JP2007307746A - Resin molded product and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing a resin molded product, on which a surface layer excellent in chemical resistance and hot water resistance and enhanced in design properties are applied, with good workability at a low cost, and the resin molded product. <P>SOLUTION: In the manufacturing method of the resin molded product P wherein the surface layer is applied to a base material B, the surface layer is preliminarily subjected to preform molding so that the sheet material A, which constitutes the surface layer, is matched with the shape of the molded product main body by a mold 5 composed of a male mold 51 and a female mold 52 and the base material B, of which the melting temperature is higher than that of the thermoplastic resin 4 applied to the rearmost surface of the surface layer, from the injection port 521 provided to the mold 5 is melted to be introduced under pressure and injection-molded so as to be welded to the back of the preform molded body. The resin molded product P is also disclosed. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a method for producing a resin molded product. More specifically, the present invention relates to a method for producing a resin molded product by injection molding using a thermoplastic resin and a resin molded product obtained by the method.

Conventionally, a resin molded product such as a bathtub obtained by molding a synthetic resin is usually made into a product by applying a surface layer material with a decorative print to the resin molded product body by a method such as hand lay-up. It was. For example, in Patent Document 1 below, a thermoplastic resin molding having sharpness and high design properties is obtained by thermally fusing a laminate of a thermoplastic resin film having a back printed on a thermoplastic resin base material. An article and a method for manufacturing the same are disclosed.
JP 2004-98372 A (pages 1 to 4, FIG. 2)

  However, the above-described method is time-consuming and poor in workability, and the skin phenomenon often appears on the surface, so it is difficult to say that a product excellent in quality is not necessarily obtained. The present invention solves such problems, and is excellent in chemical resistance and hot water resistance, and has a good workability and a low cost production method of a resin molded product having a surface layer with improved designability, and The subject is to provide the resin molded product.

  In order to solve the above problems, the present invention takes the following technical means. That is, according to the first aspect of the present invention, there is provided a method for producing a resin molded product in which a surface layer is adhered to a base material, wherein the surface layer is a male mold for forming a sheet body constituting the surface layer. A thermoplastic resin that is preformed so as to match the shape of the molded product body using a mold composed of a metal mold and a female mold, and is then formed on the outermost surface of the surface layer from an injection port provided in the mold. There is provided a method for producing a resin molded product obtained by melting and press-fitting a base material having a higher melting temperature than that of the preform and injection-molding the base material so as to be fused to the back surface of the preform molded body.

  The base material is not particularly limited as long as it is a synthetic resin used for injection molding, and examples thereof include polystyrene, ABS resin, polyethylene, polypropylene, polyvinyl chloride resin, and acrylic resin.

  In addition to the invention according to claim 1, the method for producing a resin molded product according to claim 2 comprises a surface transparent layer, a decorative print layer, an adhesive layer, and a thermoplastic resin layer. The thermoplastic resin layer provided on the back surface is melted and fused to the base material to be integrated.

  As the surface transparent layer, it is sufficient that a predetermined amount of the decorative printing layer can be seen through. For example, polyethylene, polypropylene, polyvinyl chloride resin, acrylic resin, polystyrene, ABS resin, polycarbonate, polyamide, polyester, polyacetal and the like are preferably used. It is done. This surface transparent layer not only keeps transparency, but also prevents peeling and damage of the decorative printing layer and imparts gloss.

  As the decorative printing layer, for example, a polyester film such as polyethylene terephthalate or polybutylene terephthalate is used as a printing substrate, and it is printed in a single color or a plurality of colors by various printing methods such as gravure printing, offset printing, screen printing, letterpress printing, etc. Various printed patterns and patterns are used.

  The adhesive layer preferably has a thickness of 10 to 1000 μm, and a known adhesive such as a polyamide resin, a polyacetal resin, a polyurethane resin, an epoxy resin, a petroleum resin, or a cellulose derivative is used. . Examples of the thermoplastic resin layer include polystyrene, ABS resin, polyethylene, polypropylene, polyvinyl chloride resin, and acrylic resin, and the melting temperature is higher than that of the thermoplastic resin used for injection molding as the base material. It is preferable to select and combine low ones.

  In addition to the invention described in claim 1, the method for manufacturing a resin molded product according to claim 3 is preferably performed by the vacuum molding method.

  According to invention of Claim 4, it is a resin molded product by which a surface layer is adhere | attached on a base material, Comprising: This surface layer is a sheet | seat body which comprises a surface layer from a male metal mold | die and a female metal mold | die. Is preformed so as to match the shape of the molded product body, and then the melting temperature is higher than that of the thermoplastic resin layered on the outermost surface of the surface layer from the inlet provided in the mold. A resin molded product obtained by melting and press-fitting the base material and injection-molding the base material so as to be fused to the back surface of the preform molded body is provided.

  The manufacturing method of the resin molded product according to the first aspect of the present invention is as described above, and the sheet body constituting the surface layer is matched to the shape of the molded product main body by a mold composed of a male mold and a female mold. The base material having a higher melting temperature than the thermoplastic resin layered on the outermost surface of the surface layer is melted and press-fitted from the injection port provided in the mold, and then injection molded. Therefore, compared with the conventional method of attaching a decorative sheet to a base material by a method such as hand lay-up or spray-up, a product superior in quality can be obtained and work can be performed. A resin molded product can be manufactured with good performance at low cost. Also, since the melting temperature of the base material is higher than the melting temperature of the thermoplastic resin layered on the outermost surface layer, the interface melts, the surface layer and the base material are integrated, and the rigidity is excellent Resin molded products can be manufactured.

