JP2019043054A - Resin molding and method for producing the same - Google Patents

Abstract

To provide a resin molding which has a complicated pattern and excellent designability, and to provide a method for producing the resin molding.SOLUTION: A resin molding 100 includes a thermosetting resin 10, and a pattern part 20 contained in the thermosetting resin. The pattern part includes a thermoplastic resin 21, and a magnetic filler 22 contained in the thermoplastic resin. A method for producing the resin molding includes: a dispersion step of dispersing pattern formation particles 20A having a magnetic filler and a thermoplastic resin including the magnetic filler into the inside of a liquid resin composition 10A that is a precursor of the thermosetting resin; a magnetic force imparting step of imparting magnetic force M from a plurality of portions to the liquid resin composition dispersed with the pattern formation particles to move the pattern formation particles to a position corresponding to a magnetic field at an inside of the liquid resin composition; and a curing step of curing the liquid resin composition after the magnetic force imparting step.SELECTED DRAWING: Figure 4

Description

  The present invention relates to a resin molded product and a method of manufacturing the same. In particular, the present invention relates to a resin molded product having improved designability by attaching a handle having an optical feature, and a method of manufacturing the resin molded product.

  Heretofore, resin molded articles having patterns such as flow patterns and natural marbles have been used as a water circulating member such as a top plate of a kitchen counter from the viewpoint of high design.

  As a method of forming such a resin molding, there are, for example, a method of printing a handle on the surface of a substrate, and a method of sticking a decorative film on a substrate. In addition, as a method of forming a resin molded body, in Patent Document 1, a liquid resin of different color is layered and injected into a molding cell in a layer of at least two layers or more, and then a comb-like tool is stacked in the liquid resin. And a method of curing the liquid resin after that. And in this case, it is described that an artificial marble having a stripe pattern can be obtained by moving in the liquid resin while changing the distance between the teeth of the comb-like tool.

Patent No. 2933008 gazette

  However, in the method of printing the pattern on the substrate or in the method of attaching the decorative film to the substrate, only the surface of the resin molded body obtained is decorated, so the pattern tends to disappear due to scratches, peeling, etc. Was a problem. Moreover, in these methods, since only the surface of the resin molding is decorated, three-dimensional decoration is impossible, and it is difficult to obtain a handle with a deep feeling.

  Further, in the manufacturing method of Patent Document 1, it is difficult to obtain a three-dimensional shaped product or a thin film shaped product because the liquid resin of different color is injected and formed in the forming cell, and the shape of the resin molded product obtained There was a limit to

  The present invention has been made in view of the problems of the prior art. And the objective of this invention is to provide the manufacturing method of the resin molding which has a complicated handle and was excellent in the designability, and the said resin molding.

  In order to solve the said subject, the resin molded object which concerns on a 1st aspect of this invention is equipped with a thermosetting resin and the handle part contained in the inside of a thermosetting resin. And a handle part is equipped with a thermoplastic resin and a magnetic filler contained inside a thermoplastic resin.

  The method for producing a resin molded product according to the second aspect of the present invention is a liquid resin composition which is a precursor of a thermosetting resin and which has a handle-forming particle provided with a magnetic filler and a thermoplastic resin containing the magnetic filler. The pattern forming particles are provided at positions corresponding to the magnetic field in the inside of the liquid resin composition by applying a magnetic force to the liquid resin composition in which the pattern forming particles are dispersed, and a dispersion process in which the pattern forming particles are dispersed. It has a magnetic force application process to which it moves, and a curing process which hardens a liquid resin composition after a magnetic force application process.

  ADVANTAGE OF THE INVENTION According to this invention, it has a complicated handle and can provide the manufacturing method of the resin molding which was excellent in the designability, and the said resin molding.

1 is a perspective view schematically showing a resin molded product according to an embodiment of the present invention. It is a schematic sectional drawing which shows an example of the state to which handle formation particle | grains disperse | distributed inside the liquid resin composition which is a precursor of a thermosetting resin. It is a schematic sectional drawing which shows an example of the state which provided magnetic force with respect to handle formation particle | grains inside the liquid resin composition. It is a schematic sectional drawing which shows an example of the state which hardened | cured the liquid resin composition, after providing magnetic force with respect to handle formation particle | grains.

  Hereinafter, a resin molded body according to the present embodiment and a method for manufacturing the resin molded body will be described in detail. The dimensional ratios in the drawings are exaggerated for the convenience of description, and may differ from the actual ratios.

[Resin molding]
As shown in FIG. 1, the resin molded body 100 according to the present embodiment includes a thermosetting resin 10 and a handle portion 20 included inside the thermosetting resin 10. And since the thermosetting resin 10 and the handle 20 differ in optical characteristics from each other, in the resin molded body 100, a flow handle due to the handle 20 is formed on the surface and inside thereof.

