JP2017221900A - Method for producing molded body - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for producing a molded body capable of easily producing the molded body which is excellent in durability and has a desired shape.SOLUTION: A method for producing a molded body which produces the molded body using a composition containing vinyl chloride resin and a plasticizer includes: an application step of applying the composition to a steel plate; and a solidification step of solidifying the composition applied to the steel plate, where viscosity of the composition in the application step is more than 100,000 mPa s and 400,000 mPa s or less, and a solid film having a thickness of 2 mm and being formed using the composition has a volume contraction ratio of 24% or less when the solid film is subjected to a metal weather test under conditions of irradiation intensity of 81 mW/cm, a spray cycle of 2 minutes in 120 minutes and a black panel temperature of 80°C using a metal halide lamp as a light source for 500 hours.SELECTED DRAWING: None

Description

  The present invention relates to a method for producing a molded body.

  In recent years, with the demand for higher durability of buildings, a sheet waterproof structure in which a resin sheet (waterproof sheet) is laid and used has been adopted on many rooftops and verandas of buildings (for example, Patent Document 1). reference).

  In this waterproof sheet structure, for example, a steel plate (metal plate) coated with polyvinyl chloride is disposed at the boundary between the floor on the roof and the wall provided along the outer edge of the floor. The wall portion is covered with the steel plate together with a resin sheet, thereby waterproofing the roof.

  Here, the shape of the rooftop where waterproofing is applied is naturally various. For this reason, as the steel plate, a plurality of types of shapes are prepared in advance, and those matching the shape of the rooftop or the like actually constructed are selected and used by joining them.

  Such steel plates are joined by preparing in advance a molded body formed by injection molding capable of dealing with a complicated shape, and using this molded body, the installer covers the joint.

  In general, the waterproof structure needs to stably maintain the waterproof property for a long period of time, but the injection molding product as described above becomes expensive in the mold cost and cannot cope with the shape of many kinds of small lots. In addition, a method for producing a molded body that can be used in a more durable application in the future is desired.

JP-A-11-222987

  The objective of this invention is providing the manufacturing method of the molded object which is excellent in durability and can manufacture the molded object which has a desired shape easily.

Such an object is achieved by the present inventions (1) to (2) below.
(1) A method for producing a molded body using a composition containing a vinyl chloride resin and a plasticizer,
An application step of applying the composition to a steel sheet;
A solidification step of solidifying the composition applied to the steel plate,
The viscosity of the composition in the coating step is more than 100,000 mPa · s and not more than 400,000 mPa · s,
For a solid film having a thickness of 2 mm formed using the composition, a metal halide lamp was used as a light source, irradiation intensity: 81 mW / cm ² , spray cycle: 2 minutes in 120 minutes, black panel temperature: 80 ° C. A method for producing a molded article, wherein the film has a volume shrinkage of 24% or less when the metal weather test is conducted for 500 hours.

  (2) The said solidification process is a manufacturing method of the molded object as described in said (1) performed by heating.

  ADVANTAGE OF THE INVENTION According to this invention, the manufacturing method of the molded object which is excellent in durability and can manufacture the molded object which has a desired shape easily can be provided.

It is a perspective view which shows one Embodiment of the steel plate used for manufacture of a molded object. It is a perspective view which shows one Embodiment of the molded object which concerns on this invention. It is a longitudinal cross-sectional view which shows an example of the manufacturing method of the molded object of this invention.

  Hereinafter, preferred embodiments of the present invention will be described in detail.

  FIG. 1 is a perspective view showing an embodiment of a steel sheet used for manufacturing a formed body, FIG. 2 is a perspective view showing an embodiment of a formed body according to the present invention, and FIG. 3 is a view of the formed body of the present invention. It is a longitudinal cross-sectional view which shows an example of a manufacturing method. In the following description, the upper side in FIGS. 1 and 2 is “upper” and the lower side is “lower”. The present invention is not limited to the uses described below.

  As shown in FIG. 1, a steel plate (joined body) 10 is obtained by joining a first member 1 and a second member 2 in advance.

  The joined body 10 (the first member 1 and the second member 2) is composed of a metal plate whose surface is coated (coated) with a resin. Thus, by coating with resin, corrosion of the metal plate can be reliably prevented.

