JP2022039421A - Resin composite molding - Google Patents

Abstract

To provide a resin composite molding which has appearance and texture equivalent to a natural stone material, is excellent in workability and conveyance properties as compared to a natural stone material, and is a pebbly material.SOLUTION: A resin composite molding has: a first molding has a first molding layer covered with a first light permeable resin; and a second molding layer that is provided in contact with the first molding layer and is formed by mixing a second molding and a second resin.SELECTED DRAWING: Figure 1

Description

The present invention relates to a resin composite molded body molded from a composite material containing a resin.

Traditionally, tombstones and stone monuments have been manufactured by molding stone materials. In addition, among the stairs, bathtubs, and front tags of buildings, some relatively high-class products also use stone materials.

On the other hand, since stones generally have high hardness and are easily cracked, the cost for processing them into a desired shape tends to be high. In addition, since many stones have a large specific gravity, the cost for transportation tends to be high. Therefore, the product using stone has a problem that the cost is higher than the product having the same shape using resin or the like.

In order to solve these problems, for example, a stone-grained resin material in which dark-colored colored resin particles are dispersed in a matrix resin as a base material is also known. Such a stone-grained resin material is easier to process than a stone material, has a small specific density, and is easy to transport.
However, a general stone-grained resin material has a problem that unevenness is likely to occur on the surface after molding due to the difference in shrinkage between the matrix resin and the colored resin particles, and the surface smoothness is low.

Therefore, for example, in Patent Document 1. Colored particles using a thermoplastic polymer were dispersed in a matrix resin to give a stone-grained design, and these colored particles were softened under the temperature at which the matrix resin was polymerized. A stone-grained resin molded product is disclosed. As a result, it is said that the occurrence of surface irregularities during molding due to the difference in shrinkage between the colored particles and the matrix resin can be suppressed.

Japanese Unexamined Patent Publication No. 2001-354462

However, the stone-grained resin molded product as disclosed in Patent Document 1 is such that the difference in appearance and texture can be easily recognized as compared with the natural stone material. Therefore, a stone-grained material having an appearance and texture equivalent to that of a natural stone material and having excellent processability and transportability is desired.

The present invention has been made in consideration of such circumstances, and has the same appearance and texture as natural stone material, and has a stone grain tone that is superior in processability and transportability as compared with natural stone material. It is an object of the present invention to provide a resin composite molded body which is a material.

In order to solve the above problems, the present invention proposes the following means.
That is, the resin composite molded body of the present invention is provided with the first molded body in contact with the first molded layer in which the first molded body is covered with the light-transmitting first resin and one surface of the first molded layer, and the second molded body. It is characterized by having a second molded layer in which and a second resin are mixed.

According to the resin composite molded body of the present invention, an arbitrary material, for example, a stone material having a stone-grained appearance, is imitated by forming the second molded body by mixing the second molded body with the second resin as the second molded layer. The material can be formed lighter than stone. Then, by superimposing the second molded body on the second molded body and forming a first molded layer in which the first molded body having an arbitrary design is covered with the first resin having visible light transmission, an arbitrary material, for example, a stone material can be obtained. Any design can be easily formed on the imitated second molded body.

Further, in the present invention, the first resin and the second resin may be the same resin material.

Further, in the present invention, the first molded product may contain at least one of metal, fiber, and resin.

Further, in the present invention, an intermediate layer made of a third resin may be formed between the first molded layer and the second molded layer.

Further, in the present invention, a coating layer made of a light-transmitting fourth resin may be formed in contact with the other surface of the first molded layer.

Further, in the present invention, the coating layer may cover the side surface of the first molding layer along the thickness direction.

It should be noted that the other surface of the first molded layer and the side surfaces of the first molded layer and the second molded layer are imparted with smoothness or weather resistance, and have the ability to maintain the visualization of the design portion even in a harsh environment. It can also be configured as follows.

According to the present invention, it is possible to provide a resin composite molded body which is a stone-grained material having the same appearance and texture as a natural stone material and having excellent processability and transportability as compared with a natural stone material. can.

