JP2010195871A - Reproduced melamine resin material for compression molding, reproduced melamine resin molded article, method for manufacturing the same, and tableware - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a reproduced melamine resin material for compression molding which is excellent in conformability for a molding shape, inhibits overcure even in compression molding, is surely solidified, and is also excellent in impact durability after molding; and to provide a reproduced melamine resin molded article obtained by compression molding of the material, and the like. <P>SOLUTION: A ground powder of the waste melamine resin molded article which does not contain a ground powder of the reproduced melamine resin molded article as a principal constituent is mixed with a melamine resin material containing no reproduced melamine resin material, and an amount of the blended ground powder is a ratio of 50-65% based on a total weight. The reproduced melamine resin material for compression molding of the reproduced melamine resin molded article contains a black coloring agent with a ratio of at least 0.5% based on the total weight, and mat crimp processing 1s is given across the entire surface after molding. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

  The present invention relates to a compression-molded regenerated melamine resin material used for compression molding, a regenerated melamine resin molded product obtained by compression-molding the material, a regenerated melamine resin molded product which is compression-molded into a tableware shape, and regenerated melamine The present invention relates to a method for producing a resin molded product.

  A melamine resin molded product, which is a thermosetting resin, does not remelt even when heat is applied, and becomes brittle enough to be heated and compressed. Therefore, it is difficult to use a used product for compression molding again. For this reason, in general, the used melamine resin molded article is recycled and used as a sandblasting material, an abrasive, and a heat source, or is treated as an incombustible material, and has not been put into practical use.

  However, the literature discloses a manufacturing method in which a decorative board having a melamine resin layer is finely pulverized and mixed with a thermoplastic resin material and molded by injection molding (see Patent Document 1). This is a method of manufacturing a flat plate used for drawers of desks, which are resin products, by injection molding. The top plate of desks, etc., collected as used is made of polypropylene resin material, which is a thermoplastic resin material. The plate is used as crushed pieces, and kneaded pellets obtained by mixing the crushed pieces are used.

JP 2001-113554 A

  However, the above discloses a manufacturing method by injection molding. If reclaimed melamine resin molding is performed by compression molding, shape conformability is lacking, solidification is not sure due to occurrence of overcuring, or molding is performed. It will be lacking in impact resistance later.

  These are based on the fact that the once formed melamine resin itself is not plasticized again and does not cause a curing reaction, and therefore does not solidify even if the melamine resin molded product is pulverized and molded.

  Therefore, in the present invention, a regenerated melamine resin material for compression molding that is excellent in molding shape compatibility, hardly overcurs even by compression molding, solidifies reliably, and has excellent impact durability after molding. And providing a method for producing a regenerated melamine resin molded product, tableware, and a regenerated melamine resin molded product obtained by compression molding.

In order to solve the above problems, the present invention takes the following means (1) to (6).
(1) The recycled melamine resin material 10 for compression molding according to the present invention includes a pulverized powder of a used melamine resin molded product that does not contain a pulverized powder of a recycled melamine resin molded product as a main component, and a melamine resin that does not contain a recycled melamine resin material. The material is mixed, and the blended amount of the pulverized powder is 50 to 65% in total weight ratio.

  When the blended amount of the pulverized powder is 50 to 65% by weight with respect to the entire recycled melamine resin material 10 for compression molding, it has excellent shape compatibility while enjoying the merits of recycling used melamine resin molded products. It will be a thing. This configuration corresponds to all of Examples 1 to 4 described later.

  The “used melamine resin molded product” referred to in the present invention is a primary molded product that does not contain a pulverized powder of a recycled melamine resin molded product (so-called secondary recycled melamine resin material) as a main component, and is a melamine resin molded product. The second-hand recycled melamine resin material is used under the condition that at most 50% by weight is not mixed. “Not included as a main component” means that the melamine resin material is composed of a pulverized powder of a recycled melamine resin molded product and another resin material, and the ratio of the weight ratio component of the pulverized powder of the recycled melamine resin molded product. Is not greater than the other ingredients.

  For example, a melamine resin molded article made of the recycled melamine resin material 1 for compression molding according to the present invention, wherein the molded resin material already contains 50% of the powder of the used melamine resin molded article, Therefore, it is excluded from the material of the pulverized powder 1 of the recycled melamine resin material for compression molding of the present invention.

  In the embodiment, the regenerated melamine resin material 10 for compression molding is made to contain a black colorant, and further, the mold is subjected to matte embossing 1s and molded. In addition, the recycled melamine resin molded product may be molded using only the pulverized powder of the white used melamine resin molded product.

  (2) A recycled melamine resin molded product of the present invention is a recycled melamine resin molded product containing a used melamine resin molded product molded from the above-mentioned “recycled melamine resin material 10 for compression molding”. The recycled melamine resin material 10 for use contains a black colorant having a total weight ratio of 0.5% or more, and the entire surface after molding is subjected to matte texture 1s.

Due to the synergistic effect of the black colorant content of 0.5% or more and the matte texture 1s on the entire surface, a regenerated melamine resin molded article with improved color variation and unevenness can be obtained.
This configuration corresponds to a portion where the recycled resin molded portion 1 is exposed on the outer surface of Example 1 (FIGS. 1 and 2) described later. According to this configuration, due to the synergistic effect of natural coloring based on the mixture of black colorants and the formation of matte texture 1s on the molding surface, color variations due to lots of recycled melamine resin material, gloss unevenness during tableware molding Color unevenness is improved and appearance is improved.