(Thermosetting resin)
The thermosetting resin 10 which is a matrix resin of the resin molding 100 is not particularly limited as long as the precursor before heat curing is liquid as described later. The thermosetting resin 10 is preferably one having transparency in order to make the handle 20 easily recognizable from the outside. As the thermosetting resin 10, at least one selected from the group consisting of thermosetting acrylic resin, unsaturated polyester resin, vinyl ester resin, phenol resin, urethane resin, melamine resin and epoxy resin can be used. Among these, it is preferable to use a thermosetting acrylic resin which gives a sense of depth to the resin molded body 100 to be obtained and is further excellent in strength and water resistance.

  In the resin molded body 100, the thermosetting resin 10 may contain a fiber reinforcing material. By including the fiber reinforcing material, the strength of the resin molded body 100 can be increased, and the curing shrinkage at the time of molding and after molding can be suppressed.

  The fiber reinforcing material is not particularly limited, and at least one selected from the group consisting of glass fibers, carbon fibers and Kevlar (registered trademark) fibers can be used. However, the fiber reinforcing material is preferably glass fiber. By using glass fiber as the fiber reinforcing material, it is possible to give the resin molded body 100 a sense of transparency while improving the strength, heat resistance and surface hardness of the resin molded body 100. The glass fiber can use the chopped strand which cut | disconnected glass roving to a predetermined dimension. Although the cutting dimension of glass fiber is not specifically limited, 10 mm-about 50 mm are preferable, and it is more preferable that they are 20 mm-30 mm.

  The content of the fiber reinforcing material is preferably 10 to 30% by mass in the total mass of the thermosetting resin 10. When the content of the fiber reinforcing material is in this range, it is possible to effectively increase the strength of the resin molded body 100 to be obtained, and to suppress the cure shrinkage after molding.

  In the resin molded body 100, the thermosetting resin 10 may contain a filler. By including the filler, the designability, the strength and the heat resistance of the resin molded body 100 can be enhanced, and the curing shrinkage at the time of molding and after molding can be suppressed. The filler may be contained in the entire thermosetting resin 10 or may be partially contained in the thermosetting resin 10. In addition, the density of the filler may be changed inside the thermosetting resin 10, and color shading may be present.

  Although the filler is not particularly limited, an inorganic filler composed of an inorganic compound can be used. As the inorganic filler, for example, at least one selected from the group consisting of silica, aluminum hydroxide, calcium carbonate, barium sulfate, alumina, silica sand and talc can be used. However, the inorganic filler preferably contains silica. By using silica as the inorganic filler, it is possible to obtain a resin molded body 100 with high transparency.

  It is preferable that it is 20-80 mass% in the total mass of the thermosetting resin 10, and, as for content of an inorganic filler, it is more preferable that it is 30-70 mass%. When content of an inorganic filler is 20 mass% or more, the heat resistance of the resin molding 100 can be improved, and also the cure shrinkage after shaping | molding can fully be suppressed. Moreover, when content of an inorganic filler is 80 mass% or less, the fluid fall of the resin composition at the time of shaping | molding, and the physical property fall of the resin molding 100 can be suppressed.

  Although the particle diameter of the inorganic filler is not particularly limited, it is preferably, for example, 1 μm to 50 μm, and more preferably 3 μm to 30 μm. When the particle diameter is in this range, the flowability of the inorganic filler at the time of molding can be enhanced without impairing various effects of the blending of the inorganic filler. The particle diameter of the inorganic filler can be determined by observing the thermosetting resin 10 with a scanning electron microscope.

(Pattern part)
The resin molded body 100 has a plurality of handle portions 20 for forming a pattern on the surface and the inside thereof. The handle 20 includes the thermoplastic resin 21 and the magnetic filler 22 contained in the thermoplastic resin 21.

  The thermoplastic resin used as a base material in the handle 20 is not particularly limited, and examples thereof include acrylic resin, polyethylene terephthalate resin, ethylene-vinyl oxide copolymer, polypropylene resin, polycarbonate resin and the like. One of these thermoplastic resins may be used alone, or two or more of them may be used in combination.

  In the handle portion 20, a magnetic filler having paramagnetism or ferromagnetism is contained inside the thermoplastic resin. As described later, the handle portion 20 is formed by applying a magnetic force to a handle-forming particle made of a thermoplastic resin containing a magnetic filler, and moving the handle-forming particle so as to obtain a desired pattern. . Therefore, a magnetic filler is used so that the handle-forming particles can be moved by external magnetic force.

