JP2001347607A - Molding with pattern and its manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a molding with a pattern having a natural material feeling with a depth feeling and a method for manufacturing the same. SOLUTION: A flat plate-like natural wood having a woodgrain pattern is laminated on a rear surface of a transparent molding molded in a product shape from a transparent or translucent thermoplastic resin sheet. Crushed stone-like particles are fixedly and laminated on a rear surface of the transparent or translucent thermoplastic resin sheet with a transparent or translucent adhesive resin.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a patterned molded article having a decorative surface imitating a surface pattern of a natural material such as a woodgrain pattern or a stone pattern, and a method for producing the same.

[0002]

2. Description of the Related Art In general, a patterned molded body having a decorative surface using a natural material such as a woodgrain or stone-grain pattern as a surface pattern is known.

Conventionally, as this type of patterned molded body, it has been known to use natural wood as it is for bathtubs and bathroom wall panels. In this case, there is a problem in that natural wood is complicated to clean due to problems such as rot or mold generation due to water absorption or moisture, and cannot be used for a long time. It is also known to use a decorative sheet obtained by bonding crushed stone with a binder resin (adhesive) to a floor in a washing place. Also in this case, there is a problem in that a minute gap is generated between the crushed stone and the binder resin due to use for a long time, and dust and dirt are easily accumulated.

[0004] As another patterned molded body, a molded article imitating a stone-grain pattern or the like described in Japanese Patent Application Laid-Open No. 4-2639452 is known. The same publication discloses a patterned molded body in which a plurality of paints made of an epoxy acrylate resin are sprayed on the back surface of a transparent acrylic resin sheet to form a pattern layer, and then an FRP reinforcing layer is formed on the coating film surface. ing.

However, in the acrylic resin molded article described in Japanese Patent Application Laid-Open No. 4-2639452, a coating film of a plurality of colors (gel coat) is sprayed on the back surface of the transparent acrylic resin sheet to form a coating layer. The resulting patterned molded product has a sense of depth due to the presence of the transparent acrylic resin sheet layer, and a highly designed molded product can be obtained. There was a problem that can not respond to.

[0005] In view of such circumstances, an object of the present invention is to provide a patterned molded body having a sense of depth and a natural material feeling, and a method for producing the same.

[0006]

In order to achieve such an object, a patterned molded article according to the invention of claim 1 (hereinafter referred to as a "patterned molded article of claim 1") is provided.
A flat natural tree having a woodgrain pattern is laminated on the back surface of a transparent molded body formed into a product shape from a transparent or translucent thermoplastic resin sheet.

[0007] The patterned molded article according to the second aspect of the present invention (hereinafter referred to as "patterned molded article of the second aspect")
Is characterized in that a flat or natural wood having a wood grain pattern is laminated on the back surface of a transparent or translucent thermoplastic resin sheet.

[0008] The molded article with a pattern according to the third aspect of the invention (hereinafter referred to as the "molded article with a pattern of claim 3")
The wood pattern is partially printed on the back surface of the transparent or translucent thermoplastic resin sheet, and a flat natural wood having a wood pattern is laminated on the printed resin sheet surface. Things.

The patterned molded article according to the invention of claim 4 (hereinafter referred to as “patterned molded article of claim 4”)
Is characterized in that crushed stones are fixed on the back surface of a transparent or translucent thermoplastic resin sheet with a transparent or translucent adhesive resin and laminated.

The method for producing a patterned molded article according to the invention of claim 5 (hereinafter referred to as “the method for producing a patterned molded article of claim 5”) is a method for producing a transparent or translucent thermoplastic resin sheet. Applying a transparent or translucent adhesive resin on the back side, then spraying crushed stones, pressing the crushed stones with a perforated reinforcing plate and embedding it in the coating layer to laminate the reinforcing plate It is characterized by the following.

