JP3461713B2 - Manufacturing method of patterned panel - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a patterned pad used for wall panels of equipment units such as high-end bus units.
It relates to the manufacturing method of flannel .

[0002]

2. Description of the Related Art As a wall material for a conventional high-class bus unit, there is a wall to which tiles are attached, a wall to which natural stones are attached, and these are manufactured by attaching tiles or plate-like natural stones to a substrate.
However, these are heavy, fragile, easy to stain the joints, and expensive, and in recent years, as an alternative to them, fiber reinforced plastic (FRP) molded products are painted to improve the commercial value. A wall material with a patterned pattern is being developed. Most of the manufacturing methods employ a method of transferring the pattern of the transfer film to the surface resin on the base film using a transfer film patterned with ink.
As a method for producing a patterned wall material using a transfer film, a method including steps shown in FIG. 2 is known (Japanese Patent Laid-Open No. 2-223449, etc.).

That is, (1) a step of placing uncured transparent or translucent uncured surface resin 103 in a lump form on one end of the surface of the mold 101 coated with the release agent 102. (2) The end portion side of the patterning surface of the transfer film 107, which is patterned on one surface of the base film 104 with the ink soluble in the surface resin, is pressed against the massive surface resin 103, and then,
A step of pressing the transfer film 107 from one end side of the mold surface by the roller 108 to uniformly stretch the lumpy surface resin 103 and at the same time superposing it on the surface resin. (3) After the stretched surface resin 103 is cured, the base film 104 is peeled off and the pattern 106 is formed on the surface resin.
Process of transferring. (4) A step of laminating the transparent resin layer 105 on the surface resin 103 on which the pattern 106 is transferred. (5) A step of laminating the colored opaque resin 109 after the transparent resin layer is cured. (6) After the colored opaque resin 109 is cured, a resin reinforcing layer (A) 1 containing a filler, a reinforcing material, and a low shrinkage material thereon.
A step of stacking 10. (7) A step of, after the resin reinforcing layer (A) 110 is cured, laminating and curing a resin reinforcing layer (B) 111 containing glass fiber thereon. The patterned wall material obtained by the above method is light, has a clear pattern, has a three-dimensional effect, and can be manufactured at a lower cost.

[0004]

However, the above method also has the following problems. Resin layer 103 on the surface (decorative surface) of the patterned wall material and resin reinforcing layer (B) 111 containing glass fiber
Due to the difference in the coefficient of linear thermal expansion, the patterned wall material tends to warp and deform.

Further, when the uncured surface resin is placed in a lump form on one end of the mold surface, the required amount of the surface resin is placed at one location (one end) at a time. When the stretching is started, the surface resin in front of the roller moves not only in the stretching direction but also in the direction perpendicular to the stretching direction, and this movement deviates from the mold end part to the outside of the mold as the surface resin stretches. A shortage of surface resin (before reaching the other end) causes defects. Therefore, it is necessary to correct the defective portion.

The present invention has been made in view of the above-mentioned drawbacks of the conventional method, and it is difficult for warping deformation of the wall material to occur.
Another object of the present invention is to provide a method for producing a patterned wall material having a good surface resin material yield.

[0007]

According to the present invention, (a) an uncured transparent surface resin is placed on a mold surface, and (b) a pattern is formed on one surface of a base film with an ink soluble in the surface resin. While pressing the end of the patterned surface of the attached transfer film against the surface resin on the mold surface, the transfer film is pressed from one end side to the other end side of the mold surface to uniformly stretch the surface resin and the surface resin Overlaid on top, (c) the stretched surface resin is semi-cured, the base film is peeled off to transfer the pattern onto the surface resin, and (d1) the surface resin onto which the pattern has been transferred, glass fiber and Forming an intermediate layer containing a resin, (d2) forming an admixture layer containing a filler, a low-shrinking agent and a resin on the intermediate layer, and (d3) allowing sedimentation of the filler in the admixture layer. (D4) then on the admixture layer A laminated backing layer containing a glass fiber and a resin, and cured, and (e) demolding the patterned panel.

The means for promoting the sedimentation of the filler in the step (d3) is preferably performed by rocking the whole.

The transfer film in the step (b) is preferably a transfer film in which a single color layer of an ink soluble in a surface resin and a pattern arranged on the single color layer are formed on one surface of a base film. To use.

Further, the surface resin is preferably placed in the step (a) in a zigzag band shape from one end to the other end of the mold surface.

