JP3934699B2 - Molded product and method for producing the same - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a molded article by a decorative integrated molding method using a thermoplastic resin and a method for producing the molded article.
[0002]
[Prior art]
Vinyl chloride resins have good weather resistance, surface printability, flame retardancy, and the like, and are used for automobile interior parts and construction. However, since vinyl chloride resin has a high specific gravity and is inferior in thermal stability, it is rare to obtain a molded product by direct injection molding. Usually, a method of laminating a thermoplastic resin such as polyethylene or polypropylene to vinyl chloride resin is performed. Yes.
[0003]
The vinyl chloride resin is plasticized at 70 to 90 ° C., whereas the processing temperature of the normal thermoplastic resin is about 180 to 250 ° C. Therefore, when both resins are integrally molded, the vinyl chloride resin melts. Therefore, it cannot be integrally formed.
[0004]
As a method for solving the above problems, a foam layer (foamed polypropylene, foamed polyurethane, etc.) is adhered to the back surface of the vinyl chloride sheet, and the vinyl chloride sheet on the skin is prevented from melting by the heat of the thermoplastic resin in the plasticized state. Has been proposed. Molded articles of this method are used in automobile interiors and the like as decorative molded articles in which a vinyl chloride sheet is provided with a cushioning property and a pattern is provided on the vinyl chloride skin.
[0005]
However, because the molded product is usually a foam layer of about 1.5 to 3 mm on the back surface of the vinyl chloride sheet, the transfer of the mold used for decoration cannot be accurately performed due to the effect of this foam layer, In particular, it is difficult to produce a molded product with a sharp corner portion, and the entire corner portion is a loose molded product in appearance.
[0006]
[Problems to be solved by the invention]
An object of the present invention is to provide a molded product in which the shape of a molded product can be accurately transferred from a mold using vinyl chloride as a skin, and to provide a method for producing the molded product.
[0007]
[Means for Solving the Problems]
The present inventor has intensively studied in order to solve the above problems, and has reached the present invention.
[0008]
That is, in the present invention, the outermost layer is The elongation at the maximum tensile load according to JIS K7113 according to JIS K6734 is 50% or more. PVC sheet on the back Hotmelt The object is to provide a molded article in which a non-woven fabric through an adhesive is disposed and integrally formed using a thermoplastic resin on a base material portion.
[0009]
Further, the present invention is an integral molded article using a vinyl chloride sheet as the outermost layer and a non-woven fabric with an adhesive on the back surface thereof, and using a thermoplastic resin as a base material portion, and at least one of the vertical direction and / or the horizontal direction. Another object of the present invention is to provide the above molded product having an actual structure for incorporating the same molded product into at least one of the above.
[0010]
Moreover, this invention is providing the building exterior wall material whose molded object is a molded object in any one of the said description.
[0011]
Furthermore, the present invention uses an injection molding machine as a surface layer with the mold opened. The elongation at the maximum tensile load according to JIS K7113 according to JIS K6734 is 50% or more. PVC sheet on the back Hotmelt After the multilayer sheet with the adhesive applied or intervened and the nonwoven fabric disposed between the molds is introduced between the molds, while the thermoplastic resin is injected or after the injection, the molds are closed by an injection compression molding method. It is an object of the present invention to provide a method for producing a molded product characterized by integrally molding a thermoplastic resin.
[0012]
Another object of the present invention is to provide the above-mentioned molded product or a method for producing the same, wherein the adhesive is a hot melt adhesive in the molded product or the method for producing the same according to the present invention.
[0013]
DETAILED DESCRIPTION OF THE INVENTION
The inventors of the present invention have made extensive studies on a method for integrally forming the vinyl chloride sheet having excellent weather resistance on the surface layer part and the base material part as a thermoplastic resin, and the heat of the surface layer vinyl chloride sheet and the base material. It has been found that a desired integral molded product can be obtained by integrally molding a nonwoven fabric with a plastic resin.
[0014]
An example of the molded product of the present invention and an enlarged view thereof are shown in FIGS. 4 (a) and 4 (b).
[0015]
That is, by interposing the nonwoven fabric, the heat of the thermoplastic resin in the plasticized state is not directly applied to the vinyl chloride sheet on the surface layer, and the vinyl chloride sheet in contact with the cooled mold surface is integrated quickly without being melted. Shaped.