  (3) The tableware of the present invention is a tableware in which the above-mentioned compression-molded recycled melamine resin material 10 is compression-molded into a tableware shape, and at least in a region (coating region) extending from the tableware inner surface to the upper edge 1e of the tableware. The glaze coating layer 2 made of the glaze material 20 not containing the regenerated melamine resin material is formed.

  This configuration corresponds to Examples 1 to 4 (FIGS. 1 to 7) described later. By glaze coating the surface of the molded product, the strength of the surface of the molded product can be improved. This is a new technical significance of glaze coating, and unlike the glaze coating layer 2 for mere surface processing, it also improves impact resistance by forming a uniform thin film layer. This configuration and technical significance are significant only in the resin molding of the recycled melamine resin material 10 for compression molding according to the present invention.

  In addition, the formation of the glaze coating layer 2 is hygienic because the contained food does not directly come into contact with the recycled melamine resin material molding. This eliminates the problem of foreign matter contamination in the process of recovery / pulverization, etc., and is compatible with the Food Sanitation Law.

  In the case where the glaze coating layer 2 is formed as described above, a transparent glaze material 20 containing no pigment can be used.

  In addition, the said tableware is a reproduction | regeneration melamine resin molded product which uses the reproduction | regeneration resin molding part 1 shape | molded from the reproduction | regeneration melamine resin material 10 for compression molding as described in (1) as a main component.

  (4) In the tableware, it is preferable that the foil 3 for painting is compression-molded on the surface of the glaze coating layer 2.

  This configuration corresponds to Example 1 (FIGS. 1 and 2) described later. According to this configuration, color unevenness and pattern unevenness (mottled pattern) appear on the surface of the regenerated melamine resin molded article made of the regenerated melamine resin material 10 for compression molding according to the present invention by mixing the pulverized powder of the regenerated melamine resin material. However, when the painting process using the foil 3 is performed directly on the molding resin as in the conventional case, the substrate is limited to the dark color so that the pattern cannot be seen or the color unevenness and the pattern unevenness are reversed. 3. There is a possibility that the pattern on the surface, the characters are blurred, the saturation of the coloring is lowered, or the pattern itself is distorted. On the other hand, when the colored glaze coating layer 2 such as white is used as an underlayer of the foil 3 for painting, the surface of the regenerated melamine resin molded product has no mottled pattern or show-through of color unevenness. However, in the above description, the glaze coating layer 2 is not limited to a colored one, and may be transparent or transparent. In addition, the said tableware is also a reproduction | regeneration melamine resin molded product which uses the reproduction | regeneration resin molding part 1 shape | molded from the reproduction | regeneration melamine resin material 10 for compression molding as described in (1) as a main component.

(5) The method for producing the recycled melamine resin molded product of the present invention is as follows:
The first molded part 11 and the second molded part 12 are integrally molded, and a method for producing a recycled melamine resin molded article in which the glaze coating layer 2 is formed in a coating region consisting of at least one of the inside and the outside,
A regenerated melamine resin material 10 for compression molding according to claim 1 is supplied as a first molding material into a lower mold M1, and a first molding section 11 is compression molded by an upper mold M2 corresponding to the lower mold M1. One molding process,
The molded melamine resin material 10 for compression molding according to claim 1 is secondly placed on the inverted first molded part 11 by turning the molded first molded part 11 upside down and placing it on the upper mold M2. A second molding step in which the second molding part 12 is compression-molded on the first molding part 11 by a mold (lower mold M1 ′) corresponding to the inverted upper mold M2 supplied as a molding material;
After the first molding step and before the second molding step or at least after the second molding step, the recycled melamine is applied to the coating region of the inner or outer part including the upper edge portion 1e of the recycled melamine resin molded product. A glaze forming step of forming the glaze coating layer 2 with the glaze material 20 which is not a resin material.

  This manufacturing method corresponds to Examples 2 and 3 described later. According to this manufacturing method, the glaze coating layer 2 is formed in the predetermined coating area | region of the reproduction | regeneration melamine resin molded product surface. For example, in the case of tableware, the predetermined coating region is at least a portion extending over the entire inner surface of the tableware and the edge of the outer surface of the tableware. When the glaze coating layer 2 is formed on the inner portion including the upper edge portion 1e of the compression molded product, the recycled melamine resin molded portion is not exposed on the inner upper surface inside the dish or container that is the food contact surface, The contents can be placed or housed in a sanitary manner.

  Moreover, the effect which improves impact-resistant strength arises by forming the thin film layer which consists of material which does not contain the reproduction | regeneration melamine resin molding material by the glaze coating layer 2. FIG. The glaze material 20 of the glaze coating layer 2 may be either colored or colorless. For example, when the colored glaze coating layer 2 such as white is formed on the outer portion including the upper edge portion 1e of the compression molded product, uneven color or pattern unevenness of the recycled melamine resin molded portion is not exposed on the outer surface of the container or the like. Therefore, the appearance is good.

(6) In the method for producing the recycled melamine resin molded article,
At least one of the first molding step and the second molding step supplies the reclaimed melamine resin material 10 for compression molding according to claim 1 to a position closer to the center and along an edge near the part P of the mold. A colored unmolded cosmetic melamine resin material 40 that does not contain the regenerated melamine resin material 10 for compression molding is supplied to the position, and the unmolded cosmetic melamine resin material 40 forms the part P by compression molding. The decorative melamine resin molded part 4 constituting the edge part to be included is preferable.

