JP5638279B2 - Molding method of acrylic resin molded products - Google Patents

Description

  The present invention relates to a molding method for molding a transparent molded article using an acrylic resin.

  In general, since an acrylic resin plate is excellent in transparency, it is used in a wide range of fields such as a large water tank, a product display, and a member of a mobile phone. As a method for forming the acrylic resin plate, there are usually a cell casting method and an extrusion method. Among these, the outline of the cell casting method will be described below. That is, first, a catalyst for polymerization is mixed with the raw material of the acrylic resin cell cast plate. Next, the resin liquid formulated in this manner is poured between a pair of glass plates juxtaposed in parallel, and the glass plate is regulated with a clamp to obtain a desired thickness product. Next, it is immersed in temperature-controlled warm water to polymerize the resin liquid. Further, the pair of glass plates containing the resin liquid is taken out of the hot water and heat-treated to complete the polymerization. Then, this is cooled, both glass plates are removed, and a molded article is obtained (for example, nonpatent literature 1).

“Kanase Kogyo Co., Ltd .: Acrylic business”, “Kanasellite manufacturing process”, [online], [October 9, 2009 search], Internet <http: // www. kanase. co. jp / product / acrylic / sheet. html>

  The cell casting method disclosed in Patent Document 1 is generally applicable to a relatively large thick large resin molded product, but such a large resin molded product requires fine temperature adjustment and requires a fine temperature. It is forced to control and its molding becomes difficult. In addition, the water tank itself is increased in size, and further, the drying apparatus required for completing the polymerization thereafter is also increased in size. For this reason, there is a problem that not only these facilities are enlarged but also the facility cost is increased, and the product cost is also increased.

  Therefore, the present invention has been made to solve the above-described problems, and even a large and relatively thick acrylic resin molded product can be molded at room temperature using a resin mold, temperature control is facilitated, and molding is facilitated. In addition, an object of the present invention is to provide a method for molding an acrylic resin molded product that does not require a large facility and that can suppress the facility cost and the product cost.

  In order to achieve such an object, the method of molding an acrylic resin molded product of the present invention includes a step of molding a front molded plate having the same shape as the surface of the molded product whose surface is to be molded using an acrylic resin plate, A step of forming a back side molding plate having the same shape as the back side of the molded product to be molded using an acrylic resin plate, and placing the front side molding plate and the back side molding plate in the male mold and the female mold, respectively. Injecting acrylic resin into a gap formed so as to be surrounded by the front side molding plate and the back side molding plate that match the male mold and the female mold and match each other, and polymerize and integrate them. It is characterized by becoming.

  At this time, it is preferable to form a colored gel coat resin layer on the back surface of the back-side molded plate.

  The method for molding an acrylic resin molded product according to the present invention includes a step of forming a front molded plate having the same shape as the surface of the molded product to be molded using the acrylic resin plate, and a back surface using the acrylic resin plate. Forming a back side molding plate having the same shape as the back side of the molded product to be molded, arranging the front side molding plate in a male mold and arranging the back side molding plate in a female mold, A step of matching the female mold, injecting an acrylic resin into a gap formed so as to be surrounded by the front side molding plate and the back side molding plate that are mated with each other, and polymerizing and integrating them. Therefore, the injected and melted acrylic resin contacts the inner surfaces of the front and back molding plates to cause a polymerization reaction, and these are integrated. Therefore, even a relatively thick acrylic resin molded product can be molded at room temperature using a resin mold, temperature control becomes easy, and molding is easy. Moreover, since simple vacuum forming molds and resin molds are sufficient, the equipment cost can be greatly reduced, and the product cost can be reduced.

  Also, if a colored gel coat resin layer is formed on the back side of the back side molding plate, the desired color and pattern can be seen through the transparent front side and back side molding plate, and the effect of excellent design is also achieved. Yes.

The end view of the bathtub shape | molded by the shaping | molding method which concerns on this invention. (A)-(d) is a schematic perspective view which shows the shaping | molding process of a front side shaping | molding board. (A)-(d) is a schematic perspective view which shows the shaping | molding process of a back side shaping | molding board. (A)-(C) is a schematic sectional drawing which shows the formation process of the bathtub which concerns on this invention. The end view of the back side shaping | molding board which formed the gel coat resin layer in the back surface.

  BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, the best embodiment of a method for molding an acrylic resin molded product according to the present invention will be described. Examples of the molded product include large molded products such as a bathtub, a bathtub counter, a toilet, and a counter-type basin. Among these, a bathtub will be described as an example. FIG. 1 is an end view of a bathtub molded by the molding method according to the present invention, FIGS. 2A to 2D are schematic perspective views showing a molding process of a front side molded plate, and FIGS. It is a schematic perspective view which shows the shaping | molding process of a back side shaping | molding board.

  The bathtub A, which is a molded product, is formed by overlapping three layers of a front side molding plate 1, a back side molding plate 2 and an acrylic resin layer 5 injected therebetween, which will be described in detail later. Both the front side molding plate 1 and the back side molding plate 2 are made of acrylic resin. Here, the front side molded plate 1 is formed such that the surface 1a has the same shape as the surface of the bathtub A which is a molded product to be molded. Moreover, the back side shaping | molding board 2 is shape | molded so that the back surface 2b may make the same shape as the back surface of the bathtub A which is a molded product which it is going to shape | mold. Therefore, when the front-side molded plate 1 and the back-side molded plate 2 are stacked one above the other, the bathtub A that is a molded product is completed. At this time, a gap 4 is formed between the front side molding plate 1 and the back side molding plate 2 as described later.

