JP2001071422A - Fabric laminated resin molded article and production thereof - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a resin molded article using a fabric as a surface disign and high in strength. SOLUTION: A resin molded article has a substrate 1 comprising a thermosetting resin and the decorative layer 2 laminated on the surface of the substrate. In this case, the decorative layer 2 is a layer wherein a fabric 2 is sealed in a transparent thermosetting resin and the substrate 1 and the decorative layer 2 are mutually fused at the boundary part of them. By this constitution, the resin molded article using the fabric as a surface design and high in strength can be obtained.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a resin molded article using a cloth, which is strong and has excellent design, and a method for producing the same.

[0002]

2. Description of the Related Art Conventionally, there are tableware, tableware and trays using a melamine resin or a urea resin as a thermosetting resin. However, when a design such as a pattern is applied to the surface of the tableware, it is directly applied to the surface of a resin molded product. There are a printing method and a method of attaching paper on which a pattern is printed to the surface.

In the case of a method of sticking paper, a special paper on which a pattern is printed is immersed in a melamine resin liquid, and then excess resin liquid is squeezed out with a roller. At this time, since the paper has little stretchability, there is no problem that the pattern is stretched and deformed even if pressure is applied by a roller.

[0004] It can be attached to a flat part,
Since the paper is difficult to stretch, it does not conform to curved surfaces and edges, and wrinkles and overlaps are formed in those parts, making it unworkable. Also, wrinkles and the like often crack or break when used.

Therefore, a decorative layer in which paper is stuck only on a flat portion such as a tray is formed, and the resin of the base is often exposed on the curved surface and the edge portion, which is not an excellent surface decoration means. .

[0006] In order to solve such a problem, means for attaching a cloth on which a pattern is printed instead of paper may be considered. Since the cloth is easy to stretch unlike paper, it easily fits on a curved surface, so that wrinkles and the like are unlikely to occur. However, this property of easy stretching causes a new problem.

That is, if the cloth is immersed in a resin solution and then squeezed with a roller to squeeze out excess resin liquid, the pattern of the cloth is elongated. Also, when pressure is applied by a hydraulic press when the cloth is fixed to the surface of the base, the resin flows outward due to the pressure, and the cloth is stretched together with the resin and the pattern is distorted. When the cloth is stretched and the pattern is distorted, the appearance is poor and the commercial value is lost.

Therefore, it is extremely difficult and impractical to apply a design to the surface of a resin molded product using cloth instead of paper.

Further, since melamine resin and urea resin are hard, they may be damaged when dropped and subjected to an impact, and there is a problem that chipping of the edge is particularly likely to occur.

[0010]

SUMMARY OF THE INVENTION Accordingly, an object of the present invention is to provide a resin molded article which uses a cloth, is excellent in design and has high strength, and a method for producing the same.

[0011]

The cloth-applied resin molded article of the present invention has a base (1) made of a thermosetting resin, and a decorative layer (2) laminated on the surface of the base. The layer (2) is a layer in which the cloth (3) is sealed in a transparent thermosetting resin, and the base (1) and the decorative layer (2) are fused to each other at a boundary portion. I do.

According to this, the decorative layer (2) provided with the cloth (3) is applied to the surface of the base (1), and the cloth (3) fits well with the curved surface and the edge of the base (1). It becomes a resin molded product with high designability. cloth
Since (3) is coated with a transparent resin, the pattern applied to the cloth (3) can be used as a pattern of a resin molded product.

Further, since the cloth (3) is adhered to the surface of the resin molded article, the strength is improved and the resin article is hardly damaged.

The method for producing a cloth-adhered resin molded product of the present invention comprises:
A resin-carrying cloth in which thermosetting resin powder that becomes transparent when cured is supported on both sides and the cloth of the cloth (2) is prepared in advance,
The thermosetting resin is placed on a mold and hot-pressed to form the base (1), the mold is opened, the resin-carrying cloth is placed on the base, and hot-pressed once with a low press pressure. The thermosetting resin on the surface of the resin-carrying cloth is hardened to such an extent that it does not flow out, and then the base and the resin-carrying cloth are united by increasing the press pressure and hot-pressed, and then protruded from the base. It is characterized in that the resin carrying cloth is removed.