  This manufacturing method corresponds to Examples 2 and 3 to be described later, and each manufacturing method will be described with reference to FIGS. According to this manufacturing method, since the edge part including the part part P is comprised from the decorative melamine resin molding part 4, even after finishing the part part P, the reproduction | regeneration melamine resin molded product part is not exposed to the front side. The decorative melamine resin molding part 4 will be exposed instead of the dark color reproduction resin molding part 1 containing a black colorant. The decorative melamine resin material 40 is compression-molded together with the recycled resin molding material, and the edge including the part P of the recycled melamine resin molded product is integrally formed with the recycled resin material.

  The decorative melamine resin material 40 of the decorative melamine resin molded part 4 may be either colored or colorless. For example, when the decorative melamine resin material 40 having the same color as that of the glaze coating layer 2 is used, the boundary between the glaze coating layer 2 and the melamine resin molded portion 4 is not noticeable, and the appearance is good.

  By taking the above measures, compression molded reclaimed melamine is excellent in molding shape compatibility, hardly overcured by compression molding, solidifies reliably, and has excellent impact durability after molding. It became possible to provide the resin material 10, and to provide a regenerated melamine resin molded article including tableware and a method for producing the same, using the regenerated melamine resin material.

BRIEF DESCRIPTION OF THE DRAWINGS Front view cross-section explanatory drawing of the reproduction | regeneration melamine resin molded product of Example 1 of this invention. Explanatory sectional explanatory drawing of the upper edge part 1e vicinity (alpha part of FIG. 1) of Example 1. FIG. Manufacturing process explanatory drawing which shows the 1st shaping | molding process until shaping | molding of the core shaping | molding part 11 among the manufacturing methods of the reproduction | regeneration melamine resin molded product of Example 2 of this invention. Manufacturing process explanatory drawing which shows the 2nd shaping | molding process after shaping | molding of the inner core shaping | molding part 11 among the manufacturing methods of the reproduction | regeneration melamine resin molded product of Example 2. FIG. Front view expansion cross-section explanatory drawing of the upper edge part 1e vicinity in the reproduction | regeneration melamine resin molded product of Example 2. FIG. Front view expansion sectional explanatory drawing of the upper edge part 1e vicinity in the reproduction | regeneration melamine resin molded product of Example 3 of this invention. Front view expansion cross-section explanatory drawing of the upper edge part 1e vicinity in the reproduction | regeneration melamine resin molded product of Example 4 of this invention.

  DESCRIPTION OF THE PREFERRED EMBODIMENTS The best mode for carrying out the present invention will be described below together with the drawings shown as examples. 1 and 2 show Example 1, FIGS. 3 to 5 show Example 2, FIG. 6 shows Example 3, and FIG. 7 shows the regenerated melamine resin molded product of Example 4. FIG. Among these, FIG.3, 4 is each process in the manufacturing method of Example 2. FIG.

(Recycled melamine resin material 10 for compression molding)
The regenerated melamine resin material 10 for compression molding of the present invention is a resin material for compression molding that is excellent in the shape compatibility of resin products and the impact resistance after molding. Therefore, even if it is compression molding at high temperature and pressure, it can solidify reliably. Basically, the recycled melamine resin material 10 for compression molding is obtained by kneading a pulverized powder of a used melamine resin molded product not containing the recycled melamine resin material as a main component and a melamine resin material not containing the recycled melamine resin material. The blended amount of the pulverized powder is 50 to 65% in total weight ratio, and the black colorant is contained in 0.5% or more in total weight ratio.

  The “melamine resin material” as used herein refers to a melamine / formaldehyde resin material formed by a condensation reaction of melamine and formaldehyde. For example, 60 to 70% by weight of melamine resin material (melamine / formaldehyde resin material) is impregnated in 30 to 40% by weight of pulp, and further 0.05 to 0.10% by weight of catalyst and weight. A melamine resin material is used in which a lubricant having a ratio of 0.10 to 0.50% and a colorant having a weight ratio of 0.1 to 0.5% are added.

(Ground powder)
The pulverized powder is intended to be limited to a pulverized product having a particle size of 200 μm or less per grain. In practice, the smaller the particle size, the better. The pulverized powder of the used melamine resin molded article may not contain the recycled melamine resin material as a main component, and may contain it as long as it does not become a main component. In this case, since the curing proceeds quickly and the surface becomes cloudy, it may be adopted depending on the choice of surface appearance. On the other hand, when no recycled melamine resin material is contained, impact resistance and shape compatibility can be improved by adjusting the mixing amount and the like.

(Mixed amount of pulverized powder)
The blended amount of the pulverized powder is 50 to 65% by weight with respect to the entire recycled melamine resin material 10 for compression molding. In order to make up for the lack of strength, unused melamine resin materials are combined. If the blending ratio, the balance between strength and regeneration rate is kept high. The mixing weight ratio of the pulverized powder of the used melamine molded product and the unused melamine resin material is preferably (50 to 65): (50 to 35).

  This weight ratio of 50 to 65% is based on experimental results. In particular, if it is 68% or more, it may not be solidified by compression molding, and if it is less than 50%, the practical merit of mixing used melamine ( It is poor in preventing the generation of industrial waste that requires non-combustible material treatment and improving the cost as much as or better than using new products.

