JP2011183717A - Decorative resin molding and production process of the same - Google Patents

Decorative resin molding and production process of the same Download PDF

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JP2011183717A
JP2011183717A JP2010052793A JP2010052793A JP2011183717A JP 2011183717 A JP2011183717 A JP 2011183717A JP 2010052793 A JP2010052793 A JP 2010052793A JP 2010052793 A JP2010052793 A JP 2010052793A JP 2011183717 A JP2011183717 A JP 2011183717A
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nonwoven fabric
molded product
molding compound
transparent
sheet molding
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Yuji Sawada
雄次 澤田
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Bridgestone Corp
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Abstract

<P>PROBLEM TO BE SOLVED: To provide a decorative resin molding superior to conventional ones in transparency and glossiness as well as in designability, and to provide a manufacturing method of the same. <P>SOLUTION: The decorative resin molding is constituted by laminating a sheet molding compound molding 1, a decorated nonwoven fabric 2 and a transparent resin layer 3. The transparent resin layer 3 is formed by applying a coating containing a transparent photo-curing resin with a curtain flow coater on the nonwoven fabric 2 loaded on the sheet molding compound molding 1. Also, the applied coating infiltrates in the nonwoven fabric 2 and is cured integrally with the sheet molding compound molding 1. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

本発明は加飾樹脂成形品およびその製造方法(以下、単に「製造方法」とも称する)に関し、詳しくは、ユニットバス用床パンや、壁パネルなどに使用される加飾樹脂成形品およびその製造方法に関する。   The present invention relates to a decorative resin molded product and a manufacturing method thereof (hereinafter, also simply referred to as “manufacturing method”), and more specifically, a decorative resin molded product used for a floor pan for a unit bath, a wall panel, and the like Regarding the method.

ユニットバスの床や壁用の素材として、従来、繊維強化プラスチック(FRP)が用いられている。かかるFBR製のユニットバス用床材ないし壁材は、一般にシート鋼板対比で意匠性が劣るため、圧縮成形等の際に表面を加飾することで、その意匠性を向上することが行われている。   Conventionally, fiber reinforced plastic (FRP) has been used as a material for floors and walls of unit baths. Such FBR unit bath flooring or wall materials are generally inferior in design to sheet steel plates, and thus the design is improved by decorating the surface during compression molding or the like. Yes.

例えば、特許文献1には、加飾された合成樹脂製不織布にシートモールディングコンパウンドを重ね合わせた積層物を金型内で加圧加熱して成形された加飾樹脂成形品であって、シートモールディングコンパウンドとプリプレグ化していない不織布とを重ね合わせて加圧加熱した後に、不織布表面に、シートモールディングコンパウンドの透過による透明樹脂層を形成した加飾樹脂成形品が開示されている。また、特許文献2には、模様柄を施した化粧紙または不織布と成形材料とを一体成形した後、化粧紙または不織布の模様柄を施した表面に、透明又は半透明の保護層を塗布、硬化させる模様付FRP成形品の製造方法が開示されている。   For example, Patent Document 1 discloses a decorative resin molded product formed by pressurizing and heating a laminate in which a sheet molding compound is superimposed on a decorated synthetic resin nonwoven fabric in a mold. A decorative resin molded article is disclosed in which a compound and a non-prepreg nonwoven fabric are overlaid and pressurized and heated, and then a transparent resin layer is formed on the nonwoven fabric surface by permeation of a sheet molding compound. In Patent Document 2, a decorative paper or nonwoven fabric with a patterned pattern and a molding material are integrally formed, and then a transparent or translucent protective layer is applied to the surface of the decorative paper or nonwoven fabric with a patterned pattern. A method for producing a patterned FRP molded product to be cured is disclosed.

特開2002‐113732号公報(特許請求の範囲等)JP 2002-113732 A (Claims etc.) 特開平11‐245318号公報(特許請求の範囲等)JP-A-11-245318 (Claims etc.)

