JP2009184297A - Synthetic resin molded body and bathroom member using the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a more safe and comfortable bathroom molded product, which does not require additional investment for a mold, has an excellent productivity, texture, non-slippery property, water drying property, impact absorbing property, sound insulating property, durability and cleanliness, and also has good adhesiveness regarding a surface member and a substrate part, thereby being capable of suppressing a soft material from flowing when molding, and suppressing the molded product after molding from warping. <P>SOLUTION: The synthetic resin molded body comprises the substrate part 5 and the surface member 4 which is laminated on the substrate part 5, wherein the upper surface member is soft and has a surface onto which a fabric is transferred. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a synthetic resin molded body having a woven transfer surface on the surface and a soft surface, and more specifically, a sheet mold compound (hereinafter referred to as “SMC”) or bulk molding. The present invention relates to a bathroom member in which a base such as a compound (hereinafter referred to as “BMC”) is provided and a soft surface member having a transfer surface of a fabric is provided on the surface thereof.

  The bathroom floor, waterproof pan, bathroom wall, bathtub, bathtub apron, bathroom ceiling, etc. installed in the bathroom are usually made of resin (FRP), stainless steel, or enamel, etc., and have a smooth surface and profound feeling. There was a tendency to harden this to improve. Note that FRP is a plastic whose strength is improved by reinforcing it with fibers and resin.

  In addition, in order to further improve the safety in the bathroom, a soft safety bath has been proposed in which a soft material made of polyurethane foam is coated on an existing bathtub and can be replaced after use (see Patent Document 1). ).

Also, a soft material having a thermoplastic elastomer layer and a foamed layer is molded in advance by vacuum forming, and this is set in a mold, and a FRP backup layer is laminated and integrated (see Patent Document 2), An artificial marble (see Patent Document 3) in which a surface resin layer is formed of a soft resin such as an acrylic-modified vinyl ester resin and a base resin layer is formed of a material obtained by adding a filler to a soft resin such as an acrylic-modified vinyl ester resin. Proposed.
JP-A-7-236587 Japanese Patent Laid-Open No. 10-80958 JP 2000-62098 A

  However, according to the method of Patent Document 1, since it is formed of a foamed polyurethane that is soft and weak in strength, there is a problem in that durability is insufficient and costs are further increased during replacement. Further, the soft material has a problem that it is dirty due to dirt, sliminess, and the like.

  In addition, the methods of Patent Document 2 and Patent Document 3 require many steps as compared with conventional SMC molding and the like, and require time. It was also difficult to prevent slippage.

  On the other hand, bathroom moldings have been proposed in which a soft material such as soft BMC or rubber is provided on the surface of the molded product by press-molding, and fine unevenness formed by transferring the mold shape to the surface to suppress slippage. However, in order to impart the desired fine uneven shape, it was necessary to invest a large amount of new molds to produce a mold having the desired shape.

  The present invention solves the above-mentioned problems, and does not require investment in a new mold, and it is productivity, touch, resistance to slipping, water drying, shock absorption, soundproofing, durability, and cleanliness. The purpose is to provide a safer and more comfortable bathroom molded product that has excellent adhesion between the surface member and the base and can suppress the flow of the soft material during molding and the molded product warpage after molding. And

The present invention relates to the following.
(1) A synthetic resin molding comprising a base and a surface member laminated on the base, wherein the upper surface member is soft and has a woven fabric transfer surface on the surface.
(2) In the item (1), the surface member is a multilayer structure sheet having a base fabric and a surface member adhesive layer made of rubber on either one of the front and back surfaces of the base fabric. A synthetic resin molding in which a surface member and a base are press-molded as an adhesive layer with an SMC or BMC base.
(3) In item (2), the base fabric has a surface member surface layer on a surface opposite to the surface on which the surface member adhesive layer is provided, and the surface member surface layer is a rubber layered on the base fabric. The synthetic resin molding which provided the fabric on the product side of the surface member surface layer at the time of lamination | stacking, and transcribe | transferred the shape of the fabric to the surface member surface layer.
(4) In any one of items (1) to (3), between the surface member and the base portion, there is an intermediate material that has been subjected to adhesion treatment on one or both of the front and back sides, and the surface member, the intermediate material, and the base portion. Synthetic resin molding that is integrally molded by pressing.
(5) It is constructed in the order of the surface member surface layer, the base fabric, the surface member adhesive layer, and the base portion from the product surface, or the surface member surface layer, the base fabric, the surface member adhesive layer, the intermediate material, and the base portion, and the surface member surface layer is chlorosulfone. A synthetic resin molded body in which a polyethylene polyethylene rubber, a base fabric made of polyester or nylon, a surface member adhesive layer is chloroprene rubber, an intermediate material is a metal or resin plate or film, and a base is FRP.
(6) In item (5), the surface member surface layer and the surface member adhesive layer of the surface member are rubber sheets that are vulcanized in advance, and the shape of the fabric is transferred to the surface member surface layer during vulcanization and press integral molding, Synthetic resin molded product that peels off the fabric after press molding.
(7) In the item (5) or (6), the surface member adhesive layer, which is an adhesive layer between the surface member and the base, is chloroprene rubber, and the synthetic resin in which the adhesive surface side of the chloroprene rubber and the base is buffed Molded body.
(8) The synthetic resin molded article according to any one of items (1) to (7), wherein the average value of the arithmetic average roughness Ra of the transfer surface of the woven fabric is 0.5 μm or more.
(9) A bathroom member having a bathroom floor, a waterproof pan, a bathroom wall, a bathtub, a bathtub apron, or a bathroom ceiling, using the synthetic resin molding according to any one of (1) to (8).