As the magnetic filler contained in the interior of the thermoplastic resin, at least one of a paramagnetic material and a ferromagnetic material can be used. Such a magnetic filler is not particularly limited, and for example, mica powder coated with at least one selected from the group consisting of nickel plating, chromium plating and Fe ₂ O ₃ coating can be used. Further, as the magnetic filler, stainless steel, nickel, bengala, or ferrite can be used. In addition, a magnetic filler may be used individually by 1 type of these, and may be used combining 2 or more types.

  The shape of the magnetic filler is not particularly limited, and can be, for example, spherical or scaly. Further, the particle diameter of the magnetic filler is also not particularly limited, and can be, for example, 1 μm to 100 μm. The particle diameter of the magnetic filler can be determined by observing the cross section of the resin molded body 100 with a scanning electron microscope or a transmission electron microscope.

  The handle 20 preferably contains at least one of a pigment and a dye. By adding at least one of a pigment and a dye, it is possible to color the handle 20 of the resin molded body 100 to any color.

  The pigment is not particularly limited, and for example, at least one of an organic pigment and an inorganic pigment can be used. As the organic pigment, for example, phthalocyanine type, benzimidazolone type, azo type, azomethine azo type, azomethine type, anthraquinone type, perinone / perylene type, indigo / thioindigo type, dioxazine type, quinacridone type, isoindoline type, iso Indolinone pigments and the like, carbon black pigments and the like can be mentioned. Moreover, as an inorganic pigment, an extender pigment, a titanium oxide based pigment, an iron oxide based pigment, a spinner pigment etc. are mentioned, for example. In more detail, insoluble azo pigments such as toluidine red, toluidine maroon, hanzaero, benzidine yellow, pyrazolone red, soluble azo pigments such as lithol red, helio Bordeaux, pigment scarlet, permanent red 2B, phthalocyanine blue, phthalocyanine green etc. Perinacins such as quinacridone such as phthalocyanine, quinacridone red and quinacridone magenta, perylenes such as perylene red and perylene scarlet, isoindolinone such as isoindolinone yellow and isoindolinone orange, pyranthrone such as pyranthrone red and pyranthrone orange , Thioindigo type, condensation azo type, benzimidazolone type, quinophthalone yellow, nickel azoellow, perinone orange, anthrone orange, dianthra Nonirureddo, pigments such as dioxazine violet can be used. One of these pigments may be used alone, or two or more thereof may be used in combination.

  The dye is not particularly limited, but, for example, direct dyes, basic dyes, cationic dyes, acid dyes, mordant dyes, acid mordant dyes, sulfur dyes, naphthol dyes, disperse dyes, reactive dyes and the like can be used. One of these dyes may be used alone, or two or more thereof may be used in combination.

  In addition, it becomes possible to color the handle part 20 of the resin molded object 100 in arbitrary colors by using the coloring magnetic filler which colored the magnetic filler to the desired color. Although the method to color a magnetic filler is not specifically limited, For example, the method of apply | coating at least one of the above-mentioned pigment and dye to the surface of a magnetic filler is mentioned.

  As will be described later, the handle portion 20 in the resin molded body 100 disperses a handle-forming particle made of a thermoplastic resin containing a magnetic filler in the inside of the liquid resin composition, and then the magnetic force is applied to the liquid resin composition. And then curing the liquid resin composition. Specifically, by applying a magnetic force to the liquid resin composition in which the pattern-forming particles are dispersed, the pattern-forming particles are moved to a position corresponding to the magnetic field in the liquid resin composition. Then, the liquid resin composition is heated and cured while melting the thermoplastic resin of the pattern-forming particles in a state where the pattern-forming particles are disposed at a desired position inside the liquid resin composition. Thereby, the thermoplastic resin which fuse | melted from adjacent handle-forming particle | grains couple | bonds, and it can form the handle | pattern part 20 which consists of a continuous flow pattern.

  And in the resin molding 100, the number and position of the handles 20 can be controlled by the amount of handle-forming particles dispersed in the liquid resin composition and the position of the magnetic lines of force. Therefore, it becomes possible to easily form the desired handle 20 by adjusting the amount of the handle-forming particles and the magnetic field.

  As described above, the resin molded body 100 of the present embodiment includes the thermosetting resin 10 and the handle 20 included in the thermosetting resin 10. The handle 20 includes a thermoplastic resin and a magnetic filler contained in the interior of the thermoplastic resin. Thereby, since the handle 20 is formed inside the thermosetting resin 10, it becomes possible to provide a three-dimensional complicated pattern resulting from the optical characteristics of the handle 20. Furthermore, since the handle 20 is formed inside the thermosetting resin 10, the durability of the handle 20 can be enhanced. In addition, by adjusting the length of the handle 20, it is possible to obtain the resin molded body 100 having a texture such as natural stone having a flow pattern. And since a pattern is formed by the handle part 20, the three-dimensional-shaped thing of the resin molding 100, and the thin-film-shaped molded article can be obtained easily.

