JP4192104B2 - Thermosetting resin molding method - Google Patents

Description

  The present invention relates to a thermosetting resin molding method.

  Using thermosetting resin materials such as conventional melamine resins, molded articles such as tableware are manufactured by compression molding. This thermosetting resin material is usually filled with a pulp material for reinforcement. The pulp material may cause dirt adhesion, and the pulp material is removed from the thermosetting resin material to form a resin material close to pure, that is, glaze, on the surface of the molded product (hereinafter referred to as glaze coating). Things have been done.

  When the molded product is tableware or the like, a pattern is often added. The pattern is formed on a special printing paper containing a pattern impregnated with resin, that is, a foil. This is disposed on the upper side of the molded product, and is subjected to glaze coating to apply special printing to prevent peeling (see, for example, Patent Document 1).

  A specific molding method includes a step of performing glaze coating molding on a concave mold of a molded product, a step of supplying the molded product obtained in the above process upside down to a convex mold, and a convex mold of the molded product. It is performed by a process of performing grace coating molding on the surface.

JP-A-2001-38753 Claim 1, [0006] to [0007], FIG.

In the technique described in Patent Document 1, a lower concave mold mold and an upper convex mold core mold are required to mold the first half molding step, that is, the half mold with the upper side open. And In order to form the second half molding step, that is, to form a semi-molded product in which the lower side is open, a lower convex mold and an upper concave mold having a concave groove for thread bottom of the container are required. That is, a total of four molds are required.
In the technique of Patent Document 1, the molded semi-finished product is taken out from the lower concave mold mold and the upper convex mold core mold used in the first half molding process, and the lower convex mold in the second molding process. It must be incorporated into the upper concave mold with a concave groove for the mold and the thread tail of the container. It is said that resin molded products generally require 48 hours to complete the shrinkage. Temporarily, the half-molded product taken out from the lower concave mold mold and the upper convex mold core mold used in the first half molding process is not fully contracted, etc. There is a possibility that the size of the convex mold on the side used in the molding process and the upper concave mold having the concave groove for the yarn bottom of the container do not match, and the semi-molded product may be destroyed.

  In order to avoid this, it is desirable to perform the second half molding process after the half-molded product is completely contracted. In addition, if the glaze coating in the first half molding process is completely shrunk and then the second half molding process is performed, a strain stress is generated between the two glaze coatings, and the molded product tends to break, and breaks due to temperature changes, etc. It becomes a molded product with high possibility of doing.

  In the technique of Patent Document 1, the thicknesses of both glaze coatings are uniform, and it is not possible to form a pattern by translucent (milky white) or coloring the glaze coating and changing the thickness partially. Is possible.

(the purpose)
The present invention has been made in view of the above-mentioned problems of the prior art, and it is possible to produce all molded products without taking out the molded semi-finished product from the core mold of the lower convex mold used in the first half molding process. An object of the present invention is to provide a thermosetting resin molding method that can perform steps, has high manufacturing efficiency, and requires a small area for a manufacturing apparatus.
It is another object of the present invention to provide a thermosetting resin molding method capable of producing a molded product that does not generate strain stress and is not easily broken.

  Furthermore, the present invention can easily or gradually change the thickness of the coating, and has a high-class feeling, a three-dimensional feeling, and a transparent feeling due to a change in translucency (milky white) transparency and a change in coloring density. It aims at providing the thermosetting resin molding method which can form a pattern.

The first invention includes a core mold having a molding surface coinciding with the inner surface of the inner layer of the three-layer molded article, a first mold mold having a molding surface coinciding with the outer surface of the inner layer, the outer surface of the intermediate layer, and the same outer layer Use a second mold with a molding surface that matches the outer surface of
The inner layer was compression molded with the core mold and the first mold mold, and the intermediate layer was compression molded with the second mold mold on the inner layer that was fixed to the core mold, and fixed to the core mold. It is a thermosetting resin molding method characterized in that the outer layer is compression molded using the second mold on the intermediate layer as it is.

Embodiments of the first invention are as follows.
A sheet is placed on the inner layer and pressed by the first mold, and the sheet is disposed between the inner layer and the intermediate layer.
A sheet is placed on the intermediate layer and pressed by the second mold, and the sheet is disposed between the intermediate layer and the outer layer.
The molding surface of the first mold is provided with an uneven pattern.

