JP2015217011A - Manufacturing method of tableware - Google Patents

Abstract

PROBLEM TO BE SOLVED: To retain high reliability in a continuous use under high temperature environment by securing sufficient heat resistance and versatility with respect to various high-temperature use environments, and easily and reliably add a design such as a pattern.SOLUTION: A tableware manufacturing method for manufacturing a tableware by molding a synthetic resin material R by means of a molding tool to provide an unglazed molding Mo and applying a coating material D on the surface of the unglazed molding Mo, includes: a molding step of using an SPS resin as the synthetic resin material R and molding the SPS resin by means of the molding tool to provide the unglazed molding Mo; a surface treatment step of providing a treated molding Ms by radiating corona generated by corona discharge to a surface Mof of the unglazed molding Mo and modifying the surface Mof; and a coating material application step of applying the coating material D on a part or all of a surface Msf of the treated molding Ms.

Description

  The present invention relates to a tableware manufacturing method suitable for use in applying a paint to the surface of a molded product formed of a synthetic resin material, and tableware manufactured by the manufacturing method.

  In general, since tableware used in hospitals and welfare facilities is required to have lightness, contamination resistance, durability, and the like, tableware molded from a synthetic resin material is widely used. In addition, recently, since it is often used by directly heating it with a microwave oven, a reheating cart, etc., the importance to heat resistance tends to become larger, and design is also an important factor. Tableware requires various performances. Therefore, in order to satisfy these requirements, the selection of the synthetic resin material is important, and if the requirements cannot be met by the selection of the material alone, additional improvements from the structural aspect are also required.

  Conventionally, as a tableware that meets the requirements for such tableware, in particular, heat resistance, the tableware made of resin with a pattern disclosed in Patent Document 1 and the tableware disclosed in Patent Document 2 are known. The resin tableware with a pattern disclosed in the literature 1 is intended to provide a resin tableware with a pattern having excellent heat resistance and rigidity, and specifically, within a range where transparency remains. A primary molded product of polypropylene reinforced with filler, a pattern on the outer surface of the primary molded product whose concentration is higher than the color to be displayed as viewed from the inner surface, and a polypropylene reinforced with filler and arranged on the outer surface side of the pattern And a secondary molded product. The tableware disclosed in Patent Document 2 is intended to provide tableware with excellent heat resistance. Specifically, two types of resins, polyethylene terephthalate and polybutylene terephthalate, are used in the total amount. On the other hand, an insert film made of polyethylene terephthalate is insert-bonded to the surface of a base molded product formed of a polyester molding material containing 1 to 15% by mass of methacrylic resin and 5 to 30% by mass of an inorganic filler with respect to the total amount. It is what you do.

JP 2001-095667 A JP 2002-248041 A

  However, the conventional tableware (and its manufacturing method) including the above-mentioned tableware has the following problems.

  First, because it is designed to withstand temperatures of about 120 [° C], heat resistance against hot water, etc. is ensured, but heat resistance that is continuously exposed to high temperatures of 140 ° C or higher. Sexuality is not always guaranteed. Therefore, from the viewpoint of ensuring sufficient heat resistance for various high temperature use environments such as reheating carts, steam convection, microwave ovens, etc., and maintaining high reliability even in continuous use under high temperature environments, further improvement is possible. There was room.

  Second, dishes used in hospitals and welfare facilities are required to have high contamination resistance from the viewpoint of hygiene. Therefore, a synthetic resin material to be used is usually selected from materials having excellent contamination resistance. On the other hand, being hardly contaminated means that the peel resistance is lowered. For this reason, it is not easy to attach a design such as a pattern to the surface for tableware in which washing with a detergent is frequently repeated. Usually, as in Patent Document 1, it is configured in a two-layer structure, and between two layers. Actually, it is possible to cope with this by interposing a pattern or by bonding an insert film displaying a pattern as in Patent Document 2. In the end, it has been a difficult task to ensure both basic performance as tableware and at the same time to easily and reliably apply designs such as patterns.

  The object of the present invention is to provide a tableware manufacturing method and tableware that solve the problems in the background art.

  The tableware manufacturing method according to the present invention produces a dough-molded product Mo by molding a synthetic resin material R with a mold, and manufactures the tableware 1 by applying a paint D to the surface Mof of the dough-molded product Mo. In doing so, the SPS (syndiotactic polystyrene) resin is used as the synthetic resin material R, and the molding step (S2) of obtaining the fabric molded product Mo by molding the SPS resin with a molding die; A surface treatment step (S8) for obtaining a treated molded product Ms obtained by modifying the surface Mof by radiating corona C generated by corona discharge to the surface Mof, and a part or all of the surface Msf of the treated molded product Ms. And a coating material coating step (S13) for coating the coating material D.

  In this case, according to a preferred embodiment, the molding step (S2) can be performed by an injection molding method. In the surface treatment step (S8), the ambient temperature is 5 to 40 [° C.], the ambient humidity is 17 to 70 [%], and the distance Lp from the corona discharge part 12 to the surface Mof of the molded article Mo is 5 to 40. [Mm], with respect to the surface Mof of the molded article Mo rotating at a rotation speed of 1 to 10 [rpm] while being subjected to corona discharge under a processing condition in which the discharge output is set to 0.5 to 1.0 [W]. It is desirable to emit corona C. In addition, in the surface treatment step (S8), the dough molded product Mo can be rotated at least twice or more while the corona C is being emitted. On the other hand, in the paint application step (S13), the paint D can be printed and applied by a screen printing method. On the other hand, a second synthetic resin Re having a predetermined thickness and being transparent or translucent can be attached to the surface Msf of the processed molded product Ms coated with the paint D by an insert molding method or an adhesion method. In addition, a PMP (polymethylpentene) resin can be used for the second synthetic resin Re.

  Moreover, when the tableware 1 which concerns on this invention comprises the tableware formed by apply | coating the coating material D to the surface Mof of the dough molded product Mo shape | molded by the synthetic resin material R, SPS resin is used as the synthetic resin material R In addition, the paint D is applied to a part or all of the surface Mof modified by the radiation of the corona C generated by the corona discharge. In this case, according to a preferred embodiment, the second synthetic resin Re having a predetermined thickness and being transparent or translucent can be attached to the surface Mof to which the paint D is applied.

  According to such a tableware manufacturing method and tableware 1 according to the present invention, the following remarkable effects can be obtained.

  (1) Since the SPS resin is used as the synthetic resin material R, it is possible to sufficiently guarantee the heat resistance that is continuously exposed to a high temperature of 140 [° C.] or higher. Therefore, sufficient heat resistance to various high temperature use environments such as a reheating cart, steam convection, and a microwave oven can be ensured, and versatility can be secured, and high reliability can be maintained even in continuous use in a high temperature environment.

  (2) Since a surface treatment step (S8) for obtaining a treated molded product Ms by modifying the surface Mof by radiating corona C generated by corona discharge to the surface Mof of the fabric molded product Mo is provided with an SPS resin. The surface Mof of the used dough-formed product Mo can be modified to improve the hydrophilicity at which the paint D easily adheres, and further to improve the peel resistance. Therefore, by using SPS resin, in addition to ensuring sufficient basic performance as tableware such as heat resistance, contamination resistance and chemical resistance, a special structure such as a two-layer structure should be adopted. In addition, the design such as a pattern can be easily and surely provided, so that it can be provided as an optimum manufacturing method for tableware that frequently repeats washing with a detergent.

  (3) According to a preferred embodiment, in the molding step (S2), if molding is performed by an injection molding method, from the supply of molding material to the molding process, and further, the removal of the molded product can be easily automated. It can be provided as a manufacturing method of tableware having excellent cost.

