JP2707900B2 - Recycled resin molded product and its manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a resin molded product using a recycled resin recycled from waste resin as a molding material, and more particularly to a resin molded product suitable as a resin molded product for vehicles, and a method for producing the same.

[0002]

2. Description of the Related Art A sprue portion, a runner portion, a defective molded product, or a defective product subjected to a surface treatment such as painting, which is generated by injection molding of a thermoplastic resin, has been subjected to a heat history once. Conventionally, it has been generally discarded as resin waste material due to restrictions on its use. However, from the standpoint of environmental protection and resource saving, an attempt has been made to recycle a reusable portion of these resin waste materials as a recycled resin and use it as a molding material.

[0003] However, since such a recycled resin is subjected to a thermal history, its physical properties, particularly its mechanical strength, are reduced.
The same physical properties as a new resin cannot be obtained, and the physical property values vary. In addition, since this recycled material has a part where the cured state becomes semi-permanent due to foreign matter such as dust or overheating when receiving a heat history, the fluidity is reduced even if it is reheated and melted, and molding becomes difficult. Have difficulty. And even if the molding is performed, the whole is not uniform, so the surface is roughened, the degree of the roughening is not regular, the backside treatment such as painting is difficult, and the whole has a uniform roughness. A molded article with excellent appearance cannot be obtained.

[0004]

SUMMARY OF THE INVENTION An object of the present invention is to solve the above problems by fixing a sheet material made of a new resin to the surface of a molded article, thereby improving the mechanical strength of the molded article. And to obtain a recycled resin molded product having a uniform surface.

[0005] Another object of the present invention is to provide a recycling method capable of easily and efficiently producing the above-mentioned recycled resin molded product with low flow resistance using a molding die which does not require surface accuracy of the die surface. An object of the present invention is to obtain a method for producing a resin molded product.

[0006]

SUMMARY OF THE INVENTION The present invention relates to the following recycled resin molded article and a method for producing the same. (1) A molded article body made of a thermoplastic resin containing a recycled resin and a new thermoplastic resin laminated so as to cover the surface of the molded article body, to form a uniform outer surface.
It consists of a sheet material that Yusuke, have a cavity mold and the core mold
In the forming die, arrange the sheet material so that the surface faces the die.
Thermoplastic resin containing recycled resin
In the state where it is arranged between the back surface of the material and the other mold surface, the surface is molded by integrating by heating and pressing.
The surface of the product adheres to the back of the softened sheet material,
The surface of the material is affected by the rough surface of the molded article
Recycled resin molded article which is characterized that you have had a rather uniform surface. (2) The molded article according to the above (1), wherein the molded article main body contains a fibrous or powdery reinforcing material. (3) The molded article according to the above (1) or (2), wherein the sheet material has been subjected to a surface treatment. (4) A step of inserting a sheet material made of a new thermoplastic resin and having both front and back surfaces into a cavity of a molding die and disposing the surface so as to face the mold surface; A molding resin to be introduced between the back surface of the sheet material in the cavity and the other mold surface, and the introduced molding resin is filled into the cavity by pressing at a temperature equal to or higher than the softening point, Forming a molded article main body and fixing the molded article body to a sheet material at the same time. (5) The method according to the above (4), wherein the molding resin contains a fibrous or powdery reinforcing material. (6) The method according to the above (4) or (5), wherein the front surface or the back surface of the sheet material is subjected to a surface treatment.

In the present invention, the term “recycled resin” refers to a resin material that is recycled from a resin waste material as a molding resin. Such resin materials include thermoplastic resin such as sprue portion, runner portion, defective molded product, defective product after surface treatment, trimmed offcuts and the like generated by injection molding,
Examples include cured products of thermosetting resins and pulverized products of reaction molded products.

In the present invention, the molding resin for molding the molded article main body is a thermoplastic resin containing the above-mentioned recycled resin. Such a molding resin may be composed of only a recycled resin, or may be a compound of a recycled resin and a new resin. In any case, it is necessary to include a thermoplastic resin. Therefore, when the recycled resin is a thermosetting resin, it is used by being mixed with another thermoplastic resin.

The above-mentioned molding resin preferably contains a fibrous or powdery reinforcing material. Examples of the fibrous reinforcing material include short fibers such as glass fiber, carbon fiber, aramid fiber, and vegetable fiber, and whiskers such as silicon carbide, silicon nitride, potassium titanate, and aluminum borate. Examples of the powdery reinforcing material include talc, carbon black, and silica. Of these,
Fibrous reinforcement is preferred. When these reinforcing materials are mixed with a recycled resin in a state of being mixed with a new thermoplastic resin, the effect of improving the mechanical strength of the recycled resin is great.
The molding resin may contain other components in addition to these components.

