JPH0911259A - Production of decorated molding - Google Patents

Abstract

PURPOSE: To prevent a resin component from flowing to the surface of a decorative sheet when a decorative sheet laminated molding having a design such as a free pattern or color is produced by providing a smooth part to the upper surface of a lower mold at the outer peripheral position of an uneven part and placing the end part of the decorative sheet on the smooth part. CONSTITUTION: After an upper mold 5 is heated to 140 deg.C and a lower mold 6 is heated to 150 deg.C, a decorative sheet 8 is placed on the upper surface of the lower mold 6 so that the end part thereof is positioned on the smooth part 4 of the lower mold 6 and an SMC molding material 7 cut in a predetermined size is placed on the decorative sheet 8. After the upper mold 5 is brought into contact with the SMC molding material 7, the upper mold 5 is allowed to fall at a speed of 2mm/sec to complete mold clamping and, thereafter, pressure molding is performed for 240sec under pressure of 70kg/cm<2> . Subsequently, the upper mold 5 is opened to demold a decorated molded product of a waterproof pan wherein an embossed pattern surface and narrow joints are applied to the bottom part thereof and a smooth part is formed to the outer periphery thereof. Therefore, an inferior product is hard to generate and the decorated molding is obtained with high molding efficiency.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION The present invention relates to a decorative sheet and a thermosetting molding material, which are placed in a mold in an overlapping manner and subjected to heat compression molding to integrate the decorative sheet and the molding material.
The present invention relates to a method for producing a decorative molded product that exhibits various designs having a desired pattern or color by using a decorative sheet.

[0002]

2. Description of the Related Art Conventionally, in the field of FRP (glass fiber reinforced plastic), especially in the production of FRP bathtubs, bath unit floors, etc., a method called a hand lay-up molding method or a spray-up molding method has been widely adopted. However, these methods have taken a long time and a lot of man-hours to produce one product. Therefore, as a material for significantly improving these productivity, thermosetting molding materials such as sheet molding compound (hereinafter abbreviated as SMC) or bulk molding compound (hereinafter abbreviated as BMC) have been developed. A heat compression molding method using this is widely adopted at present.

However, in the heat compression molding of SMC or BMC using only the thermosetting molding material, the color of the entire molded article is limited to a single color. The only problem is that only red ones can be produced, and the freedom of patterns and colors is narrowed. Of course, if the molded product is subjected to post-processing such as printing or painting, it is possible to add a design having an appropriate pattern or color, but in this case, it is necessary to add a complicated post-processing step, Productivity is further reduced.

Therefore, as a method of decorating these FRP products, there has been proposed a method of insert-molding a decorating sheet for adding a design having a desired pattern or color to a molded product. For example, a decorative sheet obtained by printing a desired pattern on a substrate such as a glass cloth, a glass mat, a non-woven fabric, or a woven fabric is placed on a SMC, placed in a mold, and subjected to heating and compression molding. A method of decorating a molded product by integrating a decorative sheet and a molding material has been proposed.

Further, in Japanese Unexamined Patent Publication No. 5-285973, SMC is superposed on a decorative sheet made by impregnating a thermosetting resin on titanium paper on which a desired pattern is printed, and heat compression molding is performed. A method for obtaining a decorated molded article is disclosed.

[0006]

However, in the conventional heat compression molding method as described above, in the case where the product has a shape having an embossed surface, the uneven portion of the mold and the decorative sheet are There is a drawback in that a gap is likely to be formed between the two, and this causes the resin component of the SMC to flow into the surface side of the decorative sheet. Therefore, according to the conventional method, it is possible to make a product with a very low molding efficiency and a comparatively slight flow-in defect by making a correction, but this correction work is performed manually. Because
It has a drawback that it requires labor and time, and the total cost becomes very high.