The method for producing a patterned molded article according to the invention of claim 6 (hereinafter referred to as “the method for producing a patterned molded article of claim 6”) is a method for producing a transparent or translucent thermoplastic resin sheet. On the back surface, a mixture of a crushed stone and a transparent or translucent adhesive resin is applied, and a perforated reinforcing plate is pressed on the coating layer to be laminated.

In the patterned molded article and the method for producing the same according to the present invention, the transparent or translucent thermoplastic resin sheet is made of a thermoplastic resin such as methyl methacrylate resin (acrylic resin), polycarbonate, polyvinyl chloride, polystyrene or the like. Can be used. In particular,
It is preferable that the acrylic resin is formed into a sheet or film sheet by a molding method such as extrusion molding.

The thickness of the transparent or translucent thermoplastic resin sheet is suitably 0.05 to 1.0 mm when used as a film sheet, but is 1.0 to 1.0 mm when used as a flat sheet. 10 mm is appropriate, and preferably 2.0 to 7.0 mm. When it is used as a flat sheet, if it is less than 1.0 mm, sufficient strength cannot be obtained, and if it exceeds 10 mm, heat transfer during molding heating is not sufficient, resulting in molding failure. Usually, when deep drawing is performed like a bathtub, a sheet having a thickness of 3.0 to 6.0 mm is appropriate.

The patterned molded article according to any one of claims 1 to 3,
The flat natural wood is made by cutting the raw material wood into a flat plate. The types of wood include domestic conifers such as cedar, cypress, pine, etc. ,
Domestic hardwood such as paulownia and foreign hardwood such as walnut, teak, karin, lauan etc. are used. 2.5 to 30 mm thick flat plate cut into
Thickness 3.0 to 10 in which the grain direction is perpendicular to each layer
mm plywood (plywood).

[0015] In the patterned molded article and the production method according to claims 4 to 6, the crushed stone-like particles may be natural stone, glass,
Pulverized materials such as synthetic resins and colored mica can be used.
The particle size of the crushed stone is usually 0.3 to 10 mm, but preferably 0.5 to 7 mm. 2.0mm
If the particle size exceeds, the adhesive resin may be applied to the thermoplastic resin sheet and then the crushed particles may be sprayed on the application surface. After mixing with the adhesive resin, the mixture may be applied to a thermoplastic resin sheet.

In the patterned molded article and the production method according to claims 4 to 6, the transparent or translucent adhesive resin may be an unsaturated polyester, vinyl ester, epoxy,
A thermosetting resin such as urethane, silicon, and phenol is used.

[0017]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The embodiments of the present invention will be described below in detail with reference to the drawings.

FIG. 1 is a schematic sectional view of a laminated structure of a bath tub for explaining a first embodiment of a patterned molded article according to the present invention.

In the figure, as a shape of the transparent molded body 1, a thermoplastic resin sheet 10 was heated and vacuum-formed using a bathtub type to form a bathtub shape. As the thermoplastic resin sheet 10, a 5.0 mm thick transparent acrylic resin sheet (Kuraray Co., Ltd., trade name: Kuralex) is used. A transparent adhesive resin 2 is applied to the back side of the transparent molded body 1, and as a flat natural wood 3, a decorative veneer (cypress veneer) 31 having a thickness of 0.5 mm and a cypress flat plate 32 having a thickness of 10 mm are provided.
Is affixed. As the adhesive resin 2, a transparent thermosetting adhesive such as a resorcinol resin or an epoxy resin is used, and a thermoplastic adhesive such as a vinyl acetate resin or an acrylic resin, a neoprene (registered trademark) rubber, a nitrile rubber, or the like is used. It may be an elastomer adhesive. Reference numeral 4 denotes a heat insulating and heat retaining layer to which a foamable urethane resin is sprayed and applied.