In the present invention, the sheet material laminated on the molded article main body is made of a new thermoplastic resin, but may contain other components. As the thermoplastic resin, a resin having a fixing property (welding property) with the recycled resin is preferable, and a resin of the same type as the recycled resin is preferable. In the case where the sheet material does not have fixability, it can be fixed by forming an adhesive layer on the back surface of the sheet material in advance. When the sheet material is subjected to a coloring treatment on its surface, it is preferable that the sheet material is made opaque or an opaque fixing layer is interposed between the sheet material and the molded product main body so that the molded product main body cannot be visually recognized from the outside.

[0011] The recycled resin molded article of the present invention is formed of a molded article body made of a thermoplastic resin containing the recycled resin and a new thermoplastic resin , and has a uniform outer surface.
It consists of a sheet material that Yusuke, have a cavity mold and the core mold
In the forming die, arrange the sheet material so that the surface faces the die.
Thermoplastic resin containing recycled resin
Heating while placed between the back side of
By integrating the pressure molding, molding roughened
The surface of the product adheres to the back of the softened sheet material,
The surface of the material is affected by the rough surface of the molded article
That it has no uniform surface. By this heating and pressing molding the at least part of the resin forming the molding body and the sheet material pressurized with flowable state (including softening), which is secured integrally to both resins, injection molding, A molding method involving heating and pressurization in a mold having a cavity mold and a core mold, such as compression molding, can be adopted.

In the present invention, when a surface treatment such as painting is applied to a molded product, the sheet material may be subjected to a surface treatment in advance. As the surface treatment, spray, dipping, coating by flow coating etc., vapor deposition, sputtering, vacuum metallization by ion plating, etc.,
There are plating, hard coat treatment and the like. These surface treatments can be formed on the outer surface side of the sheet material,
It can also be formed on the molded article body side. When it is formed on the molded article main body side, it is preferable to form a fixed layer having excellent adhesion to the molded article main body. When the sheet material is transparent, the fixing layer can be used as an opaque colored layer to enhance the decorativeness and prevent the molded article main body from being visually recognized from the outside.

[0013]

The recycled resin molded article of the present invention is made of a sheet material made of a new thermoplastic resin and having both front and back surfaces.
Insert the molding resin into the cavity of the mold so that the surface faces the mold surface, and insert the molding resin made of thermoplastic resin containing recycled resin between the back surface of the sheet material in this cavity and the other mold surface. It is manufactured by introducing and introducing the molding resin under pressure at a temperature equal to or higher than the softening point, filling the cavity, forming a molded product main body, and simultaneously fixing and integrating with a sheet material. In this case, the molding resin may be heated and introduced into the cavity in a flowable state, and may be pressurized while being maintained at or above the softening temperature, or after the molding resin is introduced into the cavity and heated to or above the softening temperature. Pressure may be applied. When heating after introduction, high-frequency heating can be used.

In the recycled resin molded article thus manufactured, the surface of the molded article body formed by the recycled resin is unevenly roughened, but the back surface of the sheet material and the surface of the molded article body are fixed. Thereby, the mechanical strength of the molded article is improved, and a recycled resin molded article having a uniform surface is obtained.

In the above manufacturing method, since the surface of the molded product is determined in advance by the surface of the sheet material to be used, the molding can be performed using a molding die having a low surface accuracy (high roughness) on the die surface. In addition, the surface roughness of the mold surface is less likely to be transferred to the surface of the sheet material, and a molded product with high surface accuracy (low roughness) can be obtained. Recycled resin has low fluidity because it has a partially cured part, but when the sheet material is placed on the mold surface and the molding resin is introduced, the sheet material acts as a heat insulating layer and rapidly heats the mold. Quenching hardening of the resin is small, and the flow resistance of the resin is small.
For this reason, the moldability is improved, and the molding can be easily performed.

[0016]

Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 is a perspective view showing a recycled resin molded product of an embodiment, FIG. 2 is a sectional view taken along the line AA, and FIG. 3 is an enlarged view of a part thereof.

In FIG. 1, reference numeral 1 denotes a recycled resin molded product which is applied to a finisher as a resin molded product for a vehicle. In the molded article 1, a sheet material 5 made of a new transparent thermoplastic resin is integrated by heat molding on the outer surface side of a molded article main body 4 composed of a thermoplastic resin 2 containing a recycled resin and a fibrous reinforcing material 3, The whole is integrally formed in a container shape. The reinforcing material 3 is dispersed in the new resin and is uniformly mixed with the recycled resin.

The sheet member 5 has a display portion 6 formed on the back surface, that is, on the molded product main body 4 side, as a surface treatment layer by painting. A fixing layer 7 made of an opaque colored layer is formed between the sheet material 5 and the display section 6 and the molded article main body 4, and is fixed so as to be integrated with the molded article main body 4.
Reference numeral 8 denotes a lock hole formed in the molded product 1.