  The resin molded body 100 preferably further comprises a fiber reinforcing material dispersed in the thermosetting resin 10. By including the fiber reinforcing material, it is possible to increase the strength, heat resistance and surface hardness of the resin molded body 100, and to suppress curing shrinkage after molding.

  In the resin molded body 100, the melting temperature of the thermoplastic resin contained in the handle portion 20 is preferably equal to or higher than the curing temperature of the liquid resin composition which is a precursor of the thermosetting resin 10. Thereby, when heating and hardening a liquid resin composition, a thermoplastic resin can be melted by hardening heat generation of a liquid resin composition. Therefore, it is possible to combine the thermoplastic resin melted from the adjacent pattern-forming particles and form a continuous flow pattern.

  The resin molded body 100 of the present embodiment has a configuration in which the handle portion 20 is formed inside the thermosetting resin 10, and therefore, the resin molded body 100 is excellent in strength, surface hardness, designability and water resistance. Therefore, it can be suitably used for applications requiring a good appearance, for example, water-covered members such as kitchen counters, vanities, bath tubs, floor pans (waterproof pans), and wash bowls.

[Method for producing resin molded product]
Next, a method of manufacturing the resin molded body 100 according to the present embodiment will be described. The manufacturing method of the resin molding 100 is a dispersion process in which handle-forming particles including a magnetic filler and a thermoplastic resin containing the magnetic filler are dispersed in a liquid resin composition which is a precursor of a thermosetting resin. Have. The manufacturing method further moves the handle-forming particles to a position corresponding to the magnetic field in the liquid resin composition by applying a magnetic force to the liquid resin composition in which the handle-forming particles are dispersed from a plurality of locations. It has a magnetic force application process. And the said manufacturing method has a hardening process which hardens a liquid resin composition, after moving pattern | pattern formation particle | grains by a magnetic force provision process.

(Dispersion process)
In the method of manufacturing the resin molded body 100, first, as shown in FIG. 2, a pattern-forming particle 20A including a magnetic filler 22 and a thermoplastic resin 21 including the magnetic filler 22 is manufactured. The method for producing the pattern-forming particles 20A is not particularly limited, and can be produced by a known granulation method. For example, after preparing the mixed raw material by mixing the thermoplastic resin 21 and the magnetic filler 22 according to a known method, the handle-forming particles 20A are produced by a method such as extrusion granulation, melt granulation, spray granulation, etc. Can. In addition, the above-mentioned material can be used for the thermoplastic resin 21 and the magnetic filler 22. In addition, at least one of a pigment and a dye can be added to the mixed raw material, if necessary.

  The shape of the handle-forming particles 20A is not particularly limited, but can be, for example, spherical. The size of the pattern-forming particles 20A is also not particularly limited, and may have variations. The size of the pattern-forming particles 20A is preferably 1 mm or more, more preferably 5 mm or more, and still more preferably 10 mm or more. The size of the handle-forming particles 20A is preferably 100 mm or less, more preferably 50 mm or less, and even more preferably 20 mm or less. The size of the pattern-forming particles 20A refers to the maximum value of the distance between two points on the surface of the pattern-forming particles 20A.

  Next, the handle-forming particles 20A are dispersed inside the liquid resin composition 10A which is a precursor of the thermosetting resin 10. The method for dispersing the handle-forming particles 20A in the liquid resin composition 10A is not particularly limited. For example, a method for mixing the handle-forming particles 20A into the liquid resin composition 10A using a stirrer or the like may be mentioned. The liquid resin composition 10A in which the handle-forming particles 20A are dispersed may be subjected to a defoaming treatment under a reduced pressure of, for example, about 20 to 50 Torr. At this time, if necessary, at least one of the fiber reinforcing material and the filler may be dispersed in the liquid resin composition 10A. Thereby, as shown in FIG. 2, it is possible to obtain a liquid mixture in which the handle-forming particles 20A and the fiber reinforcing material 30 are highly dispersed inside the liquid resin composition 10A.

  The liquid resin composition 10A, which is a precursor of the thermosetting resin 10, may use a liquid resin composition capable of dispersing the pattern-forming particles 20A inside and curing it by heating. Specifically, as the liquid resin composition 10A, at least one precursor selected from the group consisting of thermosetting acrylic resin, vinyl ester resin, phenol resin, urethane resin, melamine resin, and epoxy resin is liquid. It can be used.

