JP2005125614A - Resin molded product and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To simplify molding work and to prevent the boundary line between first and second thermosetting resin materials different in color from appearing by the gradation region in the boundary part of the first and second thermosetting resin materials. <P>SOLUTION: This resin molded product 10 is constituted of a molded product main body 11 formed into a cup shape. The molded product main body 11 is constituted by providing an upper forming layer 22 constituted of the first thermosetting resin material 24 and a lower forming layer 21 constituted of the second thermosetting resin material 25. The gradation region 27 is formed to the boundary part 19 of the upper forming layer 22 and the lower forming layer 21. When the height of the gradation region 27 is set to t2 and the height of the molded product main body 11 is set to t1, t2/t1 is set so as to be larger than 0.05 but smaller than 0.5. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to a resin molded product and a method for manufacturing the same, and more particularly to a resin molded product having a blurred region at the boundary between resin materials having different colors and a method for manufacturing the same.

  2. Description of the Related Art Conventionally, as a resin molded product whose surface is color-coded using resin materials having different colors, for example, there is a type shown in FIG. 5 (see Patent Document 1). In the figure, a resin molded product 50 is positioned below the first color tone layer 51 made of a resin material mixed with the first pigment and the second color pigment. The third color layer 53 which is located between the second color layer 52 made of the resin material and the first and second color layers 51, 52 and in which both the first and second pigments are mixed. And is configured.

Japanese Utility Model Publication No. 6-47697

However, in such a resin molded product 50, a total of three types (three colors) of resin materials must be sequentially injected into the mold, resulting in inconvenience that it takes time and effort for the molding operation. .
Further, when the resin molded product 50 is viewed in a vertical cross section (see FIG. 5), the boundary between the color tone layers 51 to 53 is positioned in a substantially horizontal direction, and therefore, between the first and third color tone layers 51 and 53. The boundary line 55 clearly appears between the second and third tone layers 52 and 53, and a natural appearance in which the color gradually shifts cannot be expressed.

[Object of invention]
The present invention has been devised by paying attention to such inconveniences, and an object of the present invention is to simplify the molding operation and to provide first and second thermosetting resins having different colors. An object of the present invention is to provide a resin molded product that can impart a blurring effect to the boundary portion of the material and prevent the boundary line between the resin materials from appearing, and a method for manufacturing the same.

In order to achieve the above object, the present invention sequentially injects first and second thermosetting resin materials having a viscosity of 0.1 to 50 Pa · s into a mold, and at the boundary between them. A resin molded product with a blurred area formed,
The color difference ΔE between the first and second thermosetting resin materials is set to 30 or less.

In the present invention, when the height of the blur area is t2, while the total height including the blur area is t1,
It is preferable to adopt a configuration in which t2 / t1 is larger than 0.05 and smaller than 0.5.

  In the present invention, the first and second thermosetting resin materials having translucency with a viscosity of 0.1 to 50 Pa · s and having a color difference ΔE after molding of 30 or less are formed from above from a mold. A method of manufacturing a resin molded product in which the boundary portion of these thermosetting resin materials is formed as a blurred region, and the flow direction of the thermosetting resin material is inclined with respect to the horizontal plane. After the mold is set as described above, the second thermosetting resin material is injected before the upper surface of the first thermosetting resin material becomes horizontal.

Furthermore, when the height of the blur area is t2, while the total height including the blur area is t1,
A method of injecting the second thermosetting resin material with a time difference in which t2 / t1 is larger than 0.05 and smaller than 0.5 is also preferably employed.

According to the present invention, since the viscosity of the first and second thermosetting resin materials is set to 0.1 to 50 Pa · s, it is only necessary to sequentially inject two types of thermosetting resin materials into the mold. Therefore, it is possible to easily form a blur region at the boundary portion, and it is possible to reduce labor and labor for forming.
Specifically, the second thermosetting resin material can be injected and molded before the upper surface of the first thermosetting resin material becomes horizontal in the mold, and the working time for molding is reduced. Is achieved. In addition, each resin material has translucency, and it is formed by overlapping so that the thickness at the boundary part gradually changes, and the color transition reveals a natural blur area and improves the texture. It becomes possible.
In addition, since the flow direction of the thermosetting resin material is inclined with respect to the horizontal plane, the upper surface of the resin material can be easily formed by simply injecting the thermosetting resin material due to the viscosity of the thermosetting resin material. Can be tilted in the mold.