[0016]
Like the manufacture of conventional vehicle interior materials, it is integrally molded with a thermoplastic resin through a sheet of foamed polyurethane, foamed polystyrene, foamed polypropylene, foamed polyethylene, etc. as a heat insulating material on the back of the vinyl chloride sheet and has cushioning properties In this method, since the foam sheet on the back surface has a considerable thickness, it is impossible to transfer sharp irregularities and fine shapes such as a rock pattern on the outer wall material from the mold.
[0017]
Therefore, the thickness, elongation, and heat resistance of the surface vinyl chloride sheet and the nonwoven fabric on the back surface are important factors for shape transfer. Here, when integrally molding, the nonwoven fabric interposed between the vinyl chloride sheet of the surface layer and the thermoplastic resin as the base material is generally hardly bonded as it is. For this reason, in order to obtain the molded product of the present invention, an adhesive is interposed on the back surface of the surface vinyl chloride sheet to bond the vinyl chloride sheet and the nonwoven fabric. In particular, with regard to the adhesive, it is recommended to apply a hot melt adhesive that melts and adheres at about 80 to 120 ° C. or to interpose a sheet-like hot melt adhesive.
[0018]
With such a configuration, the surface vinyl chloride sheet and the intermediate nonwoven fabric are fixed with a hot melt adhesive melted by heat from the thermoplastic resin in the plasticized state, and the nonwoven fabric is heated in the plasticized state. When the plastic resin enters between the fibers and solidifies, the molded product of the present invention can be manufactured by simultaneous integral molding.
[0019]
The molded product of the present invention is characterized in that the outermost layer is composed of a vinyl chloride sheet, the inside thereof is a non-woven fabric, and the base material portion is composed of a thermoplastic resin.
[0020]
The vinyl chloride sheet used in the present invention is not particularly limited, but a sheet obtained from a composition comprising a vinyl chloride resin so-called soft vinyl chloride and a plasticizer is preferable because it can be easily shaped in a mold.
[0021]
This composition can be used without particular limitation as long as it is a known composition comprising a vinyl chloride resin and a plasticizer, but generally 3 to 50 parts by weight, preferably 5 to 25 parts by weight of a plasticizer with respect to 100 parts by weight of the vinyl chloride resin. It is.
[0022]
The plasticizer is not particularly limited as long as it is a plasticizer used in a soft plasticized vinyl chloride composition. For example, phthalates such as dioctyl phthalate, linear dibasic esters such as dioctyl adipate, tricres Examples include phosphoric acid esters such as zilphate, and the addition of secondary plasticizers such as chlorinated paraffin.
[0023]
In particular, when the molded product of the present invention is used for building materials, it is also a preferred embodiment to use phosphate esters particularly in terms of flame retardancy.
[0024]
The vinyl chloride sheet used in the present invention is produced by extruding or calendering a composition comprising the vinyl chloride resin and a plasticizer. At this time, stabilizers for vinyl chloride resin, ultraviolet absorbers and other additives which are usually used are added as necessary.
[0025]
Since the vinyl chloride sheet of the surface layer part used in the present invention is integrally formed with a thermoplastic resin in a plasticized state, it should be possible to follow the mold shape according to the irregularities of the outer wall shape provided on the mold, fine grain shape It has a large elongation and needs a certain wall thickness.
[0026]
The wall thickness of the vinyl chloride sheet is preferably 50 μ to 300 μ, and the elongation is preferably 50% or more at the maximum tensile load according to JIS K7113 according to JIS K6734. If the wall thickness is 50 μm or less, it is easy to break when integrally molded with the thermoplastic resin of the base material, and if it is 300 μm or more, the fine unevenness transferability of the mold surface showing the outer wall material pattern is inferior and the real feeling is lost. Is called. Therefore, the preferable thickness of the vinyl chloride sheet is 50 μm or more and 300 μm or less, and the desirable thickness is 100 μm to 200 μm. In addition, the elongation cannot be defined unconditionally due to the relationship with the stress, but those with a small elongation are not preferable because there is a possibility of breakage at the acute angle portion and deep drawing portion of the mold shape. The thickness of the vinyl chloride sheet is also included in the thickness when printing and / or top coating.