  (4) According to a preferred embodiment, in the surface treatment step (S8), the ambient temperature is 5 to 40 [° C.], the ambient humidity is 17 to 70 [%], and from the corona discharge part 12 to the surface Mof of the fabric molded product Mo. The dough molded article Mo that is corona discharged under the processing conditions in which the distance Lp is set to 5 to 40 [mm] and the discharge output is set to 0.5 to 1.0 [W] and rotated at a rotation speed of 1 to 10 [rpm]. If corona C is radiated to the surface Mof, the processing conditions can be optimized particularly from the viewpoint of manufacturing tableware using SPS resin. Therefore, suitable manufacturing for manufacturing tableware made of SPS resin is preferable. It can be constructed as a method.

  (5) According to a preferred embodiment, when the dough-formed product Mo is rotated at least twice during corona C radiation in the surface treatment step (S8), particularly when producing tableware using SPS resin. Since the processing time can be optimized, it is possible to perform a good modification process on the surface Mof of the dough molding Mo using the SPS resin.

  (6) According to a preferred embodiment, if the coating material D is printed and applied by the screen printing method in the coating material coating step (S13), automation can be easily realized when a design such as a pattern is applied to the surface of the tableware 1. High quality design can be realized.

  (7) According to a preferred embodiment, a second synthetic resin Re having a predetermined thickness and transparent or translucent is inserted or bonded to the surface Msf of the processed molded article Ms coated with the paint D. If it attaches by a system, in addition to demonstrating the physical and chemical performance of SPS resin used as the formation raw material of the tableware 1 to the maximum, peeling of the apply | coated coating material D can be avoided reliably.

  (8) According to a preferred embodiment, if a PMP resin is used as the second synthetic resin Re, the heat resistance of the tableware 1 itself can be further enhanced by the PMP resin having a heat resistance of 160 [° C.] or higher.

The flowchart for demonstrating the whole process sequence of the manufacturing method of the tableware which concerns on suitable embodiment of this invention, Block configuration diagram showing an example of a processing system used for the surface treatment process in the manufacturing method, External configuration diagram of processing head and peripheral structure in surface processing step in the manufacturing method, Treatment principle explanatory diagram in the surface treatment process in the manufacturing method, Sectional front view of tableware (tea bowl) manufactured by the manufacturing method, Appearance front view of tableware (tea bowl) manufactured by the manufacturing method, A table showing the evaluation results of tableware (samples) manufactured by the manufacturing method, Sectional front view of tableware (tea bowl) manufactured by the manufacturing method according to a modified embodiment of the present invention,

  Next, preferred embodiments according to the present invention will be given and described in detail with reference to the drawings.

  First, the syndiotactic polystyrene resin (SPS resin) used in the tableware 1 according to the present embodiment and the processing system 10 for modifying the surface Mof of the dough molded product Mo using the SPS resin will be described.

  First, the SPS resin will be described. In general, melamine resins and polypropylene resins are widely known as synthetic resin materials used for tableware. On the other hand, SPS resin is an engineering plastic developed by Idemitsu Kosan Co., Ltd., and “Zarek” (trade name) manufactured by Idemitsu Kosan Co., Ltd. can be used as a commercial product of SPS resin according to this embodiment. The SPS resin is a kind of polystyrene resin obtained by polymerizing using styrene as a monomer and using a metallocene catalyst, and is mainly used for electric parts and machine parts. Therefore, there are no examples of general use as tableware in hospitals and welfare facilities.

  In addition, since the SPS resin has a syndiotactic structure, it has crystallinity, and is excellent in heat resistance (melting point: 240 to 270 [° C.]) and chemical resistance compared to a normal polystyrene resin. A general polystyrene resin has an atactic structure. Furthermore, SPS resins belong to the lightest category of engineering plastics, and are excellent in steam resistance without being hydrolyzed. In addition, it has excellent fluidity, good mold reproducibility, low dielectric loss, and good tracking resistance. In addition, it is resistant to acid, alkali, and neutral detergents, and can be sterilized with alcohol and chlorine bleach. In addition, yellowing, dissolution and cracking are unlikely to occur.

  Since the SPS resin which has such a property is used as the synthetic resin material R, the manufacturing method of the tableware and the tableware 1 which concern on this embodiment are continuously exposed to the high temperature of 140 [degrees C] or more. Heat resistance can be fully guaranteed. Therefore, sufficient heat resistance to various high temperature use environments such as a reheating cart, steam convection, and a microwave oven can be ensured, and versatility can be secured, and high reliability can be maintained even in continuous use in a high temperature environment. In particular, in the case of SPS resin, there is an advantage that high heat resistance that can sufficiently withstand a high temperature of 200 [° C.] or more can be secured by using a reinforced plastic mixed with glass fiber.

  Next, the processing system 10 will be described with reference to FIGS. The processing system 10 has a processing function of radiating corona C generated by corona discharge to a surface Mof of a dough-molded product Mo to be described later and modifying the surface Mof. As a commercially available product having such a processing function, “Air Plasma (APW-602f)” (trade name) manufactured by Kasuga Electric Co., Ltd. can be used.

  By the way, since the SPS resin is a resin particularly excellent in stain resistance and chemical resistance, it is difficult to paint or print by a general surface treatment. Therefore, in this embodiment, the corona C based on a predetermined condition generated by corona discharge is used to modify the surface of the SPS resin, thereby enabling general-purpose painting and printing.

  An example of the processing system 10 is shown in FIG. In the processing system 10, reference numeral 11 denotes a processing head including a corona discharge unit 12. The corona discharge part 12 includes a pair of opposed discharge electrodes 12p and 12n, and a high voltage is applied from the high voltage part 13 between the discharge electrodes 12p and 12n. Thereby, corona discharge can be generated between the discharge electrodes 12p and 12n. Further, 14 indicates a blower fan, and the blower W by the blower fan 14 is supplied between the discharge electrodes 12p and 12n. Thereby, as shown in FIG. 2, arc-shaped corona discharge (corona C) is radiated | emitted to the surface Mof of the dough molded product Mo used as modification | reformation object.

  Reference numeral 15 denotes a moving unit that freely changes the position and angle of the processing head 11. FIG. 3 shows a configuration of the moving unit 15 as an example. The illustrated moving unit 15 can move (displace) the processing head 11 in the X direction, the Z direction, and the rotation direction Q with the Y axis as a fulcrum. Specifically, one end is fixed to the moving body 22m, and the Z-direction moving mechanism section 22 includes a Z-axis shaft 22s supported at the lower end by the fixed base 21 and a moving body 22m that moves along the Z-axis shaft 22s. The Y-direction moving mechanism unit 23 including the X-axis shaft 23s and the moving body 23m that moves along the X-axis shaft 23s, and the rotating mechanism unit 24 fixed to the moving body 23m are provided. The processing head 11 is supported on the rotating shaft 24s. On the other hand, 31 is a setting unit for setting the molded dough product Mo in a fixed position, and is supported by the rotation drive unit 32.

  On the other hand, in FIG. 2, reference numeral 16 denotes a driver, and the high voltage unit 13, the blower fan 14, and the moving unit 15 described above are connected to the output unit of the driver 16. Reference numeral 17 denotes a controller, which includes a controller main body 17c. A driver 16 and a display 17d are connected to the control body 17c. Further, the control body 17c is attached with a memory 17m that stores various data including various setting data and a control program for automatically executing the reforming process.

  The processing system 10 configured as described above can radiate the corona C to the surface Mof of the dough-molded article Mo set in the setting unit 31 to perform the modification process of the surface Mof. Further, when performing the reforming process, selection or setting is performed so as to satisfy the following processing condition. That is, the ambient temperature is 5 to 40 [° C.], the ambient humidity is 17 to 70 [%], and the distance Lp (see FIG. 2) from the corona discharge part 12 to the surface Mof of the fabric molded product Mo is 5 to 40 [mm]. The corona discharge is generated so that the discharge output satisfies the processing condition of 0.5 to 1.0 [W]. Furthermore, the dough molding Mo set in the setting unit 31 is rotated by the rotation driving unit 32 at a rotation speed of 1 to 10 [rpm]. If corona C is radiated under such processing conditions, the processing conditions can be optimized particularly from the viewpoint of manufacturing tableware using SPS resin, which is suitable for manufacturing tableware made of SPS resin. It can be constructed as a manufacturing method.