Hereinafter, preferred embodiments of the present invention will be described with reference to the drawings.
In this specification, “translucency” means a resin molded product having a thickness of 10 mm and a turbidimeter (haze meter) having a total transmitted light of 5% or more. It is measured using a turbidimeter (haze meter) manufactured by Denshoku.
The “viscosity” is measured using a B-type viscometer manufactured by Tokyo Keiki Co., Ltd.

  FIG. 1 shows a schematic longitudinal sectional view of a resin molded product according to the present embodiment. In this figure, a resin molded product 10 is applied as a wash bowl, and includes a molded product main body 11 having a bowl shape.

Although the said molded article main body 11 is not specifically limited, The thickness is set to 6-15 mm. The molded product body 11 includes a bottom wall portion 15 having a curved shape that bulges downward, an inclined wall portion 16 that is continuous with the outer peripheral side of the bottom wall portion 15 and is inclined outward as it goes upward. A flange wall portion 17 is formed to extend outwardly from the upper end of the wall portion 16. Moreover, the molded product main body 11 includes a boundary portion 19 at the intermediate portion in the height direction of the inclined wall portion 16, and displays different colors in the vertical direction across the boundary portion 19. That is, the molded product body 11 includes a lower forming layer 21 that forms an inclined wall portion 16 and a bottom wall portion 15 that are located below the boundary portion 19, and an inclined wall portion 16 and a flange wall that are above the boundary portion 19. The upper forming layer 22 that forms the portion 17 is formed.
Here, the upper forming layer 22 is made of the first thermosetting resin material 24, while the lower forming layer 21 is made of the second thermosetting resin material 25.
The 1st and 2nd thermosetting resin materials 24 and 25 are comprised by the unsaturated polyester resin etc. by which the viscosity was set to 0.1-50 Pa.s. When the viscosity is less than 0.1 Pa · s, the blur area 27 becomes very small, and natural color transition cannot be sufficiently expressed. On the other hand, when the viscosity is larger than 50 Pa · s, the viscosity becomes too high and the filling property into the mold is inferior, and the blurring region 27 becomes too large to improve the texture.
Further, the first and second thermosetting resin materials 24 and 25 each have translucency after molding, and their color difference ΔE is set to 30 or less. If the color difference ΔE is larger than 30, it is difficult to express a natural color transition even if the blur region 27 is formed.

  As shown in FIG. 1, when the virtual horizontal line H is drawn on the boundary portion 19, the inclined wall portion 17 has an intersection angle θ between the virtual horizontal line H and the surface of the lower inclined wall portion 17. It is set to 10 ° or more and 50 ° or less (preferably 20 ° or more and 40 ° or less).

A blur region 27 is formed in the boundary portion 19, and the blur region 27 is formed so that the thickness of the upper formation layer 22 and the lower formation layer 21 becomes gradually thinner at the boundary portion 19. It is formed by overlapping in the thickness direction. That is, the boundary surfaces of the upper forming layer 22 and the lower forming layer 21 in the blurring region 27 are combined with each other in an inclined state with respect to the horizontal plane, whereby the blurring region 27 is formed in the upper forming layer 22 and the lower forming layer. An intermediate color of the colors of the layer 21 is displayed, and a gradation in which these colors gradually change is displayed.
Here, when the height of the blurred region 27 is t2, and the overall height of the molded article body 11 including the blurred region 27 is t1, the height t2 is within the range of the following expression. Is set.
0.05 <(t2 / t1) <0.5
When t2 / t1 is 0.05 or less, the blurred region 27 is clearly visible in a linear shape, whereas when t2 / t1 is 0.5 or more, the height of the blurred region 27 is increased. Thus, the color difference between the upper forming layer 22 and the lower forming layer 21 cannot be expressed.

  Next, the manufacturing procedure of the resin molded product 10 according to the present embodiment will be described with reference to FIG.