[0027]
The surface layer of the vinyl chloride sheet used in the present invention has various prints such as woody, rocky, stone-like, and brick-like, and those that have been embossed with unevenness and embossing at the same time in accordance with these printings Used. By these printing on the surface of the vinyl chloride sheet, the exterior wall material for construction obtained as the molded product of the present invention can obtain an appearance more resembling the real thing such as wood texture, rock feeling, brick feeling and the like.
[0028]
Examples of the thermoplastic resin used as the base material of the molded product of the present invention include general-purpose resins such as polystyrene resin, ABS resin, vinyl chloride resin, polyethylene resin, and polypropylene resin. Also included are polymer alloys obtained by mixing these versatile resins, or engineering plastics such as polycarbonate resins, polyamide resins, and polyester resins, directly or using a compatibilizing material.
[0029]
Moreover, in order to improve the impact resistance of the molded product, a rubber component may be added to the thermoplastic resin as necessary. Particularly preferred are acrylic rubber, EPM, EPDM, styrene-butadiene block copolymer and the like, and the addition amount is about 1 to 30 parts by weight with respect to 100 parts by weight of the thermoplastic resin.
[0030]
In the present invention, the base material retains the shape and strength of the molded product of the present invention, and a vinyl chloride sheet decorated on the surface is laminated via an adhesive.
[0031]
These thermoplastic resins used as the base material are various fillers such as talc, mica and glass fiber, various additives such as plasticizers, antistatic agents and flame retardants, and pigments and dyes as necessary. It is also possible to use a mixture in which an agent is blended and kneaded. In particular, for materials containing flame retardants, flame retardant and self-extinguishing properties can be obtained by using materials that pass UL standard V-〓, V-0, 5V standards applied to plastic materials exported from the United States. It is especially recommended for building materials because it is possible to obtain a monolithic molded product.
[0032]
In the present invention, a nonwoven fabric is bonded to the vinyl chloride resin sheet with an adhesive.
The nonwoven fabric used in the present invention is not particularly limited as long as it has a function of preventing the thermoplastic resin used in the present invention from melting the vinyl chloride sheet during molding.
[0033]
The nonwoven fabric used in the present invention preferably has a relatively thin and non-directional elongation in order to improve the mold transferability of the surface vinyl chloride sheet as much as possible.
[0034]
The thickness of the nonwoven fabric is preferably 0.05 to 0.6 mm, more preferably 0.08 to 0.4 mm. In this range, heat from the thermoplastic resin in a plasticized state passes through the nonwoven fabric during integral molding. The transmission to the surface vinyl chloride sheet is controlled, the surface appearance can be maintained without melting the surface layer part, and when a hot melt adhesive is used to adhere the surface vinyl chloride sheet and the nonwoven fabric, the melted state is preferably the surface layer part. A non-woven fabric is bonded, and a molded product having good mold transferability and excellent product appearance can be obtained.
[0035]
On the other hand, the basis weight of the nonwoven fabric is 15 to 100 g / m. ² Is preferable, and more preferably 25 to 75 g / m. ² It is.
[0036]
15g / m ² In the above, the entire nonwoven fabric is filled with thermoplastic resin with no voids, and the thermoplastic resin in the plasticized state does not reach the surface vinyl chloride sheet directly through the nonwoven fabric during integral molding, so the surface layer is melted and the surface appearance is poor 100g / m ² Below, the followability to the mold shape transfer of the nonwoven fabric is good, and the real feeling of the outer wall material molded product can be maintained. .
[0037]
The nonwoven fabric used in the present invention preferably has a tensile elongation of 5% or more according to JIS L1085 so that the nonwoven fabric is not damaged following the acute angle part and deep drawing part from the mold shape.
[0038]
Further, the surface of the nonwoven fabric used is preferably smooth, and those having embossed irregularities are not preferred. When the surface of the nonwoven fabric is smooth, the surface vinyl chloride sheet is accurately shaped in the shape of the mold when the integrally molded product of the present invention is molded. A molded product with a texture can be obtained.