  Although it does not specifically limit as a metal plate, For example, although a steel plate like a stainless steel plate and an iron plate, an aluminum plate, a copper plate, etc. are mentioned, It is preferable that it is a steel plate. Thereby, the joined body 10 can have excellent strength.

  The thickness of the metal plate is not particularly limited, but is preferably 0.1 mm or more and 3 mm or less, and more preferably 0.3 mm or more and 2.5 mm or less.

  Examples of the resin include vinyl chloride resins such as polyvinyl chloride, polyolefin resins, ethylene vinyl acetate copolymers, (meth) acrylic resins, and the like. Although it can be used in combination, it is preferably a vinyl chloride resin (particularly polyvinyl chloride). Since the resin is excellent in solvent weldability and heat-fusibility, it can reliably ensure adhesion with the waterproof sheet.

  The thickness of the resin (resin layer) that covers the metal plate is not particularly limited, but is preferably 0.03 mm or more and 2 mm or less, and more preferably 0.1 mm or more and 0.7 mm or less.

  As shown in FIG. 2, the molded body 100 includes a resin portion 20 formed using a composition 20 ′ containing a vinyl chloride resin and a plasticizer, and a steel plate (joined body) as a support portion that supports the resin portion 20. ) 10.

  The molded body 100 is disposed at a boundary portion between a floor portion and a wall portion of a housing such as a rooftop or a veranda, and covers the floor portion and the wall portion together with the molded body 100 using a waterproof sheet, thereby waterproofing the housing. It is used for a waterproof sheet structure.

  The resin portion 20 is disposed so as to cover the boundary (contact portion) between the first member 1 and the second member 2 constituting the steel plate (joined body) 10.

  Although the thickness of the resin part 20 is not specifically limited, For example, it is preferable that it is 0.2 mm or more and 7 mm or less, and it is more preferable that it is 0.3 mm or more and 3 mm or less. Thereby, while being able to make the durability (for example, waterproofness over a long period of time) of the molded object 100 more excellent, generation | occurrence | production of the unintentional unevenness | corrugation in the molded object 100 can be prevented and suppressed more effectively. be able to.

Next, a method for manufacturing the joined body 10 will be described.
[A] First, the first member 1 and the second member 2 are prepared.

  Each of the first member 1 and the second member 2 is a flat metal plate whose surface corresponding to these development views is coated (coated) with a resin, and includes a bottom portion, a rising surface, and a joint internal plane. And it can obtain by bending these so that a joint interior rising surface may be formed, respectively.

[B] Next, the first member 1 and the second member 2 are joined.
The first member 1 and the second member 2 can be joined by, for example, rivets.
The joined body 10 is manufactured through the above processes.

  Next, the manufacturing method of the molded object 100 is demonstrated.

  [1] First, a vinyl chloride resin and a plasticizer and, if necessary, other components are prepared, and these are uniformly mixed at room temperature using a mixer or the like to obtain a composition (sol composition) 20 'Is obtained (composition preparation step).

  [2] Next, the obtained composition (sol composition) 20 'is applied to the steel plate (joined body) 10 by an application method (application process, see FIG. 3A).

  Thereby, even a formed body having a complicated shape (for example, a shape having a complicated concavo-convex pattern) can be suitably manufactured. Moreover, it can respond to various shapes by changing the shape of the steel plate 10. Moreover, the manufacturing method by the application | coating method with respect to the steel plate 10 can suppress significantly the cost in the whole manufacturing process of the molded object 100 compared with injection molding.

  Further, by adopting a coating method, a composition having a high viscosity can be used as compared with the case of employing another forming method such as a dipping method (immersion method). Further, the composition 20 ′ can be selectively applied to a desired portion of the steel plate 10, and the resin portion 20 having a desired shape can be formed.

  Specifically, the viscosity of the composition 20 ′ in this step (application step) is more than 100,000 mPa · s and not more than 400,000 mPa · s.

  Thereby, for example, in order to ensure the moldability of the composition 20 ′, the content of the volatile solvent in the composition 20 ′ is increased, or the temperature of the composition 20 ′ in this step is excessively increased. Since it is not necessary, it is possible to effectively prevent the shrinkage of the composition 20 ′ in the solidification step and the like described later, and the unintentional modification and deterioration of the constituent components of the composition 20 ′. In addition, since unintentional sagging of the composition 20 ′ during molding can be effectively prevented and suppressed, even if the molded body 100 has a relatively large thickness, unintentional film thickness variation occurs. Can be effectively prevented and suppressed. As described above, the molded body 100 having excellent durability and a desired shape can be easily manufactured with high productivity.