According to this method, since the resin powder is used, there is no need to squeeze out the resin liquid permeated into the cloth with a roller as in the prior art. Is unlikely to occur. Therefore,
Even if the cloth is used for the surface design, the commercial value does not decrease.

[0016]

DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below with reference to preferred embodiments.

FIG. 1 is a schematic sectional view of a tray which is a resin molded product of the present embodiment. In the figure, (1) is a substrate made of a thermosetting resin and has a tray shape. (2) is a decorative layer disposed on the upper surface of the substrate (1),
The cloth (3) is sealed in a transparent thermosetting resin.

Since the base (1) and the decorative layer (2) are mutually melted at the boundary, the boundary is not always clear.

The cloth (3) is familiar to curved surfaces and edges, and has no wrinkles or overlaps. Moreover, there is no unnatural elongation of the pattern, and the design is high.

Further, since the cloth (3) is also adhered to the surface of the edge, the strength is improved by this, and breakage such as chipping of the edge hardly occurs even when dropped.

Next, the manufacturing process of the tray of this embodiment will be described.

Prepare an eye cloth slightly larger than the size of the tray. At this time, the cloth is selected in consideration of the fact that the pattern of the cloth becomes the pattern on the surface of the tray as it is. As a material of the cloth, cotton, cotton, or the like is suitable, but cloth of another material may be used. However, cloths made of synthetic fibers that are vulnerable to heat are not suitable.

A sieve containing a thermosetting resin powder such as a melamine resin or a urea resin is shaken above the cloth so that the resin powder is dropped on the cloth and coated.
The resin powder used at this time is a thermosetting resin powder that becomes transparent when cured.

If the resin powder is merely shaken and dropped, only the resin powder is placed on the upper surface of the cloth. Therefore, the cloth is tapped lightly many times to allow the resin powder placed on the cloth to enter the cloth. . In the embodiment, the work is performed by tapping with a hand, but the work may be performed more efficiently by using a vibration device or the like.

Next, the cloth is turned upside down, the lower side is turned up, and the resin powder is sprinkled in the same manner as before, and the cloth is beaten so that the resin powder enters the inside of the cloth. If necessary, such an operation is repeated a plurality of times so that a substantially constant amount of resin powder is carried on each part of the cloth. Specifically, attach at least 1.5 to 2 g to a 10 cm square cloth,
In particular, it is desirable that the thicker the cloth, the more it is carried.

In this embodiment, the resin powder is applied so as to be sprayed. However, the resin powder may be applied to the cloth by using compressed air so as to be pressed into the cloth.

Since the resin powder before curing is white, when the resin powder is sufficiently carried on both sides of the cloth and on the cloth by this operation, the both sides of the cloth are coated with the resin powder and become completely white, and the pattern is almost invisible.

In the case where the cloth has a pattern whose orientation is problematic, such as a stripe pattern, a mark such as a staple or a clip is attached to a predetermined position near the edge of the cloth in advance, and the cloth is placed on the substrate in a later step. Positioning work can be easily performed when placing, and the orientation of the picture can be prevented from shifting.

If temperature and humidity are applied after a sufficient amount of the resin powder has been carried, the resin powder becomes sticky and hardly falls off the cloth. In the example, it was lightly humidified by spraying and stored for about 15 minutes in a closed container at a temperature of about 30 ° C.

Thereafter, when the resin is taken out of the closed container and dried for about one day by natural drying, the resin on the surface is slightly hardened, and the handling becomes easy. For this reason, the cloth supporting the resin powder can be stacked and stored.

On the other hand, the substrate (1) is formed in a tray shape separately from the cloth (3). In this embodiment, a thermosetting resin, such as a melamine resin or a urea resin, which has been semi-cured by a preheater into a clay state, is placed on a tray-shaped mold and heated and pressed to form a tray shape.

Thereafter, the mold is opened, the cloth supporting the resin powder is placed on the substrate, the mold is closed again, and hot pressing is performed. The temperature of the mold differs depending on the type of the resin. When a melamine resin is used, about 170 to 175 ° C. is used, and when a urea resin is used, about 150 to 160 ° C. is suitable.