上記特許文献1に係る技術によれば、加飾不織布の剥がれを生じないコスト性に優れた加飾樹脂成形品が得られるものである。しかしながら、その一方、特許文献1に係る技術では、基材の成形と、基材と加飾された不織布との一体化とを同時に行うために、成形条件や不織布の条件に制約が多く、また、特許文献1に係る技術により得られる加飾樹脂成形品は、透明感や光沢の点で、さらなる向上が求められるものであった。また、特許文献2に係る技術により得られる成形品は、高級感等の意匠性の点で十分ではなかった。   According to the technique according to Patent Document 1, a decorative resin molded product excellent in cost performance that does not cause peeling of the decorative nonwoven fabric can be obtained. However, in the technique according to Patent Document 1, since molding of the base material and integration of the base material and the decorated nonwoven fabric are simultaneously performed, there are many restrictions on the molding conditions and the nonwoven fabric conditions. The decorative resin molded product obtained by the technique according to Patent Document 1 is required to be further improved in terms of transparency and gloss. In addition, the molded product obtained by the technique according to Patent Document 2 is not sufficient in terms of design properties such as high-quality feeling.

そこで本発明の目的は、従来と比較してより透明感や光沢に優れ、かつ、意匠性に優れた加飾樹脂成形品、および、その製造方法を提供することにある。   Therefore, an object of the present invention is to provide a decorated resin molded article that is more excellent in transparency and gloss than conventional ones, and that is excellent in design, and a method for producing the same.

本発明者は鋭意検討した結果、シートモールディングコンパウンド(以下、「SMC」とも称する)からなる成形品上に載置した加飾した不織布の上に、透明光硬化性樹脂をカーテンフローコーターにより塗布して透明樹脂層を形成する手法を用いることで、上記課題を解決できることを見出して、本発明を完成するに至った。   As a result of intensive studies, the present inventor applied a transparent photocurable resin on a decorative nonwoven fabric placed on a molded product made of a sheet molding compound (hereinafter also referred to as “SMC”) by a curtain flow coater. Thus, the inventors have found that the above problems can be solved by using a method for forming a transparent resin layer, and have completed the present invention.

すなわち、本発明の加飾樹脂成形品は、シートモールディングコンパウンド成形品と、加飾された不織布と、透明樹脂層とが積層されてなる加飾樹脂成形品において、
前記透明樹脂層が、前記シートモールディングコンパウンド成形品上に載置された前記不織布上に、透明光硬化性樹脂を含む塗料をカーテンフローコーターにより塗布し硬化して形成され、かつ、塗布された該塗料が前記不織布内に浸透して、前記シートモールディングコンパウンド成形品と一体的に硬化されていることを特徴とするものである。
That is, the decorative resin molded product of the present invention is a decorative resin molded product in which a sheet molding compound molded product, a decorated nonwoven fabric, and a transparent resin layer are laminated.
The transparent resin layer is formed on the nonwoven fabric placed on the sheet molding compound molded article by applying a coating containing a transparent photocurable resin by a curtain flow coater and curing, and is applied. The paint penetrates into the nonwoven fabric and is cured integrally with the sheet molding compound molded product.

また、本発明の加飾樹脂成形品の製造方法は、シートモールディングコンパウンド成形品と、加飾された不織布と、透明樹脂層とを備える加飾樹脂成形品の製造方法において、
前記シートモールディングコンパウンド成形品上に前記不織布を載置し、透明光硬化性樹脂を含む塗料をカーテンフローコーターにより該不織布上に塗布するとともに、塗布した該塗料を該不織布内に浸透させて、該塗料を、該不織布を介して前記シートモールディングコンパウンド成形品と一体的に硬化させることにより、前記透明樹脂層を形成することを特徴とするものである。
Moreover, the manufacturing method of the decorative resin molded product of the present invention is a method for manufacturing a decorative resin molded product comprising a sheet molding compound molded product, a decorated nonwoven fabric, and a transparent resin layer.
The nonwoven fabric is placed on the sheet molding compound molded article, and a paint containing a transparent photocurable resin is applied onto the nonwoven fabric by a curtain flow coater, and the applied paint is infiltrated into the nonwoven fabric, The transparent resin layer is formed by curing a paint integrally with the sheet molding compound molded product through the nonwoven fabric.

