JPH0410908A - Molding method for synthetic resin laminate structure - Google Patents

Abstract

PURPOSE:To impart an excellent pattern easily and enhance the durability by providing a colored layer on the rear side of a transparent gelcoat layer so as to represent a gradation pattern based on differences in film thickness. CONSTITUTION:A mold release agent is applied to the surface of a male mold 7, and a resin liquid consisting mainly of a transparent unsaturated polyester resin is applied thereto by a spray-up method to form a gelcoat layer 1, which is then gelled. Next, a dispersion of a gold powder or the like in a transparent unsaturated polyester resin is sprayed to form a colored pattern layer 2 having a desired rugged pattern. On the outside of the colored pattern layer 2, an admixture of a transparent unsaturated polyester resin with a pigment or the like is applied uniformly by a spray-up method to form a colored layer 3. A rear reinforcing layer 5 comprising an ortho unsaturated polyester resin, which is loaded heavily with a white pigment, and glass fibers is formed on a female mold 6. The male mold 7 and female mold 6 are mated, and a mixture of an iso unsaturated polyester resin with colored pieces or the like is poured into the resulting mold, and is hardened to form a molding compound layer 4.

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) The present invention relates to a method for manufacturing a synthetic resin laminate structure that can be used as a material for bathtubs, bathroom wall materials, counters, waterproof pans, and the like.

(Prior Art) Conventionally, fiber-reinforced plastics using unsaturated polyester resin have been used as synthetic resin laminate structures for the purpose of increasing mechanical strength in bathtubs, ships, tanks, and the like. However, in recent years, synthetic resin laminated structures with patterned patterns have been studied in order to design structures suitable for aesthetic purposes and various other uses.

For example, a laminated structure has been proposed that uses transparent resin concrete hardened with unsaturated polyester resin to prevent warping of the molded product and cracks at corners (Japanese Patent Publication No. 49426/1983). In addition, a mica layer is provided on the surface layer and colored (Special Publication No. 61-25542
No. 25543) and a molded body made of resin concrete in which a pattern layer and a gel coat layer are sequentially laminated on the surface side of the surface side reinforcing layer have been proposed (Utility Model Application No. 63-125).
No. 530).

(Problem to be solved by the invention) However, in the case of adding a pattern with excellent surface design as in the latter case, it is necessary to add an inorganic substance or metal of a certain size other than powder as a filler. However, there is a problem that the pattern is limited and the filler is not uniformly dispersed in the unsaturated polyester resin, but settles and becomes non-uniform. Furthermore, if the weight of the filler is reduced too much, there is a problem that it will float on the unsaturated polyester resin.

On the other hand, there is a method of forming a pattern by painting, but there are problems in that it requires a large amount of work and has poor heat resistance and abrasion resistance. Therefore, the challenge is how to easily impart a dipped pattern or the like to a synthetic resin molded product and make it durable without impairing its aesthetic appearance.

(Means for Solving the Problems) In order to solve the above problems, the present invention has been made as a result of intensive research.
This design was created based on the fact that not only does it give an excellent three-dimensional effect when the pattern is seen below the transparent layer on the surface, but also that the pattern can be varied in a variety of ways by changing the thickness of the colored resin layer. A process of forming a transparent gel coat layer on the surface of a mold having a shape, applying a colored resin liquid after the gel coat layer has at least gelled, and changing the coating thickness with a tool so as to form a pattern, A synthetic resin laminate structure comprising the steps of forming a colored pattern layer, and then forming a reinforcing layer and a colored layer having a different hue, brightness, or saturation from the colored pattern layer. It's in the molding method.

In the present invention, the surface layer is formed as a transparent resin or a gel coat layer made of a lightly colored transparent resin.

Here, the gel coat layer is a thin synthetic resin layer that forms the surface of the product.It is transparent or almost transparent, and is usually made only of resin, with fillers mixed in (\) to give the product gloss, heat resistance, and stain resistance. It is a layer that provides water resistance and scratch prevention functions.The above-mentioned transparent resins include unsaturated polyesters, particularly bisphenol-based or isophthalic acid-based resins that have various properties such as hot water resistance, which have been conventionally used depending on the application. Saturated polyester resin is used. This forming method is usually done by applying a mold release agent to a mold (wood mold, FRP mold, metal mold, etc.) that has the surface shape of the product, and then spraying it. The thickness is A range of about 0.3 to 0.6+n[ll] is appropriate, and a viscosity of 1800 to 3000 cps is excellent in workability, and silica, styrene monomer, and organic thixotropic agents are used to adjust the viscosity.