The resin molded product 10 is molded in a cavity C of a mold F composed of an upper mold F1 and a lower mold F2. The mold F is tilted so that the resin molded product 10 to be molded is upside down with respect to the state shown in FIG. 1, that is, the bottom wall portion 16 is located at the top and the inclined wall portion 17 is widened toward the end. Set to The molding die F is composed of an upper die F1 and a lower die F2, and an injection port F3 that communicates the top of the cavity C and the outside of the molding die F at the center in the left-right direction in FIG. Is formed.
In molding the resin molded product 10 using the molding die F, the upper die F1 and the lower die F2 are clamped together and then heated to a predetermined temperature. In this state, first, the first thermosetting resin material 24 is injected from the injection port F3. At this time, since the formation surface C1 of the lower mold F2 of the cavity C forming the inclined wall portion 17 is inclined with respect to the horizontal plane, the first thermosetting resin material 24 is formed along the formation surface C1. run down. When the first thermosetting resin material 24 has been injected, the upper surface of the resin material 24 is inclined along the formation surface C1 due to the viscosity of the resin material 24, and the upper surface gradually gradually approaches the horizontal as time passes. It will be.
After injecting the first thermosetting resin material 24, the second thermosetting resin material 25 is injected from the injection port F3 before the upper surface of the resin material 24 becomes horizontal. As a result, the thermosetting resin materials 24 and 25 are overlapped in the thickness direction of the molded product body 11, and a blur region 27 is formed at the boundary portion 19.
In this state, after a predetermined keeping time has elapsed at a predetermined temperature, the thermosetting resin materials 24 and 25 are cured, and the molded product body 11 including the upper resin layer 22 and the lower resin layer 21 is molded. The resin molded product 10 is obtained by separating the mold F1 and the lower mold F2 apart from each other.

  The resin molded product 10 is not limited to the configuration shown in FIGS. 1 and 2. For example, as shown in FIG. 3, the resin molded product 10 may have gel coat layers 29 and 30 on both the front and back sides of the molded product main body 11. In the manufacturing procedure of this configuration, a process of applying and curing the gel coat on the formation surface of the cavity C is added to the above-described manufacturing procedure before clamping the upper mold F1 and the lower mold F2.

  Examples 1 and 2 for confirming the effects of the present invention will be described below.

Here, the 1st and 2nd thermosetting resin materials 24 and 25 which mix | blended various components in the ratio shown in Table 1 were used. The viscosities of these thermosetting resin materials 24 and 25 were 5 Pa · s, respectively. Further, as the mold D, an electroforming mold having a cavity C in which the thickness of the molded resin molded article 10 is 9 mm was used.
In the molding operation, first, the mold F was heated to 40 ° C. Thereafter, 4 kg of the first thermosetting resin material 24 was injected from the injection port, and then 4 kg of the second thermosetting resin material 25 was immediately injected.
Next, the temperature of the mold F is set to 70 ° C., and left for 30 minutes to cure the thermosetting resin materials 24 and 25. Then, the upper mold F1 and the lower mold F2 are separated and removed. A resin molded product 10 was obtained.
The whole resin transmitted light and the color difference ΔE of the lower resin layer 21 and the upper resin layer 22 in the obtained resin molded product 10 were measured. The color difference ΔE was measured by measuring the color difference from the upper resin layer 22 with the lower resin layer 21 as a standard. The results are shown in Table 2. Further, when the boundary portion 19 of the resin molded product 10 was visually observed, a blurred region 27 in which the color transition was natural and beautiful was confirmed.

In Example 2, the first and second thermosetting resin materials 24 and 25 blended with various components at the ratios shown in Table 3 were used, and the viscosity of each resin material 24 and 25 was 0.3 Pa · s, respectively. Met. Moreover, the same mold F as in Example 1 was used.
In the molding operation, first, the surface on which the cavity C of the upper mold F1 and the lower mold F2 was formed was subjected to a mold release treatment, and then a thermosetting unsaturated polyester gel coat was applied to the surface at 0.3 mm. Thereafter, the gel coats 29 and 30 were cured by leaving the upper mold F1 and the lower mold F2 at a temperature of 60 ° C. for 1 hour.
After the gel coats 29 and 30 are cured, the upper mold F1 and the lower mold F2 are clamped, and 3.5 kg of the first thermosetting resin material 24 is injected from the injection port, and then the second thermosetting resin material 25 is immediately added. 3 kg was injected.
Next, the mold F was put into a curing furnace set at a furnace temperature of 40 ° C., and left for 4 hours to cure the thermosetting resin materials 24 and 25. Thereafter, the upper mold F1 and the lower mold F2 were separated and demolded to obtain a resin molded product 10.
In the obtained resin molded product 10, the entire line transmitted light and the color difference ΔE of the lower resin layer 21 and the upper resin layer 22 were measured in the same manner as in Example 1. The results are shown in Table 4. Further, when the boundary portion 19 of the resin molded product 10 was visually observed, a blurred region 27 in which the color transition was natural and beautiful was confirmed.

The best configuration, method and the like for carrying out the present invention have been disclosed in the above description, but the present invention is not limited to this.
That is, the present invention has been particularly shown and described with respect to particular embodiments, but is not limited to the embodiments described above without departing from the scope and spirit of the present invention. Various modifications may be made by those skilled in the art in terms of position, orientation, and other detailed configurations.
Therefore, the description limited to the shape disclosed above is an example for easy understanding of the present invention, and does not limit the present invention. The description in the name of the member excluding a part or all of the limitation is included in the present invention.

For example, in the illustrated configuration example, the boundary surface between the upper resin layer 22 and the lower resin layer 21 in the boundary portion 19 is linearly represented, but the boundary surface is not limited to a flat surface. For example, at the time of molding, the first thermosetting resin material 24 may be formed by a curved surface in which the central portion in the thickness direction is recessed upward, depending on the viscosity.
Further, as shown in FIG. 4, the molding die F may be tilted before or after the first thermosetting resin material 24 is poured or during molding. At this time, when the same resin material as described above is used, the time from injecting the first thermosetting resin material 24 to injecting the second thermosetting resin material 25 becomes relatively long. Thereby, the inclination angle of the forming surface C1 can be adjusted, and the thermosetting resin materials 24 and 25 stably overlap with each other in the thickness direction of the molded product body 11, and the blurring region 27 can be more reliably secured. It becomes possible to form.
Further, the molded product main body 11 can be variously modified, and the inner surface of the bottom wall portion 16 may be formed substantially flat, or the flange wall portion 17 may be omitted. The resin molded product 10 can also be applied to other resin molded products such as bathtubs and sinks.

  The resin molded product according to the present invention can be mainly used for a wash bowl or a bathtub in a general household.

The longitudinal cross-sectional view of the resin molded product which concerns on embodiment. The longitudinal cross-sectional view showing the said resin molded product with the shaping | molding die. Sectional drawing similar to FIG. 2 of the resin molded product which concerns on a modification. Sectional drawing similar to FIG. 2 which concerns on the modification which changed the shaping | molding method. The longitudinal cross-sectional view of the resin molded product which concerns on a prior art example.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 10 ... Resin molded article, 19 ... Boundary part, 24 ... 1st thermosetting resin material, 25 ... 2nd thermosetting resin material, 27 ... Blur area | region, F * ..Molding mold

Claims (4)

It is a resin molded product in which first and second thermosetting resin materials having a viscosity of 0.1 to 50 Pa · s are sequentially injected into a mold and a blur region is formed at the boundary between them. And
A resin molded product, wherein the color difference ΔE between the first and second thermosetting resin materials is set to 30 or less. When the height of the blur area is t2, while the total height including the blur area is t1,
The resin molded product according to claim 1, wherein t2 / t1 is larger than 0.05 and smaller than 0.5.   First and second thermosetting resin materials having a viscosity of 0.1 to 50 Pa · s and a color difference ΔE after molding of 30 or less are sequentially injected into the mold from above, A method of manufacturing a resin molded product formed by using the boundary portion of these thermosetting resin materials as a blurred region, and setting the mold so that the flow direction of the thermosetting resin material is inclined with respect to the horizontal plane. After that, the second thermosetting resin material is injected before the upper surface of the first thermosetting resin material becomes horizontal. When the height of the blur area is t2, while the total height including the blur area is t1,
4. The resin molded product according to claim 3, wherein the second thermosetting resin material is injected with a time difference t2 / t1 being larger than 0.05 and smaller than 0.5. Production method.

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