Since the thermoplastic resin 2 containing the recycled resin is reinforced by the fibrous reinforcing material 3, the mechanical strength of the recycled resin molded article 1 is greater than that of the recycled resin alone. In this case, since the fibrous reinforcing material 3 is mixed with the recycled resin in a state of being uniformly dispersed in the new resin, the fibrous reinforcing material 3 uniformly enters between the hardened particles formed in the recycled resin, and cracks between the particles. Etc. are prevented.

The interface between the molded article main body 4 and the sheet material 5 is roughened by the partially cured recycled resin, but is fixed to the fixing layer 7 of the sheet material 5 to form a molded article having a uniform surface. 1 is obtained, and the mechanical strength is further increased.

The interface of the molded article main body 4 is roughened.
It is blocked by the opaque fixing layer 7 and is not visible from the outside. Since the fixing layer 7 is colored, the decorative property is enhanced. Further, since the display unit 6 is visually recognized through the transparent sheet material 5, a deep display is obtained.

FIGS. 4 to 11 show the manufacturing method of the embodiment. FIG. 4 is a perspective view of the sheet material, FIG. 5 is a sectional view taken along the line BB of FIG. Cross section of the
FIG. 8 is a perspective view of the same, and FIG. 9 shows an injection mold.
FIG. 10 is a sectional view corresponding to DD, and FIG.
1 is a cross-sectional view of an injection-molded product corresponding to CC of FIG.

In manufacturing the recycled resin molded product 1, first, as shown in FIGS. 4 and 5, a display portion 6 is formed on the back surface of a sheet material 5 made of a new thermoplastic resin by coating printing or the like. Is formed on the back surface side of the sheet material 5 containing the opaque colored layer by coating or the like.

Next, the sheet material 5 is formed into a shape similar to or corresponding to the molded product 1 by vacuum forming, pressure forming, or the like, to obtain a sheet material molded product 11 shown in FIG. 12 is a concave portion corresponding to the lock hole 8. This sheet material molding 11 is trimmed while leaving a part of the flange portion 13 to be in the state of FIGS. 7 and 8.

The thus obtained sheet material molded product 11 is
As shown in FIGS. 9 and 10, the sheet material 5 is inserted into the cavity 18 formed between the cavity mold 16 and the core mold 17 of the injection mold 15 so that the outer surface side of the sheet material 5 faces the mold surface 19 of the cavity mold 16. To place. In this state, the mold is clamped, and the recess 12 of the sheet material molding 11 is
6 and the core mold 17 for fixing.

Thereafter, the molding resin 21 comprising the thermoplastic resin 2 containing the recycled resin and the fibrous reinforcing material 3 is heated and allowed to flow through an injection nozzle (not shown).
It is injected from the runner 22 through the gate 23 between the back surface of the sheet material molded product 11 of the cavity 18 and the other mold surface 20.
At this time, the molding resin 21 is pressurized while being maintained at a temperature equal to or higher than the softening point by the injection pressure to fill the cavity 18 to form the molded article main body 4 and, at the same time, to fix the fixing layer 7 of the sheet material molded article 11. And fix it.

At this time, since the molding resin 21 contains the partially cured product of the recycled resin and the reinforcing material 3, the interface is roughened, but at least the back surface of the sheet material 5 and the fixing layer 7 are in a softened state, Since the application resin is pressed, both are fixed on the roughened surface. At this time, since the front surface of the sheet material 5 does not soften as much as the back surface and maintains a certain degree of hardness, it is less affected by the rough surface of the interface of the molded product main body. The degree of transfer is low.

When the mold is opened, an injection molded product 24 as shown in FIG.
Is punched, and the flange portion 13 is trimmed by the cutter 26, whereby the recycled resin molded product 1 shown in FIGS. 1 to 3 is obtained.

In the above manufacturing method, the surface of the molded article 1 is determined in advance by the surface of the sheet material 5 to be used.
9, the surface roughness of the mold surface 19 is less likely to be transferred to the surface of the sheet material 5 even when molding is performed using the injection molding die 15 having a low surface accuracy (high roughness). A high molded product 1 is obtained. The recycled resin generally has low fluidity because a partially cured portion remains, but when the sheet material 5 is arranged on the mold surface 19 and the molding resin 21 is introduced, the sheet material 5 serves as a heat insulating layer. In addition, since curing due to rapid cooling of the resin is suppressed, the flow resistance of the resin is reduced. For this reason, the moldability is improved, and the molding can be easily performed.

In the above-described embodiment, in order to form the container-like molded product 1, the sheet material 5 is preliminarily formed into a sheet material molded product 11, which is inserted into the molding die 15, and the molded product body is formed. Although the molding of the molded article 4 was performed, when the molded article 1 has a flat plate shape or a shape close to this, the molded article main body 4 can be molded without molding the sheet material 5 in advance.