[0039]
Furthermore, since the nonwoven fabric comes into contact with the thermoplastic resin in the plasticized state at the time of shaping, it is necessary that the nonwoven fabric melts in the process of processing and does not lose its function in the method of the present invention. For this purpose, a non-woven fabric whose melting point is higher than the melting point or softening point of the thermoplastic resin, preferably a non-woven fabric higher than 10 ° C. is used.
[0040]
The nonwoven fabric used in the present invention is not particularly limited to the thickness and basis weight ranges, and there is no particular limitation on the composition.
[0041]
Accordingly, polyamide nonwoven fabrics, polyester nonwoven fabrics, polyacrylic nonwoven fabrics, and the like that are generally manufactured from thermoplastic resins are preferred that have as little orientation as possible.
[0042]
There is no particular restriction on the adhesive of the surface layer vinyl chloride sheet and the intermediate layer nonwoven fabric used in the present invention, but it is a material that can withstand heat such that it does not decompose or foam due to heat during integral molding with a thermoplastic resin. It is desirable that
[0043]
Pre-manufacturing the vinyl chloride sheet and the nonwoven fabric on the back with a sticky adhesive, various reactive adhesives, or thermosetting adhesive, or melting at a constant temperature between the vinyl chloride sheet and the nonwoven fabric. A hot-melt adhesive may be applied, or a sheet-like hot-melt adhesive may be interposed to melt and bond with heat during molding.
As an adhesive for preliminarily bonding the vinyl chloride and the non-woven fabric, for example, the adhesive is dissolved in a solvent or applied as it is for adhesion. This type of adhesive includes adhesive type adhesives (eg, ethylene-vinyl acetate copolymer, polychloroprene), reactive type adhesives (eg, acrylic emulsion type, polyurethane type, polychloroprene type) or thermosetting adhesives. Agents (for example, epoxy type, polyester epoxy type) and the like are exemplified.
[0044]
There are two types of hot-melt adhesives that exist between vinyl chloride and non-woven fabric and are bonded by heat during molding: coating-type and sheet-type hot-melt adhesives. These include modified vinyl alcohol types and polyamides, respectively. Examples thereof include a system, a copolyester system, and an atactic polypropylene system, and these can be easily obtained as commercial products. In the method of the present invention, a hot melt adhesive can be particularly preferably used.
[0045]
In order to make a molded product flame-retardant by the method of the present invention, a method of adding a flame retardant to a thermoplastic resin as a base material is performed. As the flame retardant to be added, known ones that usually make a thermoplastic resin flame retardant can be used. For example, examples of the flame retardant added to the styrene resin include tetrabromobisphenol A, tetrabromobisphenol A epoxy, tetrabromodiphenyl ether, antimony trioxide and the like, and mixtures thereof. Examples of the flame retardant added to the polyolefin include tetrabromo. Examples thereof include bisphenol A, tetrabromobisphenol S, hexabromocyclododecane, antimony trioxide and the like or a mixture thereof.
[0046]
The molded product of the present invention using the flame retardant thermoplastic resin to which these flame retardants are added is UL-standard V-II, V- for flame retardancy required for thermoplastic resin molded products for export to the United States. It is possible to satisfy 0, 5V. The flame retardant level becomes severe as V-II, V-0, and 5V. Particularly, a molded product formed from a 5V material exhibits properties close to non-flammability.
[0047]
The molded product of the present invention is characterized in that the outermost layer is composed of a vinyl chloride sheet, the inside thereof is a non-woven fabric, and the base material portion is composed of a thermoplastic resin. Due to this structure, the vinyl chloride sheet is easy to color printing with a texture of wood and rocks, embossing unevenness, and is excellent in weather resistance discoloration and weather resistance, but on the other hand, it is a general-purpose thermoplastic resin such as polystyrene resin and polypropylene resin. Compared to heat resistance.
[0048]
On the other hand, the thermoplastic resin used as the base material can be injected or injection compression molded into a mold having various desired shapes in a plasticized state, and a large amount of the same molded product can be easily produced.
[0049]
The use of the molded product of the present invention is not particularly limited, but is preferably used as a building material, and can be preferably used as an outer wall material for building.
[0050]
Commercially available outer wall materials are roughly classified into three categories: ceramics, metal, and wood.