  As will be described later, if it is 50% or more, it becomes an object of Eco Mark certification.

(Recycled melamine resin molded product)
The recycled melamine resin molded article contains a used melamine resin molded article molded from the above-mentioned recycled melamine resin material 10 for compression molding.

(Formability and appearance evaluation, impact resistance test)
Molded samples B to F (glaze coating layer 2) consisting only of recycled melamine resin material 10 for compression molding according to the blending ratio of 50%, 55%, 60%, 65% and 68% of the powder obtained by pulverizing the used melamine molded product Or a foil 3 or a decorative melamine resin molding portion 4 and a smooth surface), and the moldability and appearance of a molded product based on JIS S 2029 are made of a melamine resin material that does not contain any pulverized powder. The molded sample A was compared and evaluated.

<Molding conditions>
1) Molded product: 11.5 cm round pan 2) Mold temperature: concave: 171 ° C convex: 166 ° C
3) Degassing: Yes: Once after pressurization 4) Molding pressure: 150kg / cm ²
5) Curing time: 55 seconds 6) Materials used: MM993X21K (black raw material) manufactured by Panasonic Electric Works Yokkaichi Co., Ltd.
Lot: 8X-6109
A (0%): (Recycled raw material 0%)
B (50%): (Recycled material 50%)
C (55%): (Recycled raw material 55%)
D (60%): (Recycled raw material 60%)
E (65%): (Recycled raw material 65%)
F (68%): (Recycled raw material 68%)
The evaluation results of formability are shown in Table 1 below.

上記×ではかすれ（充填不足）が発生し、成形性に欠ける結果になった。それ以外は製品として問題なく成形された。このことから０〜６５％で成形性良好であり、６８％を臨界として成形性に劣ることが分かった。

In the case of the above x, fading (insufficient filling) occurred, resulting in poor moldability. Other than that, it was molded without any problem as a product. From this, it was found that the moldability was good at 0 to 65%, and the moldability was inferior with 68% being critical.

Further, the following appearance evaluation items (extracts) based on JIS S2029 were evaluated. The results are shown in Table 2 below.
(External appearance evaluation items based on JIS S 2029 (excerpt))
a) There shall be no cracks, cracks, cracks or lack of filling.
b) Foreign objects, bubbles, mold marks, sink marks, weld marks, float lines, flashes, blisters and other scratches shall not be noticeable.
c) Dirt that cannot be wiped off with a wet cloth should be conspicuous.
d) Discoloration, fading, color shading (except for decoration purposes), cloudiness, etc. shall not be noticeable.

サンプルＡ〜Ｄでは評価項目ａ〜ｄのいずれも良好または製品としての限度内であったが、サンプルＥでは評価項目ｄで明確な外観不良、サンプルＦではすべてで外観不良であり、そのままでは製品化できないという評価になった。

In Samples A to D, all of the evaluation items a to d were good or within the limits of the product, but in Sample E, the appearance item was clearly defective in the evaluation item d, and in Sample F, all were poor in appearance. It became evaluation that it was not possible.

(Black colorant mixing and matte texture 1s)
The appearance is clearly improved by mixing the black colorant, and the appearance is improved by applying a matte texture 1s to the product surface by processing the mold surface of the molding die. Either of these may be employed, or both may be employed.

  For example, as an embodiment in which both are adopted, the recycled melamine resin material 10 for compression molding, which is a molding raw material of a recycled melamine resin molded article, contains at least 0.5% by weight or more of a black colorant including a carbon raw material. It is preferable that the entire surface is subjected to matte texture 1s.

(About black colorant)
By containing at least 0.5% by weight of the black colorant pigment, reliable darkening is achieved, and chromaticity and color unevenness do not affect the appearance. In particular, when the content is 1.0% or more, reliable coloring can be performed to make the unevenness inconspicuous when the recycled melamine resin molded product is formed. Further, as the black colorant, for example, carbon black can be used as in Examples, and besides this, Mapico Black BL-100 / BL500 (product name), Toda Color KN320 (product name), etc. can be used. It is not limited as long as it is a black pigment.

(About appearance improvement)
Table 2 shows the case where the black colorant is not included and the molding surface is smooth. In contrast, the regenerated melamine resin material 10 for compression molding contains 0.5% of the total weight of carbon as a black colorant, and further, the surface of the molding die is matted to the entire outer molding surface. To give a rough surface.

  In each of samples A to F, samples A ′ to F ′ in which black colorant is mixed by 1.0% by weight on the surface at the time of compression molding and matt-textured 1 s are applied are created, and an appearance based on JIS S2029 Was evaluated for improvement. The evaluation results are shown in Table 3 below.

（グレーズコーティング層２）
そして本発明では、少なくとも食器内面又は外面のいずれかから上縁部１ｅに亘る領域をコーティング領域としており、このコーティング領域に、再生メラミン樹脂材料を含まない有色のグレーズ材料２０からなるグレーズコーティング層２が形成される。特に有色のグレーズ材料２０を使用した場合には、食品の接する部分がグレーズコーティングによって何色にも自在に着色されると共に保護された形態となる。食器上に載置または収容された食品は、着色されたグレーズコーティング表面に映えて食器としての使用に適した状態となる。

(Glaise coating layer 2)
In the present invention, at least a region extending from either the inner surface or the outer surface of the tableware to the upper edge 1e is used as the coating region, and the glaze coating layer 2 made of the colored glaze material 20 that does not contain the regenerated melamine resin material is provided in this coating region. Is formed. In particular, when the colored glaze material 20 is used, the portion in contact with the food can be freely colored and protected by the glaze coating. The food placed or contained on the tableware is reflected on the colored glaze coating surface and is suitable for use as tableware.