  In this case, it is desirable that the number of rotations of the dough-formed product Mo is rotated at least twice during the corona C radiation. By setting the number of rotations in this way, it is possible to optimize the processing time especially when producing tableware using SPS resin, and therefore, a good modification process for the surface Mof of the dough molded product Mo using SPS resin. There is an advantage that can be done. In addition, the frequency | count of rotation of the dough molded product Mo can be used as completion | finish conditions of a modification | reformation process.

  FIG. 4 shows the principle of reforming processing by the processing system 10. In the figure, Mo indicates a part of a fabric molded product formed of SPS resin. Due to the corona discharge, the high-energy electrons e generated in the corona C reach the surface Mof of the dough molding Mo, and the high-energy electrons e are the main chains (including side chains) of polymer bonds in the surface layer of the SPS resin. It has the effect of separating. On the other hand, since the cut polymer surface layer is scientifically radical, oxygen radicals in the gas phase and the ozone layer recombine with the main chain and side chain, so polar functions such as hydroxyl groups and carbonyl groups can be obtained. Group Xc is introduced. Thereby, hydrophilicity will arise and the printability (adhesiveness) to hydrophobic polymer will improve remarkably. The influence at this time is the surface layer of 0.1 [um] or less, and the properties of the base material itself of the dough-formed product Mo are not impaired. If necessary, it may be performed under a specific gas atmosphere or under a vacuum pressure.

  Next, a tableware manufacturing method according to this embodiment will be described with reference to the flowchart shown in FIG.

  When manufacturing the tableware according to the present embodiment, first, the above-described SPS resin is prepared as the synthetic resin material R to be a molding material (step S1). In addition, the tableware manufactured in this embodiment is the teacup 1c shown in FIG. First, a molding process using a mold is performed (step S2). In this case, since the SPS resin becomes a thermoplastic resin, an injection molding machine can be used. Therefore, it is possible to perform molding by an injection molding method in which a melted SPS resin is injection-filled into a mold (molding mold) having a cavity that represents the teacup 1c. By the above molding process, a fabric molded product Mo that is substantially the same in shape as the processed molded product Ms before the coating material D shown in FIG. 5 is applied can be obtained. By using such an injection molding method, it is possible to easily automate from the supply of the molding material to the molding process, and further the removal of the molded product, so that it can be provided as a tableware manufacturing method with excellent mass productivity and low cost. There are advantages. On the other hand, at the end of molding, the fabric molded product Mo is taken out from the mold, and the removed fabric molded product Mo is cleaned to remove foreign matters attached to the surface Mof (steps S3 and S4).

  Next, a surface treatment process for modifying the surface Mof by radiating the corona C generated by the corona discharge to the surface Mof of the fabric molded product Mo is performed. In addition, the predetermined processing conditions described above for performing corona discharge are set in advance in the memory 17m in the processing system 10 described above (step S0). When performing the surface treatment process, first, the fabric molded product Mo is set in the setting unit 31 of the treatment system 10 as shown in FIG. 3 (step S5). If set, a start switch (not shown) is turned on (step S6). Thereby, the surface treatment process automatically proceeds according to the control program stored in the memory 17m. That is, the rotation drive unit 32 is rotated to rotate the dough molding Mo (step S7). Further, an arc-shaped corona discharge is generated between the discharge electrodes 12p and 12n in the processing system 10, and the corona C based on the arc-shaped corona discharge is radiated to the surface Mof of the fabric molded product Mo. As a result, the above-described modification process for the surface Mof is performed, the moving unit 15 is controlled, and the process head 11 moves, so that the modification process for the entire surface Mof is uniformly performed (step S8).

  On the other hand, when the end condition is satisfied, the rotation of the rotation drive unit 32 and the corona discharge in the processing system 10 are stopped, and the surface treatment process is ended (steps S9 and S10). In this case, as an end condition, for example, an arbitrary end condition can be set such that, for example, the processing time can be set in advance and the elapse of the processing time can be set as the end condition. In the present embodiment, the end condition is set based on the number of rotations of the fabric molded product Mo. Therefore, if the number of rotations of the dough molded product Mo reaches the set number of rotations, the surface treatment process can be terminated. As a result, a processed molded product Ms having a modified surface Msf is obtained. When the surface treatment process is completed, the processed molded product Ms is taken out from the setting unit 31 (step S11).

  Next, a paint application process for applying the paint D to the surface Msf of the processed molded product Ms is performed. When performing the paint application process, first, the processed molded product Ms is set at a predetermined setting position in a screen printing machine (not shown) (step S12). And the coating application process which performs the screen printing process which carries out the printing application of the predetermined coating material D to the surface Msf of the process molded article Ms by the screen printing system using a screen printer is performed (step S13).

  In this case, for the paint D, for example, a two-component reaction type resin ink in which a main agent and a curing agent are blended can be used. Since the two-component reaction type resin ink can freely change the hardness and flexibility of the cured film, it has excellent adhesion to a wide range of materials from flexible materials to hard materials. In addition, the ink can be used for a long time, has excellent on-machine stability, and can form a cured film excellent in chemical resistance and solvent resistance. Moreover, if a non-yellowing type aliphatic isocyanate prepolymer is used as the curing agent, the weather resistance will be strong, and in addition, there will be no ink-specific odor due to heating after complete curing, etc. Is suitable.

  More specifically, an acrylic urethane resin-based two-component reaction type resin ink can be used. As the main agent, acrylic polyol having a functional group such as a hydroxyl group, polyester polyol, polyether polyol, vinyl chloride and vinyl acetate. A copolymer resin, an epoxy resin, or the like can be used, and an isocyanate prepolymer or the like can be used as a curing agent. In order to prevent increase in viscosity on the printing press and clogging of the printing plate, it is desirable to use hydrocarbons, esters, ketones, alcohols, polyhydric alcohol derivatives, etc. as diluent solvents. In addition, the acrylic urethane type two-component reaction type resin ink is exemplified for the ink, but it is also possible to use known inks such as general UV type, rubber type, acrylic type, vinyl type, polyester type, urethane type, etc. Is possible.

  On the other hand, the coating material D is added in a mixing ratio of 100 parts of the main agent, 10 parts of the curing agent, and about 5 to 20 parts of the diluent solvent, and is well stirred. Then, screen printing (rotational printing) is performed using the printing plate. In the case of illustration, as shown in FIG. 6, the pattern K used as the floral pattern was printed on the surface Msf in the outer surface of the processed molded product Ms. In this way, if the coating material D is printed and applied by the screen printing method, automation is easily realized when the design M or the like is applied to the surface Msf of the processed molded product Ms, that is, the surface of the tableware 1. There is an advantage that the design can be improved in quality. The example shows the case where the pattern K is printed on a part of the surface Msf, but the entire surface Msf may be coated. Specifically, it is also possible to perform a whole surface application treatment like a traditional lacquer ware.

  When the paint application process is completed, the processed molded product Ms to which the paint D has been applied (printed) is taken out from the screen printer and the necessary drying process is performed (steps S14 and S15). In the drying step, first, a touch drying process of 10 [min] at a temperature of 60 [° C.] (or 5 [min] at a temperature of 80 [° C.]) is performed. After that, when applying (printing) two or more colors of paint D, the paint application process and the touch drying process may be repeated. When the touch drying process is completed, a main drying process of 3 [days] at room temperature or 60 [minutes] at a temperature of 80 to 100 [° C.] (or 15 [minutes] at a temperature of 120 [° C.]) is performed. To completely cure the coating material D. In this case, heating at as high a temperature as possible can provide a cured film with more excellent adhesion and physical properties.