<Operation> While the transparent uncured surface resin is placed on the belt-shaped zigzag from one end of the mold surface, the transfer film is pressed onto the mold and the surface resin, and the transfer film is pressed in one direction by a roller or the like. The movement of the surface resin in the direction perpendicular to the stretching direction is suppressed, and the surface resin is uniformly stretched while defoaming. Therefore, there is little waste of material. When a transfer film in which a single color ink layer and a pattern (ink) are formed on one surface of a base film is used as the transfer film, on the surface resin on which the pattern is transferred, the surface resin layer and the pattern are sequentially arranged from the mold side. An (ink) and a monochromatic ink layer are formed, and the monochromatic ink layer plays the role of a hiding layer. Therefore, the patterned wall material manufactured by the manufacturing method of the present invention has the transparent resin layer 105 as in the prior art.
The hue of the pattern is reproduced without laminating (FIG. 2) or the colored opaque resin layer 109 (FIG. 2).

In addition, when the mixture layer is laminated after the intermediate layer is laminated, the sedimentation of the filler is promoted by shaking or the like while the mixture layer is uncured (liquid state). This causes the filler in the mixture layer to settle and separate, forming a layer with a low resin content and a layer with a high resin content. The layer with high resin content is
Since the filler is sandwiched between layers having a low resin content separated by sedimentation to maintain balance with the surface resin layer, the warp deformation of the molded product caused by the difference in the coefficient of linear thermal expansion is reduced.

[0013]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described below. FIG. 1 is an explanatory view showing the procedure of manufacturing the patterned wall material of the present invention. An uncured surface resin 3 that is transparent (used in this specification to include translucence) is placed in a zigzag band shape from one end of the surface of the mold 1 coated with the release agent 2 (procedure a), The monochromatic layer 5 is formed on one surface of the base film 4 with an ink soluble in the surface resin 3 and then the pattern 6 is arranged on the surface of the transfer film 7. The transfer film 7 onto the roller 8
The surface resin 3 is uniformly stretched by pressing from one end side of the surface of the mold 1 by a pressing / stretching means such as the above and is superposed on the surface resin 3 (procedure b). At this time, the work of placing the surface resin on the mold surface (procedure a) and the superposition of the transfer film on the surface resin (procedure b) can be carried out separately, but preferably, as shown in FIG. ) Synchronize as shown in ().

Next, the stretched surface resin 3 is semi-cured. The method of semi-curing varies depending on the type of resin and the like, but is heating, irradiation of ultraviolet rays, or the like. Then, the base film 4 is peeled off and the single color ink layer 5 and the pattern (ink) 6 are transferred onto the surface resin 3 (procedure c).

An intermediate layer 9 containing glass fibers and a resin is formed on the surface resin 3 on which the monochrome ink layer 5 and the pattern 6 have been transferred (procedure d1), and the intermediate layer 9 is changed from a liquid state to a solid state (gelation). In this state, the admixture layer 10 containing the filler, the low-shrinking agent and the resin is formed thereon (procedure d2), and while the admixture layer 10 is in an uncured (liquid) state, Accelerate sedimentation (procedure d3). The means for accelerating the sedimentation of the filler is preferably to give shaking or vibration, and the conditions for giving the shaking or vibration vary depending on the composition of the admixture layer and the size of the molded product (wall material). Therefore, the optimum conditions are appropriately determined. After the filler is settled, the back layer 11 containing the glass fiber and the resin is laminated on the mixture layer 10 and cured (procedure d4). The curing conditions at this time are such that the resin is completely cured.
The method of completely curing it depends on the type of resin and the like, but it is heating, irradiation with ultraviolet rays, or the like. Finally, demolding is performed to obtain the desired patterned wall material (procedure e).

The surface resin used in the present invention is not particularly limited, but a transparent thermosetting resin such as unsaturated polyester resin, acrylic resin or epoxy resin is preferable. A curing agent, a filler, a pigment and the like may be appropriately mixed therewith. The thickness of the transparent resin layer is preferably 100 to 300.
The range is μm.

As the mold, a mold having a shape adapted to the patterned wall material is used. Usually, it is a flat plate type with a smooth surface. A mold release agent is preferably used on the surface of the mold in order to facilitate peeling of the molded product (patterned wall material). The release agent includes a film type containing polyvinyl alcohol as a main component, wax, and the like, and is not particularly limited.

The base film constituting the transfer film is not particularly limited as long as it has heat resistance and peelability and is insoluble in the surface resin. Plastic film such as polyethylene, polypropylene, nylon, polyester, fluorine film, metal foil such as aluminum foil alone or laminated with other film, paper or plastic film coated with releasable resin Things etc. can be used. Here, the thickness of the film is preferably about 10 μm to 100 μm in order to uniformly stretch the surface resin.

The ink used for the monochrome ink layer and the pattern is selected from those soluble in the surface resin. An unsaturated polyester resin, an acrylic resin, an epoxy resin, a nitrified cotton (nitrocellulose) resin, or the like mixed with a pigment or a dye is preferable. The pattern may be any of wood grain, stone tone, abstract pattern, etc., and is not particularly limited.