It is sectional drawing which shows the resin composite molded body which is 1st Embodiment of this invention. It is sectional drawing which shows the resin composite molded body which is 2nd Embodiment of this invention. It is sectional drawing which shows the resin composite molded body which is 3rd Embodiment of this invention. It is sectional drawing which shows the resin composite molded body which is 4th Embodiment of this invention. It is an external photograph which shows the resin composite molded body of Example 1. FIG. It is an external photograph which shows the 1st molded layer of Example 1. FIG. It is an external photograph which shows the resin composite molded body of Example 2. It is an external photograph which shows the resin composite molded body of Example 3. FIG. It is an external photograph which shows the resin composite molded body of Example 4. It is a photograph which shows the state of the test piece of the verification example 1.

Hereinafter, the resin composite molded product according to the embodiment of the present invention will be described with reference to the drawings. It should be noted that each of the embodiments shown below is specifically described in order to better understand the gist of the invention, and is not limited to the present invention unless otherwise specified. In addition, the drawings used in the following description may be shown by enlarging the main parts for convenience in order to make the features of the present invention easy to understand, and the dimensional ratios of each component are the same as the actual ones. It is not always the case.

(First Embodiment)
FIG. 1 is a cross-sectional view showing a resin composite molded product according to the first embodiment of the present invention.
The resin composite molded body 10 of the present embodiment is provided in contact with a first molded layer (design layer) 13 in which the first molded body 11 is covered with the first resin 12 and one surface 13a of the first molded layer 13. It has a second molded layer (base material layer) 16 in which the second molded body 14 and the second resin 15 are mixed.

The first molded body 11 has an arbitrary design, for example, when the resin composite molded body 10 is used for a tombstone or a nameplate, a sheet-like material on which an arbitrary character is printed, or an arbitrary pattern when used as a decorative material. A sheet-like material or the like in the shape of such as can be used.

As the forming material of the first molded body 11, fibers, metals, resins and the like can be used. For example, when fibers are used as the forming material of the first molded body 11, it is preferable to use one that can be impregnated with the first resin 12.

Specific examples of the forming material of the first molded body 11 include a cloth material made of natural fiber or synthetic fiber having an arbitrary design, a metal film made of aluminum, stainless steel, copper or the like in the shape of an arbitrary design, or any shape. Examples thereof include a resin sheet made of a designed acrylic resin, vinyl chloride resin, ABS resin, olefin resin and the like.

The first resin 12 is formed of a light-transmitting resin. The light-transmitting resin referred to here means that when the resin composite molded body 10 is viewed from the other surface 13b of the first molded layer 13, the first molded body 11 covered with the first resin 12 is exposed to visible light. For example, it is formed of a resin having a degree of transparency that can be visually recognized under natural light outdoors during the daytime. Therefore, the first resin 12 is such that the first molded body 11 can be visually recognized according to the thickness from the other surface 13b of the first molded layer 13 to the first molded body 11 and the color tone of the first molded body 11. A resin having light transmission is selected.

Specific examples of the material for forming the first resin 12 include acrylic resin, epoxy resin, urethane resin and the like. Among these resins, colorless transparent or colored transparent resins having visible light transmission can be used.

The first resin 12 may have weather resistance. Having weather resistance suppresses deterioration over time and ensures its visibility.

The other surface 13b of the first molded layer 13 having such a configuration is JIS Z 8751 even after the blank is irradiated with ultraviolet rays having a center wavelength of 295 to 450 nm and an intensity of 80 (mW / cm ² ) for 150 hours. The mirror glossiness calculated by the method specified in 1) is maintained at least 50% or more.

The second molded body 14 is a material that simulates a desired constituent material when the resin composite molded body 10 is visually recognized. For example, when the resin composite molded body 10 simulates a stone material used for a tombstone, a front cover, or the like, dark resin grains, rock grains, metal grains, or the like that exhibit a stone grain tone when mixed with the second resin 15 are used.

The shape of the second molded body 14 may be selected according to the constituent material simulated by the resin composite molded body 10, and other than the above-mentioned granules, for example, various shapes such as a foil shape, a thin plate shape, and an indefinite shape. Can be used.