  And if completion conditions, such as time progress, are satisfied, while completing a drying process, required inspection processes, such as an external appearance inspection, are performed (Steps S16 and S17). Thereby, the target tableware 1 (tea bowl 1c) shown in FIG. 6 can be obtained. That is, the tableware is formed by applying the coating D to the surface Mof of the dough molding Mo molded from the synthetic resin material R. The synthetic resin material R uses SPS resin and corona C generated by corona discharge. The tableware 1 which concerns on this embodiment formed by apply | coating the coating material D to part or all of the surface Mof modified by the radiation | emission of can be obtained.

  On the other hand, FIG. 7 shows the evaluation results of the manufactured samples. In the same table, Di is a sample of tea bowl 1c manufactured by the manufacturing method according to the present embodiment. In addition, as a control plot, a teacup sample Ds manufactured by removing the surface treatment process from the manufacturing method according to the present embodiment, and PP (polypropylene) resin instead of SPS resin as the molding material according to the present embodiment. A teacup sample Dp produced by the same procedure as the production method was shown as a similar evaluation result.

  The evaluation items used were six items: manufacturability, contamination resistance, peel resistance, high frequency suitability when used in a microwave oven, durability when used in a microwave oven, and appearance. In this case, the contamination resistance is determined by applying an appropriate amount of 4 kinds of sauce, mayonnaise, ketchup, and curry to the inner and outer surfaces of the sample, drying it in a speed dry oven set at 110 [° C] for 2 hours, and then allowing it to stand naturally. After cooling to room temperature and washing, the degree of contamination of the appearance was visually observed. In addition, the peel resistance is as follows: natural standing → hot water immersion (boiling) → neutral detergent immersion → washing with running water → drying with hot air (110 [° C.]) → natural standing as one cycle (each treatment is 30 minutes). After repeating 50 times, the presence or absence of the peeled state at the time of sticking and peeling with an adhesive tape was confirmed. On the other hand, the high frequency suitability when used in a microwave oven is that the sample is placed on a tray of the microwave oven, heated for 2 minutes with a microwave output of 1.0 [kW], and then the sample becomes 23 ± 50 [° C]. The operation of allowing to cool until repeated was repeated twice to confirm whether the sample was damaged or not. Furthermore, the durability when used in a microwave oven is such that olive oil filled up to about 50% of the volume of the sample is accommodated in the microwave oven, and every 30 to 180 [seconds] using a boiling point thermometer. The oil temperature is measured and heated to a predetermined temperature of 140 [° C.] or higher. When the predetermined temperature is reached, the sample is taken out and allowed to cool to 23 ± 50 [° C.], and then −17 It was stored in a freezer at [° C.] and cooled to a predetermined temperature. The above operation was repeated 5 times to confirm whether the sample was damaged or not. However, after the second time, the operation was repeated from the cooled state.

  As a result, as shown in FIG. 7, the sample Di according to the present invention has manufacturability, contamination resistance, peel resistance, high frequency suitability when used in a microwave oven, durability when used in a microwave oven, Good results were obtained for all six items of appearance. On the other hand, the sample Ds manufactured by removing the surface treatment process from the manufacturing method according to the present embodiment does not perform the surface modification treatment, and as a result, is inferior in peel resistance. It was. In addition, since the SPS resin was used about the other items, the favorable result was obtained similarly to the sample Di. On the other hand, sample Dp manufactured by the same procedure as the manufacturing method according to the present embodiment using PP resin instead of SPS resin as a molding material is about manufacturability, high-frequency suitability when used in a microwave oven, and appearance. Although good results were obtained, the stain resistance and durability when used in a microwave oven were inferior. In addition, the peel resistance was not good, but a practically satisfactory result was obtained.

  Thus, according to the tableware manufacturing method according to the present embodiment, since the SPS resin is used as the synthetic resin material R, the heat resistance enough to be continuously exposed to a high temperature of 140 [° C.] or more is sufficient. Can be guaranteed. Therefore, sufficient heat resistance to various high temperature use environments such as a reheating cart, steam convection, and a microwave oven can be ensured, and versatility can be secured, and high reliability can be maintained even in continuous use in a high temperature environment.

  In addition, SPS resin is used to provide a surface treatment step (S8) for obtaining a treated molded product Ms obtained by modifying the surface Mof by radiating corona C generated by corona discharge on the surface Mof of the fabric molded product Mo. The surface Mof of the formed dough Mo can be modified to improve the hydrophilicity at which the coating material D easily adheres, and further improve the peel resistance. Therefore, by using SPS resin, in addition to ensuring sufficient basic performance as tableware such as heat resistance, contamination resistance and chemical resistance, a special structure such as a two-layer structure should be adopted. In addition, it is possible to provide an optimum manufacturing method for tableware in which washing with a detergent is frequently repeated.

  Furthermore, FIG. 8 shows tableware 1 according to the modified embodiment. The tableware 1 according to the modified embodiment is an insert molding method in which a second synthetic resin Re having a predetermined thickness and transparent or translucent is provided on the surface Msf of the processed molded product Ms coated with the paint D. Or it is attached by the adhesion method. Thereby, in addition to being able to exhibit the physical and chemical performance of the SPS resin used as the forming material of the tableware 1 to the maximum, peeling of the applied paint D can be avoided reliably. In this case, a PMP (polymethylpentene) resin can be used as the second synthetic resin Re, and for example, “TPX” (trade name) manufactured by Mitsui Chemicals, Inc. can be used as the PMP resin. If such a PMP resin is used, there is an advantage that the heat resistance of the tableware 1 itself can be further increased by the PMP resin having a heat resistance of 160 [° C.] or higher.

  In addition, since the modified embodiment shown in FIG. 8 uses different kinds of resins, when insert molding is performed, the resins are not compatible with each other. Therefore, adhesion can be improved by blending an additive material excellent in compatibility with styrene and olefin into the PMP resin. As an additive material, a hydrogenated styrene-based thermoplastic elastomer (SEBS: styrene / ethylene / butylene / styrene) can be used. Specifically, for example, “Tuftec” (trade name) manufactured by Asahi Kasei Chemicals Corporation. Can be used. In this case, if the blending amount is too large, the heat resistance is lowered, so about 20% by weight is desirable for 100% by weight of the PMP resin.

  Although the preferred embodiment has been described in detail above, the present invention is not limited to such an embodiment, and the detailed configuration, shape, material, method, numerical value, and the like do not depart from the gist of the present invention. It can be changed, added, or deleted arbitrarily.

  For example, using an SPS resin includes not only the use of the SPS resin alone, but also the use as a reinforced plastic compounded with the exemplified glass fiber and the use as a composite material mixed with other resins and materials. It is a concept. Moreover, although the case where it shape | molds by an injection molding system was shown as a shaping | molding process (S2), other shaping | molding systems, such as a compression molding system, are not excluded. On the other hand, although the case where the coating material D is printed and applied by the screen printing method is exemplified as the coating material coating step (S13), various other coating methods (including printing methods) such as a brush coating method and an ink jet coating method can be applied. . Furthermore, although the case where the touch drying process and the subsequent main drying process are performed as an example of the drying process is illustrated, the case where various other drying processes are performed by changing the temperature, time, and the like is not excluded. The concept of corona (corona discharge) includes plasma (plasma discharge).

  The manufacturing method of the tableware concerning this invention can be utilized for the vase and the figurine etc. which are similar to various tableware and tableware including the illustrated teacup.

  1: Tableware, 12: Corona discharge part, C: Corona, D: Paint, R: Synthetic resin material, Re: Second synthetic resin, Mo: Fabric molded product, Mof: Surface of fabric molded product, Ms: Process molding Product, Msf: surface of treated molded product, (S2): molding process, (S8): surface treatment process, (S13): paint coating process

  The present invention relates to a tableware manufacturing method suitable for use in applying a paint to the surface of a molded product molded from a synthetic resin material.