The method of pressing the transfer film is not particularly limited as long as the surface resin can be uniformly stretched over the entire surface of the mold. For example, a roller or the like is used. The thickness of the surface resin is preferably 100 μm to 300 μm.

The resin used for the intermediate layer containing the glass fiber and the resin is not particularly limited, but a thermosetting resin such as an unsaturated polyester resin, an acrylic resin or an epoxy resin is mixed with a curing agent or the like as appropriate. Those are preferable. In this intermediate layer, a filler similar to the filler used for the later-described admixture layer (improvement of elastic modulus of the layer, improvement of surface smoothness of the molded product, purpose of increasing amount, etc.), pigment or the like is appropriately added. Can be mixed. Examples of the glass fiber used include glass mat, glass cloth, glass paper and the like.

The resin used in the admixture layer and the back layer is not particularly limited, but a resin obtained by appropriately mixing a thermosetting resin such as an unsaturated polyester resin, an acrylic resin or an epoxy resin with a curing agent is preferable. .

As the filler used in the mixture layer, aluminum hydroxide, calcium carbonate, calcium sulfate,
Glass powder, plastic powder, crystalline silica powder, fused silica powder, barium sulfate, magnesium silicate (talc), clay, kaolin, magnesium oxide, or diatom
There is soil . The amount of the filler used is usually 50 to 700 parts by weight with respect to 100 parts by weight of the resin.

When a reinforcing material is used in the mixture layer, the reinforcing material includes glass short fibers, carbon short fibers, vinylon short fibers, nylon short fibers, etc., and the fiber length is 1 ~ 50
mm is preferred. The amount of the reinforcing material used is usually 1 to 10 parts by weight with respect to 100 parts by weight of the resin.

As the low-shrinking agent used in the admixture layer,
Polystyrene, polyvinyl acetate, polyacrylate, polyethylene terephthalate, styrene-vinyl acetate block copolymer, or styrene-methyl methacrylate block
Block copolymers . The amount of low shrinkage agent used is 100
It is usually 10 to 40 parts by weight with respect to parts by weight. The thickness of the admixture layer is usually in the range of 3 to 10 mm. As the glass fiber used for the back layer , a glass mat,
There are glass cloth, glass paper, etc. The intermediate layer, the admixture layer and the back layer may be laminated on the transparent surface resin layer by a known method such as application of a resin solution, pouring method or hand layup method.

[0026]

EXAMPLES Example 1 A patterned wall material was produced by the procedure shown in FIG. Procedure a: A mold release agent was previously applied uniformly on the surface of the mold with a spray gun. The composition of the surface resin used is as follows. Unsaturated polyester resin (manufactured by Hitachi Chemical Co., Ltd., trade name PS-3717): 100 parts by weight, styrene monomer: 10 parts by weight, methyl ethyl ketone peroxide (manufactured by NOF Corporation, trade name Permek N): 1 part by weight, Cobalt naphthenate: 0.5 part by weight. The mold release agent was applied to the mold every 5 moldings.

Step b: A transfer film in which a single color ink layer and a pattern ink layer are formed on one surface of a base film (polyester film; thickness 50 μm) with an ink prepared by mixing pigment and dye in a nitrified cotton (nitrocellulose) resin. Press the end side of the patterning surface against the surface resin of the band zigzag,
The transfer film was pressed by a roller from one end side of the mold surface to uniformly stretch the surface resin to a thickness of about 200 μm, and was superposed on the surface resin. At the same time as the stretching, the surface resin 3 is placed in front of the stretching direction in which the roller 8 presses. Step c: The stretched surface resin is placed in a warm air oven (70 ° C.) for 3
After treating for 0 minutes and semi-curing, the base film was peeled off, and the pattern (ink) and the monochrome ink layer were transferred onto the surface resin.

Step d1: An intermediate layer containing glass fiber and resin was laminated on the surface resin on which the pattern and the monochrome ink layer were transferred. The components and composition of the intermediate layer are as follows: glass fiber chopped strand mat: 230 g / m ² , colored unsaturated polyester resin (manufactured by Tokyo Ink Co., Ltd., trade name Color Dresin): 100 parts by weight, styrene monomer:
10 parts by weight, methyl ethyl ketone peroxide (manufactured by NOF CORPORATION, trade name Permec N): 1 part by weight, cobalt naphthenate: 0.5 part by weight.