The second invention includes a mold having a molding surface that matches the outer surface of the outer layer of the three-layer molded product, a first core mold having a molding surface that matches the inner surface of the outer layer, the inner surface of the intermediate layer, and the same inner layer. Use a second core mold with a molding surface that matches the inner surface of
The outer layer is compression-molded by the mold and the first core mold, and the intermediate layer is compression-molded by the second core mold on the outer layer that is fixed to the mold, and is fixed to the mold. An inner layer is compression molded using the second core mold on the intermediate layer as it is, a thermosetting resin molding method.

The embodiment of the second invention is as follows.
A sheet is placed on the outer layer and pressed by the first core mold, and the sheet is disposed between the outer layer and the intermediate layer.
A sheet is placed on the intermediate layer and pressed by the second core mold, and the sheet is disposed between the intermediate layer and the inner layer.
An uneven pattern is provided on the molding surface of the first core mold.

According to the thermosetting resin molding method of the present invention, all molding and manufacturing processes can be performed without taking out the molded semi-finished product from the core mold of the lower convex mold used in the first half molding process. The efficiency is high and the area required for the manufacturing apparatus is small.
According to the thermosetting resin molding method of the present invention, there is an effect that it is possible to produce a molded product which does not generate strain stress and is not easily broken.

  According to the thermosetting resin molding method of the present invention, the thickness of the coating can be easily and gradually changed, depending on a change in translucency (milky white) transparency and a change in color density. It has the effect of being able to form a high-quality, three-dimensional and transparent pattern.

The best mode for carrying out the thermosetting resin molding method of the present invention will be described below.
(First embodiment)
In the thermosetting resin molding method according to the first embodiment, taking the molded tea bowl product C as an example, as shown in FIG. A concave first concave mold 12 and a second concave mold 14 which is on the upper side and has a thread bottom groove 13 and is concave downward are used. The first concave mold 12 and the second concave mold 14 are mechanically combined together, and each has a common axis with the convex core mold 10 by a driving device (not shown). Can be selectively moved.

  As shown in FIG. 14, the molded tea bowl product C includes an inner layer 20 of a transparent thermosetting resin material, an intermediate layer 22 of an opaque thermosetting resin material, and an outer layer 24 of a transparent thermosetting resin material. An inner pattern layer 26 is disposed on the inner layer 20 side of the intermediate layer 22, and an outer pattern 28 on the intermediate layer 22 side of the outer layer 24 is disposed.

  As shown in FIG. 1, the convex core mold 10 has an outward first inner layer molding surface 30 that coincides with the inner surface of the molded tea bowl product C, that is, the inner surface of the inner layer 20. The first concave mold 12 has an inward second inner layer molding surface 32 coinciding with the outer surface of the inner layer 20. The second concave mold 14 has an inward outer surface molding surface 34 coinciding with the outer surface of the outer layer 24.

In the first step, as shown in FIG. 1, the convex core mold 10 and the first concave mold 12 are positioned so that the axes of the convex core mold 10 and the first concave mold 12 coincide. .
In the second step, as shown in FIG. 2, the transparent thermosetting resin mass 100 is disposed on the first inner layer molding surface 30 of the convex core mold 10.

In the third step, as shown in FIG. 3, the convex core mold 10 is raised so that the distance between the convex core mold 10 and the first concave mold 12 is predetermined, and the inner layer 20 having a predetermined thickness is formed. Form.
In the fourth step, as shown in FIG. 4, the convex core mold 10 is lowered, and the inner foil 102 having the inner pattern is disposed between the convex core mold 10 and the first concave mold 12.

In the fifth step, as shown in FIG. 5, the convex core mold 10 is raised and the inner foil 102 is pressed against the inner layer 20 to form the inner picture layer 26.
In the sixth step, as shown in FIG. 6, the convex core mold 10 is lowered to provide an interval between the convex core mold 10 and the first concave mold 12. Further, the first concave mold 12 is moved so that the convex core mold 10 and the second concave mold 14 are aligned so that the axes of the convex core mold 10 and the second concave mold 14 coincide. Position.