[0051]
Ceramic-type exterior wall materials are made by placing thin tiles on a fixed-size foamed cement board with mesh and fixing them with cement, or making tile patterns and rock patterns with irregularities on these cement boards. The surface is painted to produce products that look like real tiles and rocks.
[0052]
In addition, the metallic outer wall material is made by processing a colored steel plate or colored aluminum plate with irregularities, wrapping gypsum board or urethane foam, etc., cut to a certain size on the back side and inside, and graining the wood surface on the metal surface. The product is made to resemble the real thing due to the unevenness called rock-like embossing.
[0053]
On the other hand, wood-based outer wall materials have been commercialized by attaching various kinds of wood thin skin or various vinyl chloride wallpaper on the surface of phenolic plywood or calcium silicate plywood.
[0054]
Since these conventional outer wall materials are hard and fragile, it is difficult to process the terminal at the time of construction and repair partially damaged parts, and it is not possible to cut a single outer wall material into any shape or size It was.
[0055]
Therefore, it is not a suitable material for renovation such as replacement of a part of a building once constructed that is dirty, partially discolored part, and partly damaged part after a long period of time.
[0056]
For this reason, the molded article of the present invention is particularly preferably used as a material that can be cut and repaired in an arbitrary shape for renovation, not only for the outer wall material but also for the inner wall material and the ceiling material.
[0057]
When used as a building outer wall material manufactured with such a molded product, it is preferable to have a so-called actual structure for incorporating the same molded product into at least one of the vertical direction and / or at least one of the horizontal direction. used.
[0058]
In other words, by having an actual structure in the vertical and horizontal directions, it is possible to expand the continuous outer wall surface to an arbitrary area at the time of construction, improve the appearance appearance, and isolate the construction base part directly from the outdoors By covering and covering, it is possible to prevent damage due to freezing by preventing rain and snow from entering at the same time as preventing the weather resistance deterioration of the ground portion.
[0059]
The actual structure of the present invention is not particularly limited as long as it has a structure that is incorporated or overlapped with each other, and can be provided at least in one of the up and down directions and / or one of the left and right directions.
[0060]
The specific structure of the so-called actual structure for incorporating the same molded product is not particularly limited as long as it is a structure that is usually used for such a purpose. For example, the structure shown in FIG. 7 is exemplified. However, the structure is not limited to this structure as long as the above functions can be achieved.
[0061]
The present invention also provides a molded product structure, structure and molding method for easily producing a molded product having excellent weather resistance and surface appearance using a thermoplastic resin.
[0062]
The present invention provides a method for producing a molded article having excellent weather resistance and appearance by utilizing a characteristic of a thermoplastic resin, and also for producing the molded article at low cost using a normal injection molding machine. be able to.
[0063]
As a method for producing the molded product of the present invention, a decorative integrated molding method by injection compression molding using an injection molding machine is recommended.
[0064]
That is, during normal injection molding, in-mold molding in which a mold is closed with a vinyl chloride sheet or nonwoven fabric introduced into the mold, the surface vinyl chloride sheet or nonwoven fabric is the target outer wall material. It cannot follow the shape and is damaged and cannot be commercialized. In addition, if these surface vinyl chloride sheets and non-woven fabrics are pre-formed into a shaped shape, or if fine holes are provided in the surface of the mold and these skin materials are vacuum shaped, the shaped shape will be obtained. Follow and molding may be possible.
[0065]
However, in injection molding, resin is forcibly filled into the mold through a narrow hole called a gate, so even if the flow distance to the wall thickness is shortened with a multipoint gate, the resin orientation remains. In a molded product having a large area such as a wall material, warping or deformation may occur due to stress relaxation over time or temperature change during daily use.
[0066]
In order to solve such problems, a preferred method for obtaining the molded product of the present invention is to inject a thermoplastic resin as a base material in a state where a part of the mold is opened in advance, and to compress and shape the whole. In other words, it is manufactured by an injection compression molding method that makes the orientation of the resin uniform.
[0067]
Hereinafter, the outline of a specific molding process is shown about the injection compression molding method.