The present invention has been made to solve the above-mentioned drawbacks, and in molding a decorative sheet laminated molded product having a design such as a free pattern or color, a resin component is applied to the surface side of the decorative sheet. It is an object of the present invention to provide a method for producing a decorated molded product that can prevent the defective product from flowing in and that can prevent it from flowing.

[0008]

The method for producing a decorated molded product according to the present invention is devised to achieve the above object, and is provided on a lower mold having an uneven portion for forming a product embossed surface on the upper surface. , A decorative sheet is placed, a thermosetting molding material is placed on the decorative sheet, and these are heat-compressed in a state of being sandwiched by a lower mold and an upper mold, thereby forming a decorative molded product. Is provided on the upper surface of the lower mold, and a smooth portion located on the outer periphery of the uneven portion is provided, and the end portion of the decorative sheet is placed on the smooth portion.

Hereinafter, the present invention will be described in detail.

The decorative sheet used in the present invention is a colored or printed sheet-like reinforcing material. This decorative sheet can be appropriately impregnated with a thermosetting resin composition. When the thermosetting resin composition is impregnated, the thermosetting resin composition is hardened in the mold, and a hard and excellent decorated surface can be obtained.

Examples of the sheet-like reinforcing material include woven cloth and non-woven cloth made of paper, glass fiber, or synthetic fiber (polyester, polypropylene, rayon, nylon, etc.).

Specific examples of the sheet-like reinforcing material include titanium paper, overlay paper, high-quality paper, medium-quality paper, waste paper, art paper, coated paper, glass chop strand mat, glass filament mat, glass continuous mat, Examples include glass roving cloth, glass surface mat, polyester woven cloth, nylon woven cloth, polyester non-woven cloth, and polypropylene non-woven cloth.

The basis weight of the above-mentioned paper, woven fabrics and non-woven fabrics made of organic fibers is generally 10 to 300 g / m ² , while the basis weight of woven fabrics and non-woven fabrics made of inorganic fibers is generally 100 to 500 g / m ^2. .

The amount of the thermosetting resin composition impregnated in the sheet-shaped reinforcing material is, when an organic type is used as the sheet-shaped reinforcing material, relative to the total weight of the impregnated sheet after impregnation. It is preferably blended so as to be 30 to 70% by weight, more preferably 40 to 60% by weight.

On the other hand, when an inorganic material is used as the sheet reinforcing material, the impregnated amount of the thermosetting resin composition is 10 to 50% by weight based on the total weight of the impregnated sheet after impregnation. It is preferably blended so as to be, and more preferably 20 to 40% by weight.

The method of decorating the sheet includes printing and coloring. Here, the printing method may be any conventionally known method, and specific examples thereof include a gravure printing method, an offset printing method, a screen printing method, and a letterpress printing method. As a coloring method, a known method may be used, and for example, a method of using fibers colored with a dye may be used.

In order to improve the design, a sheet-shaped reinforcing material or a thermosetting resin composition is granulated with a thermosetting resin molded product crushed, natural mica, colored mica, cold water stone, natural stone powder. Pattern materials such as shells and metal powder, pigments and dyes may be added.

In the present invention, when the decorative sheet is impregnated with the thermosetting resin composition, examples of the thermosetting resin composition include unsaturated polyester resin, epoxy acrylate resin, diallyl phthalate resin, melamine resin and urethane. A composition containing various thermosetting resins such as an acrylate resin and a phenol resin as a main component can be used.

If necessary, a solvent, a copolymerizable monomer, or the like may be added to the above-mentioned thermosetting resin composition. For example, in the case of a resin having a high viscosity, a solvent or the like is added to improve the impregnating property to reduce the viscosity. Further, in the case of a resin having low reactivity, it is possible to improve the reactivity by adding a copolymerizable monomer such as styrene, α-methylstyrene, divinylbenzene, vinyltoluene, diallylphthalate, various acrylate monomers and various methacrylate monomers. .

The amount of the above-mentioned copolymerizable monomer added is usually
It is 0 to 100 parts by weight with respect to 100 parts by weight of the thermosetting resin.

