JPH07256668A - Manufacture of patterned molded product - Google Patents

Abstract

PURPOSE:To manufacture a patterned molded product at once by a compression molding method by arranging a partial nonwoven fabric to a mold of a clamped state and laminating a sheet molding compd. having decorative patterns to the nonwoven fabric and subjecting the whole to compression molding. CONSTITUTION:A mold forms a cavity having an inner surface shape of an object to be molded, for example, a waterproof pan at the time of clamping. At first, upper and lower molds 11 are heated and a nonwoven fabric 2 is arranged to the peripheral part of the washing place forming part 111 of the molding surface of the lower mold 11. Next, a sheet molding compd. (SMC) containing a decorative granular material is laminated to the entire surface of the washing place farming part 111 and a monochromatic SMC is laminated thereon to perform compression molding under pressure and heating. By this constitution, the nonwoven fabric 2 functions as a filter to prevent the outflow of the decorative material in the SMC and a non-pattern part having the nonwoven fabric 2 on the surface thereof is formed to the peripheral part of the washing place forming part and stone grain patterns composed of the SMC having decorative patterns are formed to the central part surrounded by the non-pattern part.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a sheet molding compound having a decorative pattern (hereinafter referred to as SMC).
The present invention relates to a method for producing a patterned molded article by applying a beautiful decorative pattern to a part of the surface of the molded article such as a bath tub with a washing place and a waterproof pan made of fiber reinforced resin (hereinafter referred to as FRP). .

[0002]

2. Description of the Related Art In recent years, FRP-made molded articles with a high added value having a decorative pattern such as a stone pattern on the surface have been provided.

Conventionally, as a method for producing such a patterned molded article, as described in, for example, JP-B-3-38092, a release resin surface of a polyester sheet is coated with a compound of clear resin, Grain-forming granules are attached to the surface, a colorant is further applied to form a stone sheet, this stone sheet is set so that the release sheet side faces the molding die, and the molding material is set on it. Cure
A hand lay-up method has been proposed in which the release sheet is peeled off after curing.

[0004]

However, this method is not suitable for obtaining a molded product having a partially stone pattern on the surface of the molded product (for example, entirely composed of a lattice pattern).
There is a problem that it requires a lot of hand layup work. Also, there is a problem that even if an attempt is made to express a pattern that is properly divided, the flow of the compound causes the boundary to be somewhat blurred.

SUMMARY OF THE INVENTION It is an object of the present invention to solve the above problems of the prior art and to provide a method capable of producing a patterned molded article having a beautiful decorative pattern on the surface at one time by a compression molding method. It was made as.

[0006]

SUMMARY OF THE INVENTION The present invention is a method for producing a patterned molded product using a mold that can be opened and closed, wherein a nonwoven fabric is partially disposed in the mold in the open mold state. This is a method for producing a molded article with a pattern in which SMC having a decorative pattern is laminated on a non-woven fabric and then compression molded.

In the present invention, SMC is a sheet-like material in which a paste-like mixture of a thermosetting resin and a thermosetting agent is impregnated into reinforcing fibers, and both sides are covered with a film to form a sheet.
This is a product which is kept at a predetermined temperature for a certain period of time to be thickened by a chemical reaction so as to have no tackiness.

As the thermosetting resin in SMC, for example, unsaturated polyester resin, vinyl ester (epoxy acrylate) resin, urethane acrylate resin and the like are used. The curable resin may be used alone,
A plurality of types may be mixed and used.

As the unsaturated polyester resin, an organic polyol, an aliphatic unsaturated polycarboxylic acid, and, if necessary, an aliphatic saturated polycarboxylic acid and / or an aromatic polycarboxylic acid are used by a known and commonly used method. And the like can be used.

As the vinyl ester resin, a resin produced by a known and commonly used method from an epoxy resin and a monocarboxylic acid having a reactive double bond such as (meth) acrylic acid can be used.

As the urethane acrylate resin, an organic polyisocyanate is usually reacted with an organic polyol such as an alkylene diol, an alkylene diol ester, an alkylene diol ether, a polyether polyol or a polyester polyol, and a hydroxyalkyl (meth) acrylate is further reacted. It is possible to use the one produced by the above, but it is also possible to use it by leaving a free isocyanate group at a part of the terminal and combining this with the vinyl ester resin.

As the thermosetting agent, conventionally known ones can be used, for example, t-butyl perbenzoate,
t-Butyl peroxypropyl carbonate or the like is used.

In the present invention, the amount of the thermosetting agent added in SMC is 100 parts by weight of the thermosetting resin.
A range of 0.5 to 5 parts by weight is preferably used.

As the reinforcing fibers, chopped strands such as glass fibers, mats, etc. are preferably used.

In the present invention, a filler such as calcium carbonate, a low-shrinking agent such as polystyrene, a release agent such as zinc stearate, a thickener such as magnesium oxide and the like are appropriately added to the SMC.

In the present invention, SMC having a decorative pattern
As the decorating material for forming the decorating pattern inside, a decorating granular material, a decorating fibrous material, or the like is used.

As the particulate material for decoration, for example, an inorganic material such as colored mica or metal powder, or an organic material such as FRP or resin chip, which is crushed or scraped, is used although it depends on the pattern to be applied. . In addition, these may be surface-treated in order to color them or to improve the adhesion with the molding material containing the curable resin.

As the decorative fibrous material, for example, glass chop, carbon fiber, wool, etc. are used. In addition, these may be surface-treated in order to color them or to improve the adhesion with the molding material containing the curable resin.