First, a mold processed into a target shape is attached to an injection molding machine, and the printing surface is the outermost layer with the mold open as shown in FIG. 5, and a non-woven fabric bonded with an adhesive is arranged on the back side. The vinyl chloride sheet for decoration which arranged the vinyl sheet or the hot melt adhesive layer and the nonwoven fabric is introduced.
[0068]
In this state, the mold is gradually closed to a predetermined opening degree, and a vinyl chloride sheet in which an adhesive or a hot-melt adhesive layer and a nonwoven fabric are arranged on the back side of the previously decorated vinyl chloride sheet between the half-open molds. Is in a state of being sandwiched.
[0069]
Subsequently, a thermoplastic resin in a plasticized state corresponding to the mold volume is injected onto the nonwoven fabric. At this time, the mold in the half-open state is closed as shown in FIG. 6 in the middle of the injection or after the injection is completed, and is molded while adhering the decorative vinyl chloride sheet and the thermoplastic resin to produce an integrally molded product. .
[0070]
If the actual structure is a plug-in shape, the slide mold can be actuated at the stage where the mold closes or after closing to obtain the desired shape. it can. After that, it is cooled for a predetermined time, the inserted slide mold is returned to its original position, the mold is opened, and the thermoplastic resin integrated molded product decorated with the vinyl chloride sheet is taken out from the mold.
[0071]
In this way, by changing the printing pattern and embossing shape of the vinyl chloride sheet surface for decoration, and changing the shape of the mold with the entrance frame type, etc., for example, brick tone, tile tone, or rock It is possible to manufacture various types of outer wall materials such as tempering, etc., and it is possible to easily produce various types of products.
As an injection compression molding method that can be preferably used in the method of the present invention, a vinyl chloride sheet, an adhesive, and a nonwoven fabric are used as described above in a known injection compression molding method, and a thermoplastic resin is injection compression molded thereon. It is manufactured. The injection compression molding method itself is, for example, the methods described in JP-A-4-39010 and Japanese Patent Application No. 07-68589, in particular, the method described in claim 1, specifically, the examples of the same specification, particularly the example 1 The method described in is exemplified. The molded article of the present invention can be obtained by using the vinyl chloride sheet, adhesive and nonwoven fabric of the present application instead of the skin used in these methods.
[0072]
In the above method, injection compression molding can be performed with a normal injection molding machine without using a special injection compression molding apparatus. Of course, the molded article of the present invention can also be obtained by using a dedicated injection compression molding apparatus for supplying the resin from above the mold.
[0073]
【Example】
Example 1
A flame-retardant polypropylene resin (manufactured by Mitsui Toatsu Chemical Co., Ltd .: Mitsui Noblen BJ5H UKT, UL standard V-0) is used as a thermoplastic resin as a base material, and molding of the present invention is performed using the apparatus shown in FIG. The outer wall material for the stone-like building which is a thing was shape | molded.
[0074]
Vinyl chloride sheet printed on the surface (100 parts by weight of vinyl chloride resin, sheet made from 5 parts by weight of dioctyl phthalate as a plasticizer, thickness 200 μm, elongation at maximum load measured by JIS K7113) 60%: manufactured by Fukubi Chemical Industry Co., Ltd.) was set in a stone-patterned mold so that the printing surface was on the mold side.
[0075]
A hot-melt adhesive layer (manufactured by Mitsui Toatsu Chemicals Co., Ltd .: Neunets T-2009: copolymer polyester type, basis weight 25 g / m) is provided on the back side (opposite side of the printing side) of the vinyl chloride sheet. ² ), Non-woven fabric (Nippon Vilene Co., Ltd. OL-4063: polyester, thickness 0.091 mm, basis weight 27 g / m ² ) Was set.
[0076]
As shown in FIG. 5, the above-mentioned 7 consisting of a vinyl chloride sheet, a hot-melt adhesive layer and a non-woven fabric is attached with an exclusive mold to an injection molding machine (Japan Steel Works Co., Ltd .: J1300EE) having a clamping capacity of 1300 t. Between the molds set at 20 ° C. on the movable side and 40 ° C. on the fixed side, the thermoplastic resin composition 4 plasticized at 200 ° C. from the nozzle part of the injection molding machine is extruded onto the nonwoven fabric, and then the mold 10 is closed. It was. At the same time, the slide mold 11 for making the actual structure part for incorporation was operated.