As described above, the viscosity of the composition 20 ′ in this step (coating step) may be more than 100,000 mPa · s and not more than 400,000 mPa · s, but may be from 150,000 mPa · s to 350,000 mPa · s. It is preferable that it is 200,000 mPa · s or more and 300,000 mPa · s or less.
Thereby, the effects as described above are more remarkably exhibited.

  The film obtained by molding the composition 20 'under predetermined conditions satisfies the following conditions.

For a solid film with a thickness of 2 mm formed using the composition 20 ′, using a metal halide lamp as a light source, irradiation intensity: 81 mW / cm ² , spray cycle: 2 minutes in 120 minutes, black panel temperature: 80 When the metal weather test under the condition of ° C. is performed for 500 hours, the volume shrinkage of the film is 24% or less.

  By using the composition 20 ′ that satisfies such conditions, shrinkage due to aging of the molded body 100 manufactured using the composition can be effectively prevented and suppressed, and the durability of the molded body 100 can be reduced. The property can be made excellent.

The volume shrinkage rate of the film when the metal weather test is performed under the above conditions can be calculated from changes in the length, width, and thickness of the film before and after the test. Further, the volume shrinkage may be 24% or less, but is preferably 22% or less, and more preferably 20% or less.
Thereby, the effects as described above are more remarkably exhibited.

  The metal weather test can be performed using a metal weather tester such as KW-R5TP (Daipura Wintes Co., Ltd.), SUV-W151 (Iwasaki Electric Co., Ltd.), M6T (Suga Test Instruments Co., Ltd.), or the like. it can.

  The application (application) of the composition (sol composition) 20 ′ to the steel sheet 10 may be performed by a coating method, and more specifically, for example, brush coating, dispensing method, squeegee method, spray method, It can be performed by a method such as an extrusion method using a flow gun.

  [3] Next, the composition 20 ′ applied to the steel plate 10 is solidified (solidification step, see FIG. 3B).

  Thus, by solidifying the composition 20 ′ in a state of being molded into a predetermined shape, the composition 20 ′ loses fluidity and becomes a resin part 20 as a solid, and a molding provided with the resin part 20. A body 100 is obtained.

  In one embodiment, the composition 20 'may be solidified by heating. Although the heating conditions of the solidification step vary depending on the constituent material of the composition 20 ', for example, the temperature is preferably 120 ° C or higher and 250 ° C or lower, and more preferably 140 ° C or higher and 230 ° C or lower. The heating time also varies depending on the constituent material of the composition 20 ', etc., but is preferably 3 minutes or longer and 30 minutes or shorter, and more preferably 5 minutes or longer and 20 minutes or shorter.

  In the case where the composition 20 ′ provided for the coating step contains a volatile solvent, this step (solidification step) can be performed by removing the solvent.

  The solvent can be removed from the composition 20 'by, for example, heating the composition 20' or placing the composition 20 'under reduced pressure.

As described above, the composition 20 ′ includes a vinyl chloride resin and a plasticizer.
Among various resin materials, the vinyl chloride resin has excellent water resistance, acid resistance, and alkali resistance, is flame retardant, and is electrically insulating. Moreover, it is excellent in solvent weldability and heat-fusibility. Therefore, the molded body 100 made of a material containing a vinyl chloride resin can be suitably applied and can be suitably applied to a waterproof structure excellent in durability.

  Further, the composition 20 ′ contains a plasticizer, whereby the moldability of the molded body 100 can be improved, and the occurrence of cracks and the like in the molded body 100 can be more effectively prevented and suppressed. Thus, the durability of the molded body 100 can be improved.

  The content of the vinyl chloride resin in the composition 20 ′ is not particularly limited, but may be, for example, 40% by mass or more and 80% by mass or less, and more preferably 55% by mass or more and 75% by mass or less. it can.

  In the composition 20 ′, the vinyl chloride-based resin may be included in any form, for example, it may be included in a molten state, or may be included in a dissolved state. It may be included in a solid particle state.

  The shape of the particles composed of the vinyl chloride resin is, for example, in the form of granules (eg, a combination of a plurality of spheres), pellets (lumps), blocks (eg, porous bodies), etc. You can also.