本発明においては、前記不織布として、目付け量が30〜200g/cmのものを用いることが好ましい。また、前記塗料の粘度は、好適には50〜500mPa・sとする。 In the present invention, it is preferable to use a nonwoven fabric having a basis weight of 30 to 200 g / cm 2 . The viscosity of the paint is preferably 50 to 500 mPa · s.

本発明によれば、上記構成としたことにより、従来と比較して透明感や光沢に優れ、かつ、意匠性に優れる加飾樹脂成形品を実現することが可能となった。また、本発明の加飾樹脂成形品の製造方法によれば、かかる意匠性に優れた加飾樹脂成形品を、簡易な工程で製造することができるものである。   According to the present invention, the above configuration makes it possible to realize a decorated resin molded product that is superior in transparency and gloss as compared to conventional ones and is excellent in design. Moreover, according to the manufacturing method of the decorative resin molded product of this invention, the decorative resin molded product excellent in this designability can be manufactured in a simple process.

本発明の加飾樹脂成形品の一例を示す幅方向断面図である。It is width direction sectional drawing which shows an example of the decorating resin molded product of this invention.

以下、本発明の実施の形態について、図面を参照しつつ詳細に説明する。
図1に、本発明の加飾樹脂成形品の一例を示す幅方向断面図を示す。本発明の加飾樹脂成形品は、ユニットバス用床パンや壁パネル等に好適に適用できるものであって、図示するように、シートモールディングコンパウンドからなる成形品1と、加飾された不織布2と、透明樹脂層3とが積層されてなるものである。
Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings.
FIG. 1 is a cross-sectional view in the width direction showing an example of the decorative resin molded product of the present invention. The decorative resin molded product of the present invention can be suitably applied to floor pans and wall panels for unit baths, and as shown in the drawing, a molded product 1 made of a sheet molding compound and a decorated nonwoven fabric 2 And the transparent resin layer 3 are laminated.

本発明においては、透明樹脂層3が、SMC成形品1上に載置された不織布2上に、透明光硬化性樹脂を含む塗料をカーテンフローコーターにより塗布し硬化して形成されてなる。本発明において、不織布2上に塗布されたかかる塗料は、図示するように、不織布2内に浸透して、SMC成形品1と一体的に硬化されている。本発明によれば、かかる構成としたことで、意匠性に優れた加飾樹脂成形品を得ることができる。また、本発明においては、一体成形時に不織布の折れや破れ等の生ずるおそれがないことに加え、透明樹脂層3の透明度および平滑性が良好であるので表面の光沢度が高く、また、透明樹脂層3を一定厚みで形成できるので、かかる点でも意匠性を向上する効果が得られるものである。   In the present invention, the transparent resin layer 3 is formed on the nonwoven fabric 2 placed on the SMC molded product 1 by applying and curing a paint containing a transparent photocurable resin with a curtain flow coater. In the present invention, the paint applied on the nonwoven fabric 2 penetrates into the nonwoven fabric 2 and is integrally cured with the SMC molded product 1 as shown in the figure. According to the present invention, a decorative resin molded product excellent in design can be obtained by adopting such a configuration. In addition, in the present invention, there is no risk of the nonwoven fabric being folded or torn during integral molding, and the transparency and smoothness of the transparent resin layer 3 are good, so that the glossiness of the surface is high, and the transparent resin Since the layer 3 can be formed with a constant thickness, the effect of improving the design is also obtained in this respect.

本発明の加飾樹脂成形品に用いるSMCとしては、公知のものを使用することができ、特に制限されるものではない。具体的には例えば、不飽和ポリエステル樹脂、エポキシ樹脂またはフェノール樹脂と、硬化剤、強化繊維および増粘剤とにより構成される組成物が好適である。強化繊維としては、ガラス繊維の他、各種の無機繊維および有機繊維等を使用してもよい。また、SMCには、必要に応じて硬化促進剤や低収縮化剤、顔料、無機充填材等を加えることもできる。   As SMC used for the decorative resin molded product of the present invention, known ones can be used, and are not particularly limited. Specifically, for example, a composition composed of an unsaturated polyester resin, an epoxy resin, or a phenol resin, a curing agent, a reinforcing fiber, and a thickener is preferable. As the reinforcing fiber, various inorganic fibers and organic fibers other than glass fibers may be used. Moreover, a hardening accelerator, a low shrinkage agent, a pigment, an inorganic filler, etc. can also be added to SMC as needed.