  In general, since tableware used in hospitals and welfare facilities is required to have lightness, contamination resistance, durability, and the like, tableware molded from a synthetic resin material is widely used. In addition, recently, since it is often used by directly heating it with a microwave oven, a reheating cart, etc., the importance to heat resistance tends to become larger, and design is also an important factor. Tableware requires various performances. Therefore, in order to satisfy these requirements, the selection of the synthetic resin material is important, and if the requirements cannot be met by the selection of the material alone, additional improvements from the structural aspect are also required.

  Conventionally, as a tableware that meets the requirements for such tableware, in particular, heat resistance, the tableware made of resin with a pattern disclosed in Patent Document 1 and the tableware disclosed in Patent Document 2 are known. The resin tableware with a pattern disclosed in the literature 1 is intended to provide a resin tableware with a pattern having excellent heat resistance and rigidity, and specifically, within a range where transparency remains. A primary molded product of polypropylene reinforced with filler, a pattern on the outer surface of the primary molded product whose concentration is higher than the color to be displayed as viewed from the inner surface, and a polypropylene reinforced with filler and arranged on the outer surface side of the pattern And a secondary molded product. The tableware disclosed in Patent Document 2 is intended to provide tableware with excellent heat resistance. Specifically, two types of resins, polyethylene terephthalate and polybutylene terephthalate, are used in the total amount. On the other hand, an insert film made of polyethylene terephthalate is insert-bonded to the surface of a base molded product formed of a polyester molding material containing 1 to 15% by mass of methacrylic resin and 5 to 30% by mass of an inorganic filler with respect to the total amount. It is what you do.

JP 2001-095667 A JP 2002-248041 A

  However, the conventional tableware (and its manufacturing method) including the above-mentioned tableware has the following problems.

  First, because it is designed to withstand temperatures of about 120 [° C], heat resistance against hot water, etc. is ensured, but heat resistance that is continuously exposed to high temperatures of 140 ° C or higher. Sexuality is not always guaranteed. Therefore, from the viewpoint of ensuring sufficient heat resistance for various high temperature use environments such as reheating carts, steam convection, microwave ovens, etc., and maintaining high reliability even in continuous use under high temperature environments, further improvement is possible. There was room.

  Second, dishes used in hospitals and welfare facilities are required to have high contamination resistance from the viewpoint of hygiene. Therefore, a synthetic resin material to be used is usually selected from materials having excellent contamination resistance. On the other hand, being hardly contaminated means that the peel resistance is lowered. For this reason, it is not easy to attach a design such as a pattern to the surface for tableware in which washing with a detergent is frequently repeated. Usually, as in Patent Document 1, it is configured in a two-layer structure, and between two layers. Actually, it is possible to cope with this by interposing a pattern or by bonding an insert film displaying a pattern as in Patent Document 2. In the end, it has been a difficult task to ensure both basic performance as tableware and at the same time to easily and reliably apply designs such as patterns.

  The object of the present invention is to provide a tableware manufacturing method that solves the problems in the background art.

  The tableware manufacturing method according to the present invention produces a dough-molded product Mo by molding a synthetic resin material R with a mold, and manufactures the tableware 1 by applying a paint D to the surface Mof of the dough-molded product Mo. In doing so, the SPS (syndiotactic polystyrene) resin is used as the synthetic resin material R, and the molding step (S2) of obtaining the fabric molded product Mo by molding the SPS resin with a molding die; The surface Mof is subjected to corona discharge under the processing conditions in which the distance Lp from the corona discharge part 12 to the surface Mof of the dough molding Mo is set to 5 to 40 [mm] and rotates at a rotation speed of 1 to 10 [rpm]. Surface treatment step for obtaining a treated molded product Ms obtained by modifying the surface Mof by radiating the corona C generated by the corona discharge to the surface Mof of the fabric molded product Mo And S8), and characterized in that a part or the whole of the surface Msf of the process moldings Ms and a coating material coating step of applying a coating D (S13).

  In this case, according to a preferred embodiment, the molding step (S2) can be performed by an injection molding method. In the surface treatment step (S8), the dough-formed product Mo can be rotated at least twice while the corona C is emitted. On the other hand, in the paint application step (S13), the paint D can be printed and applied by a screen printing method. On the other hand, a second synthetic resin Re having a predetermined thickness and being transparent or translucent can be attached to the surface Msf of the processed molded product Ms coated with the paint D by an insert molding method or an adhesion method. In addition, a PMP (polymethylpentene) resin can be used for the second synthetic resin Re.

  According to the tableware manufacturing method according to the present invention having such steps, the following remarkable effects can be obtained.

  (1) Since the SPS resin is used as the synthetic resin material R, it is possible to sufficiently guarantee the heat resistance that is continuously exposed to a high temperature of 140 [° C.] or higher. Therefore, sufficient heat resistance to various high temperature use environments such as a reheating cart, steam convection, and a microwave oven can be ensured, and versatility can be secured, and high reliability can be maintained even in continuous use in a high temperature environment.

  (2) Since a surface treatment step (S8) for obtaining a treated molded product Ms by modifying the surface Mof by radiating corona C generated by corona discharge to the surface Mof of the fabric molded product Mo is provided with an SPS resin. The surface Mof of the used dough-formed product Mo can be modified to improve the hydrophilicity at which the paint D easily adheres, and further to improve the peel resistance. Therefore, by using SPS resin, in addition to ensuring sufficient basic performance as tableware such as heat resistance, contamination resistance and chemical resistance, a special structure such as a two-layer structure should be adopted. In addition, the design such as a pattern can be easily and surely provided, so that it can be provided as an optimum manufacturing method for tableware that frequently repeats washing with a detergent.

  (3) In the surface treatment step (S8), the corona discharge is performed under the treatment conditions in which the distance Lp from the corona discharge part 12 to the surface Mof of the molded article Mo is set to 5 to 40 [mm] and 1 to 10 [rpm The processed molded product Ms is obtained by modifying the surface Mof by radiating the corona C generated by the corona discharge to the surface Mof of the fabric molded product Mo rotating at the number of rotations of The processing conditions can be optimized from the viewpoint of manufacturing tableware using SPS resin, and can be constructed as a suitable manufacturing method when manufacturing tableware made of SPS resin.

  (4) According to a preferred embodiment, in the molding step (S2), if molding is performed by an injection molding method, from the supply of molding material to molding processing, and further, the removal of molded products can be easily automated. It can be provided as a manufacturing method of tableware having excellent cost.

  (5) According to a preferred embodiment, when the dough-formed product Mo is rotated at least twice during corona C radiation in the surface treatment step (S8), particularly when producing tableware using SPS resin. Since the processing time can be optimized, it is possible to perform a good modification process on the surface Mof of the dough molding Mo using the SPS resin.

  (6) According to a preferred embodiment, if the coating material D is printed and applied by the screen printing method in the coating material coating step (S13), automation can be easily realized when a design such as a pattern is applied to the surface of the tableware 1. High quality design can be realized.

  (7) According to a preferred embodiment, a second synthetic resin Re having a predetermined thickness and transparent or translucent is inserted or bonded to the surface Msf of the processed molded article Ms coated with the paint D. If it attaches by a system, in addition to demonstrating the physical and chemical performance of SPS resin used as the formation raw material of the tableware 1 to the maximum, peeling of the apply | coated coating material D can be avoided reliably.

  (8) According to a preferred embodiment, if a PMP resin is used as the second synthetic resin Re, the heat resistance of the tableware 1 itself can be further enhanced by the PMP resin having a heat resistance of 160 [° C.] or higher.