  As long as the glaze coating layer 2 is formed on at least one side, the layer is formed only on one side including the inner surface of the tableware, the layer is formed not only on the inner surface of the tableware but also on the inner surface of the tableware, or only on the outer surface, and the layer is formed on both sides. Any form of layer formation may be used.

  The glaze material 20 that is a constituent material of the glaze coating layer 2 may be colorless or colored. In the embodiment, a colored glaze material 20 containing a colorant, in particular, a white glaze material 20 is used to bring out the vividness of the color development. However, a transparent glaze material 20 may also be used. The results of improving the appearance of the glaze coating layer 2 are listed below.

(Results of impact resistance test by glaze coating layer 2)
In each of samples A to F, samples A ′ ′ to F ′ ′ having a glaze coating layer formed on the surface by further compression molding were prepared, and the improvement in appearance based on JIS S 2029 was evaluated. The evaluation results are shown in Table 4 below.

さらに製品表面のグレーズコーティング層２（重量比１％配合）の有無による耐衝撃性を評価した。結果を下表５，６に示す。なお耐衝撃性は、ＪＩＳ Ｓ ２０２９に基づく耐衝撃性試験（表５）とシャルピー衝撃試験による評価（表６）とした。

Furthermore, the impact resistance by the presence or absence of the glaze coating layer 2 (1% by weight ratio) on the product surface was evaluated. The results are shown in Tables 5 and 6 below. The impact resistance was evaluated by an impact resistance test (Table 5) and a Charpy impact test (Table 6) based on JIS S2029.

ＪＩＳ Ｓ ２０２９に基づく耐衝撃性試験によれば、耐衝撃性は、再生原料配合率が高い程、低下する傾向にあることが判明した。またグレーズ有無での耐衝撃性の相違については、グレーズ無よりグレーズ有の耐衝撃性が向上することが判明した。

According to the impact resistance test based on JIS S 2029, it was found that the impact resistance tends to decrease as the blending ratio of the recycled raw materials increases. Further, regarding the difference in impact resistance with and without glaze, it was found that the impact resistance with glaze was improved over that without glaze.

デュポン式耐衝撃性結果によれば、表５と同様に、再生原料の配合率が高いほど耐衝撃性が劣るものであったが、サンプルＢ〜Ｄでは、グレーズコーティング層２を形成することでグレーズコーティング層２がない再生メラミン樹脂を含まない場合と同程度の耐衝撃性を確保できることが判明した。

According to the DuPont impact resistance results, as in Table 5, the higher the blending ratio of the recycled material, the worse the impact resistance, but in Samples B to D, the glaze coating layer 2 was formed. It was found that the same level of impact resistance as when no regenerated melamine resin without the glaze coating layer 2 was included could be secured.

  From the above evaluation, the blending ratio up to 65% is the range that can be molded. However, if the appearance is taken into account, 60% is the limit if the surface is smooth and matte texture 1s is not applied. It was confirmed that the impact resistance had sufficient practicality without any problems at all blending ratios. In particular, it has been found that the product strength is further increased by the glaze coating layer 2.

  The regenerated melamine resin molded product of Example 1 (FIGS. 1 and 2) is a regenerated melamine resin molded product containing a used melamine resin molded product, which is formed from the regenerated melamine resin material 10 for compression molding. The regenerated melamine resin material 10 for molding contains a black colorant having a total weight ratio of 0.5% or more, and is integrally molded with a regenerated resin material for compression molding. Further, in this example, a recycled melamine resin material 10 for compression molding, in which a pulverized powder of a used melamine resin molded product not containing a recycled melamine resin material and an unused melamine resin material not containing a recycled melamine resin material were kneaded. Is compression molded into tableware.

  The molding surface of the outer surface is finished to a rough surface by being compression-molded by a mold having a matte texture 1s. Further, a glaze coating layer 2 made of a white colored glaze material 20 not containing a regenerated melamine resin material is formed on the molding surface of the inner surface, and a painting foil 3 is compressed and formed on the surface of the layer (FIG. 1). , FIG. 2). Thereby, even if the color of the base of the recycled resin molding part 1 is strong, free painting with the foil 3 becomes possible.

(Glaise coating layer 2)
The glaze coating layer 2 of Example 1 is obtained by performing a glaze coating molding with a white glaze material 20 that is not a regenerated melamine resin material in a coating region extending from the upper edge to the inner side surface and the inner bottom surface of the container. The glaze material 20 is made of a cosmetic unused material that does not contain a recycled melamine resin material.

(Foil 3)
The glaze coating layer 2 of the tableware of Example 1 is formed by compression-molding a foil 3 for painting on the surface of the layer. The foil 3 for painting is a material for painting a recycled melamine resin molded article. It is a paper or cloth material that has little stretch, strength, and transparency. It was obtained by printing a pattern, a pattern, or characters with ink, impregnating with a melamine resin material, and drying. The impregnated paper or impregnated cloth that has been printed and impregnated with the resin liquid is cut into a predetermined shape and bonded so as to conform to the product shape. For example, when painting on the side surface of a small bowl or the like, it is extracted and pasted into a sector shape along the side surface shape. In the present invention, in particular, the foil 3 is pasted on the colored glaze coating layer 2 in order to ensure the aesthetics and appearance exceeding the standard even for a recycled melamine resin molded product. In particular, by using the white glaze coating layer 2 which is a light color as a base material, color developability of a pattern or the like applied to the surface of the foil 3 is improved.