  According to the present invention, there is no need to invest in a new mold, and it is excellent in productivity, touch, resistance to slipping, dryness, shock absorption, soundproofing, durability, cleanliness, and the surface member and the base. It is possible to provide a safer and more comfortable bathroom molded article having good adhesiveness and capable of suppressing the flow of the soft material during molding and the molded product warpage after molding.

The present invention will be described below with reference to the drawings.
As shown in FIGS. 1, 2, and 3, the cross-sectional structure of the synthetic resin molded body having a soft member on the surface in the present invention is the surface member 4 and the base portion 5 or the surface member 4 and the intermediate member 6 and the base portion. 5, the surface member 4 is a multilayer structure sheet in which rubber is laminated (topped) on both sides or one side of the base fabric 2, the base portion 5 is FRP using SMC or BMC, and the intermediate material 6 is made of metal or resin A plate or film is formed by press-molding the above-mentioned surface member and base, or the surface member, intermediate material, and base.

The multilayer structure sheet used for the surface member 4 can be formed by topping the various rubbers on the upper and lower sides of the fibers to be the base fabric 2 or only on the fibers to be the base fabric 2 in accordance with the purpose and application. The surface layer 1 of the surface member 4 that is the product surface includes chlorosulfonated polyethylene rubber having excellent durability, weather resistance, oil resistance, and wear resistance, silicon rubber, natural rubber, butadiene rubber, chloroprene rubber, Various soft materials such as fluororubber, EPDM, polyurethane, and polyamide can be used.
In addition, it is preferable to use chloroprene rubber that is easy to bond and strong and suitable for applications that require adhesion processing, as the surface member adhesive layer 3 of the surface member 4 that serves as an adhesive surface with FRP. Various soft materials such as sulfonated polyethylene rubber, silicon rubber, natural rubber, butadiene rubber, fluororubber, EPDM, polyurethane, polyamide and the like can be used.
The topping process is thin on one side or both sides of the cloth by applying a sheet and cloth or resin of various cloth-like materials through two constant speed rolls while simultaneously pressing them. This is a process to make a composite with a rubber layer.

The soft material used for the surface member 4 is preferably a vulcanized rubber material in order to suppress deformation and flow of the soft material during molding and warpage of the molded product after molding. The vulcanized state can be adjusted according to the adhesion to the base 5 and the fluidity at the time of molding, and an unvulcanized or semi-vulcanized rubber material may be used. Here, the semi-vulcanized state refers to a state in which the rubber material is not completely vulcanized but vulcanized once before the crosslinking reaction is completed. The semi-vulcanized state is 70 to 90% when the torque value measured with a curast meter (model: JSR-3 type, manufactured by Nippon Synthetic Rubber Co.) is 100% of the complete vulcanized state. It is desirable that If it is less than 70%, the flow of the soft material becomes large at the time of molding, and if it exceeds 90%, the transferability and adhesion are reduced to the same level as in a completely vulcanized state. Soft materials such as a vinyl chloride sheet, a thermoplastic elastomer, and a foam material can also be used.
Further, the hardness of the surface member 4 is not particularly specified, but the hardness when measured by the durometer hardness test type D is preferably 80 or less. This is for imparting shock absorption and suppressing warpage after molding.