The flowchart for demonstrating the whole process sequence of the manufacturing method of the tableware which concerns on suitable embodiment of this invention, Block configuration diagram showing an example of a processing system used for the surface treatment process in the manufacturing method, External configuration diagram of processing head and peripheral structure in surface processing step in the manufacturing method, Treatment principle explanatory diagram in the surface treatment process in the manufacturing method, Sectional front view of tableware (tea bowl) manufactured by the manufacturing method, Appearance front view of tableware (tea bowl) manufactured by the manufacturing method, A table showing the evaluation results of tableware (samples) manufactured by the manufacturing method, Sectional front view of tableware (tea bowl) manufactured by the manufacturing method according to a modified embodiment of the present invention,

  Next, preferred embodiments according to the present invention will be given and described in detail with reference to the drawings.

  First, a syndiotactic polystyrene resin (SPS resin) used for the tableware 1 manufactured by the manufacturing method according to the present embodiment and a processing system for modifying the surface Mof of the fabric molded product Mo using the SPS resin 10 will be described.

  First, the SPS resin will be described. In general, melamine resins and polypropylene resins are widely known as synthetic resin materials used for tableware. On the other hand, SPS resin is an engineering plastic developed by Idemitsu Kosan Co., Ltd., and “Zarek” (trade name) manufactured by Idemitsu Kosan Co., Ltd. can be used as a commercial product of SPS resin in this embodiment. The SPS resin is a kind of polystyrene resin obtained by polymerizing using styrene as a monomer and using a metallocene catalyst, and is mainly used for electric parts and machine parts. Therefore, there are no examples of general use as tableware in hospitals and welfare facilities.

  In addition, since the SPS resin has a syndiotactic structure, it has crystallinity, and is excellent in heat resistance (melting point: 240 to 270 [° C.]) and chemical resistance compared to a normal polystyrene resin. A general polystyrene resin has an atactic structure. Furthermore, SPS resins belong to the lightest category of engineering plastics, and are excellent in steam resistance without being hydrolyzed. In addition, it has excellent fluidity, good mold reproducibility, low dielectric loss, and good tracking resistance. In addition, it is resistant to acid, alkali, and neutral detergents, and can be sterilized with alcohol and chlorine bleach. In addition, yellowing, dissolution and cracking are unlikely to occur.

  Since the tableware manufactured by the manufacturing method according to the present embodiment uses the SPS resin having such properties as the synthetic resin material R, the heat resistance is such that it is continuously exposed to a high temperature of 140 [° C.] or higher. Can be fully guaranteed. Therefore, sufficient heat resistance to various high temperature use environments such as a reheating cart, steam convection, and a microwave oven can be ensured, and versatility can be secured, and high reliability can be maintained even in continuous use in a high temperature environment. In particular, in the case of SPS resin, there is an advantage that high heat resistance that can sufficiently withstand a high temperature of 200 [° C.] or more can be secured by using a reinforced plastic mixed with glass fiber.

  Next, the processing system 10 will be described with reference to FIGS. The processing system 10 has a processing function of radiating corona C generated by corona discharge to a surface Mof of a dough-molded product Mo to be described later and modifying the surface Mof. As a commercially available product having such a processing function, “Air Plasma (APW-602f)” (trade name) manufactured by Kasuga Electric Co., Ltd. can be used.

  By the way, since the SPS resin is a resin particularly excellent in stain resistance and chemical resistance, it is difficult to paint or print by a general surface treatment. Therefore, in this embodiment, the corona C based on a predetermined condition generated by corona discharge is used to modify the surface of the SPS resin, thereby enabling general-purpose painting and printing.

  An example of the processing system 10 is shown in FIG. In the processing system 10, reference numeral 11 denotes a processing head including a corona discharge unit 12. The corona discharge part 12 includes a pair of opposed discharge electrodes 12p and 12n, and a high voltage is applied from the high voltage part 13 between the discharge electrodes 12p and 12n. Thereby, corona discharge can be generated between the discharge electrodes 12p and 12n. Further, 14 indicates a blower fan, and the blower W by the blower fan 14 is supplied between the discharge electrodes 12p and 12n. Thereby, as shown in FIG. 2, arc-shaped corona discharge (corona C) is radiated | emitted to the surface Mof of the dough molded product Mo used as modification | reformation object.

  Reference numeral 15 denotes a moving unit that freely changes the position and angle of the processing head 11. FIG. 3 shows a configuration of the moving unit 15 as an example. The illustrated moving unit 15 can move (displace) the processing head 11 in the X direction, the Z direction, and the rotation direction Q with the Y axis as a fulcrum. Specifically, one end is fixed to the moving body 22m, and the Z-direction moving mechanism section 22 includes a Z-axis shaft 22s supported at the lower end by the fixed base 21 and a moving body 22m that moves along the Z-axis shaft 22s. The Y-direction moving mechanism unit 23 including the X-axis shaft 23s and the moving body 23m that moves along the X-axis shaft 23s, and the rotating mechanism unit 24 fixed to the moving body 23m are provided. The processing head 11 is supported on the rotating shaft 24s. On the other hand, 31 is a setting unit for setting the molded dough product Mo in a fixed position, and is supported by the rotation drive unit 32.

  On the other hand, in FIG. 2, reference numeral 16 denotes a driver, and the high voltage unit 13, the blower fan 14, and the moving unit 15 described above are connected to the output unit of the driver 16. Reference numeral 17 denotes a controller, which includes a controller main body 17c. A driver 16 and a display 17d are connected to the control body 17c. Further, the control body 17c is attached with a memory 17m that stores various data including various setting data and a control program for automatically executing the reforming process.

  The processing system 10 configured as described above can radiate the corona C to the surface Mof of the dough-molded article Mo set in the setting unit 31 to perform the modification process of the surface Mof. Further, when performing the reforming process, selection or setting is performed so as to satisfy the following processing condition. That is, the ambient temperature is 5 to 40 [° C.], the ambient humidity is 17 to 70 [%], and the distance Lp (see FIG. 2) from the corona discharge part 12 to the surface Mof of the fabric molded product Mo is 5 to 40 [mm]. The corona discharge is generated so that the discharge output satisfies the processing condition of 0.5 to 1.0 [kW]. Furthermore, the dough molding Mo set in the setting unit 31 is rotated by the rotation driving unit 32 at a rotation speed of 1 to 10 [rpm]. If corona C is radiated under such processing conditions, the processing conditions can be optimized particularly from the viewpoint of manufacturing tableware using SPS resin, which is suitable for manufacturing tableware made of SPS resin. It can be constructed as a manufacturing method.

  In this case, it is desirable that the number of rotations of the dough-formed product Mo is rotated at least twice during the corona C radiation. By setting the number of rotations in this way, it is possible to optimize the processing time especially when producing tableware using SPS resin, and therefore, a good modification process for the surface Mof of the dough molded product Mo using SPS resin. There is an advantage that can be done. In addition, the frequency | count of rotation of the dough molded product Mo can be used as completion | finish conditions of a modification | reformation process.

  FIG. 4 shows the principle of reforming processing by the processing system 10. In the figure, Mo indicates a part of a fabric molded product formed of SPS resin. Due to the corona discharge, the high-energy electrons e generated in the corona C reach the surface Mof of the dough molding Mo, and the high-energy electrons e are the main chains (including side chains) of polymer bonds in the surface layer of the SPS resin. It has the effect of separating. On the other hand, since the cut polymer surface layer is scientifically radical, oxygen radicals in the gas phase and the ozone layer recombine with the main chain and side chain, so polar functions such as hydroxyl groups and carbonyl groups can be obtained. Group Xc is introduced. Thereby, hydrophilicity will arise and the printability (adhesiveness) to hydrophobic polymer will improve remarkably. The influence at this time is the surface layer of 0.1 [um] or less, and the properties of the base material itself of the dough-formed product Mo are not impaired. If necessary, it may be performed under a specific gas atmosphere or under a vacuum pressure.

  Next, a tableware manufacturing method according to this embodiment will be described with reference to the flowchart shown in FIG.