As the second resin 15, a resin capable of mixing the second molded body 14, for example, an epoxy resin or a urethane resin can be used. The second resin 15 may be visible light transmissive or visible light light-shielding property, and may be a resin colored in various colors according to the appearance pattern of the constituent material simulated by the resin composite molded body 10. It is preferable to use it.

Further, as the second resin 15, it is preferable to use a resin having a bonding property with respect to the first resin 12. As a result, the first molded layer (design layer) 13 and the second molded layer (base material layer) 16 can be integrated without forming an adhesive layer or the like.

Further, when a resin having visible light transmission is used as the second resin 15, the same resin as the first resin 12 can be used. Thereby, the first molded layer (design layer) 13 and the second molded layer (base material layer) 16 can be easily integrated.

According to the resin composite molded body 10 of the present embodiment having the above-described configuration, the second molded body 14 is mixed with the second resin 15 to form the second molded body 16 as the base material layer. For example, a material imitating a stone material having a stone-grained appearance can be formed to be lighter than the stone material. For example, if rock grains are mixed with the second resin 15 as the second molded body 14, the second molded body 14 having an appearance closer to that of the stone material and being a base material layer lighter than the stone material is formed.

Then, by superimposing the second molded body 14 on the second molded body 14 and forming the first molded layer 13 in which the first molded body 11 having an arbitrary design is covered with the first resin 12 having visible light transmission, an arbitrary material is formed. For example, any design can be easily formed on the second molded body 14 that imitates a stone material.

As a result, the resin composite molded body 10 of the present embodiment has an arbitrary design formed on the surface side based on a resin that is lightweight and easy to be molded and processed into an arbitrary shape, for example, a stone-grained appearance. It is possible to form a molded product having.

Such a resin composite molded body 10 has a stone-grained appearance similar to that of an actual stone material as compared with a stone monument formed by using a stone material, for example, but the labor and cost of scraping the surface like the stone material are required. It is possible to easily form an arbitrary design, for example, a character, etc., easily to process the outer shape, and it is lightweight and excellent in transportability.

Further, by covering the second molding layer 16 which is the base material layer with the first molding layer (design layer) 13 having the first resin 12 having visible light transmission, for example, the second molding in which rock grains and the like are mixed is mixed. Even if the surface of the layer 16 is uneven, the other surface 13b of the first molded layer 13, which is the surface of the resin composite molded body 10, can be smoothed, and the resin composite molded body 10 having excellent surface smoothness can be realized. can.

In the present embodiment, as the second molded layer 16 to be the base material layer, a stone material having a stone-grained appearance is mentioned, but in addition to this, the second molded body is formed on the second resin 15. 14 can be formed so as to have an arbitrary appearance (texture) as a base material, such as one having a metallic appearance mixed with metal powder.

(Second Embodiment)
Next, a second embodiment of the resin composite molded product of the present invention will be described. In the following description, the same configuration as that of the first embodiment described above will be assigned the same number, and duplicate description will be omitted.
FIG. 2 is a cross-sectional view showing a resin composite molded product according to a second embodiment of the present invention.
In the resin composite molded body 20 of the present embodiment, a first molded body (design layer) 13 in which the first molded body 11 is covered with the first resin 12, and the second molded body 14 and the second resin 15 are mixed. It has a second molded layer (base material layer) 16 and an intermediate layer 17 formed between the first molded layer (design layer) 13 and the second molded layer (base material layer) 16.

The intermediate layer 17 is formed of a third resin. As the third resin constituting the intermediate layer 17, a resin having bondability to the first molded layer (design layer) 13 and the second molded layer (base material layer) 16, for example, acrylic resin, epoxy resin, and urethane. A resin, a vinyl chloride resin, or the like can be used.

Further, as the third resin, it is preferable to use a resin having visible light transmission so that the appearance of the second molded layer 16 as the lower layer, for example, the stone-grained appearance can be visually recognized from the first molded layer 13 side. As the third resin constituting the intermediate layer 17, the same resin as the first resin 12 of the first molding layer 13 and the second resin 15 constituting the second molding layer 16 can be used.