The surface member surface layer 1 and the surface member adhesive layer 3 of the surface member 4 can be subjected to surface treatment for the purpose of protecting the surface member surface layer 1 and improving adhesion to the base 5 of the surface member adhesive layer 3. The surface member surface layer 1 can be subjected to surface treatment with surface treatment agents such as various top coat agents and hot melt agents, in addition to, for example, coating or film application.
For the surface member adhesive layer 3, for example, buffing treatment, painting, film application, epoxy resin adhesive, cyanoacrylate adhesive, polyurethane adhesive, urea resin adhesive, melamine resin adhesive , Acrylic modified silicone resin adhesive, phenol resin adhesive, vinyl acetate resin adhesive, chloroprene rubber solvent adhesive, synthetic rubber latex adhesive, isocyanate adhesive, emulsion adhesive, hot melt In addition to applying various adhesives such as a shape adhesive and a silane coupling agent, a degreasing treatment, a sanding treatment, a corona discharge treatment, a plasma treatment, a flame treatment, an ozone treatment, an acid treatment and the like can be performed. In addition, various additives such as fillers, foaming agents, antioxidants, heat stabilizers, ultraviolet absorbers, and light stabilizers can be added and colored as necessary during the surface treatment. Moreover, it can contain antifungal and antibacterial agents, and commercially available industrial antibacterial agents can be used. In general, industrial antibacterial agents are roughly classified into inorganic antibacterial agents and organic antibacterial agents, and any antibacterial agent can be used for the surface member 4 of the present invention.

  The base fabric 2 used for the surface member 4 can use various fibers such as polyester fiber, nylon fiber, glass fiber, natural fiber, metal fiber, and ceramic fiber, and can be subjected to treatment such as adhesion treatment as necessary. . The form of the fiber may be any form such as plain weave, satin weave, non-woven fabric, and mat.

  Various additives such as a filler, a foaming agent, an antioxidant, a heat stabilizer, an ultraviolet absorber, and a light stabilizer can be added to the surface member 4 as necessary. Moreover, it can contain antifungal and antibacterial agents, and commercially available industrial antibacterial agents can be used. In general, industrial antibacterial agents are roughly classified into inorganic antibacterial agents and organic antibacterial agents, and any antibacterial agent can be used for the surface member 4 of the present invention.

  The surface member 4 can be colored and colored by adding a pigment or a liquid or pasty pigment as a toner to the material constituting the surface member 4. Moreover, the film etc. which performed printing of gravure printing, screen printing, inkjet printing, etc. on the sheet-like surface member 4 or printing of gravure printing, screen printing, inkjet printing etc. on the product surface side of the surface member 4 etc. Can be prepared.

  The thickness of the surface member 4 shall be 10-5000 micrometers. This is because when the thickness is less than 10 μm, the effect of the soft texture and the impact absorption is reduced, and when it exceeds 5000 μm, the strength balance of the molded product becomes poor. The thickness ratio between the surface member 4 and the base 5 is determined by the required soft texture, shock absorption, strength, and the like.

  As the material of the base 5, it is preferable to use SMC and BMC which are inexpensive, high strength and excellent in productivity, but in addition, thermosetting resins such as polyester resins and epoxy resins, and thermoplastic resins are used. Can do. Moreover, it is preferable that the thickness of the base 5 shall be 1-20 mm. This is because when the thickness is less than 1 mm, the strength of the molded product gradually decreases, and when it exceeds 20 mm, the weight of the molded product gradually increases and the moldability also decreases.

  The SMC used for the material of the base 5 is an unsaturated polyester resin that is a thermosetting resin, a polymerizable monomer, a low shrinkage agent, a curing agent, a polymerization inhibitor, a filler, and a thickener. A fiber-reinforced molding material obtained by impregnating a saturated polyester resin composition into a fiber reinforcing material, which is formed into a sheet shape. BMC is a lump clay-shaped molding material in which various additives and fiber reinforcing materials are added to a resin.

  As the thermosetting resin, an unsaturated polyester resin is often used, and a vinyl ester resin, an epoxy acrylate resin, a urethane acrylate resin, a phenol resin, a diallyl phthalate resin, or the like can be used.

  The polymerizable monomer is, for example, styrene derivatives such as styrene, chlorostyrene, divinylbenzene, tertiary butyl styrene, styrene bromide, methacrylic acid such as methyl methacrylate, ethyl methacrylate, ethyl acrylate, butyl acrylate, or the like. Examples thereof include alkyl esters of acrylic acid, hydroxyalkyl esters of methacrylic acid or acrylic acid such as β-hydroxyethyl methacrylate and ethyl β-hydroxyacrylate, diallyl phthalate, acrylamide, and phenylmaleimide.

  As the low shrinkage agent, thermoplastic resins such as polymethyl methacrylate, polystyrene, polycaprolactone, polyvinyl acetate, polyethylene, and butadiene rubber are used. The amount used is determined in consideration of surface properties such as molding shrinkage, surface smoothness, and surface gloss of the molded product, and is not particularly limited. The low shrinkage agent is preferably used in a range of 20 to 50% by mass with respect to the total amount of the unsaturated polyester resin and the polymerizable monomer.