不織布2についても、特に制限されず、公知の合成樹脂からなる不織布を適宜使用することができ、好適には、ポリエステル繊維を不織布に加工したものを用いる。かかる不織布2に対する加飾は、所望に応じ、凸版印刷、グラビア印刷、オフセット印刷、シルク印刷、転写印刷等の各種印刷法により行うことができる。本発明においては、かかる不織布2上に塗布した透明光硬化性樹脂を不織布2内に浸透、含浸させて、SMC成形品1、不織布2および透明樹脂層3を一体化するものであるので、かかる観点から、不織布2としてはプリプレグ化されていないものを好ましく用いることができ、また、不織布2の目付け量は、好適には30〜200g/cm、より好適には50〜100g/cmとする。 The non-woven fabric 2 is not particularly limited, and a non-woven fabric made of a known synthetic resin can be used as appropriate. A non-woven fabric obtained by processing a polyester fiber is preferably used. The decoration on the nonwoven fabric 2 can be performed by various printing methods such as letterpress printing, gravure printing, offset printing, silk printing, and transfer printing, as desired. In the present invention, the transparent photocurable resin applied on the nonwoven fabric 2 is infiltrated and impregnated into the nonwoven fabric 2 so that the SMC molded product 1, the nonwoven fabric 2 and the transparent resin layer 3 are integrated. From a viewpoint, what is not prepreg can be preferably used as the nonwoven fabric 2, and the basis weight of the nonwoven fabric 2 is preferably 30 to 200 g / cm 2 , more preferably 50 to 100 g / cm 2 . To do.

透明樹脂層3を形成するために用いられる透明光硬化性樹脂としては、塗布後、UV照射により硬化して、硬化後においても透明性を維持できるものであれば、いかなるものを用いてもよく、特に制限されるものではない。具体的には例えば、DIC(株)製のV−4205,ユニディック17806等の光硬化性樹脂を用い、チバ・ジャパン(株)製のIRGACURE184,754,907等の光重合開始剤を添加して調製された塗料を用いることができる。また、かかる塗料の粘度は、50〜500mPa・s、特には100〜200mPa・sとすることが好ましい。塗料の粘度が高すぎると、塗料が不織布2内に十分に浸透しないおそれがあり、塗料の粘度が低すぎると、透明樹脂層3の厚みを十分に確保できないおそれがある。本発明における透明樹脂層3の厚みは、かかる塗料の粘度と不織布2の目付け量とを適宜選定することにより、適切に調整することができ、これにより、加飾樹脂成形品における意匠性の自由度を高めることができる。   As the transparent photocurable resin used for forming the transparent resin layer 3, any resin may be used as long as it is cured by UV irradiation after application and can maintain transparency even after curing. There is no particular limitation. Specifically, for example, a photopolymerization initiator such as IRGACURE 184, 754, 907 or the like manufactured by Ciba Japan Co., Ltd. is added using a photo-curable resin such as V-4205 or Unidic 17806 manufactured by DIC Corporation. The paint prepared in this way can be used. Moreover, it is preferable that the viscosity of this coating material shall be 50-500 mPa * s, especially 100-200 mPa * s. If the viscosity of the paint is too high, the paint may not sufficiently penetrate into the nonwoven fabric 2, and if the viscosity of the paint is too low, the thickness of the transparent resin layer 3 may not be sufficiently secured. The thickness of the transparent resin layer 3 in the present invention can be appropriately adjusted by appropriately selecting the viscosity of the paint and the basis weight of the nonwoven fabric 2, thereby freeing designability in the decorative resin molded product. The degree can be increased.