  Therefore, first, a transparent acrylic resin plate P1 is prepared as shown in FIG. The acrylic resin plate P1 is selected from 1 to 5 mm, for example, and is rectangular and has a predetermined size. Then, as shown in FIG. 2 (b), heaters H, H are arranged above and below the acrylic resin plate P1, and the acrylic resin plate P1 is heated at a predetermined temperature. Next, as shown in FIG. 2 (c), the acrylic resin plate P1 heated to a predetermined temperature is placed on the upper surface of the vacuum forming mold D1 and the inside is sealed, and the air inside is sucked so-called vacuum. It is bent into a predetermined shape by a molding method. Thereby, the front side molded board 1 is shape | molded as shown in FIG.

  Similarly, in order to mold the back side molding plate 2, a transparent acrylic resin plate P2 is prepared as shown in FIG. The acrylic resin plate P2 is also selected, for example, from 1 to 5 mm, and is rectangular and has a predetermined size. Then, as shown in FIG. 3 (b), heaters H, H are arranged above and below the acrylic resin plate P2, and the acrylic resin plate P2 is heated at a predetermined temperature. Next, as shown in FIG. 3C, the acrylic resin plate P2 heated at a predetermined temperature is placed on the upper surface of the vacuum forming mold D2 and the inside is sealed, and the inside air is sucked and vacuumed. It is bent into a predetermined shape by a molding method. Thereby, as shown in FIG.3 (d), the back side shaping | molding board 2 is shape | molded. In this way, the front and back side molded plates 1 and 2 are molded, and both unnecessary surrounding portions are cut out and the front side molded plate 1 is overlaid on the back side molded plate 2, so that the bathtub A to be molded is formed. It becomes.

  Next, as shown in FIG. 4 (a), the front-side molded plate 1 molded in this way is placed so as to cover the upper surface of the male mold G1, which is the resin mold 3, and firmly fixed. Further, the back side molding plate 2 is arranged on the lower surface of the female die G2 which is the resin die 3 so as to correspond to the front side molding plate 1, and is firmly fixed. In this state, as shown in FIG. 4B, the male die G1 and the female die G2 are overlapped, and the sealing member C is interposed between the upper end surface around the front side molding plate 1 and the lower end surface around the back side molding plate 2. And fix in close contact. At this time, a sealed gap 4 is formed between the front side molding plate 1 and the back side molding plate 2.

  In this state, a molten transparent acrylic resin is injected from the injection port K into the gap 4 between the front side molding plate 1 and the back side molding plate 2. The injected acrylic resin contacts the back surface 1 b of the front side molding plate 1 and the front surface 2 a of the back side molding plate 2. As a result, a polymerization reaction occurs at the contact surfaces 1b and 2a of the front side molding plate 1 and the back side molding plate 2 made of the same acrylic resin as the acrylic resin layer 5, and the acrylic resin is fused to the front side and back side molding plates 1 and 2. And integrated. At this time, since the same acrylic resin is in contact, the contact surface does not become cloudy even if a slight temperature change occurs. In the figure, R is an air vent hole.

  Then, after the injected acrylic resin layer 5 is cured, the male mold G1 and the female mold G2 are opened and the bathtub A is taken out. As shown in FIG. 4 (c), the bathtub A originally has a three-layer structure including a front-side molded plate 1, a back-side molded plate 2 and an acrylic resin layer 5, but is transparent from the outside. I don't know the distinction between them. By going through each of the steps as described above, the bathtub A is formed.

  Thus, the molding method of the bathtub A which is an acrylic resin molded product according to the present invention matches the shape of the bathtub A in the resin mold 3 through the process of molding the front and back molding plates 1 and 2 by the vacuum molding method. Thus, the front side molding plate 1 and the back side molding plate 2 are arranged so as to overlap each other, and acrylic resin is only injected into the gap 4 formed so as to be surrounded by the front side molding plate 1 and the back side molding plate 2. Thus, the bathtub A can be formed. Therefore, even a relatively thick acrylic resin molded product such as the bathtub A can be molded at room temperature using a resin mold, temperature control becomes easy, and molding is easy. In addition, since simple vacuum forming molds and resin molds are sufficient, large equipment is not required, equipment costs can be greatly reduced, and product costs can be reduced.

  In addition, since the bathtub A is entirely made of an acrylic resin, it can be recycled as an acrylic resin as it is when it has been used for many years, and it is not necessary to be separated and is extremely easy to dispose of.

  Further, a little color pigment may be mixed in the front side molding plate 1 or the back side molding plate 2 so as to be colored to a desired color. In addition, as shown in FIG. 5, if a colored gel coat resin layer 6 is applied and formed on the back surface 2b of the back-side molded plate 2, various textures can be expressed and the design is improved. It can also be made. Furthermore, if necessary, the strength can be increased by FRP molding of the back surface 2b of the back-side molded plate 2 using glass fiber.

DESCRIPTION OF SYMBOLS 1 Surface molding board 1a Front surface 1b Back surface 2 Back surface molding board 2a Front surface 2b Back surface 3 Resin type 4 Crevice 5 Acrylic resin layer 6 Gel coat resin layer A Molded article (bathtub)

Claims (1)

A step of forming a front side molding plate having the same shape as the surface of the molded product to be molded using an acrylic resin plate,
Forming a back side molded plate having the same shape as the back side of the molded product to be molded using an acrylic resin plate;
A process of forming a colored gel coat resin layer on the back surface of the back side molding plate;
The front side molding plate and the back side molding plate are arranged in the male mold and the female mold, respectively, and the gap formed so as to be surrounded by the front molding plate and the rear molding plate that match the male mold and the female mold and match each other. Injecting acrylic resin into the polymer, polymerizing and integrating them,
A method for molding an acrylic resin molded product, comprising:

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