  When manufacturing tableware, first, the above-described SPS resin is prepared as a synthetic resin material R to be a molding material (step S1). The tableware manufactured by the manufacturing method according to the present embodiment is a tea bowl 1c shown in FIG. First, a molding process using a mold is performed (step S2). In this case, since the SPS resin becomes a thermoplastic resin, an injection molding machine can be used. Therefore, it is possible to perform molding by an injection molding method in which a melted SPS resin is injection-filled into a mold (molding mold) having a cavity that represents the teacup 1c. By the above molding process, a fabric molded product Mo that is substantially the same in shape as the processed molded product Ms before the coating material D shown in FIG. 5 is applied can be obtained. By using such an injection molding method, it is possible to easily automate from the supply of the molding material to the molding process, and further the removal of the molded product, so that it can be provided as a tableware manufacturing method with excellent mass productivity and low cost. There are advantages. On the other hand, at the end of molding, the fabric molded product Mo is taken out from the mold, and the removed fabric molded product Mo is cleaned to remove foreign matters attached to the surface Mof (steps S3 and S4).

  Next, a surface treatment process for modifying the surface Mof by radiating the corona C generated by the corona discharge to the surface Mof of the fabric molded product Mo is performed. In addition, the predetermined processing conditions described above for performing corona discharge are set in advance in the memory 17m in the processing system 10 described above (step S0). When performing the surface treatment process, first, the fabric molded product Mo is set in the setting unit 31 of the treatment system 10 as shown in FIG. 3 (step S5). If set, a start switch (not shown) is turned on (step S6). Thereby, the surface treatment process automatically proceeds according to the control program stored in the memory 17m. That is, the rotation drive unit 32 is rotated to rotate the dough molding Mo (step S7). Further, an arc-shaped corona discharge is generated between the discharge electrodes 12p and 12n in the processing system 10, and the corona C based on the arc-shaped corona discharge is radiated to the surface Mof of the fabric molded product Mo. As a result, the above-described modification process for the surface Mof is performed, the moving unit 15 is controlled, and the process head 11 moves, so that the modification process for the entire surface Mof is uniformly performed (step S8).

  On the other hand, when the end condition is satisfied, the rotation of the rotation drive unit 32 and the corona discharge in the processing system 10 are stopped, and the surface treatment process is ended (steps S9 and S10). In this case, as an end condition, for example, an arbitrary end condition can be set such that, for example, the processing time can be set in advance and the elapse of the processing time can be set as the end condition. In the present embodiment, the end condition is set based on the number of rotations of the fabric molded product Mo. Therefore, if the number of rotations of the dough molded product Mo reaches the set number of rotations, the surface treatment process can be terminated. As a result, a processed molded product Ms having a modified surface Msf is obtained. When the surface treatment process is completed, the processed molded product Ms is taken out from the setting unit 31 (step S11).

  Next, a paint application process for applying the paint D to the surface Msf of the processed molded product Ms is performed. When performing the paint application process, first, the processed molded product Ms is set at a predetermined setting position in a screen printing machine (not shown) (step S12). And the coating application process which performs the screen printing process which carries out the printing application of the predetermined coating material D to the surface Msf of the process molded article Ms by the screen printing system using a screen printer is performed (step S13).

  In this case, for the paint D, for example, a two-component reaction type resin ink in which a main agent and a curing agent are blended can be used. Since the two-component reaction type resin ink can freely change the hardness and flexibility of the cured film, it has excellent adhesion to a wide range of materials from flexible materials to hard materials. In addition, the ink can be used for a long time, has excellent on-machine stability, and can form a cured film excellent in chemical resistance and solvent resistance. Moreover, if a non-yellowing type aliphatic isocyanate prepolymer is used as the curing agent, the weather resistance will be strong, and in addition, there will be no ink-specific odor due to heating after complete curing, etc. Is suitable.

  More specifically, an acrylic urethane resin-based two-component reaction type resin ink can be used. As the main agent, acrylic polyol having a functional group such as a hydroxyl group, polyester polyol, polyether polyol, vinyl chloride and vinyl acetate. A copolymer resin, an epoxy resin, or the like can be used, and an isocyanate prepolymer or the like can be used as a curing agent. In order to prevent increase in viscosity on the printing press and clogging of the printing plate, it is desirable to use hydrocarbons, esters, ketones, alcohols, polyhydric alcohol derivatives, etc. as diluent solvents. In addition, the acrylic urethane type two-component reaction type resin ink is exemplified for the ink, but it is also possible to use known inks such as general UV type, rubber type, acrylic type, vinyl type, polyester type, urethane type, etc. Is possible.

  On the other hand, the coating material D is added in a mixing ratio of 100 parts of the main agent, 10 parts of the curing agent, and about 5 to 20 parts of the diluent solvent, and is well stirred. Then, screen printing (rotational printing) is performed using the printing plate. In the case of illustration, as shown in FIG. 6, the pattern K used as the floral pattern was printed on the surface Msf in the outer surface of the processed molded product Ms. In this way, if the coating material D is printed and applied by the screen printing method, automation is easily realized when the design M or the like is applied to the surface Msf of the processed molded product Ms, that is, the surface of the tableware 1. There is an advantage that the design can be improved in quality. The example shows the case where the pattern K is printed on a part of the surface Msf, but the entire surface Msf may be coated. Specifically, it is also possible to perform a whole surface application treatment like a traditional lacquer ware.

  When the paint application process is completed, the processed molded product Ms to which the paint D has been applied (printed) is taken out from the screen printer and the necessary drying process is performed (steps S14 and S15). In the drying step, first, a touch drying process of 10 [min] at a temperature of 60 [° C.] (or 5 [min] at a temperature of 80 [° C.]) is performed. After that, when applying (printing) two or more colors of paint D, the paint application process and the touch drying process may be repeated. When the touch drying process is completed, a main drying process of 3 [days] at room temperature or 60 [minutes] at a temperature of 80 to 100 [° C.] (or 15 [minutes] at a temperature of 120 [° C.]) To completely cure the coating material D. In this case, heating at as high a temperature as possible can provide a cured film with more excellent adhesion and physical properties.

  And if completion conditions, such as time progress, are satisfied, while completing a drying process, required inspection processes, such as an external appearance inspection, are performed (Steps S16 and S17). Thereby, the target tableware 1 (tea bowl 1c) shown in FIG. 6 can be obtained. That is, the tableware is formed by applying the coating D to the surface Mof of the dough molding Mo molded from the synthetic resin material R. The synthetic resin material R uses SPS resin and corona C generated by corona discharge. The tableware 1 manufactured by the manufacturing method according to the present embodiment in which the paint D is applied to a part or the whole of the surface Mof modified by the radiation of can be obtained.

  On the other hand, FIG. 7 shows the evaluation results of the manufactured samples. In the same table, Di is a sample of tea bowl 1c manufactured by the manufacturing method according to the present embodiment. In addition, as a control plot, a teacup sample Ds manufactured by removing the surface treatment process from the manufacturing method according to the present embodiment, and PP (polypropylene) resin instead of SPS resin as the molding material according to the present embodiment. A teacup sample Dp produced by the same procedure as the production method was shown as a similar evaluation result.

  The evaluation items used were six items: manufacturability, contamination resistance, peel resistance, high frequency suitability when used in a microwave oven, durability when used in a microwave oven, and appearance. In this case, the contamination resistance is determined by applying an appropriate amount of 4 kinds of sauce, mayonnaise, ketchup, and curry to the inner and outer surfaces of the sample, drying it in a speed dry oven set at 110 [° C] for 2 hours, and then allowing it to stand naturally. After cooling to room temperature and washing, the degree of contamination of the appearance was visually observed. In addition, the peel resistance is as follows: natural standing → hot water immersion (boiling) → neutral detergent immersion → washing with running water → drying with hot air (110 [° C.]) → natural standing as one cycle (each treatment is 30 minutes). After repeating 50 times, the presence or absence of the peeled state at the time of sticking and peeling with an adhesive tape was confirmed. On the other hand, the high frequency suitability when used in a microwave oven is that the sample is placed on a tray of the microwave oven, heated for 2 minutes with a microwave output of 1.0 [kW], and then the sample becomes 23 ± 50 [° C]. The operation of allowing to cool until repeated was repeated twice to confirm whether the sample was damaged or not. Furthermore, the durability when used in a microwave oven is such that olive oil filled up to about 50% of the volume of the sample is accommodated in the microwave oven, and every 30 to 180 [seconds] using a boiling point thermometer. The oil temperature is measured and heated to a predetermined temperature of 140 [° C.] or higher. When the predetermined temperature is reached, the sample is taken out and allowed to cool to 23 ± 50 [° C.], and then −17 It was stored in a freezer at [° C.] and cooled to a predetermined temperature. The above operation was repeated 5 times to confirm whether the sample was damaged or not. However, after the second time, the operation was repeated from the cooled state.