In the present invention, as the non-woven fabric, for example, a non-woven fabric made of natural fibers or synthetic fibers such as cotton, rayon, acetate, nylon, polyvinyl chloride, polypropylene and the like is used. The non-woven fabric is obtained by impregnating a thermosetting resin such as an unsaturated polyester resin, an epoxy resin, or a phenol resin with a resin compound containing a polymerization initiator such as a peroxide and a release agent such as a fatty acid metal salt. Good.

As the non-woven fabric, a non-woven fabric is used when the decorative pattern is a single color, and a non-woven fabric having a printed pattern is appropriately used for other patterns. Further, the basis weight of the nonwoven fabric is appropriately determined according to the decorative material forming the decorative pattern.

In the present invention, the molding die is, for example, a compression molding die comprising a lower die and an upper die,
A cavity having an inner surface shape corresponding to the outer surface shape of the molded product to be molded is formed between the lower mold and the upper mold in the flat mold, and is used, for example, for molding a waterproof pan for a bathroom unit washroom. . Further, it is possible to use a mold in which a concave groove for forming a rib of a molded product to be molded is provided on the mold surface forming the cavity of the lower mold or the upper mold.

[0022]

The method for producing a patterned molded article of the present invention is a method for producing a patterned molded article using a mold that can be opened and closed, in which a nonwoven fabric is partially arranged in the open mold. By laminating the SMC having a decorative pattern on the non-woven fabric and then compression-molding the non-woven fabric, the non-woven fabric acts as a filter, and the granular particles for decoration or the fibrous substance for decoration in the SMC having the decorative pattern. Since the decorative material such as SFC does not flow out to the surface, a patterned molded product formed of SMC with a decorative pattern only on a part of the surface without distortion is formed by compression molding. It can be manufactured with high productivity.

[0023]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below with reference to the drawings by embodiments. Example 1 FIG. 1 is a cross-sectional view showing an example of a molding die for compression molding for molding a waterproof pan made of FRP having a stone pattern partially used for an example of the present invention. The molding die 1 is composed of a lower die 11 and an upper die 12, and between the lower die 11 and the upper die 12, a cavity 13 having an inner surface shape corresponding to the outer surface shape of the waterproof pan to be molded when being flat. Are formed.

First, the temperature of the lower mold 11 is 140 ° C., and the upper mold 1
With the temperature of 2 kept at 145 ° C., as shown in FIG. 2, polyester fiber non-woven fabric (manufactured by Unitika Ltd., product name “Marix”) 2 is placed around the washing surface forming part 111 on the mold surface of the lower mold 11. Set up. Next, although not particularly shown, SMC (manufactured by Dainippon Ink and Chemicals, Inc., trade name "Dixut 9201") 3 having a thickness of 2 mm is formed on the entire surface of the washing place forming portion 111, although not particularly shown. 3 plies are laminated, and a single color SMC (manufactured by Nippon Shokubai Kagaku Co.,
Product name "2531GBR") having a thickness of 2 mm is laminated on one ply, and compression molding is performed under a pressure and heating pressure of 75 kg / cm ² , and a thickness of 10 mm and a size of 1100 mm x
A 1600 mm FRP waterproof pan was obtained.

As shown in FIG. 3, in the obtained FRP waterproof pan 4, a non-patterned portion 2'having a nonwoven fabric on the surface is formed in the peripheral portion of the washing area 41 and surrounded by the non-patterned portion 2 '. A beautiful stone pattern 3 having no distortion and made of SMC having a decorative pattern in the central portion was formed.

Embodiment 2 As shown in FIG. 4, the washing area forming portion 111 on the die surface of the lower die 11
The polyester fiber non-woven fabric 5 is disposed in the nine positions of the above, and the SMC and the monochromatic SM having the stone pattern including the particulates for decoration (not shown) are provided on the entire surface of the washing place forming portion 111.
FRP was prepared in the same manner as in Example 1 except that C was laminated.
Got a waterproof pan made of. The FRP obtained as shown in FIG.
The waterproof pan 7 made of water has a non-patterned part 5'having a non-woven fabric on its surface at 9 places in the washing place 71, and a beautiful stone without distortion that is made of SMC having a lattice-like decorative pattern at the parts other than 9 places. The pattern 6 was formed.

[0027]

The method for producing a patterned molded article of the present invention comprises:
Since it is configured as described above, only a part of the surface,
It is possible to simultaneously produce by compression molding a patterned molded article, which is formed of SMC having a decorative pattern and has a beautiful decorative pattern without distortion, by compression molding.

[0028]

[Brief description of drawings]

FIG. 1 is a cross-sectional view showing an example of a molding die used in an embodiment of the present invention.

FIG. 2 is a plan view illustrating a process of an example of the present invention.

FIG. 3 is a plan view showing a waterproof pan obtained according to an embodiment of the present invention.

FIG. 4 is a plan view illustrating a process of another embodiment of the present invention.

FIG. 5 is a plan view showing a waterproof pan obtained according to another embodiment of the present invention.

[Explanation of symbols]

 1 Mold 2,5 Non-woven fabric 2 ', 5' Unpatterned part 3,6 Stone pattern 11 Lower mold 12 Upper mold 13 Cavity 111 Washing place forming part 41,71 Washing place

Claims (1)

[Claims] 1. A method of manufacturing a patterned molded article using a mold that can be opened and closed, wherein a nonwoven fabric is partially disposed in the mold in an open state, and a decorative pattern is provided on the nonwoven fabric. A method for producing a molded article with a pattern, which comprises compression-molding after laminating sheet molding compounds.