JP2004050741A - Plastic molded article with double pattern and manufacturing method thereof - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a plastic molded article with a double pattern improved in three-dimensional appearance, and a manufacturing method thereof. <P>SOLUTION: The plastic molded article with the double pattern is manufactured through a process (a) wherein a lump of transparent or semitransparent surface resin is placed, in a striped appearance, on the surface of a mold 11 and stretched so that a surface resin layer 1 is formed, a process (b) wherein a transparent resin sheet 2 with a double-sided pattern having a principal pattern 2a on one side and a subordinate pattern 2c on the other is laid on the surface resin layer 1 in such a manner that these patterns are put together so that the the side of the principal pattern 2a faces the mold side, a process (c) wherein the surface resin layer 1 is hardened, a process (d) wherein a nontransparent colored FRP layer 3 containing a resin is laid on the transparent resin sheet 2, a process (e) wherein the resin of the nontransparent colored FRP layer 3 is hardened and a process (j) wherein the molded article is removed from the mold. <P>COPYRIGHT: (C)2004,JPO

Description

[0001]
TECHNICAL FIELD OF THE INVENTION
The present invention relates to a double-patterned plastic molded product used for a wall material of a luxury bathroom unit and a method for producing the same.
[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 patterned 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) A transfer film patterned with ink soluble in the surface resin on one side of the base film is pressed from one end side of the mold surface by a roller to uniformly stretch the bulk 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. In addition, 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 feature that the pattern appears to float three-dimensionally in the resin (the so-called high relief effect) is obtained. is there. However, this manufacturing method is still complicated (in particular, a 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 provides an "improved method for producing a patterned plastic molded article" that further shortens and simplifies the production process, and a molded article obtained by the production method, in which the applied pattern looks more three-dimensional (double The purpose of the present invention is to provide a patterned plastic molded product.
[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 double-patterned plastic molded product" including the following steps (a) to (j).
(A) On the surface of the mold 11, a lump of transparent or translucent surface resin (liquid) is streaked (
Or on a belt-shaped zigzag) and stretching it to form the surface resin layer 1;
(B) A transparent resin sheet 2 with a double-sided pattern having a main pattern 2a on one surface and a pattern 2c on the other surface on the surface resin layer 1 so that the main pattern 2a faces the mold side. Laminating according to;
(C) a step of curing the surface resin layer 1;
(D) a step of laminating an opaque colored FRP layer 3 containing a resin on the transparent resin sheet 2;
(E) curing the resin of the opaque colored FRP layer 3;
(J) Demolding.
The curing of the surface resin, the resin in the FRP layer, or the resin in the resin concrete layer described below can be performed by leaving the resin at room temperature or heating it to a curing temperature (in a curing furnace). . 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 carried out simultaneously (simultaneously) with the lamination of the double-sided patterned transparent resin sheet 2 in the step (b) by using a stretching means such as a roller or a bar. . This is because both the formation of the surface resin layer 1 and the lamination of the transparent resin sheet 2 with a double-sided pattern can be performed in one step.
[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 outermost FRP layer (an outermost FRP layer containing a resin and a fibrous reinforcing material) 5;
(I) curing the resin of the outermost FRP layer;
Thereafter, the mold is removed, the periphery of the molded article is removed by a cutting machine, and the molded article is trimmed to obtain a double-patterned plastic molded article.
[0008]
Note that the back side of the transparent resin layer 2 with the double-sided pattern 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 both sides by a sandwich type FRP layer). If required, the required strength can be achieved with a small molding material.
[0009]
One of the preferable substrates of the transparent resin sheet 2 with a double-sided pattern used in the present invention is an acrylic resin sheet (a kind of thermoplastic resin sheet). The main pattern 2a is printed on one side of the acrylic resin sheet 2b, and the pattern 2c is printed on the other side (screen printing, gravure printing, or the like). The main pattern 2a and the sub-pattern 2c are, for example, a case where the main pattern 2a is "printing a seagull flying in the sky" and the sub-pattern 2c is "printing a sky in which clouds float". The subsidiary pattern 2c may be printed in a single color.
[0010]