  The viscosity of the liquid resin composition 10A is not particularly limited. However, as described later, in the manufacturing method of the present embodiment, the magnetic flux is applied from a plurality of locations to the liquid resin composition 10A in which the handle-forming particles 20A are dispersed, thereby forming the handle-forming particles in the position corresponding to the magnetic field. It is necessary to move 20A. Therefore, the viscosity of the liquid resin composition 10A is preferably 1000 Pa · s or less so that the handle-forming particles 20A can be moved by magnetic force.

  As described above, it is preferable to use a thermosetting acrylic resin as the thermosetting resin 10 from the viewpoint of giving a sense of depth to the resin molded body 100 and further being excellent in strength and water resistance. Therefore, as the liquid resin composition 10A, a methyl methacrylate syrup or an acrylic resin composition formed by dissolving a methyl methacrylate polymer in a methyl methacrylate monomer can be used.

<Methyl methacrylate syrup>
The methyl methacrylate syrup is a polymerizable liquid mixture obtained by mixing a methyl methacrylate polymer and a liquid methyl methacrylate monomer.

  The methyl methacrylate-based polymer is a polymer containing methyl methacrylate as a main component. The methyl methacrylate polymer may be a homopolymer of methyl methacrylate or a copolymer with another copolymerizable monomer.

  Other copolymerizable monomers are not particularly limited, and examples thereof include ethyl (meth) acrylate, n-propyl (meth) acrylate, isopropyl (meth) acrylate, n-butyl (meth) acrylate, (Meth) acrylate isobutyl, t-butyl (meth) acrylate, 2-ethylhexyl (meth) acrylate, 2-hydroxyethyl (meth) acrylate, hydroxypropyl (meth) acrylate, lauryl (meth) acrylate, ( (Meth) acrylic acid esters such as cyclohexyl acrylic acid; unsaturated acids such as methacrylic acid and acrylic acid; styrene, vinyl toluene, α-methylstyrene, t-butylstyrene, styrene such as chlorostyrene and derivatives thereof; acetic acid Vinyl esters of vinyl, vinyl propionate and the like; acrylonitrile, methacrylo It is possible to use a tolyl. One of these may be used alone, or two or more may be used in combination. In the present specification, the term "(meth) acrylic" means acrylic or methacrylic, and the term "(meth) acrylate" means acrylate or methacrylate.

  The methyl methacrylate polymer can be produced by a known radical polymerization method such as bulk polymerization, solution polymerization, suspension polymerization and the like.

  The weight average molecular weight of the methyl methacrylate polymer is not particularly limited. The weight average molecular weight can use the thing within the range of 5000-150,000 in the value measured by using a methyl methacrylate polymer as a standard sample using gel permeation chromatography (GPC), for example.

  The proportion of methyl methacrylate in the total monomer units of the methyl methacrylate polymer is preferably 50 to 100% by mass, and more preferably 90 to 100% by mass. By being within this range, it becomes possible to easily dissolve the obtained methyl methacrylate based polymer in the methyl methacrylate based monomer.

  The methyl methacrylate-based monomer is a monomer containing methyl methacrylate as a main component, and may be a mixture with other copolymerizable monomers besides methyl methacrylate alone. The other copolymerizable monomers are not particularly limited, but, for example, those described above can be used.

  In the methyl methacrylate monomer, the ratio of methyl methacrylate is preferably 50 to 100% by mass, and more preferably 90 to 100% by mass, based on all monomers. By being within this range, it becomes possible to easily dissolve the methyl methacrylate-based polymer in the methyl methacrylate-based monomer.

  The methyl methacrylate syrup can be obtained by dissolving a methyl methacrylate polymer in a methyl methacrylate monomer. The ratio of the methyl methacrylate polymer to the methyl methacrylate monomer is not particularly limited, and can be appropriately adjusted in consideration of the viscosity, the evaporation rate, and the like.

<Acrylic resin composition>
The acrylic resin composition contains a (meth) acrylic acid ester monomer and a polymerization initiator. In addition, the acrylic resin composition can optionally contain at least one selected from the group consisting of an internal mold release agent, a crosslinkable polyfunctional monomer, and a polymerization inhibitor.

[(Meth) acrylic acid ester monomer]
The acrylic resin composition is blended with a (meth) acrylic acid ester monomer. The (meth) acrylic acid ester monomer has a role of dissolving and mixing other components in the acrylic resin composition, and a role of improving the fluidity of the acrylic resin composition at the time of molding.

  As a (meth) acrylic acid ester monomer, for example, methyl (meth) acrylate, ethyl (meth) acrylate, n-propyl (meth) acrylate, n-butyl (meth) acrylate, (meth) acrylic At least one selected from the group consisting of i-propyl acid, isobonyl (meth) acrylate, cyclohexyl (meth) acrylate and glycidyl (meth) acrylate can be used. One of these may be used alone, or two or more may be used in combination.