Step d2: The mixture layer was laminated on the above intermediate layer, and the whole system was shaken for 1 minute while it was uncured (liquid state). Oscillation conditions: 1 reciprocation / sec in the horizontal direction for 60 seconds, stroke length 100
mm. The components and composition of the mixture layer are unsaturated polyester resin (Hitachi Chemical Co., Ltd., trade name PS-51
81PT): 100 parts by weight , styrene-acetic acid as a low-shrinking agent
Vinyl block copolymer (manufactured by NOF CORPORATION, trade name: Modiper SV30): 15 parts by weight, calcium carbonate coarse particles (manufactured by Nitto Koka Kogyo Co., Ltd., trade name Kansui stone # 40):
300 parts by weight, calcium carbonate fine particles (manufactured by Nitto Koka Kogyo Co., Ltd., product name Cal TS-70): 200 parts by weight, methyl ethyl ketone peroxide (manufactured by NOF Corporation,
Product name Permek N): 4 parts by weight, cobalt naphthenate 2 parts by weight.

Step d3: A back layer containing a glass fiber and a resin was laminated on the mixture layer obtained by separating the filler by sedimentation. Components and composition of the back layer are glass fiber chopped strand mat: 230 g / m ² , unsaturated polyester resin (Hitachi Chemical Co., Ltd., trade name PS-5
182APT): 100 parts by weight, styrene monomer: 1
0 parts by weight, methyl ethyl ketone peroxide (manufactured by NOF CORPORATION, trade name Permec N): 1 part by weight, cobalt naphthenate: 0.5 parts by weight. Then, the hot air oven (70
(° C) for 40 minutes to completely cure the resin. Step d4: Mold release was performed to obtain a molded product (patterned wall material).

[0031]

INDUSTRIAL APPLICABILITY The patterned wall material obtained by the manufacturing method of the present invention is less likely to warp. In addition, it is clear, has a three-dimensional appearance, and has a luxurious feel. In the production method of the present invention, when a monochromatic ink layer is transferred to the surface resin in addition to the pattern (ink), the monochromatic ink layer plays a role of a masking layer, so that a transparent resin layer or a colored opaque resin layer is laminated as in the conventional case. The hue of the surface pattern can be reproduced without any. Therefore, the number of stacking steps is smaller than in the past. Further, the surface resin does not move out of the frame during pressing and stretching, and it is not necessary to correct it.

[Brief description of drawings]

FIG. 1 is a process explanatory view showing an example of a method for producing a patterned wall material of the present invention.

FIG. 2 is a process explanatory view showing a conventional method for producing a patterned wall material.

[Explanation of symbols]

1. Type 2. Release agent 3. Surface resin 4. Base film 5. Monochromatic ink layer 6. Pattern (ink) 7. Transfer film 8. Laura 9. Intermediate layer containing glass fiber and resin 10. Admixture layer containing filler, low shrinkage agent and resin 11. Back layer containing glass fiber and resin 12. 13. Layer with high filler content (layer with low resin content) 13. Layer with low filler amount (layer with high resin content) 101. Mold 102. Release agent 103. Surface resin 104. Base film 105. Transparent resin layer 106. Pattern (ink) 107. Transfer film 108. Laura 109. Colored opaque resin layer 110. Resin reinforcement layer A 111. Resin reinforcement layer B

─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Hisagi Kasagi, 1010 Ippongi, Toyama City, Toyama Prefecture, Hitachi Chemical Unit Co., Ltd. (56) Reference JP-A-5-318469 (JP, A) JP-A-62-97833 ( (58) Fields surveyed (Int.Cl. ⁷ , DB name) B32B 1/00-35/00 B29C 41/00-41/52

Claims (4)

(57) [Claims] 1. A patterning surface of a transfer film, comprising: (a) an uncured transparent surface resin placed on a mold surface, and (b) one surface of a base film patterned with an ink soluble in the surface resin. While pressing the end part of the mold against the surface resin on the mold surface, the transfer film is pressed from one end side to the other end side of the mold surface to uniformly stretch the surface resin and superimpose it on the surface resin (c). The stretched surface resin is semi-cured, the base film is peeled off, and the pattern is transferred onto the surface resin. (D1) An intermediate layer containing glass fiber and resin is formed on the surface resin onto which the pattern is transferred. And (d2) forming an admixture layer containing a filler, a low-shrinking agent and a resin on the intermediate layer, (d3) promoting the sedimentation of the filler in the admixture layer, (d4) Contains glass fiber and resin on the mixture layer That the back layer are laminated, cured, (e) demolding method for producing a patterned containing panel, characterized in that. 2. The production method according to claim 1, wherein the means for promoting the sedimentation of the filler in step (d3) is to rock the whole. 3. The transfer film in step (b) is a transfer film having a monochromatic layer of ink soluble in a surface resin and a pattern arranged on the monochromatic layer formed on one surface of a base film. The manufacturing method according to claim 1 or 2, characterized in that. 4. The method according to any one of claims 1 to 3, characterized in that the surface resin is placed in step (a) in a band-shaped zigzag from one end to the other end of the mold surface.