JP2002059452A - Method for manufacturing synthetic resin molding - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a synthetic resin molding solving various problems occurring on a surface of the molding, not bringing about a defective product even by adhering a dust or the like to a surface of a mold, having excellent working environment at a molding time, small defective ratio at a production time, a difficulty in adhesion of a dirt, easy removal of the dirt and further a long useful life. SOLUTION: The method for manufacturing the synthetic resin molding comprises the steps of laminating a protective film softer than that of a resin sheet to become a surface material of the molding on the sheet via an adhesive material layer to form a laminated material, setting the laminated material to a predetermined position in a mold to mold the molding with the protective film set toward a mold surface, then filling the synthetic resin in the mold to integrally contact the sheet with the filled resin, and thereafter releasing he protective film.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

TECHNICAL FIELD The present invention relates to a bathtub, a sink,
The present invention relates to a method for producing a synthetic resin molded body such as a wall, a floor, a ceiling, and a door.

[0002]

2. Description of the Related Art A door in a system kitchen in which a PET mirror film is stuck on the surface will be described as an example.
Usually, the decorated PET mirror surface film and the plywood are bonded and manufactured by press working or laminating.

[0003] In the above-mentioned production method, when dirt or the like adheres to the mold surface or the film design surface in the above-mentioned production method, the dust directly digs into the surface of the molded product, not only roughening the so-called mirror surface of the molded product surface but also forming distortion. Was to be brought. For this reason, the molding operation is performed in a clean room, but the molding process becomes complicated, which inevitably leads to an increase in cost.

[0004]

SUMMARY OF THE INVENTION The present invention has been made in view of the above-mentioned prior art, and is intended to solve various problems that occur on the surface of a molded article. No defective products are produced even if they adhere, and the working environment at the time of molding is excellent, there is little occurrence of rejection during production, it is difficult for dirt to adhere and it is easy to remove, and it is made of synthetic resin with a long service life An object of the present invention is to provide a method for producing a molded article.

[0005]

Means for Solving the Problems The basic invention of the present invention is to laminate a protective film softer than a resin sheet (film, plate, etc.) with an adhesive layer on a resin sheet (film, plate, etc.) as a surface material of a synthetic resin molded article. Forming a material, setting the protective film at a predetermined position in a mold for molding the laminated material into a synthetic resin molded body, facing the mold surface, and then filling the mold with a synthetic resin to form a resin sheet. The present invention relates to a method for producing a synthetic resin molded article, which comprises contacting and integrating a filled synthetic resin, and then peeling off a protective film. The method of molding the synthetic resin molded article is a method of producing a synthetic resin molded article that is vacuum molding, injection compression molding, press molding, or injection molding.

A second aspect of the present invention relates to an injection compression molding method, in which a transparent resin sheet (film, plate, etc.) serving as a surface material of a synthetic resin molded article is provided with a protective film softer than the transparent resin sheet as an adhesive layer. To form a laminated material, set the protective film surface of the laminated material toward the mold surface of an injection compression molding machine for forming a synthetic resin molded body, and inject the thermoplastic resin heated and melted into the mold. The thermoplastic resin is compressed while contacting the transparent resin film with the thermoplastic resin, the transparent resin film and the thermoplastic resin are bonded and integrated, and then the protective film is peeled off.

[0007]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be further described based on the second invention by a method using an injection compression molding method for heating and melting a thermoplastic resin, wherein a transparent resin serving as a surface material is formed on the thermoplastic resin. The film is molded integrally, and the surface material is damaged by dust etc. during molding,
It is devised so that molding distortion does not occur, preferably by improving the adhesiveness between the transparent resin film and the thermoplastic resin to prevent poor adhesion and peeling between the resins. For this reason, it is characterized in that the occurrence rate of defective products is extremely reduced.

[0008] Characteristically, a protective film is provided on the surface of the transparent resin film with an adhesive layer, and more preferably,
The backing film is laminated on the transparent resin sheet, the protective film protects the transparent resin film from dust etc. existing in the mold at the time of molding, and the backing film is between the thermoplastic resin to be injection-compressed and molded. This contributes to bonding and integration. In addition, even in the molding operation, there is almost no manual production process of the operator, and the molding operation is mainly performed in the molding die. Therefore, the working environment and the safety and health are excellent.

In the (transparent) resin film used as a surface material of the synthetic resin molded article used in the present invention, for example, acrylic resin, PET resin, AS resin, PVC resin, PP resin, PE resin, ABS resin, PS resin A film selected from resins is used. Among them, an acrylic resin film or a PET resin film is suitably used, and the thickness thereof is not particularly limited, and is preferably about 5 μm to 20 mm.

The acrylic resin film is a material having a glossy and soft feeling, and is characterized by being resistant to dirt and scratching, and is also advantageous in terms of repair.
It is an excellent surface material. It is to be noted that it is possible to use the composition as it is with a transparent feeling, but it may be a composition containing a coloring agent such as a pigment or an inorganic mineral selected as necessary. Also, it is possible to improve the design by applying a pattern on the back side of the acrylic resin film, for example, with an acrylic paint. The thickness of the transparent resin film constituting the surface material is appropriately selected. The acrylic resin film is, for example, a cast film made of an acrylic resin of polymethyl methacrylate, and is used even if it is not cross-linked.However, a partially cross-linked acrylic resin film has excellent surface hardness and chemical resistance, and It has excellent properties during molding and is preferably used in the present invention.

As a surface material, a PET resin film is also preferably used, which is obtained by condensation polymerization of dimethyl terephthalate and ethylene glycol, and has excellent mechanical strength and excellent abrasion resistance. It is.

The protective film to be laminated on these transparent resin films is preferably a film that is more flexible than the transparent resin film, whereby it easily deforms dust and the like in the mold and surrounds it. It is because. A typical example of the protective film is a PE resin, but it goes without saying that PP, PVC, and the like are also used. It is preferable that the protective film is coated with an adhesive layer such as an olefin polymer or a tackifier in advance, and is provided for lamination with a transparent resin film.

[0013] As the backing resin film, it is preferable to select a resin which is highly fusible with the resin to be injection-compressed.
The same type of resin as the resin to be subjected to injection compression molding is preferable.

Such a laminated material is usually used as a surface material of a synthetic resin molded product which is usually obtained by vacuum forming, and is formed so that the protective film side becomes the surface. . In addition, the vacuum forming method using a female mold is preferable because a molded product having a smooth surface is obtained. Of course, it is a matter of course that an unshaped flat plate can be used as the surface material.

The thermoplastic resin (used for injection compression molding) is not particularly limited as long as it can be fused with a surface material (or a backing film), and typical examples of such a thermoplastic resin include: For example, acrylic resin, PET resin, AS resin, PVC resin, PP resin,
It is selected from PE resin, ABS resin, PS resin and the like. A decorating treatment can also be performed by blending a coloring agent, an inorganic filler or the like with such a thermoplastic resin. Needless to say, it is preferable that the resin is the same as the resin constituting the surface material, and both can be thermally welded. If different materials are used, an adhesive or the like may be interposed. In the first invention, it goes without saying that a thermosetting resin can also be used, and for example, a polyester resin, an epoxy resin, a urea resin, a melamine resin, or the like is used. Those reinforced with glass fibers are preferred.

Since the thermoplastic resin undergoes an injection step and a compression step in a molding die, the melt flow rate is an important factor, and the melt flow rate is 2 or more, preferably 5 or more, more preferably 15 or more. Is good.

Above all, an ABS resin having good adhesion to the surface material, excellent impact resistance, and high rigidity in a high temperature range is particularly preferable. Needless to say, various additives can be added to the thermoplastic resin in addition to the coloring agent described above. Glass fiber, talc, inorganic fillers such as mica, flame retardants, silver complex antibacterial agents and the like.
There are fungicides, foaming agents such as azodicarbonamine, and the like.
In addition, it is preferable to add glass fiber because it becomes excellent in rigidity.

The above-mentioned thermoplastic resin is heated and melted in advance, and the pressure at the time of injecting it into the mold is set as small as possible in order to avoid a large projected area of the mold and damage to the surface material. It is preferable to perform injection molding at a low pressure, and it is about 50 to 150 kg / cm ² .

Then, the thermoplastic resin which has been heated and melted is injected into the mold, and then (or simultaneously) starts compression. The resin is compressed by the mold with the surface material set. With this, the resin is spread to every corner of the mold and is brought into complete contact with the set surface material, where the two are integrated. The injection molding machine to be used may be either a vertical type or a horizontal type, but it is preferable to use a vertical type, that is, a structure in which the molding die is relatively opened and closed in the vertical direction.

In order to further enhance the bonding effect between the two, it is natural that an adhesive is used as appropriate. For example, there is a method of applying a two-part urethane-based adhesive as an example of the adhesive. However, the adhesive is appropriately selected depending on the properties of both resins.

In the injection compression molding method, a molten resin is supplied through a gate into a cavity formed by a plurality of molding dies opposed to each other, and the molded body is formed by moving the mold, pressurizing and cooling. How to get. Since the resin has a low shear stress at the time of shaping and can be cooled with a substantially uniform pressure after shaping, it has the characteristics that the residual strain is small and the deformation is small. On the other hand, according to the conventional method, the shearing rate of the resin is increased, so that the residual strain at the time of molding is large, and the deformation after molding is correspondingly large.

[0022]

The present invention will be described in more detail with reference to a second preferred embodiment of the present invention. As a specific example, a molding example of a door of a system kitchen will be described. The PET resin film 1 used has a thickness of 100 μm. Then, a PE resin film (thickness: 100 μ) was used as the protective film 2 for the film 1, and an adhesive containing an olefin-based polymer was used as the adhesive layer 3 on the surface of the PE resin film. Further, a urethane adhesive layer 4 is applied to the back surface of the PET resin film 1 to form a backing resin film 5.
Used was an ABS resin film (thickness: 100 μ).
These were guided to a pair of rolls 6 as shown in FIG.

In the case of the present invention, since a door having a relatively flat shape is taken as an example, it is not necessary to shape the laminate 10 in advance, but a molded article having a relatively uneven surface such as a bathtub is obtained. In this case, as shown in FIG. 2, it is preferable to shape the formed body (that is, the inner surface shape) by a vacuum forming machine. That is, the laminating material 10 is vacuum-molded (female mold) 20.
Set in a vacuum forming machine having
Thereafter, it is preferable to obtain a surface material (laminated material) 10 having the inner shape of the molded body by vacuum evacuation.

Next, a vertical injection compression molding machine (3000)
The above surface material (laminated material) 10 is set in a male mold 30 of a ton press, and colored alumina oxide is filled therein, and granite-processed ABS resin 40 is placed in a mold 25.
The resin 40 was melt-injected at 0 ° C., and then the resin 40 was compressed by the male mold 30 and cooled to obtain a door provided with the ABS resin layer 40 using the PET resin film 1 as the surface material.

FIG. 3 is a conceptual view showing the injection / compression step. The obtained laminated material 1 is set so as to be in contact with the surface of the movable die (convex side) 30 of the injection molding die. With the laminated material 1 set, the mold 30 is moved in the closing direction of the mold, that is, toward the lower side, and the female mold (fixed mold) 31
And the movable mold 30 are closed.

After the molds 30 and 31 are closed, the thermoplastic resin 40 heated and melted in advance is injected from the gate 32 into the mold surrounded by the laminate 1 and the fixed mold 31. The heated and melted thermoplastic resin 40 is transferred to a gate 32.
It is preferable to perform injection molding at a pressure as low as possible.
g / cm ² . The melt flow rate is 20
Met.

Then, the thermoplastic resin 40 in the molding die is
The male mold 30 with the laminated material 1 set therein is slid and compressed to fill the mold with the thermoplastic resin 40 and contact the laminated material 1 to be integrated. Next, the mold is cooled, the molded product is cooled, and the mold is opened, whereby a door whose outer surface is reinforced with a transparent PET resin film 1 and whose back surface is decorated with a thermoplastic resin 40 is obtained. Was.

If dust or the like adheres to the surface of the molding die 30 at the time of such molding, the PET resin film 1 comes into direct contact with the surface if there is no ordinary (protective film). However, in the case of the present invention, the molded body can be obtained in a state in which the surface PET resin 1 does not come into contact with and is absorbed by the protective film 2 which is a softer resin, so that the door has few defects. If the size of the dust is about 30% of the thickness of the protective film 2, the dust can be absorbed.

[0029]

According to the method of the present invention for producing a molded article made of synthetic resin, the occurrence of defects in the production process is reduced, and the work environment such as spraying of FRP is not required as in the prior art. Also, the synthetic resin molded article of the present invention uses a thermoplastic resin as the outer reinforcing layer instead of the conventionally used FRP, so that it has excellent heat retention properties, and furthermore, the resin on the surface material side and the thermoplastic resin are used. Difference in thermal expansion coefficient with
Durability is also improved.

[Brief description of the drawings]

FIG. 1 is an explanatory view showing one embodiment of a method for producing a laminate material of the present invention.

FIG. 2 is an explanatory view showing an outline of a vacuum forming machine when forming a laminate.

FIG. 3 is an explanatory view showing one embodiment of a method for producing a synthetic resin molded article of the present invention.

[Explanation of symbols]

 1) PET resin film (surface material), 2) protective film, 3) adhesive layer, 4) adhesive layer, 5) backing resin film, 6) roll, 10) laminate material, 20) vacuum forming mold (female mold) , 30 ‥ male side mold (moving side mold) of injection compression molding machine, 31 ‥ female side mold (fixed side mold), 32 ‥ gate of injection molding machine, 40 ‥ ABS resin.

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) // B29K 25:00 B29K 25:00 B29L 9:00 B29L 9:00 F term (Reference) 4F100 AK03G AK04B AK07B AK12B AK15B AK25B AK27B AK42B AK51G AK74B AL01B AT00A BA02 CB05 EH362 EJ202 EJ242 EJ303 EJ422 EJ911 EJ933 EJ952 GB08 JL00 JL02 JL06 4F204 AA04 AA11 AA13 AA15 AA21 AA24 AD08 AG03 AH48 AH49 FA01 FA15 FB01 FB12 FB24 FF01 FF50 FG02 FJ29 FN06 FN20 FQ38 4F206 AA04 AA11 AA13 AA15 AA21 AA24 AD08 AG03 AH48 AH49 JA02 JA03 JB02 JB12 JB24 JF05 JW50 4F208 AA04 AA11 AA13 AA15 AA21 AA24 AD08 AG03 AH48 AH49 MA01 MB01 MB11 MB22 MC03 MG04 MH06 MH17 MJ05 MJ13

Claims (10)

[Claims] 1. A laminating material is formed by laminating a softer protective film with a pressure-sensitive adhesive layer on a resin sheet to be a surface material of a synthetic resin molded body, and forming the laminated material into a synthetic resin molded body. Setting a protective film at a predetermined position in the mold toward the mold surface, then filling the mold with a synthetic resin, contacting and integrating the resin sheet and the filled synthetic resin, and then peeling off the protective film. A method for producing a synthetic resin molded article, characterized by the following. 2. The method for producing a synthetic resin molded product according to claim 1, wherein the molding die of the synthetic resin molded product is a vacuum molding die, an injection compression molding die, a press molding die, or an injection molding die. 3. A laminated material is formed by laminating a protective film softer than an adhesive layer on a transparent resin film to be a surface material of a synthetic resin molded body, and forming a protective film surface of the laminated material on the synthetic resin. Set towards the mold surface of the injection compression molding machine to form the body, inject the thermoplastic resin heated and melted into the mold, compress the thermoplastic resin while contacting the transparent resin film and the thermoplastic resin, The transparent resin film and the thermoplastic resin are bonded and integrated,
Thereafter, the protective film is peeled off. 4. The method according to claim 3, wherein a backing resin film is laminated on the transparent resin film. 5. The method for producing a synthetic resin molded article according to claim 1, wherein the laminated material is shaped as a surface side of a molded article. 6. The method for producing a synthetic resin article according to claim 1, wherein the protective film is a PE resin. 7. The resin film is made of an acrylic resin or PET.
Resin, AS resin, PVC resin, PP resin, PE resin, A
The method for producing a synthetic resin molded article according to claim 1, wherein the film is a film selected from a BS resin and a PS resin. 8. The thermoplastic resin forming the backing resin film may be an acrylic resin, a PET resin, an AS resin, or a PVC.
The method according to claim 4, wherein the resin is a resin selected from the group consisting of a resin, a PP resin, a PE resin, an ABS resin, and a PS resin. 9. A thermoplastic resin having a melt flow rate,
4. The method for producing a synthetic resin molded article according to claim 1, wherein the number is 2 or more. 10. The method for producing a synthetic resin molded article according to claim 1, wherein injection and compression of the thermoplastic resin are performed simultaneously.