At this time, if a strong pressure is suddenly applied, the cloth expands and contracts. Therefore, the pressure of the press is gently applied. In this embodiment, pressing was performed at a pressure of 10 to 20 kg / cm ² for 3 seconds. After a lapse of 3 seconds, the mold is slightly opened, and gas is released from the gap. Incidentally, this gas is mainly formalin gas generated from resin.

At this stage, the resin on the surface of the cloth is hardened to some extent and stops flowing, so that the cloth is hardly stretched by the flow of the resin.

When 1.5 seconds have elapsed after the start of degassing, the pressure of the press is increased again and maintained at 50 kg / cm ² for 3 seconds. Thereafter, the press pressure is increased and finally raised to about 200 kg / cm ² and held. The holding time depends on the thickness of the cloth,
About 60 to 70 seconds was preferable for a thin cloth, and about 80 to 100 was preferable for a thick cloth.

As a result, the thermosetting resin constituting the base (1) and the thermosetting resin carried on the cloth (3) are melted near the boundary between them, and the two are integrated. And cloth (3)
The thermosetting resin carried on the resin is cured to form a transparent resin layer, and the pattern of the cloth (3) can be seen through the surface of the resin molded product. That is, the cloth (3) is in a state where it is sandwiched between the transparent resin layers from both sides and sealed.

After the elapse of a predetermined time, the mold is opened and the tray is taken out. If the whole is warped or distorted, a slight force is applied before the tray cools down to correct the shape.

Since the cloth is slightly larger than the substrate, the cloth protrudes from the edge of the tray. Therefore, the protruding cloth is roughly cut off with scissors, and is finally shaved off by a polishing means such as a grinder so that the cloth does not protrude from the edge of the base.

In the tray thus formed, the fabric is well adapted to curved portions and edges, and the design is high without any unnatural distortion of the picture.

In the present invention, thick cloth such as curtain cloth, denim, canvas and the like can be used as cloth. or,
Flags, furoshiki, curtains, fukusa, handkerchiefs, parts of Japanese and Western clothes, etc. can be processed to produce resin molded products that utilize these patterns as they are.

Although the above embodiment has been described by taking a tray as an example of a resin molded product, the present invention is not limited to a tray and can be widely applied to a resin molded product. For example, stationery, tableware, furniture, It can be applied to toys, furniture, building interiors, equipment exteriors, and the like.

[0042]

As described above, according to the present invention, it is possible to provide a high-strength resin molded product using a cloth as a surface design.

[Brief description of the drawings]

FIG. 1 is a schematic sectional view of an embodiment of the present embodiment.

[Explanation of symbols]

 (1) Base (2) Decorative layer (3) Cloth

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) // B29K 101: 10 105: 08 F term (Reference) 4F100 AK01A AK01B BA02 BA10A BA10B BA15 DG11B DH02B EC052 EG002 EH761 EJ201 EJ202 EJ421 EJ422 GB08 GB16 GB23 GB71 GB81 HB00B JB13A JB13B JL16 JN01B 4F204 AA36 AD16 AF00 AG03 AH48 AH53 AH55 AH56 FA01 FB01 FB13 FB19 FB23 FB24 FF06 FF51 FG09 FH06 FN17

Claims (2)

[Claims] 1. A substrate comprising a thermosetting resin and a decorative layer laminated on the surface of the substrate, wherein the decorative layer is a layer in which a cloth is sealed in a transparent thermosetting resin, A cloth-bonded resin molded product, wherein the base and the decorative layer are fused to each other at a boundary portion. 2. A resin-carrying cloth in which thermosetting resin powder that becomes transparent when cured is supported on both sides of the cloth and on the cloth is prepared in advance, and the thermosetting resin is placed on a mold and hot-pressed. The base is molded, the mold is opened, the resin-carrying cloth is placed on the base, and the thermosetting resin on the surface of the resin-carrying cloth is prevented from flowing out by once hot-pressing with a low press pressure. And then heat-pressing while increasing the press pressure to integrate the base and the resin-carrying cloth, and then removing the resin-carrying cloth protruding from the base, producing a cloth-bonded resin molded article. Method.