Next, the colored pattern layer formed on this gel coat layer is formed after the gel coat layer is at least gelatinized (cured to the extent that the next spray does not blend). Therefore, it is preferable to perform heating at 50° C. for 30 minutes, for example.

This colored pattern layer may be made of a resin composition made of the same or similar transparent resin as the matrix resin of the gel coat layer, which is colored more strongly than the gel coat layer, and usually a resin composition with a viscosity of 500 to 4000 cps is used. .

This colored pattern layer is formed by applying the resin to a thickness of approximately 0.5 mm and rubbing the sprayed surface from under a tool such as a roller, spatula, etc. to form an uneven pattern as shown in Figure 3. Various uniformities can be formed by changing the thickness. Alternatively, the pattern layer may be formed by directly applying the resin to the gel coat layer using this tool.

As representative examples of the above-mentioned tools, those shown in FIGS. 6 to 8 can be used. Figure 6 shows 8mm with 16+nm spacing.
Diameter 30mm (, length 150n +
Figure 7 is a spatula with 8 square width grooves at 16 mm intervals, and Figure 8 is a brush with 8 + nm width grooves at 20 mm intervals. These can be used alone or in combination to create parallel continuous patterns, wavy patterns, etc. Patterns and irregular patterns can be formed.

A colored layer that forms the background of the pattern and a reinforcing layer that ensures the structural strength of the product are required as layers that are continuous with the surface layer and the colored spot layer. This colored layer is a spotted layer, hue, brightness,
The saturation must be the same (=must not exist, and one of them must be different.This colored layer is made of a transparent resin that is the same as or of the same type as the matrix resin of the upper gel coat layer, and is colored differently from the colored spot layer. It is preferable to use a resin composition that has been prepared.

The above-mentioned back reinforcing layer is usually formed by impregnating glass fiber with an unsaturated polyester resin; it is formed from fiber-reinforced plastic, but is not limited to such a reinforcing layer, and may include other reinforcing layers such as fibers. Non-thermosetting resins, wood, metal plates, etc. may be used.

A compound layer may be formed in place of the colored layer or between the colored layer and the reinforcing layer. In order to provide strength, this compound layer contains a large amount of filler in a transparent resin, forms a fairly thick layer, and is adjusted to be opaque or slightly transparent. As the transparent resin, unsaturated polyester resin may be used as in the surface layer. Glass frit, aluminum hydroxide, and other materials can be used as fillers. When the colored layer is omitted, it is preferable to color this compound layer.

As mentioned above, the embodiments of the present invention include the following embodiments.

1. G/Colored pattern layer/Colored G/C/FRP (Figure 2) 2. G/Colored pattern layer/Colored G/FRP or C (
(Fig. 4) 3. G/Colored pattern layer/Colored C/FRP (Fig. 5) Here, G means a gel coat layer, C means a compound layer, and FRP means fiber reinforced plastic.

(Operations and Effects of the Invention) According to the present invention, the colored layer is formed on the back side of the transparent gel coat layer in a shading pattern with uneven thickness as shown in Fig. 3, creating a sense of perspective when viewed from the surface. It is possible to create deep color patterns. That is, coloring is applied depending on the balance, and shading is formed depending on the step.

Also, by setting various shading conditions (pitch, groove width, step, balance), the size and proportion of the pattern can be changed arbitrarily, making it possible to produce patterns with various designs. It's easy.

In particular, the gel coat layer on the surface can impart heat resistance and abrasion resistance to the pattern.

Hereinafter, embodiments according to the present invention will be described in detail.

(Example 1) As shown in Figure 1 (■), a mold release agent was applied to the surface of the male mold 7, and
Pearl pigment (average diameter 20-200
0.1 part by weight of 14% by weight coating) was added and uniformly dispersed by stirring. A predetermined amount of a curing agent and a curing accelerator were added thereto, and to adjust the viscosity, a styrene monomer and an organic thixotropic agent were added to adjust the viscosity to a range of 1,800 to 3,000 cps. was applied uniformly to a thickness of 0.3 m to form a gel coat layer 1.