One of other preferable substrates for the transparent resin sheet 2 with a double-sided pattern used in the present invention is a thermosetting resin (containing glass fiber) sheet.
[0011]
The transparent or translucent surface resin (liquid) used in the present invention is selected according to the type of the base material of the transparent resin sheet 2 having a double-sided pattern 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 the acrylic resin sheet 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 making the pattern stand out.
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 (rear side) of the resin concrete layer 4, that is, the outermost FRP layer 5, the same as the fibrous reinforcing material used in the opaque colored FRP layer 3, glass mat, glass cloth, glass paper, etc. There is a glass fiber.
[0016]
As a method of laminating the opaque colored FRP layer 3, the resin concrete layer 4, and the outermost FRP layer 5 on the transparent resin sheet 2 with a double-sided pattern, a resin (liquid) application, a casting method, and a hand lay-up method are used. And other known methods.
[0017]
The present invention also relates to a double-patterned plastic molded product produced by the above production method. That is, in order from the surface, a transparent or translucent surface resin layer 1, a main pattern layer (first pattern layer) 2a, a transparent resin layer 2b, a sub-pattern layer (second pattern layer) 2c, and an opaque colored FRP layer 3 Is a double-patterned plastic molded article 10 on which is formed.
[0018]
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.
[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 present invention, since a transparent resin sheet having a constant thickness (with a double-sided pattern) is used, reproducibility (accuracy) of the thickness of the transparent resin sheet layer is high, and there is a risk that a thick portion and a thin portion (variation) may occur. Few.
The plastic molded article with a double pattern obtained by the present invention includes a transparent or translucent surface resin layer having a predetermined thickness (in order from the surface side), a main pattern layer (for example, printing of a flying seagull), and a predetermined thickness. The transparent resin layer, the sub-pattern layer (for example, printing of the sky where the cloud floats) and the opaque colored FRP layer have a laminated structure, so that the pattern appears to float three-dimensionally in the transparent resin (the so-called high relief effect). In addition, the relationship between the main pattern and the sub-pattern becomes three-dimensional (for example, a seagull appears to be flying in the sky over which clouds are flowing).
[0020]
BEST MODE FOR CARRYING OUT THE INVENTION
FIG. 1 is an example of the “method of manufacturing a double-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) A transparent resin sheet with a double-sided pattern (a transparent resin sheet 2 with a double-sided pattern) having a main pattern 2a on one side and a pattern 2c on the other side, with the main pattern 2a facing the mold side. At the same time, the transparent resin sheet 2 with a double-sided pattern is laminated on the mold 11 by stretching the surface resin from the end using a roller 6 or the like.
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 and opaque resin is applied thereon (that is, on the side of the sub-pattern 2c of the 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 double-molded plastic molded product.
[0022]
FIG. 2 shows the obtained double-patterned plastic molded product (cross-sectional view), in which the upper side is the mold surface side (that is, the front surface side of the molded product) and the lower side is the lamination surface side (that is, the back surface side of the molded product). It is. Includes, in order from the top, a surface resin layer 1, a main pattern layer 2a, a transparent resin sheet layer 2b, a sub-pattern layer 2c, an opaque colored FRP layer 3, a resin concrete layer 4, a resin and a fibrous reinforcing material. And the outermost FRP layer 5.
[0023]
Example 1 Production example using a patterned acrylic resin sheet A double-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) A lump of a mixture (surface resin) of a mixture of 100 parts by weight of a vinyl ester resin (manufactured by Hitachi Chemical Co., Ltd.) and a curing agent (Perloyl TCP: 2 parts by weight, Percure O: 1 part by weight) is streaked at the end of the mold. Placed.
3) A resin sheet with double-sided printing having a thickness of 125 μm, in which a main pattern and a sub-pattern were gravure-printed on both sides of an acrylic resin sheet, was placed on the mold such that the main pattern faced the mold side.
4) A resin stretching roller is applied to the resin sheet so as to sandwich the surface resin, and is moved to the opposite end while rotating to uniformly stretch the surface resin to a thickness of 0.3 mm, and the 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 (wall material with a double pattern).
[0025]