  Examples of the curing agent include ketone peroxides, peroxydicarbonates, hydroperoxides, diacyl peroxides, peroxyketals, dialkyl peroxides, peroxyesters, alkyl peresters, and the like. The amount of the curing agent is preferably 0.5 to 5.0 mass%, more preferably 1.0 to the total amount of the unsaturated polyester resin and the polymerizable monomer in terms of the storage stability of the material and the molding cycle. 3.0% by mass.

  Examples of the polymerization inhibitor include p-benzoquinone, naphthoquinone, tolquinone, hydroquinone, mono-t-butylhydroquinone, dibutylhydroxytoluene and the like. The polymerization inhibitor is preferably used in an amount of 0.8% by mass or less based on the total amount of the unsaturated polyester resin and the polymerizable monomer.

  As the filler, calcium carbonate or aluminum hydroxide can be used. The content is determined in consideration of thickening, molding surface properties, mechanical properties, etc., but is added so that the content in the unsaturated polyester resin composition is 10% by mass or more and 60% by mass or less. It is done.

  As the thickener, magnesium oxide, magnesium hydroxide, potassium oxide, potassium hydroxide or the like is used, and generally magnesium oxide is used. The amount of the thickener is determined according to the workability of the molding material, but is preferably 0.5 to 5.0% by mass with respect to the total amount of the unsaturated polyester resin and the polymerizable monomer. Preferably it is 0.7-2.0 mass%.

  As the fiber reinforcing material, glass fiber or organic fiber can be used. The glass fiber is used in the form of continuous fiber, woven fabric, etc., but it is preferable to use a roving-shaped one cut to 5 to 30 mm.

  A release agent, a stabilizer, a colorant, and the like can be further appropriately blended with the unsaturated polyester resin composition.

  SMC can be manufactured by a normal method using a normal SMC manufacturing apparatus. For example, the unsaturated polyester resin composition is applied to a carrier film disposed above and below so as to have a uniform thickness, and a fiber reinforcing material of a predetermined size unwound from an unwinding device is moved up and down as described above. After saturating with the unsaturated polyester resin composition on the placed carrier film and then passing the whole through an impregnation roll to apply pressure to impregnate the unsaturated polyester resin composition with the fiber reinforcement, Wind it up in a roll and fold it into flat folds. Moreover, when using a single fiber as a fiber reinforcement, there also exists the method of apply | coating an unsaturated polyester resin composition to a carrier film, and then spraying a single fiber on it. Thereafter, aging or the like is performed as necessary. When a thickener is blended, it is preferably aged by heating to room temperature to 60 ° C.

  The viscosity of SMC is preferably adjusted to 15,000 to 150,000 Pa · s at 40 ° C., and particularly preferably adjusted to 60,000 to 120,000 Pa · s.

  When the SMC produced as described above is used as the base 5, cracks are less likely to occur when subjected to an impact during transportation or the like, and excellent strength and characteristics can be imparted as a bathroom member.

The intermediate material 6 can be a metal or resin plate or film, and can alleviate the influence of deformation of the surface member 4 due to the flow pressure of the SMC 9 and the molding temperature and pressure during molding, and the solvent component can be applied to each layer. Can be prevented from moving. The intermediate material 6 can be, for example, an aluminum plate, a steel plate, a copper plate, an aluminum foil, a steel plate, a copper foil, a metal vapor deposition film, or a film made of various resins such as a PET film, and can be appropriately selected depending on a molding method and molding conditions. Use.
Further, the front or back or both surfaces of the intermediate material 6 can be subjected to an adhesive treatment, for example, buffing treatment, painting, film application, epoxy resin adhesive, cyanoacrylate adhesive, polyurethane adhesive , Urea resin adhesive, melamine resin adhesive, acrylic modified silicone resin adhesive, phenol resin adhesive, vinyl acetate resin adhesive, chloroprene rubber solvent adhesive, synthetic rubber latex adhesive, Apply various adhesives such as isocyanate adhesives, emulsion adhesives, hot melt adhesives, silane coupling agents, etc., degreasing treatment, sanding treatment, corona discharge treatment, plasma treatment, flame treatment, ozone treatment Further, treatment such as acid treatment can be performed. In addition, various additives such as fillers, foaming agents, antioxidants, heat stabilizers, ultraviolet absorbers, and light stabilizers can be added and colored as necessary during the surface treatment.

  The bathroom member provided with a soft material on the surface of the present invention, as shown in FIGS. 4, 5, 6 and 7, is a surface member 4 and SMC9, a surface member 4 and an intermediate material 6 and SMC9, or a fabric. 10, the surface member 4, the intermediate material 6, and the SMC 9 can be manufactured by pressing (heating and pressurizing) integral molding, and the surface member 4 and the SMC 9 are bonded to each other by heat or pressure in the mold, and the surface member 4 and the SMC 9 are intermediate. The material 6 is bonded, the shape of the surface member 4 is given to the surface member surface layer 1, and the shape is given to the surface member surface layer 1 of the surface member 4 by the fabric 10 to obtain the molded products shown in FIGS. 1, 2, and 3.