本発明の加飾樹脂成形品は、具体的には、以下のようにして製造できる。すなわち、まず、あらかじめ成形されたSMC成形品1上に、所望に加飾を施した不織布2を載置して、透明光硬化性樹脂を含む塗料を、カーテンフローコーターにより不織布2上に塗布する。このカーテンフローコーターとは、0.1〜1.0mm程度の細いスリットから塗布材料を膜状に流下させて、下方に載置した被塗布物に対し塗布する塗布装置である。また、カーテンフローコーターとしては、塗布材料をオーバーフローさせて膜状に流下させるタイプの装置もあり、本発明においては、いずれのタイプの装置を用いてもよい。カーテンフローコーターを用いて塗布を行うことで、大きな被塗布物に対し短時間で塗布が可能であって、塗料が被塗布物表面の凹凸に追随しやすいというメリットが得られる。本発明において、かかるカーテンフローコーターによる塗布条件については、目的とする透明樹脂層3の厚み等により適宜決定することができ、特に制限されるものではない。   Specifically, the decorated resin molded product of the present invention can be produced as follows. That is, first, a desired decorated non-woven fabric 2 is placed on a pre-molded SMC molded product 1, and a paint containing a transparent photocurable resin is applied onto the non-woven fabric 2 by a curtain flow coater. . The curtain flow coater is a coating device that applies a coating material to a coating object placed below by causing a coating material to flow down from a thin slit of about 0.1 to 1.0 mm into a film shape. Further, as a curtain flow coater, there is a type of apparatus that causes the coating material to overflow and flow down into a film shape, and any type of apparatus may be used in the present invention. By applying using a curtain flow coater, it is possible to apply to a large object in a short time, and it is possible to obtain the merit that the paint easily follows the unevenness of the surface of the object. In the present invention, the application conditions by such a curtain flow coater can be appropriately determined depending on the thickness of the target transparent resin layer 3 and the like, and are not particularly limited.

本発明においては、不織布2の目付け量と塗料の粘度とを適切に調整することにより、不織布2上に塗布された塗料を、不織布2内に浸透させる。その後、塗料を、不織布2を介してSMC成形品1と一体的に硬化させて、透明樹脂層3を形成することで、SMC成形品1上に不織布2および透明樹脂層3が順次積層された加飾樹脂成形品を得ることができる。なお、この透明光硬化性樹脂を含む塗料の硬化条件については、特に制限されるものではなく、一般的な光強度および光照射時間の範囲内で適宜決定することができる。   In the present invention, the paint applied on the nonwoven fabric 2 is allowed to penetrate into the nonwoven fabric 2 by appropriately adjusting the basis weight of the nonwoven fabric 2 and the viscosity of the paint. Then, the non-woven fabric 2 and the transparent resin layer 3 were sequentially laminated on the SMC molded product 1 by curing the paint integrally with the SMC molded product 1 through the nonwoven fabric 2 to form the transparent resin layer 3. A decorative resin molded product can be obtained. In addition, the curing conditions of the paint containing the transparent photocurable resin are not particularly limited, and can be appropriately determined within the range of general light intensity and light irradiation time.

本発明の製造方法によれば、意匠性に優れた加飾樹脂成形品が容易に得られることに加え、加飾された不織布の位置決めの精度を向上することができ、また、サイクルタイムが短縮できるなどの効果も得られるものである。   According to the production method of the present invention, in addition to easily obtaining a decorative resin molded product having excellent design properties, it is possible to improve the positioning accuracy of the decorated nonwoven fabric and to shorten the cycle time. The effect of being able to be obtained is also obtained.

以下、本発明を、実施例を用いてより詳細に説明する。
<実施例>
不飽和ポリエステル、硬化剤、ガラス繊維および増粘剤からなるSMCをパネル状に成形し、このSMC成形品上に、模様が印刷されたポリエステル繊維からなる不織布(目付け量70g/m)を載置した。この不織布上に、光硬化性樹脂(V−4205,DIC(株)製)100質量部と、光重合開始剤(IRGACURE184,チバ・ジャパン(株)製)5質量部とからなる粘度200mPa・sの塗料を、カーテンフローコーターにより塗布した。塗布した塗料が不織布内に浸透した後、照射強度1000mW/cmにてUV(紫外線)を30秒間照射することにより、この塗料を、不織布を介してSMC成形品と一体的に硬化させて、透明樹脂層を形成した。硬化後の透明樹脂層の膜厚は、50μmであった。
Hereinafter, the present invention will be described in more detail with reference to examples.
<Example>
SMC composed of unsaturated polyester, curing agent, glass fiber and thickener is molded into a panel shape, and a nonwoven fabric (weight per unit area 70 g / m 2 ) composed of polyester fiber printed with a pattern is placed on this SMC molded product. I put it. On this nonwoven fabric, a viscosity of 200 mPa · s consisting of 100 parts by mass of a photocurable resin (V-4205, manufactured by DIC Corporation) and 5 parts by mass of a photopolymerization initiator (IRGACURE184, manufactured by Ciba Japan Co., Ltd.). Were applied by a curtain flow coater. After the applied coating has penetrated into the nonwoven fabric, UV (ultraviolet light) is irradiated for 30 seconds at an irradiation intensity of 1000 mW / cm 2, so that the coating is cured integrally with the SMC molded product through the nonwoven fabric, A transparent resin layer was formed. The film thickness of the transparent resin layer after curing was 50 μm.