By forming such an intermediate layer 17, the resin composite molded body 20 is formed on the surface of the second molded layer (base material layer) 16 when, for example, the thickness of the first molded layer (design layer) 13 is thinly molded. Deformation of the first molding layer (design layer) 13 is prevented, such as the unevenness being reflected on the first molding layer 13 as it is. The unevenness of the surface of the second molded layer (base material layer) 16 is alleviated by the intermediate layer 17, and the other surface (outer surface) 13b side of the first molded layer 13 is smoothed to clarify the design of the first molded body 11. Can be made visible. Further, since the thickness can be reduced, if the resin 12 is expensive, the cost can be reduced.

(Third Embodiment)
Next, a third embodiment of the resin composite molded product of the present invention will be described. In the following description, the same configuration as that of the second embodiment described above will be assigned the same number, and duplicate description will be omitted.
FIG. 3 is a cross-sectional view showing a resin composite molded product according to a third embodiment of the present invention.
In the resin composite molded body 30 of the present embodiment, the first molded body 11 is covered with the first resin 12, the first molded layer (design layer) 13, and the second molded body 14 and the second resin 15 are mixed. It has a second molded layer (base material layer) 26 and an intermediate layer 17 formed between the first molded layer (design layer) 13 and the second molded layer (base material layer) 26.

The second molded layer (base material layer) 26 is formed in a hollow cylindrical shape, and the inside is hollow.
According to the resin composite molded body 30 of the third embodiment, for example, light is irradiated from the opening end side of the hollow second molded layer (base material layer) 26 toward the first molded layer (design layer) 13. As a result, when viewed from the other surface 13b side of the first molded layer 13, the first molded body 11 is clearly displayed so as to be illuminated by the backlight. Therefore, it is possible to realize the resin composite molded body 30 having excellent visibility of the first molded layer (design layer) 13.

(Fourth Embodiment)
Next, a fourth embodiment of the resin composite molded product of the present invention will be described. In the following description, the same configuration as that of the first embodiment described above will be assigned the same number, and duplicate description will be omitted.
FIG. 4 is a cross-sectional view showing a resin composite molded product according to a fourth embodiment of the present invention.
The resin composite molded body 40 of the present embodiment is provided with the first molded body 11 in contact with the first molded layer (design layer) 13 covered with the first resin 12 and the other surface 13b of the first molded layer 13. A second molded layer (base material layer) 16 in which the second molded body 14 and the second resin 15 are mixed, and a coating layer 18 provided in contact with the other surface 13b of the first molded layer 13 are provided. is doing.

The coating layer 18 is formed of a fourth resin. As the fourth resin constituting the coating layer 18, the first molding layer 13 has visible light transmission visible from the surface of the coating layer 18 via the first resin 12 of the first molding layer (design layer) 13. However, a resin having a bondability to the first molding layer (design layer) 13, for example, an acrylic resin, an epoxy resin, a urethane resin, a vinyl chloride resin, or the like can be used.

Further, as the fourth resin, it is preferable to use a resin having visible light transmission so that the appearance of the second molded layer 16 as the lower layer, for example, the stone-grained appearance can be visually recognized from the first molded layer 13 side. As the fourth resin, the same resin as the first resin 12 constituting the first molding layer 13, the second resin 15 constituting the second molding layer 16, and the third resin constituting the intermediate layer 17 is used. You can also.

In the resin composite molded body 40, even when the thickness of the first molded layer (design layer) 13 is thinly molded by forming such a coating layer 18, the first molded layer 13 is damaged by external stress. It is also possible to prevent deterioration of the first molded layer 13 due to ultraviolet rays or rainwater. Further, after the first molded layer 13 and the second molded layer 16 are individually molded, they are combined and arranged in a mold, and the coating layer 18 is used to cover and solidify the first molded layer 13 and the second molded layer 16 to improve workability at the time of manufacturing.

The coating layer 18 may be formed so as to cover the other surface 13b of the first molding layer 13 and further cover the side surface of the resin composite molded body 40 along the thickness direction (see the dotted line region in FIG. 4). .. As a result, it is possible to prevent rainwater or the like from infiltrating between the layers of each layer from the side surface of the resin composite molded body 40 in the thickness direction, and it is possible to further improve the weather resistance of the resin composite molded body 40.

