clamping speed is 1.
Performs a mold clamping at 0mm / sec., 1 at 65kg / cm ²
After compression molding for 0 minutes, the mold was opened to obtain a molded product.

When the surface of the obtained molded article was visually observed, the large-sized pattern material was not washed away by the action of the surface mat 22 used, and the pattern of the large-sized pattern material was continuous even at the bent portion of the sleeve. Thus, there was no cutting of the pattern as seen in the conventional method, and a beautiful decorative surface was exhibited.

(Comparative Example) An SMC without a surface mat was prepared in exactly the same manner as in the example except that the surface mat 22 was not used.
Was subjected to compression molding in exactly the same manner as in Example except that SMC was used in place of SMC for surface decoration, to obtain a molded product. The surface layer portion of the SMC without surface mat used at this time is a decorative layer containing a large amount of a large-sized (2.0 mm) pattern material, and the intermediate layer is made of a fiber-reinforced material and a small-sized (0.5 mm). Was a layer impregnated with the compound. On the surface of the obtained molded product, a large-sized pattern material of the surface layer flows in some places, and especially in the bent portion of the sleeve portion, only a layer having a large number of small-sized pattern materials of the middle layer appears on the surface layer, and the pattern has a breaking line. The appearance was poor and the appearance was impaired.

[0034]

According to the present invention, the method for producing a surface decoration SMC of the present invention has the above-described structure. According to the present invention, even when a large-sized pattern material is used, the flow of the pattern material does not occur at the time of compression molding, and a molded product is formed. SMC that gives beautiful appearance to the surface.

[Brief description of the drawings]

FIG. 1 is a schematic explanatory view showing steps of a method for manufacturing a surface decoration SMC of the present invention.

[Explanation of symbols]

 11, 12, 21 Feeding roll 12, 14, Film 22 Surface mat 31, 35 Compound 32, 35 Doctor blade 41 Roving 42 Cutting machine 43 Glass fiber 6 Position regulating roll 7 Impregnation belt

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) B32B 27/04 B32B 27/04 A // B29K 101: 10 105: 08 105: 12 B29L 31:10 F term (Reference) 4F201 AA36 AD08 AD16 AD19 AD20 AG03 AH47 AH48 AH49 BA03 BA09 BC01 BC12 BC37 BM07 BM13 BM16 4F204 AA36 AD08 AD16 AD19 AD20 AG03 AH47 AH48 AH49 FA01 FB01 FB22 FF01 FG02 FG09 FN11

Claims (1)

[Claims] 1. A surface mat is superimposed on one film, a thermosetting resin compound containing a pattern material is applied to the surface mat surface, and a fiber reinforced material is dropped thereon, and the pattern material is dropped on the other film. A thermosetting resin compound containing or not containing is applied, the applied surfaces of both films are laminated together, and the fiber reinforcing material is impregnated with the compound. Production method.