得られた加飾樹脂成形品は、表面が平滑で不織布の損傷や露出等もなく、印刷された模様が鮮明であって、極めて意匠性に優れるものであった。   The obtained decorative resin molded article had a smooth surface, no damage or exposure of the nonwoven fabric, a clear printed pattern, and extremely excellent design.

1 シートモールディングコンパウンド(SMC)成形品
2 不織布
3 透明樹脂層
1 Sheet molding compound (SMC) molded product 2 Non-woven fabric 3 Transparent resin layer

Claims (5)

シートモールディングコンパウンド成形品と、加飾された不織布と、透明樹脂層とが積層されてなる加飾樹脂成形品において、
前記透明樹脂層が、前記シートモールディングコンパウンド成形品上に載置された前記不織布上に、透明光硬化性樹脂を含む塗料をカーテンフローコーターにより塗布し硬化して形成され、かつ、塗布された該塗料が前記不織布内に浸透して、前記シートモールディングコンパウンド成形品と一体的に硬化されていることを特徴とする加飾樹脂成形品。
In a decorative resin molded product in which a sheet molding compound molded product, a decorated nonwoven fabric, and a transparent resin layer are laminated,
The transparent resin layer is formed on the nonwoven fabric placed on the sheet molding compound molded article by applying a coating containing a transparent photocurable resin by a curtain flow coater and curing, and is applied. A decorative resin molded product, wherein a coating material penetrates into the nonwoven fabric and is cured integrally with the sheet molding compound molded product.
前記不織布の目付け量が30〜200g/cmである請求項1記載の加飾樹脂成形品。 Claim 1 decorated resin molded article according basis weight of the nonwoven fabric is 30 to 200 g / cm 2. シートモールディングコンパウンド成形品と、加飾された不織布と、透明樹脂層とを備える加飾樹脂成形品の製造方法において、
前記シートモールディングコンパウンド成形品上に前記不織布を載置し、透明光硬化性樹脂を含む塗料をカーテンフローコーターにより該不織布上に塗布するとともに、塗布した該塗料を該不織布内に浸透させて、該塗料を、該不織布を介して前記シートモールディングコンパウンド成形品と一体的に硬化させることにより、前記透明樹脂層を形成することを特徴とする加飾樹脂成形品の製造方法。
In a method for producing a decorative resin molded product comprising a sheet molding compound molded product, a decorated nonwoven fabric, and a transparent resin layer,
The nonwoven fabric is placed on the sheet molding compound molded article, and a paint containing a transparent photocurable resin is applied onto the nonwoven fabric by a curtain flow coater, and the applied paint is infiltrated into the nonwoven fabric, A method for producing a decorative resin molded product, wherein the transparent resin layer is formed by curing a paint integrally with the sheet molding compound molded product via the nonwoven fabric.
前記不織布として、目付け量が30〜200g/cmのものを用いる請求項3記載の加飾樹脂成形品の製造方法。 As the nonwoven fabric manufacturing process according to claim 3, wherein the decorated resin molded article basis weight used as a 30 to 200 g / cm 2. 前記塗料の粘度を50〜500mPa・sとする請求項3または4記載の加飾樹脂成形品の製造方法。   The method for producing a decorated resin molded article according to claim 3 or 4, wherein the viscosity of the paint is 50 to 500 mPa · s.
JP2010052793A 2010-03-10 2010-03-10 Decorative resin molding and production process of the same Pending JP2011183717A (en)

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Country Link
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