Thereafter, it is heated at 50° C. for 30 minutes to form a gel.

Next, as shown in FIG. Add 0.5 parts by weight of 14% by weight coating) and disperse uniformly by stirring to give a viscosity of 2.000 cps. Apply this in an amount of 200
g/min for minutes, and a desired uneven pattern is formed on the sprayed layer using the tools shown in FIGS. 6 to 8 described above to form the colored pattern layer 2.

As shown in FIG. 3, this colored pattern ranges from 1 to 5 mm in diameter and 0.5 to 2 mm in step depending on the unevenness conditions.

From above this colored pattern layer, 15 parts by weight of pigment (dark green) was added to 100 parts by weight of transparent unsaturated polyester resin (gel coat resin), as shown in Figure 1 (■).
Uniform dispersion was achieved by stirring. Add a predetermined amount of curing agent and curing accelerator to this, and further adjust the viscosity.
Add silica, styrene monomer, and organic thixotropic agent, and the viscosity is 1.
Colored layer 3
was formed.

On the other hand, as shown in Fig. 1 (■), a back reinforcing layer 5 made of ortho-unsaturated polyester resin containing a large amount of white pigment and glass fiber (mixed with 30% by weight) was applied to the female mold 6 by a hand lay-up method. Laminated at 0.8 m.

Fit the male mold 7 and the female mold 6 with a gap of about 10 nwn using Uni, and then add 100 parts by weight of iso-based unsaturated polyester resin, 180 parts by weight of glass frit, and a colored piece (white spherical unsaturated polyester resin). 10 parts by weight (average particle size 1 nn), a predetermined amount of a curing agent, and a curing accelerator are mixed, injected from the injection lower 1, and cured to form a casting compound layer 4.

In the appearance of the top-grained synthetic resin laminate molded product shown in Figure 2, the colored spot layer existing in the middle can be seen through the pearly layer, making it possible to obtain a molded product with a very deep patterned design. did it. Furthermore, the appearance differs depending on the viewing angle, and a molded article with a very high-class appearance is obtained.

(Example 2) A gel coat layer is formed in the same manner as in Example 1.

Next, a colored pattern layer was applied directly by placing resin on the tool, and the same procedure as in Example 1 was carried out except that the second colored gel coat layer (colored layer) 3 was not formed thereon, and the cross section shown in FIG. A laminated molded body having a shape is formed.

(Example 3) While the composition and formation method of the surface gel coat layer 11, colored pattern layer 2, and second gel coat layer 3 were the same as in Example 1,
In the second gel coat layer, a back reinforcing layer 5 made of an ortho-unsaturated polyester resin containing a large amount of white pigment and glass fiber (30% by weight) was thickened by hand lay-up method and laminated to a thickness of 8 nwn.

A laminate molded body having a cross-sectional shape shown in FIG. 4 was formed.

[Brief explanation of drawings]

Figures 1 - ■ are cross-sectional views showing the structural steps of a bathtub laminate molded body produced by the method of the present invention, Figure 2 is a cross-sectional view of a laminate molded body produced by the method of the present invention, and Figure 3 is a partially enlarged view of the same. figure,
Figures 4 and 5 are cross-sectional views of other embodiments of the laminate molded product manufactured by the method of the present invention, Figure 6 is a roller used in the method of the present invention, Figure 7 is a spatula, and Figure 8 is a brush. FIG. l... Surface gel coat layer, 2... Colored pattern layer, 3...
...Colored layer, 4... Compound layer, 5... Reinforcement layer Fig. 1 ■ 1 r ■ Fig. 2 Fig. 3 Fig. 4 Fig. 6 Fig. 7 Flash Fig. 8

Claims (1)

[Claims] 1. A step of forming a transparent gel coat layer on the surface of a mold having a product surface shape, and after the gel coat layer has at least gelled, a colored resin liquid is applied to form a pattern. The method includes a step of forming a colored pattern layer by changing the coating thickness using a tool, and a step of forming a reinforcing layer and a colored layer different in hue, brightness, or saturation from the colored pattern layer. Characteristic molding method for synthetic resin laminated structures.