A method for producing a patterned molded body in this embodiment will be described. First, the thermoplastic resin sheet 10 is heated and then vacuum-formed using a bathtub mold to obtain a bathtub-shaped transparent molded body 1. Next, using a brush on the back side of the transparent molded body 1, a transparent thermosetting adhesive is used as the adhesive resin 2 for 10 minutes.
２５０250 g / m ² , and then veneer veneer 3
1 and the flat plate 32 are arranged by hand, lightly pressed with a pressing roller, and attached. Subsequently, the adhesive 2 is conveyed into a drying furnace whose temperature is controlled within a range of 40 to 180 ° C. to cure the adhesive 2. Finally, a reinforcing plywood, a pedestal, and the like are attached to the back side of the transparent molded body 1, and then a foamable urethane resin having a foaming ratio of 5.0 times is sprayed to form the heat insulating and heat retaining layer 4.

The bathtub-shaped patterned molded body obtained as described above can be seen because the natural wood 3 on which the decorative veneer 31 and the flat plate 32 are arranged can be seen through the transparent thermoplastic resin sheet 10. Wood pattern can be formed on the surface of natural wood.

FIG. 2 is a schematic sectional view of a laminated structure of a wall panel for explaining a second embodiment of a patterned molded body according to the present invention.
In the figure, as the shape of the transparent molded body 1A, a thermoplastic resin sheet 10a cut into a size of a flat wall panel was used. The thermoplastic resin sheet 10a is a transparent acrylic resin sheet having a thickness of 2.0 mm (Kuraray Co., Ltd.
(Product name: CLAREX) is used. A transparent adhesive resin 2a is applied to the back side of the transparent molded body 1A, and a decorative veneer (cypress veneer) having a thickness of 0.5 mm is attached as a flat natural wood 3a. Reference numeral 4a denotes a heat insulating and heat insulating layer to which a foamable urethane resin is sprayed and applied.

Next, a method of manufacturing a patterned molded body in the second embodiment will be described. First, the thermoplastic resin sheet 10
a is the size of the wall panel width 600 mm, length 195
It is cut to 0 mm to obtain a transparent molded body 1A. Next, using a roll coater on the rear surface side of the transparent molded body 1A, a transparent thermosetting adhesive is used as the adhesive resin 2a for 10 to 150 minutes.
g / m ² , and then a flat natural wood 3a
Are arranged by hand, and 0.5 to 3.0 MPa by a press having a hot plate whose temperature is adjusted within a range of 50 to 180 ° C.
The adhesive resin 2a is cured by press molding at a molding pressure of a. Lastly, a foamable urethane resin having a foaming ratio of 5.0 times is sprayed to form the heat insulating and heat retaining layer 4.

The patterned molded body obtained as described above can be used as a wall panel of a bathroom unit, a washroom, a toilet room, etc., and the natural wood 3a is a transparent thermoplastic resin sheet 1.
Since it can be seen through 0a, a grain pattern of the natural tree 3a can be formed on the surface of the molded body.

FIG. 3 is an exploded perspective view of a laminated structure of a wall panel for explaining a third embodiment of a patterned molded body according to the present invention.

In the figure, as the transparent molded body 1B, one obtained by printing a wood grain pattern 5 on the back surface of a thermoplastic resin film sheet 10b at intervals is used. As the thermoplastic resin film sheet 10b, a transparent acrylic resin film having a thickness of 0.1 mm is used. The wood pattern 5 is formed by sequentially printing three types of pattern inks 5a, 5b, and 5c on the back surface of the thermoplastic resin film sheet 10b by gravure printing. At this time, a transparent portion 50 that is not printed is formed between the grain patterns 5 of the cypress.

As the flat natural wood 3b, cedar plywood having a thickness of 8.0 mm and having a grain direction perpendicular to each other was used.

Next, a method of manufacturing a patterned molded body in the third embodiment will be described. First, using a roll coater on the surface side of cedar plywood, which is a flat natural wood 3b, a transparent thermosetting adhesive as an adhesive resin 2b is used in an amount of 10 to 200 g /.
from application of the coating amount m ^2, wood 3 cedar plywood thermoplastic resin film sheet 10b which grain pattern 5 of cypress are printed
Affixed so that it is in the same direction as the direction of 0,
The thermosetting adhesive is cured by press molding at a molding pressure of 0.5 to 3.0 MPa with a press having a hot plate adjusted to a temperature of 180 ° C.