In the above embodiment, the sheet material 5 is fixed only on the outer surface side of the molded article. However, when the back surface is also visible, the sheet material can be fixed on the back surface side. In this case, the two sheet materials are arranged so that the surface side of the sheet material 5 faces the mold surfaces on both sides of the molding die, and the molded product body is molded.

Further, in the above-described embodiment, the example in which the molded article main body is molded by injection molding has been described. However, compression molding, injection compression molding, or other molding methods can be used. In addition, the present invention is not limited to molded articles for vehicles, and can be applied to other molded articles in general. In this case, it is possible to determine the shape and structure according to each purpose and determine the arrangement of the sheet material.

[0033]

As described above, the recycled resin molded article of the present invention is formed of a molded article body made of a thermoplastic resin containing a recycled resin, and a new thermoplastic resin , and has a uniform shape.
Consists of a sheet material that having a outer surface, cavity and co
In a mold having a mold, the surface of the sheet material faces the mold surface
Thermoplastic resin containing recycled resin
The grease is placed between the back of the sheet material and the other mold surface
In, by integrating by hot pressing, roughening
The surface of the molded body adheres to the back of the softened sheet material
However, the surface of the sheet material is affected by the rough surface of the
Kicking because have a uniform surface without, even if the surface of the molded article of the recycled resin is roughened, and fixed to the sheet material, improves the mechanical strength of the molded article by which a uniform surface A recycled resin molded product having the same can be obtained.

Further, according to the method for producing a recycled resin molded product of the present invention, the above-mentioned sheet material is inserted into a molding die, and the molding material containing the recycled resin is placed in a state where the surface thereof faces the die surface. Since the resin is introduced and pressed at a temperature above the softening point to mold the molded product body and simultaneously adhere to the sheet material, a low flow resistance is obtained by using a molding die that does not require surface accuracy on the die surface. Thus, the recycled resin molded article as described above can be easily and efficiently manufactured.

[Brief description of the drawings]

FIG. 1 is a perspective view of a recycled resin molded product of an embodiment.

FIG. 2 is a sectional view taken along line AA of FIG.

FIG. 3 is a partially enlarged view of FIG. 2;

FIG. 4 is a perspective view of a sheet material.

FIG. 5 is a sectional view taken along line BB of FIG. 4;

FIG. 6 is a sectional view of a sheet material molded product.

FIG. 7 is a cross-sectional view of a formed sheet material after trimming.

FIG. 8 is a perspective view of a sheet material molded product.

9 is a cross-sectional view corresponding to CC of FIG. 8 showing an injection mold.

FIG. 10 is a sectional view corresponding to DD in FIG. 8, showing an injection mold.

FIG. 11 is a cross-sectional view corresponding to CC of FIG. 8 showing an injection molded product.

[Explanation of symbols]

 REFERENCE SIGNS LIST 1 Recycled resin molded product 2 Thermoplastic resin containing recycled resin 3 Fibrous reinforcing material 4 Molded product main body 5 Sheet material 6 Display unit 7 Fixed layer 11 Sheet material molded product 13 Flange 15 Injection molding 16 Cavity mold 17 Core mold 18 Cavity 19, 20 Mold surface 21 Molding resin 25 Punch 26 Cutter

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁶ Identification code Agency reference number FI Technical display location B29K 105: 26

Claims (6)

(57) [Claims] And 1. A molding body made of a thermoplastic resin containing a recycled resin, formed from the new thermoplastic resin is laminated so as to cover the surface of the molding body, uniform outer
It consists of a sheet material that have a surface, in a mold having a cavity mold and the core mold, the sheet material
Recycled resin placed so that the surface faces the mold surface
Between the back surface of the sheet material and the other mold surface
The arrangement state, the integrated child by hot pressing
As a result, the surface of the roughened molded product
Sheet material and the sheet material surface
Recycled resin molded article which is characterized that you have a uniform surface without being affected by the surface. 2. The molded article according to claim 1, wherein the molded article body contains a fibrous or powdery reinforcing material. 3. The molded article according to claim 1, wherein the sheet material has been subjected to a surface treatment. 4. A sheet material made of a new thermoplastic resin and having both front and back surfaces is inserted into a cavity of a molding die.
A step of arranging the surface so as to face the mold surface, a step of introducing a molding resin made of a thermoplastic resin containing a recycled resin between the back surface of the sheet material in the cavity and another mold surface, And filling the cavity into the cavity by pressurizing the molded resin at a temperature equal to or higher than the softening point, and simultaneously forming the molded product main body and fixing the molded resin to the sheet material. Production method. 5. The method according to claim 4, wherein the molding resin includes a fibrous or powdery reinforcing material. 6. The method according to claim 4, wherein the surface or the back surface of the sheet material has been subjected to a surface treatment.