(Example of manufacturing method)
The recycled melamine resin molded article of Example 1 is manufactured by including at least the following steps in order.
A molding process in which the regenerated melamine resin material 10 for compression molding is supplied as an inner molding material onto the lower mold M1, and the concave melamine resin molded product 1 is compression molded by the upper mold M2 corresponding to the lower mold M1. The glaze coating layer 2 is subjected to glaze coating molding with a glaze material 20 that is not a recycled melamine resin material in the coating region of the inner or outer portion of the recycled melamine resin molded product obtained by the molding process. Foil molding process for compression-molding foil 3 for painting on the surface of the layer (matte texture 1s)
Among the above, particularly in the molding step, the lower mold M2 is subjected to surface processing for matte embossing on the mold surface corresponding to the outer peripheral side surface of the tableware. As a result, the lower outer side (the entire surface from the outer surface to the back surface) with the upper edge portion 1e of the first embodiment as a boundary is subjected to the matte texture 1s at the same time as the forming process is obtained (FIG. 1).

  The recycled melamine resin molded product of Example 2 (FIGS. 3 to 5) is formed with a decorative melamine molded part 4 on the upper edge 1e including the part P, and a foil 3 is compression-formed on both sides, and from above to both sides. The glaze coating layer 2 is formed. Specifically, as shown in FIG. 5, the foils 31 and 32 are fixed to the surfaces of the core molding part 11 and the outer core molding part 12 that are integrally molded, respectively, and in the regions including the surfaces of the foils 31 and 32, respectively. The glaze coating layer 2 is formed as the outermost layer. Further, the center position in the height direction of the edge tip is the part part P. A decorative melamine resin molding part 4 extending from the upper side to the lower side of the part part P is provided at the edge tip, so that the recycled resin molding part 1 is not exposed to the outside.

(Cosmetic melamine resin molding part 4)
The decorative melamine resin molded part 4 is a molded part formed by compression molding the melamine resin material powder 40 (FIG. 5). At the time of molding of the outer core molding part 12, the edge part including the part part P is supplied to a position along the edge part near the part part P of the mold and is compression-molded together with the recycled melamine resin material 10 for compression molding. A decorative melamine resin molded part 4 is obtained.

(Example of manufacturing method)
The recycled melamine resin molded product of Example 2 is largely divided into a first process until the core molding part 11 shown in FIG. 3 is molded and a second process after molding the core molding part 11 shown in FIG. Separated. Specifically, at least the following steps are sequentially provided.

(First step (Fig. 3))
An inner core molding step in which the regenerated melamine resin material 10 for compression molding is supplied as an inner core molding material onto the lower mold M1, and the concave core molding section 11 is compression molded by the upper mold M2 corresponding to the lower mold M1. Inner surface foil forming step of compressing and molding inner surface painting foil 31 on the inner surface of inner core molded part 11 obtained by the molding process. After the foil molding process, from the foil 3 molded part of the inner part of inner core molded part 11 A glaze molding process in which a glaze coating molding is performed with a glaze material 20 that is not a recycled melamine resin material in a larger coating area. ・ Burr generated at the upper edge portion 11e0 of the inner core molding portion 11 after the glaze molding step is polished to obtain an upper edge portion. Finishing process to finish the core molded product with 11e (Figure 3)
(Second step (Fig. 4))
-The core molded product obtained in the first step is placed on the lower die M2 for the second step, in which the upper die M2 is inverted, and compressed as a core molding material in the vicinity of the central portion above it. The recycled melamine resin material 10 for molding is supplied, and the decorative melamine resin material powder 40 is supplied in the vicinity of the part P, and the upper mold M1 ′ corresponding to the lower mold M2 (the lower mold M1 in the first step is used in the embodiment). A mold that is the same as the one that has been inverted and that has been subjected to surface processing for matte texture 1s), and the outer molded part 12 is compression molded and integrated with the inner molded product. Inner foil forming process in which outer surface painting foil 31 is compression-molded on the outer surface of the integrally molded product obtained by the outer mold forming process. Coating larger than the foil 3 molding on the inner part Glaze molding process for performing glaze coating molding with glaze material 20 that is not a recycled melamine resin material in the region. ・ Burr generated on upper edge 12e0 of the integrally molded product after the glaze molding process is polished to prepare upper edge 12e. Finishing process to finish recycled melamine resin molded product (Fig. 4 so far)
(Molding process of cosmetic melamine resin molding part 4)
In the second step, in particular, in the outer molding step, the edge is formed in advance in the inner molding step in order to form the decorative melamine resin molded portion 4 at the edge tip, and only in the outer molding step. The cosmetic melamine resin material powder 40 is supplied. This saves the labor of creating the decorative melamine resin molding part 4 in the inner molding part 11, and the cosmetic melamine resin molding part 4 based on the cosmetic melamine resin material powder 40 is integrally formed inside the outer core molding part 12, respectively. Is done. That is, the decorative melamine resin molded portion 4 of Example 2 is formed by being fixed to both the molded portions 11 and 12 from the edge of the inner molded portion 11 to the edge of the outer molded portion 12.