The thickness of the laminated portion of the obtained molded product (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 a double-sided pattern, and the opaque colored (white) FRP layer 3. Was 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 thermosetting resin sheet with a pattern (A) Preparation of thermosetting resin sheet with a double-sided pattern First, a preparation example of a thermosetting resin sheet with a double-sided pattern (containing glass fiber) will be described. I do.
1) On a printed surface of FRP transfer paper (manufactured by Dai Nippon Printing Co., Ltd.) on which a “flying seagull pattern” is screen-printed on one side of a 50 μm PET film (substrate), a glass fiber nonwoven fabric having a basis weight of 30 g / m ² ( Nittobo; surface mat).
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) Place FRP transfer paper (manufactured by Dai Nippon Printing Co., Ltd.), on which gravure-printed “sky pattern with floating clouds” is printed on one side of a 50 μm PET film (substrate), so that the printed surface of the FRP transfer paper is overlaid on the nonwoven fabric. The resin was stretched by a roller so as to sandwich the resin, and at the same time, the resin was impregnated in the nonwoven fabric.
4) This was heated in a curing oven at 65 ° C. for 35 minutes to be cured.
5) Thereafter, both the PET film on the pattern side of the flying seagull and the PET film on the pattern side of the sky where the cloud floats were peeled off to obtain a thermosetting resin sheet with a double-sided pattern.
[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) 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 (2 parts by weight of Parloyl TCP, 1 part by weight of Percure O) and a lump of a mixture were streaked at the end of the mold. It was arranged in the shape.
3) The thermosetting resin sheet was overlaid on a mold such that the printing surface (that is, the side surface of the flying seagull pattern) faced the mold side.
4) to 17) Thereafter, the same operation as in Example 1 was performed to obtain a double-walled 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 as compared with the related art. Also, there is no need to significantly modify the conventional manufacturing equipment. Further, since the thickness of the transparent resin layer of the patterned plastic molded product is determined by the thickness of the used (with pattern) transparent resin sheet, the occurrence of thick portions and thin portions (generation of variation) is small, uniform, and small in variation. A plastic molding is obtained.
The double-patterned plastic molded product obtained in the present invention comprises a transparent or translucent surface resin layer having a predetermined thickness (in order from the surface side), a main pattern layer, a transparent resin layer, a sub-pattern layer and an opaque colored FRP layer. Since they are laminated, the relationship between the main pattern and the sub-pattern gives a three-dimensional effect in addition to the effect that the pattern appears to float three-dimensionally in the transparent resin (so-called high relief effect).
[Brief description of the drawings]
FIG. 1 is an explanatory view illustrating the order of steps in a manufacturing method of the present invention.
FIG. 2 is a schematic cross-sectional view of a plastic molded article with a double pattern according to the present invention.
[Explanation of symbols]
1: Surface resin layer 2: Transparent resin layer with a double-sided pattern (transparent resin sheet)
2a: Main pattern layer (first pattern layer or printing surface)
2b: transparent resin layer (transparent resin sheet)
2c: follower layer (second pattern layer or printing surface)
3: opaque colored FRP layer 4: resin concrete layer 5: outermost FRP layer 6: resin stretching roller 10: patterned plastic molded product 11: mold

Claims (7)

A method for producing a double-patterned plastic molded product comprising the following steps.
(A) forming a transparent or translucent surface resin layer on the surface of the mold;
(B) On the surface resin layer, a transparent resin sheet having a double-sided pattern having a main pattern on one surface and a sub-pattern on the other surface is laminated so that the main pattern surface faces the mold side. Process;
(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 with a double-sided pattern 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 FRP layer as an outermost 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 main pattern printed on one side and a pattern printed on the other side is used as the transparent resin sheet with a double-sided pattern. The method according to any one of claims 1 to 3, wherein a thermosetting resin sheet having a main pattern printed on one surface and a pattern printed on the other surface is used as the transparent resin sheet with a double-sided pattern. In order from the surface,
Transparent or translucent surface resin layer,
Main pattern layer,
Transparent resin layer,
A double-patterned plastic molded article having a sub-pattern layer and an opaque colored FRP layer. 7. The double-patterned plastic molded product according to claim 6, wherein a resin concrete layer and an FRP layer are further laminated on the back side of the opaque colored FRP layer.

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