[0077]
After cooling the molded product, a molded product with a stone pattern shown in FIG. 1 was obtained. This molded product had a length of about 45 cm, a width of about 90 cm, and a height of about 2.5 cm.
[0078]
The molded product obtained in this example was flame retardant and had a V-0 performance according to UL standard 94, which is a combustion test of plastic materials for export to the United States.
[0079]
The molded product obtained in this example is excellent in pattern and shape, and the shape of the mold is accurately transferred especially in the acute angle part, and since this molded product is made of resin, it can be easily cut. It can be preferably used as a wall material for renovation.
Example 2
Flame retardant polypropylene resin (Mitsui Toatsu Chemical Co., Ltd .: Mitsui Noblen BJ5H UKT, UL standard V-0) is used as the base material thermoplastic resin, and the vinyl chloride sheet (vinyl chloride resin) is printed on the surface layer in a brick pattern. 100 parts by weight, sheet manufactured from 8 parts by weight of dioctyl adipate as a plasticizer, thickness 185 μm, elongation 54% at the maximum tensile load measured by JISK7113: manufactured by Fukubi Chemical Industry Co., Ltd., printing of this vinyl chloride sheet Hot melt adhesive layer (Mitsui Toatsu Chemical Co., Ltd .: Neunets T-2009: copolymer polyester type, basis weight 25 g / m on the back side of the surface ² ), Non-woven fabric (manufactured by Japan Vilene Co., Ltd .: LMW-9004: polyester series, thickness 0.40 mm, basis weight 42.6 g / m ² ) Is used, and the molding of the present invention is performed by changing the mold shape of the same molding machine as in Example 1 and the same apparatus as in Example 1 shown in FIG. 5 as the basic structure. Was molded. At this time, the resin temperature in the plasticized state was set to 205 ° C., the movable side of the mold was set to 20 ° C., and the fixed side was set to 40 ° C., and the slide mold was also operated in the same manner as in Example 1 to perform shaping.
[0080]
Thus, a brick-shaped building outer wall material molding having an actual structure for incorporating a molding different from that of Example 1 having a length of about 45 cm, a width of about 90 cm, and a height of about 2 cm shown in FIG. 2 was obtained. .
[0081]
The molded product obtained in this example was flame retardant and had a V-0 performance according to UL standard 94, which is a combustion test of plastic materials for export to the United States.
The molded product obtained in this example is excellent in pattern and shape, and in particular, the shape of the mold is accurately transferred at the acute angle portion, and since the molded product is made of resin, it can be easily cut and is particularly remodeled. It can be preferably used as a wall material.
Example 3
A flame retardant ABS resin (manufactured by Mitsui Toatsu Chemical Co., Ltd .: Santac MR-40, UL standard V-0) is used as a thermoplastic resin for the base material, and a vinyl chloride sheet (vinyl chloride) with a surface layer printed in a rock pattern Sheet made of 100 parts by weight of resin, 3 parts by weight of dioctyl adipate as plasticizer and 5 parts by weight of chlorinated paraffin, thickness 185 μm, elongation 60% at the maximum tensile load measured by JIS K7113: Fukubi Chemical Co., Ltd. Manufactured), a hot-melt adhesive layer (manufactured by Mitsui Toatsu Chemical Co., Ltd .: Neunets T-2026: copolymer polyester, basis weight 30 g / m) on the back side of the printed surface of this vinyl chloride sheet ² ), Non-woven fabric (manufactured by Japan Vilene Co., Ltd .: OL-570, modified polyamide system, thickness 0.18 mm, basis weight 73 g / m) ² ) Is used, the molding machine of the present invention is changed by changing the mold shape of the same molding machine as in Example 1 and the same apparatus as in Example 1 shown in FIG. 5 as the basic structure. Molded. At this time, the resin temperature in the plasticized state was set to 220 ° C., the movable side of the mold was set to 30 ° C., the fixed side was set to 65 ° C., and the slide mold was also operated in the same manner as in Example 1 to perform shaping.
[0082]
The building exterior wall material molding with a rock-like pattern having a real structure for incorporating a molded product different from that of Example 1 having a length of about 45 cm, a width of about 60 cm, and a height of about 3.5 cm shown in FIG. Got.