  The method for producing a resin molded product according to claim 2 is as described above. In addition to the effects of the method for producing a resin molded product according to claim 1, the surface layer comprises a surface transparent layer, a decorative printing layer, an adhesive layer, It consists of a thermoplastic resin layer, and the thermoplastic resin layer on the backmost surface is melted and fused and integrated with the base material, preventing peeling and damage of the decorative print layer, and a glossy surface layer as the base It can be formed on the surface of the material, and a resin molded product excellent in design can be produced.

  The method for producing a resin molded product according to claim 3 is as described above. In addition to the effects of the method for producing a resin molded product according to claim 1, the preform molding is performed by a vacuum molding method, so that vacuum molding is possible. By using a simple injection mold, the two steps can be performed with a single device. As a result, handling is facilitated, work time can be reduced, and productivity can be improved. .

  The resin molded product according to claim 4 is as described above, and is a resin molded product in which a surface layer is attached to a base material, and the surface layer is a male mold that is a sheet body constituting the surface layer. From a thermoplastic resin layered on the outermost surface of the surface layer from the injection port provided in the mold, preformed in advance by a mold composed of a female mold so as to match the shape of the molded product body Also, it is obtained by melting and press-fitting a base material having a high melting temperature and injection-molding the base material so as to be fused to the back surface of the preform molded body. Used for.

  Hereinafter, an embodiment of a method for producing a resin molded product of the present invention will be described in detail with reference to the drawings. In the present embodiment, a bathtub will be described as an example of a resin molded product. FIG. 1 is an explanatory view schematically showing a state in which a sheet body A constituting a surface layer according to the present invention is preform-molded using an injection mold 5 that can be vacuum-molded. As shown in FIG. 1, the mold 5 includes a male mold 51 and a female mold 52, and the sheet body A is placed on the male mold 51 and includes an injection port 521 for injecting molten resin. By mounting the female mold 52 and removing the air in the space between the male mold 51 and the female mold 52, the sheet A is preformed into a shape that fits the inner surface of the bathtub as a resin molded product.

  2 is a cross-sectional view taken along line XX shown in FIG. As shown in FIG. 2, the sheet body A has a surface transparent layer 1, a decorative printing layer 2, an adhesive layer 3, and a thermoplastic resin layer 4 laminated in this order from the front side. FIG. 3 is an explanatory view schematically showing a state in which the thermoplastic resin constituting the base material B is melted and injected from the injection port 521 on the back side of the sheet body A preform-formed by the above-described method and injection-molded. It is.

  In FIG. 3, the thermoplastic resin constituting the base material B is in a molten state and comes into contact with the thermoplastic resin layer 4 provided on the outermost back surface of the sheet body A, but the melting temperature of the base material B is the thermoplastic resin. Since it is higher than the melting temperature of the layer 4, the thermoplastic resin layer 4 is melted and fused and integrated with the thermoplastic resin constituting the base material B. And after the base material B cools and solidifies, the metal mold | die 5 can be divided | segmented and the bathtub as the resin molded product P shown in FIG. 4 can be obtained.

  In FIG. 4, since the sheet body A backed up by the base material B is positioned as a surface layer of the bathtub, the decorative printing layer 2 can be visually recognized through the surface transparent layer 1, and a bathtub having excellent design can be obtained. In addition, since the adhesive layer 3 and the thermoplastic resin layer 4 are also fused, the surface layer and the base material B are integrated so that the bath has excellent chemical resistance and hot water resistance, and excellent rigidity. it can. In addition, in this embodiment, although the case where the method of this invention was applied to manufacture of a bathtub was demonstrated as an example, it is not limited to a bathtub, The method of this invention can be implemented to manufacture of various resin molded products. . In particular, the method of the present invention is suitably applied to water-circulating members that require chemical resistance and hot water resistance, and a resin molded product having excellent characteristics as described above can be obtained.

It is explanatory drawing which shows typically the state which preforms the sheet | seat body which comprises the surface layer concerning this invention. It is sectional drawing which follows the XX line shown in FIG. It is explanatory drawing which shows typically the state which melts and press-fits the thermoplastic resin which comprises a base material, and is injection-molded. It is a perspective view which shows the resin molded product concerning this invention.

Explanation of symbols

A sheet body B base material P resin molded product 1 surface transparent layer 2 decorative printing layer 3 adhesive layer 4 thermoplastic resin layer 5 mold 51 male mold 52 female mold 521 inlet

Claims (4)

  A method for producing a resin molded product in which a surface layer is adhered to a base material, wherein the surface layer is a molded product main body formed by a mold comprising a male mold and a female mold. The base material having a melting temperature higher than that of the thermoplastic resin layered on the outermost surface of the surface layer is melted and press-fitted from an injection port provided in the mold in advance. A method for producing a resin molded product obtained by injection molding a base material so as to be fused to the back surface of the preform molded body.   The resin molded product according to claim 1, wherein the surface layer comprises a surface transparent layer, a decorative printing layer, an adhesive layer, and a thermoplastic resin layer, and the thermoplastic resin layer is melted and fused and integrated with the base material. Manufacturing method.   The method for producing a resin molded product according to claim 1, wherein the preform molding is performed by a vacuum molding method.   A resin molded product in which a surface layer is attached to a base material, and the surface layer matches the shape of the molded product main body with a mold comprising a male mold and a female mold. Then, the preform is melted and pressed into a base material having a higher melting temperature than the thermoplastic resin layered on the outermost surface of the surface layer from the injection port provided in the mold. A resin molded product obtained by injection molding a base material so as to be fused to the back of the molded body.

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