Although some embodiments of the present invention have been described above, these embodiments are presented as examples and are not intended to limit the scope of the invention. These embodiments can be implemented in various other embodiments, and various omissions, replacements, and changes can be made without departing from the gist of the invention. These embodiments and variations thereof are included in the scope of the invention described in the claims and the equivalent scope thereof, as are included in the scope and gist of the invention.

An example of producing the resin composite molded product of the present invention is shown.
(Example 1)
A stone-grained relief was created as the resin composite molded body having the configuration of the first embodiment described above.
As the first molded body of the first molded layer (design layer), a design (a pattern of a spirit cow in this embodiment) was printed on a fiber, and this fiber was coated with an acrylic resin as the first resin.
Stone grains were used as the second molded body of the second molded layer (base material layer), and the stone grains were mixed with the urethane resin as the second resin. Then, the first molded layer and the second molded layer were joined to obtain the resin composite molded body of Example 1.

FIG. 5 shows an external photograph of the obtained resin composite molded product. Further, an external photograph of the second molded layer is shown in FIG. According to Example 1, a white granite-like relief having a stone-grained appearance and a design on the surface was obtained.

(Example 2)
A stone-grained nameplate was created as the resin composite molded body having the configuration of the fourth embodiment described above.
As the first molded body of the first molded layer (design layer), a design (name, cat pattern in this embodiment) was applied to a carbon fiber sheet, and this sheet was coated with an acrylic resin as the first resin.

Stone grains were used as the second molded body of the second molded layer (base material layer), and the stone grains were mixed with the urethane resin as the second resin. Then, the first molded layer and the second molded layer were joined, and the surface of the first molded layer (design layer) was coated with an unsaturated polyester resin as a coating layer.

FIG. 7 shows an external photograph of the obtained resin composite molded product. According to the second embodiment, a black granite-like nameplate having a stone-grained appearance and a design on the surface was obtained.

(Example 3)
As Example 3, a resin composite molded body having the above-mentioned second embodiment was prepared. An example of a method for manufacturing this resin composite molded product will be described.
First, a weather-resistant epoxy resin (first resin) was injected into a cylindrical plastic container, and then defoaming treatment was performed. Next, after injecting the weather-resistant epoxy resin (first resin), a high-quality paper (first molded body) on which the design image is printed is placed, and heat treatment is performed in an oven to obtain the high-quality paper (first molded body). A first molded layer covered with a weather-resistant epoxy resin (first resin) was obtained.

Next, after injecting a general-purpose epoxy resin (third resin) into one surface side of the first molded layer, heat treatment was performed in an oven to form an intermediate layer on one surface side of the first molded layer.

Next, Oiso sand (second molded body) is put into the intermediate layer side, polyurethane resin (second resin) is further injected and mixed, plugged with a flat silicon sheet, and cured to form the intermediate layer. A second molded layer in contact was obtained.

Through such a step, a resin composite molded product of Example 3 having a first molded layer and a second molded layer joined via an intermediate layer was obtained. FIG. 8 shows an external photograph of the resin composite molded product of Example 3. According to Example 3, it was possible to obtain a cylindrical resin composite molded product having a stone-grained appearance, a green surface, and a design on the surface side.

(Example 4)
As a resin composite molded body based on the configuration of the third embodiment described above, a hollow cylindrical display body having a part thereof as an empty wall was created.
As the first molded body of the first molding layer (design layer), a design (company name in this embodiment) is applied to high-quality paper, and this sheet is coated with a weather-resistant epoxy resin as the first resin in a circular molding mold. After degassing by vacuum defoaming, it was cured by heating to obtain a disk-shaped transparent first molded product.

Next, a general-purpose epoxy resin layer was formed as an intermediate layer on one surface of the first molded body, and then a cylindrical silicon rubber (molding mold) was placed on the general-purpose epoxy resin layer. Oiso sand (second molded body) is filled around this silicone rubber, black polyurethane resin (second resin) is injected and mixed, plugged with a flat silicone sheet, and cured to form a cylindrical shape. The second molded layer of the above was obtained.