  10-85 mass% in the total mass of an acrylic resin composition is preferable, and, as for content of the (meth) acrylic acid ester monomer, 15-80 mass% is more preferable. When content of a (meth) acrylic acid ester monomer is 10 mass% or more, it can suppress that the viscosity at the time of the mixing of the said acrylic resin composition becomes high too much. When the content of the (meth) acrylic acid ester monomer is 85% by mass or less, the monomer volatilizes during molding, and the component balance of the resin molded body 100 is lost, or the resin molded body 100 The generation of air bubbles can be suppressed. Moreover, when it is 85 mass% or less, it can suppress that a crack is generated at the time of shaping | molding.

[Polymerization initiator]
In the acrylic resin composition according to the present embodiment, a polymerization initiator for polymerizing a (meth) acrylic acid ester monomer is blended. The polymerization initiator is preferably a radical polymerization initiator. Examples of radical polymerization initiators include azo compounds such as azobisisobutyronitrile and 1,1′-azobis (cyclohexanecarbonitrile), and organic peroxides. Among these, organic peroxides are preferred. preferable.

  As the organic peroxide, for example, methyl ethyl ketone peroxide, benzoyl peroxide, lauroyl peroxide, stearoyl peroxide, bis (4-t-butylcyclohexyl) peroxydicarbonate, t-hexylperoxy-2-ethylhexano It is possible to use at least one selected from the group consisting of aate, t-butylperoxy-2-methylcyclohexane, t-amylperoxybenzoate and dicumyl peroxide.

  It is preferable that it is 0.05-3 mass% with respect to the (meth) acrylic acid ester monomer, and, as for content of an organic peroxide, it is more preferable that it is 0.1-2 mass%. When the content of the organic peroxide is 0.05% by mass or more, it becomes possible to accelerate the curing rate at the time of molding. In addition, when the content of the organic peroxide is 3% by mass or less, it is possible to suppress the decrease in fluidity of the acrylic resin composition at the time of molding and the generation of a crack at the time of molding.

  In the range which does not impair the effect of this embodiment, the acrylic resin composition which concerns on this embodiment can add another component in addition to said component. Examples of such other components include internal mold release agents, crosslinkable polyfunctional monomers, and polymerization inhibitors such as hydroquinone. In addition, functional resins such as fluorocarbon resins and silicone resins, or organic fillers such as cellulose and polystyrene can also be blended.

[Internal mold release agent]
The acrylic resin composition according to the present embodiment preferably contains an internal release agent in order to enhance the releasability of the resin molded product from the mold. Examples of internal mold release agents include stearic acid, hydroxystearic acid, zinc stearate, aluminum stearate, magnesium stearate, stearates such as calcium stearate, soya oil lecithin, silicone oil, fatty acid ester and fatty acid alcohol Basic acid esters and the like can be mentioned. Among these, the internal mold release agent is more preferably zinc stearate.

[Crosslinkable multifunctional monomer]
The acrylic resin composition according to the present embodiment, the crosslinkable polyfunctional monomer having two or more vinyl groups (H 2 _{C =} CH-) in the molecule may be blended. By blending the crosslinkable polyfunctional monomer, a three-dimensional crosslinking reaction can be generated at the time of polymerization of the (meth) acrylic acid ester monomer in the acrylic resin composition. It is possible to develop the heat resistance and strength of the The upper limit of the number of vinyl groups in one molecule of the crosslinkable polyfunctional monomer is not particularly limited, but may be, for example, 10 or less.

  As the crosslinkable polyfunctional monomer, for example, ethylene glycol di (meth) acrylate, diethylene glycol di (meth) acrylate, polyethylene glycol di (meth) acrylate, 1,6-hexanediol di (meth) acrylate, neopentyl glycol Di (meth) acrylate, 1,9-nonanediol di (meth) acrylate, 1,10-decanediol di (meth) acrylate, bisphenol A type di (meth) acrylate, trimethylolpropane tri (meth) acrylate, pentaerythritol At least one selected from the group consisting of tetra (meth) acrylate, glycerin tri (meth) acrylate, and dipentaerythritol poly (meth) acrylate can be used. One of these may be used alone, or two or more may be used in combination.

  The content of the crosslinkable polyfunctional monomer is preferably 0.3 to 20% by mass in the total mass of the acrylic resin composition. When the content of the crosslinkable polyfunctional monomer is 0.3% by mass or more, the degree of crosslinking of the resin molded product obtained by the polymerization of the acrylic resin composition can be increased to obtain desired performance. . Moreover, when content of a crosslinkable polyfunctional monomer is 20 mass% or less, it can suppress that a crack generate | occur | produces at the time of shaping | molding of an acrylic resin composition.