[0083]
The molded product obtained in this example was flame retardant and had a V-0 performance according to UL standard 94, which is a combustion test of plastic materials for export to the United States.
The molded product obtained in this example is excellent in pattern and shape, and the shape of the mold is accurately transferred to the acute angle part, and since the molded product is made of resin, it can be easily cut. In particular, it can be preferably used for remodeling.
[0084]
【The invention's effect】
The molded product produced by integrally molding with a thermoplastic resin through a non-woven fabric without a foam heat insulation layer on the back surface while taking advantage of the weather resistance of the vinyl chloride sheet is excellent in product appearance and is a building wall material In particular, it can be widely used for remodeling. In addition, by changing the printed pattern of the vinyl chloride sheet of the skin material and the shape of the die entry, it is possible to easily produce a wide variety of products such as wall materials, ceiling materials, floor materials, etc. Can be used as
[Brief description of the drawings]
FIG. 1 is a schematic diagram of a stone-like molded product as an example of an exterior wall material for building which is integrally molded with decoration according to the present invention and has excellent weather resistance.
FIG. 2 is a schematic diagram of a brick-like molded product as an example of an exterior wall material for building which is integrally molded with decoration according to the present invention and has excellent weather resistance.
FIG. 3 shows a simulated view of a rock-like molded product as an example of an exterior wall material for building which is integrally molded with decoration according to the present invention and has excellent weather resistance.
FIG. 4 (a) is a schematic cross-sectional view of an exterior wall material for a building which is integrally molded with decoration according to the present invention. An example of a so-called actual structure for incorporation is shown at both ends.
(B) shows the partial expanded cross-section simulated figure of the building exterior wall material by which the decoration integral molding of this invention was carried out. The expanded cross section of A part of Fig.4 (a) is shown.
FIG. 5 shows the injection compression molding method used in the present invention in a state where a vinyl chloride sheet having a nonwoven fabric arranged on the back surface for decoration is introduced into the mold in a half-open state of the mold and a thermoplastic resin is injected. FIG. The slide mold for creating the actual structure shows a state where it is pulled up and returned to its original position.
FIG. 6 shows an injection compression molding method used in the present invention, in which a mold is closed, a slide mold for creating an actual structure is inserted, and a vinyl chloride sheet having a non-woven fabric on the back surface is bonded to a thermoplastic resin; A simulated sectional view in a state of being integrally formed is shown.
FIG. 7 is a schematic view showing an example of an actual structure for incorporating the same molded product of the building wall material of the present invention.
[Explanation of symbols]
1: Vinyl chloride sheet
2: Adhesive
3: Nonwoven fabric
4: Thermoplastic resin
5: Real structure insertion recess for incorporating the same molded product
6: Real structure insertion protrusion for incorporating the same molded product
7: Vinyl chloride sheet with non-woven fabric on the back
8: Injection molding machine nozzle
9: Movable mold
10: Fixed side mold
11: Slide mold
12: Hydraulic cylinder for slide mold operation

Claims (4)

The outermost layer is a vinyl chloride sheet having an elongation at the maximum load of 50% or more according to JIS K7113 according to JIS K6734, a non-woven fabric with a hot melt adhesive is arranged on the back surface, and a thermoplastic resin is used for the base material portion. A molded product that is integrally molded and has an acute end .   The outermost layer is a vinyl chloride sheet, a non-woven fabric with an adhesive is arranged on the back surface thereof, and an integrally molded product using a thermoplastic resin for the base material part, at least one of the vertical direction and / or at least one of the horizontal direction, The molded product according to claim 1, which has a real structure for incorporating the same molded product.   The molded article according to claim 1 or 2, wherein the molded article is a building outer wall material.   Using an injection molding machine, with a mold open, a vinyl chloride sheet with a maximum tensile load of 50% or more according to JIS K6733 according to JIS K6734 as a surface layer, and hot melt adhesive applied or interposed on the back surface After the multilayer sheet with non-woven fabric is introduced between the molds, the above-mentioned skin material and the thermoplastic resin of the base material are integrally molded by injection compression molding method while injecting the thermoplastic resin or closing the mold after injection. A method for producing a molded product, comprising:

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