  Specifically, as a method in which the upper edge 1e including the part part P of the mold is a decorative molded part, in the manufacturing method described in Example 1, in at least one of the inner molding process and the outer molding process, While supplying the reproduction | regeneration melamine resin material 10 for compression molding to the position near a center, the colored or colorless melamine resin material powder 40 which does not contain the reproduction | regeneration melamine resin material to the position along the edge part near the part part P of a metal mold | die After being supplied, it is compression molded. The melamine resin material powder 40 becomes the decorative melamine resin molded portion 4 by compression molding.

  The cosmetic melamine resin material powder 40 is preferably a colored material containing a pigment of the same color as the glaze material 20 in terms of aesthetics and appearance after finishing. In particular, it is preferable that the cosmetic melamine resin material powder 40 and the glaze material 20 have the same composition because the cosmetic melamine resin molded portion 4 and the glaze coating layer 2 are easily compatible and the layer boundary is not noticeable. In addition, even when the edge is finished by polishing, the outer shaping part 12 made of the regenerated melamine resin material for compression molding can be completely wrapped, and the problem in terms of safety and hygiene is solved. In addition, other configurations not specifically mentioned are the same as those in the first embodiment, such as the matte texture 1s on the outer peripheral surface and the outer shape of the tableware.

  As shown in FIG. 6, the recycled melamine resin molded product of Example 3 of the present invention has a first decorative melamine resin molded part 41 in which the decorative melamine resin molded part 4 is a part of the inner molded part 11, and outer mold. It consists of a second decorative melamine resin molding part 42 which is a part of the part 12. This is obtained by supplying the melamine resin material powder 40 in both the inner core molding step and the outer core molding step among the respective steps of the manufacturing method of Example 2. A decorative melamine resin molded portion 4 based on the decorative melamine resin material powder 40 is integrally formed on the inner edge portion 1e and the outer edge molded portion 12, respectively, on the upper edge portion 1e and the inner edge portion thereof.

  Specifically, in the core molding step, the recycled melamine resin material 10 for compression molding according to claim 1 is supplied into the lower mold M1, and the recycled melamine is formed along the edge near the part P of the mold. The first cosmetic melamine resin material powder 40 not containing the resin material is supplied. The first cosmetic melamine resin material powder 40 becomes a first cosmetic melamine resin molded portion 41 by compression molding. The first decorative melamine resin molding part 41 is integrally formed with the recycled resin material as a part of the core molding part 11 and constitutes the edge tip including the part part P.

  In the outer core molding step, the recycled melamine resin material 10 for compression molding according to claim 1 is supplied onto the first molding portion 11 that is inverted and arranged in a convex shape, and the mold corresponding to the upper edge portion 1e is provided. A second cosmetic melamine resin material powder 40 that does not contain the regenerated melamine resin material is supplied along the edge near the part P (that is, near the upper part of the tableware including the upper edge 1e). The second cosmetic melamine resin material powder 40 becomes a second cosmetic melamine resin molded portion 42 by compression molding. The second decorative melamine resin molding part 42 is integrally formed with the recycled resin material as a part of the outer core molding part 12 and constitutes an edge part including the part part P.

  In terms of aesthetics and appearance after finishing, the first decorative melamine resin molded portion 41 is a colored material that has the same color as the second decorative melamine resin molded portion 42 and contains the same color pigment as the glaze material 20. Preferably there is. Other configurations not specifically mentioned are the same as those in the second embodiment.

  As shown in FIG. 7, in the recycled melamine resin molded product of Example 4 of the present invention, the foil 3 is not compression-formed on the inner surface, and the glaze coating layer 2 is exposed on the inner surface. Further, both the inner and outer surfaces are smooth and are not subjected to matte texture 1s. In the manufacturing process of Example 4, the foil molding process is excluded from the manufacturing method of Example 1. Further, in the molding process, the outer surface mold is not subjected to surface processing for matte texture 1s. Other configurations not specifically mentioned are the same as those in the first embodiment.

(Regarding the standard of 50% or more)
The Japan Environment Association has certified the Eco Mark, but in order to receive the Eco Mark certification for resource conservation, it is necessary to mix 50% or more of products collected from the market. In other words, if it is 50% or more, it is recognized that it is useful for environmental conservation. If the material contains 60% of the used melamine resin molded product, even if a non-recycled material is used for the glaze coating layer 2 or the decorative melamine molded part 4, the standard of 50% or more can be easily achieved. Other configurations not specifically mentioned are the same as those in the second embodiment. In the present invention, even if the molded product is glaze-coated, the ratio of the used melamine resin molded product is set as follows to satisfy the criterion of 50% or more.
(A) First, in the case of the single-sided glaze region as in Examples 1 and 4, the general product weight is about 100 to 500 g, and the glaze material 20 at this time is about 2 to 3 g. Even if the product is large, it is not necessary to increase the glaze material 20 so much, so the blending ratio of the glaze material 20 is higher when the product is small. Therefore, if the total product weight is 100 g, and the glaze material 202 g at this time is calculated, the recycled melamine resin material is 98 g. Therefore, if the blending amount of the pulverized powder of the used melamine resin molded product is 50% or more, 50 g ÷ 98 g × 100 = 51.02%. In order to increase the decimal fraction and secure a total blend amount of 50% or more, a blend amount of the pulverized powder of the used melamine resin molded product needs to be 52% or more.