In the seventh step, as shown in FIG. 7, the colored thermosetting resin mass 104 is disposed on the inner layer 20 of the convex core mold 10 and the inner layer 20 that remains on the inner pattern layer 26.
In the eighth step, as shown in FIG. 8, the convex core mold 10 is raised, and the intermediate layer 22 is formed with a predetermined distance between the convex core mold 10 and the second concave mold 14. A thread tail 29 is formed in the intermediate layer 22.

In the ninth step, as shown in FIG. 9, the convex core mold is lowered, and the outer foil 106 having the outer pattern is disposed between the convex core mold 10 and the second concave mold 14.
In the tenth step, as shown in FIG. 10, the convex core mold 10 is raised and the outer foil 106 is pressed against the intermediate layer 22 to form the outer picture layer 28.

In the eleventh step, as shown in FIG. 11, the transparent thermosetting resin mass 108 is disposed on the inner layer forming surface 30 of the convex core mold 10 and the intermediate layer 22 remaining on the inner pattern layer 26.
In the twelfth step, as shown in FIG. 12, the convex core mold 10 is raised, and the outer layer 24 is formed with a predetermined distance between the convex core mold 10 and the second concave mold 14.
In the thirteenth step, as shown in FIG. 13, the convex core mold 10 is lowered, and the molding of the molded tea bowl product C is completed.

(Second embodiment)
This is a thermosetting resin molding method in which a three-dimensional pattern is formed by partially changing the thickness of a translucent (milky white) or colored inner layer on the inner surface of a molded tea bowl product C or the like. Only parts different from the first embodiment will be described.
As shown in FIG. 15, the convex pattern portion 300, the concave pattern portion 302, or both are provided on the second inner layer molding surface 32 of the first concave mold 12. As a result, as shown in FIG. 16, in the step corresponding to step 4 of the first embodiment, the convex pattern portion 300 and the concave / convex pattern portion 310 having concave and convex portions opposite to those of the concave pattern portion 302 are formed on the outer surface of the inner layer 20. That is, in the molded tea bowl product C, as shown in FIG. 17, a pattern is formed on the inner layer 20 due to a change in thickness due to unevenness on the intermediate layer 22 side.

  As a modification of the second embodiment, as shown in FIG. 18, the thickness of the inner layer 20 is gradually increased from the bottom side toward the opening side. As a result, the colored intermediate layer 22 can be seen near the bottom, and the intermediate layer 22 gradually disappears toward the opening.

(Third embodiment)
In the first embodiment, the inner layer 20, the intermediate layer 22, and the outer layer 24 are formed in this order. In the third embodiment, the outer layer, the intermediate layer, and the inner layer are formed in this order. That is, in the thermosetting resin molding method according to the third embodiment, as shown in FIG. 19, the concave core mold 410 has an outward first outer layer molding surface that coincides with the outer surface of the molded tea bowl product C, that is, the inner surface of the outer layer. I have 430. The first convex mold 412 has an outward second outer layer molding surface 432 that coincides with the inner surface of the intermediate layer. The second convex mold 444 has an inward inner surface molding surface 434 that coincides with the outer surface of the inner layer.
Since the molding step using these molds is substantially the same as the first step, the description thereof is omitted.

(Fourth embodiment)
This is a thermosetting resin molding method in which a three-dimensional pattern is formed by partially changing the thickness of a translucent (milky white) or colored inner layer on the outer surface of a molded product teacup or the like.
As shown in FIG. 20, the convex pattern portion 450, the concave pattern portion 452, or both are provided on the second outer layer molding surface 432 of the first convex mold 412.

  In the thermosetting resin molding method of the present invention, a three-dimensional pattern is formed by partially changing the thickness of the intermediate layer. However, the second inner layer molding surface or the second inner layer is provided so as to provide an opening in the intermediate layer. By providing an uneven pattern on the molding surface, it is possible to mold a molded product having a transparent part or a semi-transparent part on the side wall part thereof.