The patterned molded body obtained as described above can be used as a wall panel of a bathroom unit, a washroom, a toilet room, or the like, and the wood pattern 30 of the cedar plywood is formed of the thermoplastic resin film sheet 10b. Cedar plywood grain 30 and cypress grain 5
Are combined to form a wood grain pattern.

FIG. 4 is a partially enlarged cross-sectional view schematically showing a laminated structure of a wall panel for explaining a patterned molded article according to a fourth embodiment of the present invention.

In the figure, the patterned molded body is used for a decorative panel of a wall panel. The crushed stone 6 is fixed to the back surface of the transparent molded body 1C with a transparent or translucent adhesive resin 2c. Laminated, and furthermore a perforated reinforcing plate 7
Are adhesively fixed. As the shape of the transparent molded body 1C, a thermoplastic resin sheet 10c cut into a size of a flat wall panel was used. In this embodiment, a 1.0 mm thick transparent acrylic resin sheet 10c is used as the thermoplastic resin sheet 10c. Further, as the crushed stones 6, crushed natural stone having an average particle size of 2.2 to 3.5 mm is used, and as the perforated reinforcing plate 7, a 9 mm thick plywood having a hole diameter of 5 mm is used as shown in FIG. The holes 71 were formed at intervals of 100 mm.

FIGS. 5 to 7 are schematic views of the manufacturing process for explaining a fourth embodiment of the patterned molded article of the present invention. First, the thermoplastic resin sheet 10c is set to the size 6
The transparent molded body 1C is obtained by cutting to a length of 00 mm and a length of 1950 mm. Next, as shown in FIG.
The transparent molded body 1 </ b> C is placed on the upper transport frame 20 with the back surface facing upward, and then supplied to the roll coater 22.

Subsequently, a transparent thermosetting adhesive was applied as an adhesive resin 2c to the back surface of the transparent molded body 1C using a roll coater 22 at an application amount of 200 to 350 g / m ² . As shown in FIG.
While rotating the rotating brush 25 from the hopper 24. At this time, the crushed stones 6 are dispersed on the surface of the thermosetting adhesive in the uncured state. Finally, as shown in FIG. 7, the plywood 7 is placed on the scattered surface of the crushed stone 6, and the weight 26 is placed on the plywood 7, and the temperature is 50 to 180.
The adhesive is conveyed into a drying oven controlled within a temperature range of ℃ to cure the adhesive. In this case, the applied layer of the thermosetting adhesive 2c pressed by the weight 26 is partially formed of the adhesive through the through hole 7 of the plywood 7.
1 and the adhesive is hardened, and the plywood 7 is firmly joined to the thermoplastic resin sheet 10c.

The patterned molded body obtained as described above can be used as a decorative board having a stone-grain pattern on a wall panel, a floor, or a washbasin of a bathroom unit, a washroom, a toilet room, or the like.

Although the embodiment of the present invention has been described in detail with reference to the drawings, the specific embodiment is not limited to this embodiment, and a design change or the like may be made without departing from the gist of the present invention. Even if present, it is included in the present invention.

For example, in the third embodiment, the woodgrain pattern 5 is formed by sequentially printing three kinds of pattern inks 5a, 5b, and 5c to form a wood grain of a cypress, but a part of the woodgrain pattern 5 may be used in combination with flip-flop ink or magnetic paint. Then, the shade of the pattern may be changed depending on the angle at which the pattern surface is viewed and the position of the light source.

In the fourth embodiment, the crushed stones 6 are sprayed from the hopper 24 of the sprayer 23 to the adhesive-applied surface while rotating the rotary brush 25. A mixture obtained by mixing the adhesive resin may be applied to the back surface of the thermoplastic resin sheet 10c.