  As described above, it is preferable to use a thermosetting acrylic resin as the thermosetting resin 10 from the viewpoint of giving a sense of depth to the resin molded body 100 and further being excellent in strength and water resistance. However, as the thermosetting resin 10, it is also preferable to use an unsaturated polyester resin which is excellent in strength and water resistance. In this case, an unsaturated polyester resin composition can be used as the liquid resin composition 10A.

<Unsaturated polyester resin composition>
The unsaturated polyester resin composition contains at least an unsaturated / saturated polycarboxylic acid, an organic polyol, a polymerization initiator, and a polymerizable monomer.

[Unsaturated and saturated polycarboxylic acid]
The unsaturated polyester resin composition is blended with unsaturated / saturated polycarboxylic acid. As unsaturated or saturated polycarboxylic acid, for example, at least one selected from the group consisting of aliphatic unsaturated polycarboxylic acid, aliphatic saturated polycarboxylic acid and aromatic polycarboxylic acid can be used.

  Examples of aliphatic unsaturated polycarboxylic acids include maleic anhydride and fumaric acid. Examples of aliphatic saturated carboxylic acids include sebacic acid, succinic anhydride and adipic acid. Examples of the aromatic polycarboxylic acid include phthalic anhydride, isophthalic acid and terephthalic acid. One of these may be used alone, or two or more may be used in combination.

[Organic polyol]
The unsaturated polyester resin composition is blended with an organic polyol. As the organic polyol, at least one of an aliphatic polyol and an aromatic polyol can be used.

  Examples of aliphatic polyols include ethylene glycol, propylene glycol, dipropylene glycol, butylene glycol, triethylene glycol, neopentyl glycol, trimethylene glycol, glycerin, hydrogenated bisphenol A and the like. As an aromatic polyol, bisphenol A, bisphenol S etc. are mentioned. One of these may be used alone, or two or more may be used in combination.

[Polymerization initiator]
The unsaturated polyester resin composition is blended with a polymerization initiator. The polymerization initiator is not particularly limited, and the same acrylic resin composition as described above can be used.

[Polymerizable monomer]
As a polymerizable monomer, unsaturated polyester and a crosslinkable unsaturated monomer can be used in the range which does not impair the effect of this embodiment. Examples of the polymerizable monomer include styrene, vinyl toluene, vinyl acetate, diallyl phthalate, triallyl cyanurate, methyl acrylate, ethyl acrylate, methacrylic acid ester, methyl methacrylate, ethyl methacrylate and the like. One of these may be used alone, or two or more may be used in combination.

(Magnetic force application process)
Next, a magnetic force is applied to the liquid resin composition 10A in which the handle-forming particles 20A are dispersed, from a plurality of places. Specifically, first, the liquid resin composition 10A in which the handle-forming particles 20A are dispersed is injected into a mold. The form to be used is not particularly limited as long as magnetic force can act on the pattern-forming particles 20A from the outside. As a formwork, for example, those made of plastic or ceramics can be used.

  Then, as shown in FIG. 3, the magnetic force M is applied from a plurality of locations to the liquid resin composition 10A in which the handle-forming particles 20A are dispersed, and the handle-forming particles 20A are moved to the position corresponding to the magnetic field. The application position of the magnetic force M is not particularly limited, and can be adjusted so that the desired handle 20 is formed. For example, as shown in FIG. 3, the magnetic force M may be applied from both the upper surface and the lower surface of the liquid resin composition 10A. The magnetic force M may be applied from one of the upper surface and the lower surface of the liquid resin composition 10A. This makes it possible to three-dimensionally orient the plurality of pattern-forming particles 20A along the magnetic lines of force inside the liquid resin composition 10A.

  The method for applying the magnetic force M to the liquid resin composition 10A in which the handle-forming particles 20A are dispersed is not particularly limited, and for example, known permanent magnets and electromagnets can be used.

(Curing process)
After the handle-forming particles 20A are moved to the position corresponding to the magnetic field in the liquid resin composition 10A, the liquid resin composition 10A is cured. The curing method of the liquid resin composition 10A is not particularly limited. For example, the liquid resin composition 10A can be cured by heating the liquid resin composition 10A from the outside. In addition, although the heating conditions of the liquid resin composition 10A can be suitably set by the liquid resin composition 10A to be used, for example, it is preferable to heat at 60-150 degreeC for 0.1 hour-4 hours.

  Here, when the liquid resin composition 10A is heated, the thermoplastic resin 21 constituting the handle-forming particles 20A is melted by the curing heat of the liquid resin composition 10A. As a result, the handle-forming particles 20A adjacent to each other are bonded together by the melted thermoplastic resin 21, and a three-dimensionally continuous handle 20 is formed inside the thermosetting resin 10 as shown in FIG. .