  In the case of heat and pressure integral molding, the surface member 4 and the SMC 9, the surface member 4 and the intermediate material 6 and the SMC 9, Alternatively, the fabric 10, the surface member 4, the intermediate material 6, and the SMC 9 are set and heated and pressurized. The molding temperature is preferably 70 to 180 ° C., and the molding pressure is preferably 0.05 to 10 MPa.

  The surface shape of the surface member surface layer 1 of the surface member 4 is determined by the method of transferring the shape of the mold to the surface member surface layer 1 at the time of press integral molding, and the shape of the fabric at the time of vulcanization of the surface member surface layer 1 or at the time of press integral molding. There is a method of transferring to the surface member surface layer. The fabric used in the latter method is preferably adhered to the surface member surface layer 1 before vulcanization, vulcanized and press-integrated in this state, and the fabric is peeled off from the surface member surface layer 1 after molding. The shape of the fabric can be transferred to the surface of the surface member surface layer 1 by bringing the fabric into close contact with the surface member surface layer 1 at the time of molding and peeling the fabric after the molding.

  The transfer surface of the fabric 10 when the shape of the fabric is transferred to the surface member surface layer 1 is an evaluation length of 20 mm, a measurement speed of 0.6 mm / s, a cut-off value of 0.08 mm, and a filter. If the woven fabric has an average value of the arithmetic average roughness Ra of 0.5 μm or more, more preferably 0.7 μm or more when measuring three or more arbitrarily selected points with a type of Gaussin and a cutoff ratio of 300 Good. Moreover, although the kind of fabric is determined according to a use, for example, various fibers, such as polyester fiber, nylon fiber, glass fiber, natural fiber, metal fiber, ceramic fiber, can be used, and the form of the fabric is plain weave, Any form such as satin weave, non-woven fabric, and mat may be used. In addition, the unevenness of the surface member surface layer 1 obtained by transferring the shape of the fabric makes the surface of the surface member surface layer 1 hydrophilic to improve water drying, and prevents slipping and falling by the grip effect of the fine unevenness. Can do.

  In addition to the transfer shape of the fabric, the surface of the surface member surface layer 1 is provided with narrow and deep grooves having a width of 200 to 5000 μm, a depth of 200 to 5000 μm, and a substantially U-shaped or V-shaped cross section, and an uneven shape. it can. In this case, the surface of the surface member 1 is provided with a thin deep groove or uneven shape in addition to the transfer shape of the fabric by press-molding with a mold having a thin deep groove or uneven shape on the surface and peeling the fabric after forming. Can be formed.

  The transfer of the fabric can also be performed on the surface of the base 5. In this case, a synthetic resin molded body having a woven fabric transfer surface on the surface can be obtained by integrally molding the fabric and the base material without molding the surface member 4 at the time of molding and peeling the fabric after molding. In addition to SMC and BMC, thermosetting resin, thermoplastic resin, etc. can be used for the material of a base, and it can manufacture with various shaping | molding methods, such as press molding and injection molding.

(Production of SMC)
In the following examples and comparative examples, SMCs were produced as follows.
85 parts by mass of unsaturated polyester resin dissolved in styrene (trade name: PS-9415, manufactured by Hitachi Chemical Co., Ltd.) (60 parts by mass of styrene) and 15 parts by mass of polystyrene dissolved in styrene (60 parts by mass of styrene) 100 parts by mass of the mixture, 1.0 part by mass of the curing agent, 0.77 parts by mass of the parabenzoquinone polymerization inhibitor, 2.5 parts by mass of the zinc stearate release agent, and magnesium oxide 2 of the thickener 0.0 part by mass and 150 parts by mass of calcium carbonate as a filler were blended to obtain an unsaturated polyester resin composition. The unsaturated polyester resin composition obtained by blending in this manner was impregnated into glass fibers to produce SMC.

(Example 1)
A multilayer structure sheet 4 topped with chlorosulfonated polyethylene rubber on the surface member surface layer 1 side of the polyester base fabric 2 and completely vulcanized, and SMC 9 are placed on the lower mold 8 as shown in FIG. Then, a 200 mm square molded product having the configuration shown in FIG. 1 was obtained by heat and pressure molding. As the multilayer structure sheet 4, Hypalon (DuPont Performance Elastomers LLC) registered rubber (trade name: T-10, manufactured by Achilles Co., Ltd.) was used. The molding conditions were such that the SMC input weight was 300 g, the charge area was 0.05 m ² (15 cm square), the molding pressure was 3 MPa, and the holding time was 10 minutes, and the lower mold 8 was a mirror surface mold.

(Example 2)
As shown in FIG. 5, a multilayer structure sheet 4 topped with chlorosulfonated polyethylene rubber and vulcanized completely on both the surface member surface layer 1 side and the surface member adhesive layer 3 side of the polyester base fabric 2 and SMC 9 Then, it was put on a mold, and a 200 mm square molded product having the configuration shown in FIG. 2 was obtained by heat and pressure molding. As the multilayer structure sheet 4, Hypalon (DuPont Performance Elastomers LLC) registered rubber (trade name: T-10, manufactured by Achilles Co., Ltd.) was used. The molding conditions were such that the SMC input weight was 300 g, the charge area was 0.05 m ² (15 cm square), the molding pressure was 3 MPa, and the holding time was 10 minutes, and the lower mold 8 was a mirror surface mold.

(Example 3)
As shown in FIG. 5, a multilayer structure sheet 4 topped with chlorosulfonated polyethylene rubber on the surface member surface layer 1 side of the polyester base fabric 2 and chloroprene rubber on the surface member adhesive layer 3 side and completely vulcanized, and SMC 9 are shown in FIG. Then, it was put on the lower mold 8 and molded by heating and pressing to obtain a 200 mm square molded product having the configuration shown in FIG. As the multilayer structure sheet 4, Hypalon (DuPont Performance Elastomers LLC) registered rubber (trade name: T-10, manufactured by Achilles Co., Ltd.) was used. The molding conditions were such that the SMC input weight was 300 g, the charge area was 0.05 m ² (15 cm square), the molding pressure was 3 MPa, and the holding time was 10 minutes, and the lower mold 8 was a mirror surface mold.

Example 4
FIG. 5 shows a multilayer structure sheet 4 in which a chlorosulfonated polyethylene rubber is topped on the surface member surface layer 1 side of the polyester base fabric 2 and a chloroprene rubber is topped on the surface member adhesive layer 3 side to be in a semi-vulcanized state, and SMC 9. As described above, a 200 mm square molded article having the configuration shown in FIG. As the multilayer structure sheet 4, Hypalon (DuPont Performance Elastomers LLC) registered rubber (trade name: T-10, manufactured by Achilles Co., Ltd.) was used. The semi-vulcanized state here is 80% when the torque value measured with a curast meter (model: JSR-3 type, manufactured by Nippon Synthetic Rubber Co., Ltd.) is 100% as the complete vulcanized state. It became a state. The molding conditions were such that the SMC input weight was 300 g, the charge area was 0.05 m ² (15 cm square), the molding pressure was 3 MPa, and the holding time was 10 minutes, and the lower mold 8 was a mirror surface mold.

(Example 5)
After covering the polyester base fabric 2 with chlorosulfonated polyethylene rubber on the surface member surface layer 1 side and chloroprene rubber on the surface member adhesive layer 3 side and completely vulcanizing it, buffing the surface of the chloroprene rubber to be the adhesive surface with SMC9 The multilayer structure sheet 4 and the SMC 9 were placed on the lower mold 8 as shown in FIG. 5, and a 200 mm square molded product having the configuration shown in FIG. 2 was obtained by heat and pressure molding. As the multilayer structure sheet 4, Hypalon (DuPont Performance Elastomers LLC) registered rubber (trade name: T-10, manufactured by Achilles Co., Ltd.) was used. Buffing was performed using # 100 abrasive paper. The molding conditions were such that the SMC input weight was 300 g, the charge area was 0.05 m ² (15 cm square), the molding pressure was 3 MPa, and the holding time was 10 minutes, and the lower mold 8 was a mirror surface mold.

(Example 6)
After covering the polyester base fabric 2 with chlorosulfonated polyethylene rubber on the surface member surface layer 1 side and chloroprene rubber on the surface member adhesive layer 3 side and completely vulcanizing it, buffing the surface of the chloroprene rubber to be the adhesive surface with SMC9 The multilayer structure sheet 4, the intermediate material 6, and the SMC 9 were put on the lower mold 8 as shown in FIG. 6, and a 200 mm square molded product having the configuration shown in FIG. 3 was obtained by heat and pressure molding. . As the multilayer structure sheet 4, Hypalon (DuPont Performance Elastomers LLC) registered rubber (trade name: T-10, manufactured by Achilles Co., Ltd.) was used. Buffing was performed using # 100 abrasive paper. The intermediate material 6 is a 0.3 mm steel plate, polished with a hot melt adhesive on the adhesive surface of the intermediate material with the surface member adhesive layer, and polished with # 100 abrasive paper on the adhesive surface with the base, and then the cup. Ring agent treatment was performed. The molding conditions were such that the SMC input weight was 300 g, the charge area was 0.05 m ² (15 cm square), the molding pressure was 3 MPa, and the holding time was 10 minutes, and the lower mold 8 was a mirror surface mold.

(Example 7)
After covering the polyester base fabric 2 with chlorosulfonated polyethylene rubber on the surface member surface layer 1 side and chloroprene rubber on the surface member adhesive layer 3 side and completely vulcanizing it, buffing the surface of the chloroprene rubber to be the adhesive surface with SMC9 The multilayer structure sheet 4, the intermediate material 6, and the SMC 9 were put on the lower mold 8 as shown in FIG. 6, and a 200 mm square molded product having the configuration shown in FIG. 3 was obtained by heat and pressure molding. . As the multilayer structure sheet 4, Hypalon (DuPont Performance Elastomers LLC) registered rubber (trade name: T-10, manufactured by Achilles Co., Ltd.) was used. Buffing was performed using # 100 abrasive paper. The intermediate material is a 0.3 mm steel plate, the surface of the intermediate material is bonded to the surface member adhesive layer with a hot melt adhesive, and the surface of the intermediate material is ground with # 100 abrasive paper before coupling. Agent treatment was performed. The molding conditions were as follows: SMC input weight 300 g, charge area 0.05 m ² (15 cm square), molding pressure 3 MPa, pressure holding time 10 minutes, and the lower mold 8 had an average value of arithmetic average roughness Ra on the surface. Used a mold with 1.1 μm fine irregularities.

(Example 8)
The polyester base fabric 2 is topped with a chlorosulfonated polyethylene rubber on the surface member surface layer 1 side and a chloroprene rubber on the surface member adhesive layer 3 side, and a polyester fabric 10 is brought into close contact with the product surface side of the surface member surface layer 1 After the vulcanization, the multilayer structure sheet 4, the intermediate material 6 and the SMC 9 buffed with the surface of the chloroprene rubber to be bonded to the SMC 9 are put on the lower mold 8 as shown in FIG. After the heat and pressure molding, the fabric 10 was peeled from the molded product to obtain a 200 mm square molded product having the configuration shown in FIG. As the multilayer structure sheet 4, Hypalon (DuPont Performance Elastomers LLC) registered rubber (trade name: T-10, manufactured by Achilles Co., Ltd.) was used. Buffing was performed using # 100 abrasive paper. The intermediate material is a 0.3 mm steel plate, the hot melt adhesive is applied to the adhesive surface of the intermediate material with the surface member adhesive layer, and the adhesive surface with the base is polished with # 100 abrasive paper, A coupling agent treatment was performed. The molding conditions were such that the SMC input weight was 300 g, the charge area was 0.05 m ² (15 cm square), the molding pressure was 3 MPa, and the holding time was 10 minutes, and the lower mold 8 was a mirror surface mold.

(Comparative Example 1)
SMC9 was put on the lower mold 8 and a 200 mm square molded product was obtained by heat and pressure molding. The molding conditions were as follows: SMC input weight 300 g, charge area 0.05 m ² (15 cm square), molding pressure 3 MPa, pressure holding time 10 minutes, and the lower mold 8 had an average value of arithmetic average roughness Ra on the surface. Used a mold with 1.1 μm fine irregularities.

(Test method)
(1) Evaluation of shock absorbency A table tennis ball was dropped from a height of 500 mm on the obtained molded product, the bounce height was measured, and the shock absorbency was compared and evaluated.
(2) Adhesive evaluation between surface member and base portion Adhesive evaluation between the surface member 4 and the base portion 5 is evaluated when the strength when the tensile test of the surface member 4 of the integrally molded product is 30 N or more is 10N. The case of less than 30N was evaluated as Δ, and the case of 10N or less was evaluated as x.
(3) Evaluation of deformation of soft material at the time of integral molding Evaluation of deformation of the soft material used as the surface member 4 when the surface member 4 and the base 5 are integrally formed by pressing is performed by the pressure of the soft material at the time of molding in the integral molding. The case where the shape was maintained without being deformed due to the influence was evaluated as ◯, the case where the shape was slightly deformed was evaluated as Δ, and the case where the shape was deformed and could not be maintained was evaluated as ×.
(4) Evaluation method of resistance to slipping The obtained molded product was poured with 5% strength soap water, a weight of 90 g was placed, the molded product was tilted little by little, and the angle at which the weight began to slide down was read.
(5) Necessity evaluation of mold investment The necessity of mold investment when the average value of arithmetic average roughness Ra is 0.5 μm or more, more preferably 0.7 μm or more is given to the surface of the molded product. evaluated.
(6) Evaluation of soundproofing performance When the bathroom chair is dragged on the obtained molded product, the case where the value is 10 dB or more smaller than the noise value 65 dB of the SMC molded product is less than ◯, less than 10 dB or equivalent, The case where it was equal or less was marked with x.

As a result, as shown in Tables 1 and 2, the molded product in which the base 5 of the present invention is arranged and the soft surface member 4 and the intermediate material 6 are provided on the surface of the molded product is more impact than the conventional SMC molded product. It is absorptive and can suppress impact even when something is dropped.
Further, by transferring the fine irregularities and the shape of the fabric onto the surface of the soft member, the angle on which the weight on the molded product starts to slide when the molded product is tilted is large and difficult to slide. After covering the polyester base fabric 2 with chlorosulfonated polyethylene rubber on the surface member surface layer 1 side and chloroprene rubber on the surface member adhesive layer 3 side and completely vulcanizing it, buffing the surface of the chloroprene rubber to be the adhesive surface with SMC9 When the multilayer structure sheet 4 was used and when the intermediate material 6 was used, excellent results were obtained with excellent suppression of deformation of the soft material, integral adhesion, and productivity during integral molding.

It is a cross-sectional block diagram of the bathroom molded product of Example 1 of this invention. It is a section lineblock diagram of a bathroom molding of Examples 2-5 of the present invention. The lower mold uses either a mirror surface or a surface with fine irregularities on the surface, but the latter is represented by the latter in this figure. It is a section lineblock diagram of a bathroom molding of Examples 6-8 of the present invention. It is a figure which shows the manufacturing method of the bathroom molded product of the bathroom molded product of Example 1 of this invention. It is a figure which shows the manufacturing method of the bathroom molded product of the bathroom molded product of Examples 2-5 of this invention. The lower mold uses either a mirror surface or a surface with fine irregularities on the surface, but the latter is represented by the latter in this figure. It is a figure which shows the manufacturing method of the bathroom molding of the bathroom molding of Examples 6-7 of this invention. It is a figure which shows the manufacturing method of the bathroom molded article of the bathroom molded article of Example 8 of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Surface member surface layer (rubber), 2 ... Base cloth, 3 ... Surface member adhesion layer (rubber), 4 ... Surface member (multilayer structure sheet), 5 ... Base part (FRP), 6 ... Intermediate material, 7 ... Upper metal Mold, 8 ... Lower mold, 9 ... SMC, 10 ... Textile

Claims (9)

  A synthetic resin molding comprising a base and a surface member laminated on the base, wherein the upper surface member is soft and has a woven fabric transfer surface on the surface.   In Claim 1, the surface member is a multilayer structure sheet having a base fabric and a rubber surface member adhesive layer on one of the front and back surfaces of the base fabric, and the surface member adhesive layer is made of SMC or BMC. A synthetic resin molding in which a surface member and a base are press-molded integrally as an adhesive layer with the base.   3. The base cloth according to claim 2, wherein the base cloth has a surface member surface layer on a surface opposite to the surface on which the surface member adhesive layer is provided, and the surface member surface layer is a rubber layered on the base cloth. A synthetic resin molding comprising a woven fabric on the product surface side of the member surface layer and transferring the shape of the woven fabric to the surface member surface layer.   The synthetic resin according to any one of claims 1 to 3, wherein an intermediate material having an adhesive treatment applied to one or both of the front and back sides is provided between the surface member and the base, and the surface member, the intermediate material, and the base are press-molded integrally. Molded body.   It is constructed in the order of surface member surface layer, base fabric, surface member adhesive layer, base from the product surface, or surface member surface layer, base fabric, surface member adhesive layer, intermediate material, base, and the surface member surface layer is chlorosulfonated polyethylene rubber. A synthetic resin molding in which the base fabric is a polyester or nylon base fabric, the surface member adhesive layer is chloroprene rubber, the intermediate material is a metal or resin plate or film, and the base is FRP.   In claim 5, the surface member surface layer and the surface member adhesive layer of the surface member are rubber sheets vulcanized in advance, the shape of the fabric is transferred to the surface member surface layer during vulcanization and press integral molding, and after press integral molding Synthetic resin molding that peels fabric.   The synthetic resin molded body according to claim 5 or 6, wherein the surface member adhesive layer which is an adhesive layer between the surface member and the base is chloroprene rubber, and the adhesive surface side between the chloroprene rubber and the base is buffed.   The synthetic resin molded body according to any one of claims 1 to 7, wherein the average value of the arithmetic average roughness Ra of the transfer surface of the woven fabric is 0.5 µm or more.   The bathroom member of the bathroom floor, waterproof pan, bathroom wall, bathtub, bathtub apron, or bathroom ceiling using the synthetic resin molding as described in any one of Claims 1 thru | or 8.

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