[0038]

As described above, the patterned molded article according to any one of claims 1 to 3, which has a simple structure, has a sense of depth, and the grain and texture of the natural tree can be seen as a surface pattern as it is, and furthermore, a thermoplastic resin sheet. Since the surface is covered with water, it does not rot or mold due to water absorption or moisture, and has excellent durability. In the molded article with a pattern according to the fourth aspect, there is a sense of depth with a simple structure, a natural stone-grained pattern is obtained, and the surface is covered with a thermoplastic resin sheet. It is easy to clean because no fine gaps are formed between the resin and the binder resin (adhesive) to accumulate dust and dirt. Claims 5-6
In the method for producing a patterned molded body of (1), by pressing and laminating the perforated reinforcing plate, the adhesive resin infiltrates into the holes and is hardened, so that the thermoplastic resin sheet is hardened together with the crushed granules. , So that a product having excellent durability can be obtained.

[Brief description of the drawings]

FIG. 1 is a schematic sectional view of a lamination structure of a bathtub for explaining a first embodiment of a patterned molded article of the present invention.

FIG. 2 is a partially enlarged cross-sectional view schematically showing a laminated structure of a wall panel for explaining a second embodiment.

FIG. 3 is an exploded perspective view of a laminated structure of a wall panel similarly illustrating a third embodiment.

FIG. 4 is a partially enlarged cross-sectional view schematically showing a laminated structure of a wall panel for explaining a fourth embodiment.

FIG. 5 is a schematic diagram for explaining a step of applying an adhesive resin in a manufacturing method according to the fourth embodiment.

FIG. 6 is a schematic view illustrating a step of spraying crushed stones of the production method in the fourth embodiment.

FIG. 7 is a schematic view illustrating a step of stacking plywood in the manufacturing method according to the fourth embodiment.

FIG. 8 is a partially enlarged plan view showing a plywood used in the manufacturing method according to the fourth embodiment.

[Explanation of symbols]

 1, 1A, 1B, 1C Transparent molded body 10, 10b, 10c Thermoplastic resin sheet 2, 2a, 2b, 2c Adhesive resin 3, 3a, 3b Natural wood 30d, 30e Mixed color pattern sheet 5 Wood pattern 6 Crushed stone 7 perforated reinforcing plate

 ──────────────────────────────────────────────────続 き Continued on the front page F term (reference) 4F100 AC06B AC06H AK01A AP01B AR00C AT00A BA03 BA07 BA10A CB00B CB00G DE01B DE01H GB08 GB71 GB81 HB01B HB31A JB16A JL02 JL06 JL09 JN01A

Claims (6)

[Claims] 1. A pattern-forming molding characterized in that a flat natural wood having a wood grain pattern is laminated on the back surface of a transparent molded body molded into a product shape from a transparent or translucent thermoplastic resin sheet. body. 2. A patterned molded article comprising a transparent or translucent thermoplastic resin sheet and a flat natural wood having a grain pattern laminated on a back surface thereof. 3. A transparent or translucent thermoplastic resin sheet, in which a wood pattern is partially printed on the back surface, and a flat natural wood having a wood pattern is laminated on the printed resin sheet surface. Molded body with pattern. 4. A molded article with a pattern, characterized in that crushed granules are fixed on a back surface of a transparent or translucent thermoplastic resin sheet with a transparent or translucent adhesive resin and laminated. 5. A transparent or translucent thermoplastic resin sheet is coated with a transparent or translucent adhesive resin on the back surface thereof, and then crushed stone particles are sprayed, and the crushed stone particles are pressed by a perforated reinforcing plate. And embedding in a coating layer to laminate a reinforcing plate. 6. A mixture of crushed stones and a transparent or translucent adhesive resin is applied to the back surface of a transparent or translucent thermoplastic resin sheet, and a perforated reinforcing plate is pressed against the coating layer. A method for producing a patterned molded body, comprising: