JP2004034314A - Improved manufacturing method for patterned plastic molded product and molded product - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To further shorten/simplify a manufacturing process and to improve a manufacturing method for a patterned plastic molded product without largely remodeling conventional manufacturing equipment. <P>SOLUTION: The patterned plastic molded product is manufactured through a process (a) placing lumps of a transparent or translucent surface resin on the surface of a mold 11 in a stripe form and stretching the same to form a surface resin layer 1, a process (b) laminating a transparent resin sheet 2b having a pattern 2a applied to the single surface thereof on the surface resin layer 1 so that the pattern surface thereof is opposed to the mold surface, a process (c) for curing the surface resin layer 1, a process (d) for laminating an opaque color FRP layer 3 on a patterned transparent resin sheet 2, a process (e) for curing the resin of the opaque color FRP layer 3 and a process (j) for demolding the molded product from a mold 11. <P>COPYRIGHT: (C)2004,JPO

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to an improved method for producing a patterned plastic molded product used for a wall material of a luxury bathroom unit and the like, and a patterned plastic molded product.
[0002]
[Prior art]
Patterned plastic moldings with a glossy surface and a heavy marble-like pattern can be used, for example, as wall materials for construction materials "Mavelas" (registered trademark of Hitachi Chemical Co., Ltd.) as wall materials for luxury bathroom units. [0003] widely used
The present inventors have already disclosed a method for producing such a molded plastic molded article in Japanese Patent Application Laid-Open No. 62-97832 (Japanese Patent Publication No. 3-47183). The manufacturing method includes the following steps.
(A) A step of placing a transparent or translucent uncured surface resin in a lump on one end of a mold surface coated with a release agent.
(B) On one side of the base film, a transfer film patterned with ink that is acceptable to the surface resin is pressed from one end side of the mold surface by a roller to uniformly stretch the massive surface resin and simultaneously onto the surface resin. The step of polymerizing.
(C) a step of curing the stretched surface resin, peeling off the base film, and transferring a pattern onto the surface resin.
(D) a step of laminating a transparent resin layer on the surface resin to which the pattern has been transferred.
(E) a step of laminating a colored opaque resin after curing the transparent resin layer.
(F) a step of laminating and curing the resin reinforcing layer containing glass fibers after curing the colored opaque resin.
[0004]
[Problems to be solved by the invention]
In the above manufacturing method, the formation of the surface resin layer and the transfer of the pattern ink can be performed in one step. Also, by forming a transparent resin layer on the surface resin layer to which the pattern ink has been transferred (that is, on the background side of the pattern), the pattern appears to float three-dimensionally in the resin (the so-called high relief effect). Having. However, this manufacturing method is still complicated (particularly, the step of applying and curing a transparent resin layer on the surface resin layer to which the pattern ink has been transferred), and it takes a long time as a whole.
The present invention further shortens and simplifies the manufacturing process, and does not require significant modification of conventional manufacturing equipment. "Improved manufacturing method of patterned plastic molded article" and patterned plastic obtained by the manufacturing method. It is intended to provide a molded article.
[0005]
[Means for Solving the Problems]
To achieve the above object, the present invention has the following configuration. That is, the present invention is a “method of manufacturing a patterned plastic molded product” including the following steps (a) to (j).
(A) a step of placing a block of transparent or translucent surface resin (liquid) on the surface of the mold 11 in a streak shape (or in a strip zigzag), and then stretching the same to form the surface resin layer 1;
(B) a step of laminating a transparent resin sheet 2b (patterned transparent resin sheet 2) having a pattern 2a on one side thereof on the surface resin layer 1 so that the pattern surface faces the mold side;
(C) a step of curing the surface resin layer 1;
(D) laminating an opaque colored FRP layer 3 containing an opaque colored resin and a fibrous reinforcing material on the patterned transparent resin sheet 2;
(E) curing the resin of the opaque colored FRP layer 3;
(J) removing the mold from the mold 11;
The hardening of the surface resin, the resin in the FRP (fiber reinforced plastic) layer, or the resin in the resin concrete layer described below is performed by leaving the resin at room temperature or heating it to a temperature at which it hardens in a heating furnace. be able to. If a resin that is cured by irradiation with light such as ultraviolet rays is selected, the resin can be treated with light (ultraviolet rays).
[0006]
In the present invention, the formation of the surface resin layer 1 in the step (a) is preferably performed simultaneously with the lamination of the patterned transparent resin sheet 2 in the step (b) using a stretching means such as a roller or a bar. This is because both formation of the surface resin layer 1 and lamination of the patterned transparent resin sheet 2 can be performed in one step without involving air bubbles.
[0007]
Further, it is preferable that the following step is further included between the step (e) and the step (j).
(F) forming a resin concrete layer 4 on the opaque colored FRP layer 3;
(G) a step of curing the resin of the resin concrete layer 4;
(H) further laminating an FRP layer (outermost FRP layer) containing a resin and a fibrous reinforcing material;
(I) curing the resin of the outermost FRP layer 5;
Thereafter, the mold is removed, and the periphery of the molded product is removed by a cutting machine and trimmed to obtain a patterned plastic molded product.
[0008]
In addition, the back side (background) of the patterned transparent resin layer 2 has a three-layer structure of an opaque colored FRP layer 3, a resin concrete layer 4, and an outermost FRP layer (a structure in which the resin concrete layer is sandwiched between FRP layers in a sandwich manner from both sides). The reason for this is to satisfy the strength required with a small amount of molding material.
[0009]
One of the preferable substrates for the patterned transparent resin sheet 2 in the present invention is an acrylic resin sheet (a kind of thermoplastic resin sheet). The gravure printed acrylic resin sheet is available from Dai Nippon Printing Co., Ltd.
[0010]
One of the other preferable substrates for the patterned transparent resin sheet 2 is a thermosetting resin sheet. The thermosetting resin sheet printed on one side can be manufactured by the method disclosed in JP-A-6-134785.
[0011]
The transparent or translucent surface resin (liquid) used in the present invention is selected according to the type of the substrate of the patterned transparent resin sheet 2 to be used. When the base material of the transparent resin sheet 2 is an acrylic resin sheet, a low styrene vinyl ester resin (manufactured by Hitachi Chemical Co., Ltd.) is preferable. This is because it is transparent (or translucent) and has good compatibility with the acrylic resin sheet, and cracks (stress corrosion cracking of the resin) and wrinkles (swelling due to styrene in the resin) do not easily occur in the acrylic resin sheet.
When the base material of the transparent resin sheet 2 is a thermosetting resin sheet, the surface resin is selected from a transparent or translucent resin having good adhesion to the used thermosetting resin sheet. As such a resin, a resin obtained by appropriately mixing a curing agent or the like with a thermosetting resin such as an unsaturated polyester resin, an acrylic resin, or an epoxy resin is used. Among them, one of the preferable ones is an unsaturated polyester resin.
[0012]
The resin used in the opaque colored FRP layer 3, the resin concrete layer 4, or the outermost FRP layer 5 is not particularly limited. There is a thermosetting resin such as an unsaturated polyester resin, an acrylic resin, or an epoxy resin in which a curing agent or the like is appropriately mixed.
[0013]
In the opaque colored FRP layer 3, a colorant such as a pigment is mixed. The colored (colored) color is preferably white or black. This is for hiding the resin concrete layer 4 and for embossing the pattern of the pattern layer 2a.
Examples of the fibrous reinforcing material used include glass fibers such as glass mat, glass cloth, and glass paper.
[0014]
In the resin concrete layer 4, in addition to the resin serving as a binder, calcium carbonate, aluminum hydroxide, calcium sulfate, and the like are used for the purpose of improving the elastic modulus of the layer, improving the surface smoothness of the molded product, or increasing the amount of the molded product. A filler such as glass powder, plastic powder, crystalline silica powder, fused silica powder, barium sulfate, magnesium silicate (talc), clay, kaolin, magnesium oxide, and diatomaceous earth is mixed. The amount of the filler is usually 50 to 700 parts by weight based on 100 parts by weight of the resin.
In addition, an appropriate amount of a low-shrinkage agent such as polystyrene, polyvinyl acetate, polyacrylate, polyethylene terephthalate, styrene-vinyl acetate block copolymer, and styrene-methyl methacrylate block copolymer can be added. The thickness of the resin concrete layer 4 is usually in the range of 3 to 10 mm.
[0015]
As the fibrous reinforcing material used in the outer side of the resin concrete layer 4, that is, in the outermost FRP layer 5, as in the fibrous reinforcing material used in the opaque colored FRP layer 3, glass fibers such as glass mat, glass cloth, glass paper, etc. There is.
[0016]
The method of laminating the opaque colored FRP layer 3, the resin concrete layer 4, and the outermost FRP layer 5 on the patterned transparent resin sheet 2 includes application of resin (liquid), pouring method, and hand lay-up method. It can be performed by a known method.
[0017]
The present invention also relates to a "patterned plastic molded article" manufactured by the above manufacturing method. That is, it is a patterned plastic molded product 10 in which a transparent or translucent surface resin layer 1, a pattern layer 2a, a thermoplastic acrylic resin layer 2b, and an opaque colored FRP layer 3 are formed in this order from the surface.
In this case, it is preferable that a resin concrete layer 4 and an FRP layer 5 are further formed on the back side of the opaque colored FRP layer 3.
[0018]
Further, the present invention provides a patterned plastic molded product in which a transparent or translucent surface resin layer 1, a pattern layer 2a, a thermosetting resin layer 3 containing glass fibers, and an opaque colored FRP layer 4 are formed in this order from the surface. Also provide.
Also in this case, it is preferable that the resin concrete layer 4 and the FRP layer 5 are further formed on the back side of the opaque colored FRP layer 3.
[0019]
[Action]
In the production method of the present invention, as disclosed in Japanese Patent Publication No. 3-47183, a transfer film patterned with ink on one side of a base film is pressed from one end side of a mold surface with a roller. After the step (B) in which the lump surface resin is uniformly stretched and simultaneously polymerized on the surface resin, the base film (after curing of the stretched surface resin) is peeled off or the pattern is transferred onto the surface resin. Since the work of laminating the resin layers is unnecessary, the manufacturing process can be shortened and simplified.
Further, in the manufacturing method of the present invention, since a transparent resin sheet with a pattern having a constant thickness is used, the reproducibility (accuracy) of the thickness of the transparent resin sheet layer is higher than that of the conventional method, and the thick part and the thin part (variation) are different. There is little danger.
[0020]
BEST MODE FOR CARRYING OUT THE INVENTION
FIG. 1 is an example of the “method of manufacturing a patterned plastic molded product” of the present invention, and the procedure is as follows.
1) A release agent is applied to the surface of the mold 11 in advance (not shown).
2) A transparent or translucent lump of surface resin (liquid) is placed on this in a streak shape (or in a zigzag strip shape).
3) The transparent resin sheet 2b (patterned transparent resin sheet 2) on which the pattern 2a is printed on one side is overlaid on the mold such that the printed surface (that is, the patterned surface) faces the mold side, and the rollers 6 and the like are used. At the same time, the surface resin is stretched from the end, and the patterned transparent resin sheet 2 is laminated.
4) This is heated in a curing furnace (for example, at 65 ° C. for 45 minutes) to cure the surface resin layer 1.
5) A colored opaque resin is applied thereon (that is, on the non-printing surface side of the patterned transparent resin sheet 2).
6) While the colored opaque resin is not yet cured, a fibrous reinforcing material (glass fiber or the like) is placed thereon.
7) The fibrous reinforcing material (glass fiber or the like) is impregnated with the resin by the roller 6 or the like.
8) This is heated in a curing furnace (for example, at 45 ° C. for 10 minutes) to cure the resin and form the opaque colored FRP layer 3.
[0021]
9) Apply resin concrete (a mixture of resin and calcium carbonate powder).
10) This is heated and cured in a curing furnace (for example, 45 ° C., 15 minutes) to form the resin concrete layer 4.
11) Place a fibrous reinforcement (glass fiber, etc.) on the cured resin concrete.
12) A resin is applied to a fibrous reinforcing material (glass fiber or the like) and impregnated using a roller 6 or the like.
13) This is heated and cured in a curing furnace (for example, 65 ° C., 40 minutes) to form an FRP layer 5 containing a resin and a fibrous reinforcing material.
14) After cooling, remove from the mold to obtain a patterned plastic molded product.
[0022]
FIG. 2 shows the obtained patterned plastic molded product (cross-sectional view), in which the upper side is the mold surface side and the lower side is the lamination surface side. In order from the upper side (that is, the surface side of the molded product), the surface resin layer 1, the pattern layer 2a, the transparent resin sheet layer 2b, the opaque colored FRP layer 3, the resin concrete layer 4, the resin and fibrous reinforcing material And an FRP layer 5 containing
[0023]
Example 1 Production example using a patterned acrylic resin sheet A patterned wall material was produced by the following procedure.
1) A mold release agent (Chemrease PMR; Chemrease, USA) was applied to a tempered glass plate serving as a mold.
2) 100 parts by weight of a vinyl ester resin (manufactured by Hitachi Chemical Co., Ltd.) are mixed with a curing agent (Perroyl TCP: 2 parts by weight, Percure O: 1 part by weight), and a lump of the mixture is streaked at the end of the mold. did.
3) A 125 μm-thick printed sheet (manufactured by Dai Nippon Printing Co., Ltd.) obtained by gravure printing on one side of an acrylic resin sheet was overlaid on the mold such that the printed surface (that is, the pattern surface) was on the mold side.
4) A resin stretching roller is applied to the acrylic resin sheet so as to sandwich the resin, and is moved to the opposite end while rotating to uniformly stretch the resin to a thickness of 0.3 mm, and the acrylic resin sheet is formed into a mold. Stuck together.
5) The resin was cured by heating in a curing furnace at 65 ° C. for 60 minutes.
6) A mixture of 100 parts by weight of a white colored unsaturated polyester resin (manufactured by Tokyo Ink; PCG0G279WHITE) and 1 part by weight of a curing agent (Permec N; manufactured by NOF CORPORATION) was placed on an acrylic resin sheet at 0.6 kg / m ^2. Applied.
7) A glass chopped strand mat (Fuji Fiberglass; MC230N) with a basis weight of 230 g was placed on the resin.
8) The FRP roller was reciprocated so that the resin permeated the glass mat.
9) The resin was cured by heating in a curing furnace at 60 ° C. for 10 minutes (lamination of the FRP layer).
[0024]
10) 100 parts by weight of unsaturated polyester resin (Hitachi Kasei Kogyo; PS5182PT), 200 parts by weight of calcium carbonate (manufactured by Nitto Powder Co., Ltd .; 100% by weight of cold water stone), 100 parts by weight of calcium carbonate (manufactured by Nitto Powder Co., Ltd .; NS100) Resin concrete mixed with 2 parts by weight of a low-shrinking agent (manufactured by NOF; SV10B) and 1 part by weight of a hardening agent (manufactured by NOF; Permec N) was laminated on the FRP layer at a thickness of 4 mm.
11) It was left at room temperature for 20 minutes to cure.
12) A glass chopped strand mat (Fuji Fiberglass; MC230N) with a basis weight of 230 g was placed on the cured resin concrete layer.
13) A mixture of 100 parts by weight of an unsaturated polyester resin (manufactured by Hitachi Chemical Co., Ltd .; PS5182APT) and 1 part by weight of a curing agent (manufactured by NOF Corporation; Permec N) was applied onto the mixture at 0.6 kg / m ² .
14) The FRP roller was reciprocated so that the resin permeated the glass mat.
15) Curing was performed by heating at 60 ° C. for 90 minutes in a curing furnace.
16) Allowed to reach room temperature and removed from mold.
17) The periphery was cut with a tip saw to obtain a molded product (patterned wall material).
[0025]
The thickness of the laminated portion of the obtained molded article (patterned wall material) is approximately 0.3 mm for the surface resin layer 1, 0.13 mm for the transparent resin sheet layer 2 with pattern, and the opaque colored (white) FRP layer 3. 0.5 mm, the resin concrete layer 4 was 4.0 mm, and the outermost FRP layer 5 was 0.5 mm.
[0026]
Example 2 Production example using a patterned thermosetting resin sheet (A) Preparation of a patterned thermosetting resin sheet First, a preparation example of a patterned thermosetting resin sheet will be described.
Placing the surface mat); 1) PET (polyethylene terephthalate) manufactured by 50μm film (Unitika; S50) on the basis weight 30 g / ^{m 2} glass fiber nonwoven fabric (Nitto Boseki Co., Ltd..
2) A mixture of 100 parts by weight of an unsaturated polyester resin (manufactured by Hitachi Chemical Co., Ltd .; PS3717) and 3 parts by weight of a curing agent (Perroyl TCP: 2 parts by weight, Percure O: 1 part by weight) was placed on the end of the glass fiber nonwoven fabric. The mass was streaked.
3) A transfer paper (FRP transfer paper, manufactured by Dai Nippon Printing Co., Ltd.) on which gravure printing has been performed on one side of a 50 μm PET film is placed so that its printed surface is overlapped with the nonwoven fabric, and the resin is sandwiched by the roller so as to sandwich the polyester resin. And the resin was impregnated into the nonwoven fabric at the same time.
4) This was heated in a curing furnace at 65 ° C. for 35 minutes to be cured.
5) Thereafter, both the PET film on the glass fiber nonwoven fabric side and the PET film on the transfer paper side were peeled off to obtain a thermosetting resin sheet with a pattern (printed surface).
[0027]
(B) Using the thermosetting resin sheet, a patterned wall material was manufactured in the following procedure.
1) A release agent was applied to a tempered glass plate serving as a mold.
2) A lump of a mixture of 100 parts by weight of an unsaturated polyester resin (manufactured by Hitachi Chemical Co .; PS3717), 3 parts by weight of a curing agent (2 parts by weight of Parloyl TCP, 1 part by weight of Percure O) is streaked on the end of the mold. It was arranged in the shape.
3) The thermosetting resin sheet was overlaid on the mold such that the printing surface (that is, the pattern surface) faced the mold side.
4) to 17) Thereafter, the same operation as in Example 1 was performed to obtain a patterned wall material.
[0028]
【The invention's effect】
According to the improved manufacturing method of the present invention, the manufacturing process can be further shortened and simplified. Also, there is no need to significantly modify the conventional manufacturing equipment.
In the patterned plastic molded article obtained by the production method of the present invention, the thickness of the transparent resin layer is determined by the thickness of the used (patterned) transparent resin sheet. . A plastic molded article with a uniform pattern can be obtained.
[Brief description of the drawings]
FIG. 1 is an explanatory view illustrating steps of a manufacturing method of the present invention.
FIG. 2 is a cross-sectional view of a patterned plastic molded product obtained by the production method of the present invention.
[Explanation of symbols]
1: Surface resin layer 2: Patterned transparent resin layer (transparent resin sheet)
2a: Pattern layer (print side)
2b: transparent resin layer (transparent resin sheet)
3: Opacity colored FRP layer 4: Resin concrete layer 5: Outermost FRP layer 6: Roller 10: Patterned plastic molded product 11: Mold

Claims (9)

A method for producing a patterned plastic molded product comprising the following steps.
(A) a step of placing a lump of transparent or translucent surface resin on the surface of a mold and stretching it to form a surface resin layer;
(B) a step of laminating a patterned transparent resin sheet having a pattern on one surface on the surface resin layer so that the pattern surface faces the mold side;
(C) a step of curing the surface resin layer;
(D) laminating an opaque colored FRP layer containing a resin on the transparent resin sheet;
(E) curing the resin of the opaque colored FRP layer;
(J) Demolding. The method according to claim 1, wherein the formation of the surface resin layer in the step (a) is performed together with the lamination of the transparent resin sheet in the step (b). The method according to claim 1 or 2, further comprising the following step between step (e) and step (j).
(F) forming a resin concrete layer on the opaque colored FRP layer;
(G) curing the resin of the resin concrete layer;
(H) further laminating an outermost FRP layer;
(I) curing the resin of the outermost FRP layer; The method according to any one of claims 1 to 3, wherein a thermoplastic acrylic resin sheet having a printed surface on one side is used as the transparent resin sheet having a pattern on one side. The method according to any one of claims 1 to 3, wherein a thermosetting resin sheet having a printed surface on one side is used as the transparent resin sheet having a pattern on one side. In order from the surface,
Transparent or translucent surface resin layer;
Pattern layer;
A thermoplastic acrylic resin layer; and an opaque colored FRP layer;
A plastic molded article with a pattern on which is formed. The patterned plastic molded product according to claim 6, wherein a resin concrete layer and an FRP layer are further formed on the back side of the opaque colored FRP layer. In order from the surface,
Transparent or translucent surface resin layer;
Pattern layer;
A thermosetting resin layer containing glass fibers; and an opaque colored FRP layer;
A plastic molded article with a pattern on which is formed. The patterned plastic molded product according to claim 8, wherein a resin concrete layer and an FRP layer are further formed on the back side of the opaque colored FRP layer.

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