  As described above, the handle 20 is formed by melting the handle-forming particles 20A including the magnetic filler 22 with the thermoplastic resin 21 and bonding them together. Therefore, in the resin molded body 100, the handle 20 includes the thermoplastic resin 21 and the magnetic filler 22 contained in the thermoplastic resin 21. However, the handle 20 does not have to be all three-dimensionally continuous as shown in FIGS. 1 and 4. For example, the handle-forming particle 20A is not bonded to the other handle-forming particle 20A, and the handle alone is used. 20 may be formed.

  In the method of manufacturing the resin molded body 100 according to the present embodiment, a liquid resin composition which is a precursor of the thermosetting resin 10 is a handle-forming particle 20A including the magnetic filler 22 and the thermoplastic resin 21 containing the magnetic filler 22. It has a dispersing step of dispersing inside the object 10A. The manufacturing method further forms a handle at a position corresponding to the magnetic field in the liquid resin composition 10A by applying a magnetic force M to the liquid resin composition 10A in which the handle-forming particles 20A are dispersed from a plurality of locations. It has a magnetic force application step of moving the particles 20A. And the said manufacturing method has a hardening process of hardening liquid resin composition 10A after a magnetic force provision process.

  In the manufacturing method of the present embodiment, a magnetic force M is applied to the liquid resin composition 10A in which the handle-forming particles 20A are dispersed to arrange the handle-forming particles 20A at a desired position, and then the liquid resin composition 10A. Is cured. As described above, since the plurality of pattern-forming particles 20A can be juxtaposed at a desired position by changing the application location of the magnetic field, it is possible to form the handle 20 having a continuous flow pattern by a simple method. it can. In addition, the number of handle portions 20 can be controlled by the amount of handle forming particles 20A dispersed in the liquid resin composition 10A. Therefore, it becomes possible to easily form the desired handle 20 by adjusting the amount of the handle-forming particles 20A and the magnetic field.

  As described above, the handle 20 of the resin molded body 100 is formed of the handle-forming particles 20 A in which the magnetic filler 22 is encapsulated with the thermoplastic resin 21. The magnetic filler 22 is used to move the pattern-forming particles 20A inside the liquid resin composition 10A, and the magnetic filler 22 itself does not impart a pattern. Therefore, the magnetic filler 22 only needs to contain an amount by which the pattern-forming particles 20A can move inside the liquid resin composition 10A, so that the content of the magnetic filler 22 can be reduced by increasing the applied magnetic force M. It becomes possible.

  In the manufacturing method of the present embodiment, the melting temperature of the thermoplastic resin 21 contained in the handle-forming particles 20A is preferably equal to or higher than the curing temperature of the liquid resin composition 10A. As a result, when the liquid resin composition 10A is heated and cured, the thermoplastic resin 21 contained in the handle-forming particles 20A can be melted by the curing heat of the liquid resin composition 10A. As a result, the thermoplastic resin 21 melted from the adjacent pattern-forming particles 20A is bonded, and it becomes possible to form a continuous flow pattern.

  The contents of the present embodiment have been described above, but the present embodiment is not limited to these descriptions, and it is obvious to those skilled in the art that various modifications and improvements are possible.

DESCRIPTION OF SYMBOLS 10 thermosetting resin 10A liquid resin composition 20 handle part 20A handle formation particle 21 thermoplastic resin 22 magnetic filler 30 fiber reinforcement 100 resin molding M magnetic force

Claims (5)

Thermosetting resin,
A handle included in the inside of the thermosetting resin;
Equipped with
The resin molded body, wherein the handle comprises a thermoplastic resin and a magnetic filler contained in the thermoplastic resin.   The resin molded body according to claim 1, further comprising a fiber reinforcing material dispersed inside the thermosetting resin.   The resin molding according to claim 1, wherein a melting temperature of the thermoplastic resin contained in the handle portion is equal to or higher than a curing temperature of a liquid resin composition which is a precursor of the thermosetting resin. A dispersing step of dispersing pattern-forming particles comprising a magnetic filler and a thermoplastic resin containing the magnetic filler in a liquid resin composition which is a precursor of a thermosetting resin;
A magnetic force application step of moving the pattern-forming particles to a position corresponding to the magnetic field in the liquid resin composition by applying a magnetic force from a plurality of locations to the liquid resin composition in which the pattern-forming particles are dispersed; ,
A curing step of curing the liquid resin composition after the magnetic force application step;
The manufacturing method of the resin molding which has.   The method for producing a resin molded product according to claim 4, wherein a melting temperature of the thermoplastic resin contained in the pattern-forming particles is equal to or higher than a curing temperature of the liquid resin composition.

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