  As a result, as shown in FIG. 7, the sample Di according to the present invention has manufacturability, contamination resistance, peel resistance, high frequency suitability when used in a microwave oven, durability when used in a microwave oven, Good results were obtained for all six items of appearance. On the other hand, the sample Ds manufactured by removing the surface treatment process from the manufacturing method according to the present embodiment does not perform the surface modification treatment, and as a result, is inferior in peel resistance. It was. In addition, since the SPS resin was used about the other items, the favorable result was obtained similarly to the sample Di. On the other hand, sample Dp manufactured by the same procedure as the manufacturing method according to the present embodiment using PP resin instead of SPS resin as a molding material is about manufacturability, high-frequency suitability when used in a microwave oven, and appearance. Although good results were obtained, the stain resistance and durability when used in a microwave oven were inferior. In addition, the peel resistance was not good, but a practically satisfactory result was obtained.

  Thus, according to the tableware manufacturing method according to the present embodiment, since the SPS resin is used as the synthetic resin material R, the heat resistance enough to be continuously exposed to a high temperature of 140 [° C.] or more is sufficient. Can be guaranteed. Therefore, sufficient heat resistance to various high temperature use environments such as a reheating cart, steam convection, and a microwave oven can be ensured, and versatility can be secured, and high reliability can be maintained even in continuous use in a high temperature environment.

  In addition, SPS resin is used to provide a surface treatment step (S8) for obtaining a treated molded product Ms obtained by modifying the surface Mof by radiating corona C generated by corona discharge on the surface Mof of the fabric molded product Mo. The surface Mof of the formed dough Mo can be modified to improve the hydrophilicity at which the coating material D easily adheres, and further improve the peel resistance. Therefore, by using SPS resin, in addition to ensuring sufficient basic performance as tableware such as heat resistance, contamination resistance and chemical resistance, a special structure such as a two-layer structure should be adopted. In addition, it is possible to provide an optimum manufacturing method for tableware in which washing with a detergent is frequently repeated.

  Further, FIG. 8 shows tableware 1 according to the modified example. The tableware 1 according to the modified example uses an insert molding method or a second synthetic resin Re that has a predetermined thickness and is transparent or translucent with respect to the surface Msf of the processed molded product Ms to which the paint D is applied. It is attached by the bonding method. Thereby, in addition to being able to exhibit the physical and chemical performance of the SPS resin used as the forming material of the tableware 1 to the maximum, peeling of the applied paint D can be avoided reliably. In this case, a PMP (polymethylpentene) resin can be used as the second synthetic resin Re, and for example, “TPX” (trade name) manufactured by Mitsui Chemicals, Inc. can be used as the PMP resin. If such a PMP resin is used, there is an advantage that the heat resistance of the tableware 1 itself can be further increased by the PMP resin having a heat resistance of 160 [° C.] or higher.

  In addition, since the example of a change shown in FIG. 8 uses different kind of resin, when performing insert molding, mutual resin is hard to be compatible. Therefore, adhesion can be improved by blending an additive material excellent in compatibility with styrene and olefin into the PMP resin. As an additive material, a hydrogenated styrene-based thermoplastic elastomer (SEBS: styrene / ethylene / butylene / styrene) can be used. Specifically, for example, “Tuftec” (trade name) manufactured by Asahi Kasei Chemicals Corporation. Can be used. In this case, if the blending amount is too large, the heat resistance is lowered.

  Although the preferred embodiment has been described in detail above, the present invention is not limited to such an embodiment, and the detailed configuration, shape, material, method, numerical value, and the like do not depart from the gist of the present invention. It can be changed, added, or deleted arbitrarily.

  For example, using an SPS resin includes not only the use of the SPS resin alone, but also the use as a reinforced plastic compounded with the exemplified glass fiber and the use as a composite material mixed with other resins and materials. It is a concept. Moreover, although the case where it shape | molds by an injection molding system was shown as a shaping | molding process (S2), other shaping | molding systems, such as a compression molding system, are not excluded. On the other hand, although the case where the coating material D is printed and applied by the screen printing method is exemplified as the coating material coating step (S13), various other coating methods (including printing methods) such as a brush coating method and an ink jet coating method can be applied. . Furthermore, although the case where the touch drying process and the subsequent main drying process are performed as an example of the drying process is illustrated, the case where various other drying processes are performed by changing the temperature, time, and the like is not excluded. The concept of corona (corona discharge) includes plasma (plasma discharge).

  The manufacturing method of the tableware concerning this invention can be utilized for the vase and the figurine etc. which are similar to various tableware and tableware including the illustrated teacup.

  1: Tableware, 12: Corona discharge part, C: Corona, D: Paint, R: Synthetic resin material, Re: Second synthetic resin, Mo: Fabric molded product, Mof: Surface of fabric molded product, Ms: Process molding Product, Msf: surface of treated molded product, (S2): molding process, (S8): surface treatment process, (S13): paint coating process

Claims (9)

  A method for producing tableware by producing a dough-molded product by molding a synthetic resin material with a mold and applying a paint to the surface of the dough-molded product to produce tableware, wherein the synthetic resin material is SPS. (Syndiotactic polystyrene) resin is used to mold the SPS resin with a molding die to obtain a dough-molded product, and the surface of the dough-molded product is radiated with corona generated by corona discharge. A method for producing tableware, comprising: a surface treatment step for obtaining a treated molded product obtained by modifying the surface of the treated molded product; and a paint applying step for applying a paint to a part or all of the surface of the treated molded product.   2. The tableware manufacturing method according to claim 1, wherein the molding step is performed by an injection molding method.   In the surface treatment step, the ambient temperature is 5 to 40 [° C.], the ambient humidity is 17 to 70 [%], the distance from the corona discharge part to the surface of the dough molded product is 5 to 40 [mm], and the discharge output is The corona discharge is performed under the processing conditions set to 0.5 to 1.0 [W], and the corona is radiated to the surface of the dough-molded product rotating at a rotation speed of 1 to 10 [rpm]. The method for producing tableware according to claim 1 or 2.   4. The tableware manufacturing method according to claim 1, wherein in the surface treatment step, the dough-molded product is rotated at least twice while the corona is radiated.   The said coating-material application | coating process prints and applies a coating material by a screen printing system, The manufacturing method of the tableware in any one of Claims 1-4 characterized by the above-mentioned.   A second synthetic resin having a predetermined thickness and being transparent or translucent is attached to the surface of the treated molded article coated with the paint by an insert molding method or an adhesion method. The manufacturing method of the tableware in any one of Claims 1-5.   The method for producing tableware according to any one of claims 1 to 6, wherein a PMP (polymethylpentene) resin is used as the second synthetic resin.   A tableware made by applying a paint to the surface of a fabric molded product molded from a synthetic resin material, wherein the synthetic resin material uses SPS resin and is modified by radiation of corona generated by corona discharge. Tableware characterized by coating a part or all of the surface with a paint.   The tableware according to claim 8, wherein a second synthetic resin having a predetermined thickness and being transparent or translucent is attached to the surface to which the paint is applied.

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