It is explanatory drawing of the 1st step of the 1st embodiment of the thermosetting resin molding method of this invention. It is explanatory drawing of the 2nd step of the 1st embodiment of the thermosetting resin molding method of this invention. It is explanatory drawing of the 3rd step of the 1st embodiment of the thermosetting resin molding method of this invention. It is explanatory drawing of the 4th step of the 1st embodiment of the thermosetting resin molding method of this invention. It is explanatory drawing of the 5th step of the 1st embodiment of the thermosetting resin molding method of this invention. It is explanatory drawing of the 6th step of the 1st embodiment of the thermosetting resin molding method of this invention. It is explanatory drawing of the 7th step of the 1st embodiment of the thermosetting resin shaping | molding method of this invention. It is explanatory drawing of the 8th step of the 1st embodiment of the thermosetting resin molding method of this invention. It is explanatory drawing of the 9th step of the 1st embodiment of the thermosetting resin molding method of this invention. It is explanatory drawing of the 10th step of the 1st embodiment of the thermosetting resin molding method of this invention. It is explanatory drawing of the 11th step of the 1st embodiment of the thermosetting resin molding method of this invention. It is explanatory drawing of the 12th step of the 1st embodiment of the thermosetting resin shaping | molding method of this invention. It is explanatory drawing of the 13th step of the 1st embodiment of the thermosetting resin molding method of this invention. It is a fragmentary sectional view of the molded product teacup by the 1st embodiment of the thermosetting resin molding method of the present invention. It is explanatory drawing corresponding to FIG. 1 in the 2nd embodiment of the thermosetting resin molding method of this invention. It is explanatory drawing corresponding to FIG. 4 in the 2nd embodiment of the thermosetting resin molding method of this invention. It is sectional drawing of the molded product teacup by the 2nd embodiment of the thermosetting resin shaping | molding method of this invention. It is sectional drawing of the molded product teacup by the modification of the 2nd embodiment of the thermosetting resin molding method of this invention. It is explanatory drawing corresponding to FIG. 1 in the 2nd embodiment of the thermosetting resin molding method of this invention. It is explanatory drawing corresponding to FIG. 4 in the 2nd embodiment of the thermosetting resin molding method of this invention.

Explanation of symbols

C Molded Product Tea Bowl 10 Convex Core Mold 12 First Concave Cavity Mold 14 Second Concave Cavity Mold 20 Inner Layer 22 Intermediate Layer 24 Outer Layer 26 Inner Pattern Layer 28 Outer Pattern Layer 30 First Inner Layer Molded Surface 32 Second Inner Layer Molded Surface 34 External molding surface 100 Transparent thermosetting resin mass 102 Inner foil 104 Colored thermosetting resin mass 106 Outer foil 108 Transparent thermosetting resin mass 300 Convex pattern portion 302 Concave pattern portion

Claims (8)

The core mold having a molding surface that matches the inner surface of the inner layer of the three-layer molded product, the first mold having the molding surface that matches the outer surface of the inner layer, the outer surface of the intermediate layer, and the outer surface of the same outer layer Use a second mold with a molding surface,
The inner layer was compression molded with the core mold and the first mold mold, and the intermediate layer was compression molded with the second mold mold on the inner layer that was fixed to the core mold, and fixed to the core mold. A thermosetting resin molding method, wherein the outer layer is compression-molded on the intermediate layer using the second mold.   The thermosetting resin molding method according to claim 1, wherein a sheet is placed on the inner layer and pressed by the first mold, and the sheet is disposed between the inner layer and the intermediate layer. .   2. The thermosetting resin molding according to claim 1, wherein a sheet is placed on the intermediate layer and pressed by the second mold, and the sheet is disposed between the intermediate layer and the outer layer. Method.   The thermosetting resin molding method according to claim 1, wherein a pattern with unevenness is provided on the molding surface of the first mold. A mold mold having a molding surface that matches the outer surface of the outer layer of the three-layer molded product, a first core mold having a molding surface that matches the inner surface of the outer layer, an inner surface of the intermediate layer, and an inner surface of the same inner layer Use a second core mold with a molding surface,
The outer layer is compression-molded by the mold and the first core mold, and the intermediate layer is compression-molded by the second core mold on the outer layer that is fixed to the mold, and is fixed to the mold. An inner layer is compression-molded using the second core mold on the intermediate layer as it is, and a thermosetting resin molding method.   6. The thermosetting resin molding method according to claim 5, wherein a sheet is placed on the outer layer and pressed by the first core mold, and the sheet is disposed between the outer layer and the intermediate layer. .   The thermosetting resin molding according to claim 5, wherein a sheet is placed on the intermediate layer and pressed by the second core mold, and the sheet is disposed between the intermediate layer and the inner layer. Method.   6. The thermosetting resin molding method according to claim 5, wherein an uneven pattern is provided on the molding surface of the first core mold.

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