  (B) Next, in the case of the double-sided glaze region, the general minimum product total weight is about 100 g, and the glaze material 20 at this time is about 5 g. Since the recycled melamine resin material is 95 g, if the blended amount of the pulverized powder of the used melamine resin molded product is 50% or more, 50 g ÷ 95 g × 100 = 52.63%. In order to increase the decimal fraction and secure an overall ratio of 50% or more, a blending amount of 53% or more of the pulverized powder of the used melamine resin molded product is required.

  (C) When the cosmetic melamine resin molded portion 4 is formed and both sides are made to be a glaze area as in Examples 2 and 3, the general minimum product total weight is about 100 g, The resin molded part 4 and the glaze material 20 are about 16 g in total. Since the difference in the recycled melamine resin material is 84 g, if the blended amount of the pulverized powder of the used melamine resin molded product is 50% or more, 50 g ÷ 84 g × 100 = 59.52%. In order to increase the decimal fraction and secure a total blend amount of 50% or more, a blend amount of the pulverized powder of the used melamine resin molded product needs to be 60% or more.

(Operational effect of this embodiment)
The reclaimed melamine resin molded article or reclaimed melamine resin material of the present example has the following functions and effects due to the above-described configuration and manufacturing method.
-Glaze formed. The product strength could be reinforced. The color tone could be changed freely. There is no longer a problem of contamination of food and oil on the contact surface of food.
A pattern that can be colored can be formed by compressing the foil 3 for painting on the surface of the white glaze coating layer 2.
・ By reducing waste, a melamine resin molded product useful for environmental conservation was obtained.
・ Manufacturing costs could be reduced by using recycled melamine resin materials.
・ Molding was possible using existing compression molding equipment.

  In addition, this invention is not limited to the Example mentioned above, The combination of a structure, extraction, deletion, and extraction of a process are possible suitably in the range which does not deviate from the meaning of this invention. For example, in each embodiment, the presence or absence of the foil 3 as a painting process and the presence or absence of the formation of the transparent glaze coating layer 23 (outer layer) on the outermost surface are selected as necessary. Changes in layer combinations and layer combinations are also made as appropriate. In each embodiment, the shape of the molded product, the glaze region, the presence / absence of layer formation of the glaze coating layer 2, and the presence / absence of compression formation of the foil 3 are appropriately set.

DESCRIPTION OF SYMBOLS 1 Recycled resin molding part 10 Recycled melamine resin material 11 for compression molding 1st shaping | molding part 12 2nd shaping | molding part 1e Upper edge part 1s Matte embossing 2 Glaze coating layer 20 Glaze material 3 Foil 31 Inside foil 32 Foil 32 Outside Foil for painting 40 Cosmetic melamine resin material powder 4 Cosmetic melamine resin molding part 41 First cosmetic melamine resin molding part 42 Second cosmetic melamine resin molding part P Part part M1 First mold M2 Second mold

Claims (6)

  The pulverized powder of the used melamine resin molded product not containing the pulverized powder of the recycled melamine resin molded product as a main component and the melamine resin material not containing the recycled melamine resin material are mixed, and the blended amount of the pulverized powder is the total weight ratio. A recycled melamine resin material for compression molding, characterized by being 50 to 65%.   A recycled melamine resin molded article containing a used melamine resin molded article molded from the recycled melamine resin material for compression molding according to claim 1, wherein the recycled melamine resin material for compression molding is 0.5% by weight. A regenerated melamine resin molded article containing the above black colorant and having the matte texture applied to the entire molded surface.   The reclaimed melamine resin material for compression molding according to claim 1 is a tableware compression molded into a tableware shape having an upper edge portion, and does not contain the regenerated melamine resin material at least in a region extending from the inner surface of the tableware to the upper edge portion. Tableware in which a glaze coating layer made of a glaze material is formed. Tableware obtained by compression-molding foil for painting on the surface of the glaze coating layer 2 according to claim 3. A method for producing a recycled melamine resin molded article in which a first molding part and a second molding part are integrally molded, and a glaze coating layer is formed in a coating region consisting of at least one side of the inside or outside,
A first molding step of supplying the regenerated melamine resin material for compression molding according to claim 1 as a first molding material into a lower mold, and compression molding the first molded portion with an upper mold corresponding to the lower mold;
2. The regenerated melamine resin material for compression molding according to claim 1 is supplied as a second molding material on the inverted first molding portion by inverting the top and bottom of the molded first molding portion. And a second molding step of compression molding the second molded part on the first molded part by the lower mold,
After at least one of the first molding step and before the second molding step or after the second molding step, the recycled melamine resin is applied to the coating region of the inner or outer part including the upper edge of the recycled melamine resin molded article. The manufacturing method of the reproduction | regeneration melamine resin molded article which comprises the glaze molding process which performs the glaze coating molding by the glaze material which is not a material.   At least one of the first molding step and the second molding step supplies the regenerated melamine resin material for compression molding according to claim 1 to a position near the center and a position along an edge near the part P of the mold. Is supplied with an unmolded cosmetic melamine resin material that does not contain a regenerated melamine resin material for compression molding, and this unmolded cosmetic melamine resin material constitutes an edge including the part P by compression molding. The manufacturing method of the reproduction | regeneration melamine resin molded product of Claim 5 used as a decorative melamine resin molding part.

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