FIG. 9 shows an external photograph of the obtained resin composite molded product. According to Example 4, a cylindrical display body was obtained in which one open surface side of a cylindrical second molded body having a black stone-grained appearance was covered with a light-transmitting first molded body. ..

(Verification example 1)
Next, the weather resistance (ultraviolet resistance) of the resin composite molded product having the configuration of the first embodiment was verified.
A test piece (3 cm square, thickness 2 mm) made of the weather-resistant epoxy resin (first resin) used in Example 3 was prepared. Then, the mirror glossiness of the prepared test piece (blank) was measured. Next, the mirror glossiness of the test piece (UV150H) obtained by irradiating the test piece (blank) with ultraviolet rays for 150 hours was measured. The state of the test piece is shown in FIG. The upper part of FIG. 10 shows a test piece (blank), and the lower part shows a test piece (UV150H).

UV irradiation: Eye Super UV Tester (manufactured by Iwasaki Electric Co., Ltd. (UV light source: metal hydrolamp), black panel temperature: 63 ° C, humidity 50%, water spray spray time: 15 seconds / hour, irradiation intensity: 80 mW
Mirror gloss measurement: Gloss checker IG331 (manufactured by HORIBA, Ltd.), measuring angle 60 ° meter, standard plate gloss: 90

As a result of the measurement in this way, the test piece (blank) had a glossiness of 83, and the test piece (UV150H) had a glossiness of 77. Even after irradiation with ultraviolet rays for 150 hours, the rate of decrease in mirror gloss was suppressed to less than 10%. Therefore, it was confirmed that the resin composite molded body in which the first molded layer was formed by using such a weather resistant epoxy resin (first resin) has excellent weather resistance (ultraviolet resistance).

(Verification example 2)
Next, the surface smoothness of the resin composite molded product having the configuration of the first embodiment was verified.
Using the resin composite molded body of Example 3, the front surface of the second molded layer (the surface on the intermediate layer side), the back surface of the second molded layer (the opposite surface on the intermediate layer side), and the surface of the first molded layer (weather resistance). The surface roughness Ra of each of the epoxy resins) was measured.
Surface roughness measurement: Surface roughness measuring machine SJ-210 (manufactured by Mitutoyo Co., Ltd.)

As a result of measuring the surface roughness with the above-mentioned measuring machine, the surface roughness Ra of the surface of the second molded layer is 2.949 (μm), and the surface roughness Ra of the back surface of the second molded layer is 6.231 (μm). The surface roughness Ra of the surface of the first molded layer was 0.080 (μm).

Therefore, according to the resin composite molded body of the present embodiment, the first molded layer having the first resin is overlaid on the second molded layer having a large surface roughness in which rock grains and the like are mixed with the second resin. As a result, it was confirmed that the large surface roughness of the second molded layer was not reflected on the surface of the first molded layer, and a resin composite molded body having a smooth surface and excellent visibility of the design could be obtained. ..

10, 20, 30, 40 ... Resin composite molded body 11 ... First molded body 12 ... First resin 13 ... First molded layer 14 ... Second molded body 15 ... Second resin 16 ... Second molded layer 17 ... Intermediate layer 18 ... Coating layer

Claims (6)

A first molded layer in which the first molded body was covered with a light-transmitting first resin, and
A resin composite molded body provided in contact with one surface of the first molded layer and having a second molded body in which a second molded body and a second resin are mixed. The resin composite molded product according to claim 1, wherein the first resin and the second resin are the same resin material. The resin composite molded product according to claim 1 or 2, wherein the first molded product contains at least one of a metal, a fiber, and a resin. The resin composite molded product according to any one of claims 1 to 3, wherein an intermediate layer made of a third resin is formed between the first molded layer and the second molded layer. .. The resin composite molded product according to any one of claims 1 to 4, wherein a coating layer made of a light-transmitting fourth resin is formed in contact with the other surface of the first molded layer. The resin composite molded body according to claim 5, wherein the coating layer covers a side surface of the first molded layer along the thickness direction.

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