  Although it does not specifically limit as a plasticizer, For example, aliphatics, such as a phthalate plasticizer, DOA (di-2-ethylhexyl adipate), DIDA (diisodecyl adipate), DOS (di-2-ethylhexyl sebacate) Dibasic acid ester plasticizers, aromatic carboxylic acid ester plasticizers such as ethylene glycol benzoates, polyester plasticizers, and trimellitic acid ester plasticizers such as TOTM (trioctyl trimellitate) These can be used, and one or more of these can be used in combination.

  The phthalate ester plasticizer is represented by the general formula (1).

〔式中、Ｒ_１、Ｒ_２は、炭素数が４以上１２以下の直鎖状又は分岐状のアルキル基を示す。Ｒ_１、Ｒ_２は、同一でも異なっていてもよい。〕

[Wherein R ₁ and R ₂ represent a linear or branched alkyl group having 4 to 12 carbon atoms. R ₁ and R ₂ may be the same or different. ]

  Specific examples of the alkyl group include, for example, n-butyl, isobutyl, n-hexyl, isohexyl, n-heptyl, isoheptyl, n-octyl, 2-ethylhexyl, isooctyl, n-nonyl, isononyl, n-decyl, isodecyl. , N-undecyl, isoundecyl, n-lauryl, isolauryl and the like.

  Specific examples of the phthalate ester plasticizer represented by the general formula (1) include, for example, dibutyl phthalate, di-n-heptyl phthalate, diisoheptyl phthalate, di-n-octyl phthalate, and di-2-ethylhexyl phthalate. , Diisooctyl phthalate, di-n-nonyl phthalate, diisononyl phthalate, di-n-decyl phthalate, diisodecyl phthalate, di-n-undecyl phthalate, di-n-lauryl phthalate, butyl octyl phthalate, n-octyl-n -Decyl phthalate etc. can be mentioned.

  Although the content rate of the plasticizer in composition 20 'is not specifically limited, For example, with respect to 100 mass parts of vinyl chloride resin, it can be 40 mass parts or more and 90 mass parts or less, Furthermore, 50 mass parts. The amount can be 80 parts by mass or more.

  When the content of the plasticizer is less than the lower limit, depending on the type of the plasticizer, there is a possibility that sufficient flexibility cannot be imparted to the resin portion 20 of the molded article 100 to be obtained. Moreover, when content exceeds the said upper limit, there exists a possibility that shrinkage | contraction may become large depending on the kind of plasticizer.

  In addition, the composition 20 'may contain components other than the vinyl chloride resin and the plasticizer.

  Examples of such components include fillers, stabilizers, stabilizers, ultraviolet absorbers, flame retardants, fiber reinforcing agents, colorants, lubricants, diluents, thickeners, and the like.

  The preferred embodiments of the present invention have been described above. However, the present invention is not limited to the above-described embodiments, and modifications, improvements, and the like within the scope that can achieve the object of the present invention are included in the present invention. It is.

  For example, in the method for producing a molded article of the present invention, one or more optional steps may be added as necessary.

  Further, in the present invention, the molded body, the joined body, or these constituent members can be replaced with any one capable of exhibiting the same function, or any constituent can be added. .

  In the above-described embodiment, the bonding method has been described as an example in which two members are bonded to each other via a molded body to obtain a bonded body. You may make it apply when obtaining the conjugate | zygote by which three or more members are joined via the molded object.

  In the present invention, each member is not limited to the shape as described above, and may have any shape.

100 molded body 10 joined body (steel plate)
DESCRIPTION OF SYMBOLS 1 1st member 2 2nd member 20 'Composition (sol composition)
20 Resin part

Claims (2)

A method for producing a molded article using a composition comprising a vinyl chloride resin and a plasticizer,
An application step of applying the composition to a steel sheet;
A solidification step of solidifying the composition applied to the steel plate,
The viscosity of the composition in the coating step is more than 100,000 mPa · s and not more than 400,000 mPa · s,
For a solid film having a thickness of 2 mm formed using the composition, a metal halide lamp was used as a light source, irradiation intensity: 81 mW / cm ² , spray cycle: 2 minutes in 120 minutes, black panel temperature: 80 ° C. A method for producing a molded article, wherein the film has a volume shrinkage of 24% or less when the metal weather test is conducted for 500 hours.   The said solidification process is a manufacturing method of the molded object of Claim 1 performed by heating.

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