If desired, various fillers and additives may be added to the thermosetting resin composition. Specifically, fillers such as calcium carbonate, alumina, aluminum hydroxide, polymerization initiators such as organic peroxides, polymerization inhibitors such as parabenzoquinone, internal mold release agents such as zinc stearate, fungicides, Preservatives, antioxidants, etc. are added in appropriate amounts.

The sheet base material can be impregnated with the resin by a conventionally known method. That is, for example, a method of immersing a sheet base material in a tank containing the resin to impregnate the resin, pressing the base material with a roll or the like to remove excess resin, and drying in a drying furnace as necessary, or There is a method in which a sheet base material is flown on a belt, a resin is placed on the base material, and the base material is pressed by a roll or a blade.

In the present invention, as the thermosetting molding material, those conventionally used as various thermosetting molding materials such as SMC and BMC can be used.

An example of preparation of the thermosetting molding material is as follows. That is, an unsaturated polyester resin, an epoxy acrylate resin, a urethane acrylate resin or the like is used as the thermosetting resin, and if necessary, various fillers,
Reinforcing materials, additives, etc. are added, and by a conventionally known method,
A thermosetting resin composition having a form such as SMC or BMC is prepared.

The manufacturing method of the present invention is carried out using the above-mentioned materials, and the specific operation is as follows.

As the molding machine used in the present invention, a conventionally known press molding machine can be used. As the mold, conventionally known molds, casting molds and the like can be used.

In general, the upper and lower molds are preferably used as the form of the mold. In this case, the upper mold is usually used as a movable mold and the lower mold as a fixed mold.

It is necessary that the upper surface of the lower mold is provided with an uneven portion for forming a product embossed surface. As the uneven portion, for example, a flow pattern, a stone pattern, an emboss, a geometric pattern,
It consists of joints. The height of the uneven portion is generally 2 mm or less. If the height of the uneven portion is increased, the decorative sheet may be broken. Further, it is necessary to provide a smooth portion on the outer peripheral portion of the uneven portion. Here, the width of the smooth portion is generally 2 mm or more. If the width of the smooth portion is too short, the effect of preventing the inflow is reduced.

The above molding machine is attached to the above molding machine,
After heating to 80 to 180 ° C., the decorative sheet that is the material to be compressed and the molding material are stacked and placed in the target position in the mold with the mold opened.

Then, the end portion of the decorative sheet is placed on the smooth portion of the lower mold. At this time, it is preferable to place the decorative sheet on the smooth portion for at least 1 mm or more. If it is less than 1 mm, the flow-in prevention effect becomes small. Next, the molding material is placed on it.

Here, the charge of the thermosetting molding material is
When the size of the decorative sheet is used to decorate the entire surface of the molded product, it is preferable to charge a thermosetting molding material that is slightly smaller than the decorative sheet. If it is considerably smaller than the decorative sheet, the decorative sheet may be broken. If it is larger than the decorative sheet, flow-in tends to occur.

When only a part of the surface of the molded product is to be decorated, a thermosetting molding material a little smaller than the decorative sheet is placed on the decorative sheet, and almost all the surface of the molded product is placed on it. It is preferable to mount a thermosetting material. With other charges, the decorative sheet may be broken and the thermosetting molding material may flow in.

The surface on which the decorative sheet is placed on the lower mold is usually a surface that is printed or colored more, but if necessary, the molding material side may be printed or printed. It may be a colored surface.

After that, the mold was closed, and 2 to 150 kg /
If pressure molding is performed at a pressure of cm ² for 30 seconds to 15 minutes to cure the molding target, the mold is opened, and the product is demolded.
A laminated decorative molded product is obtained.

Here, the molding pressure is 2 to 150 kg.
/ Cm ² , preferably 10 to 120 kg / cm ² . In particular, when a molding material such as general-purpose SMC or BMC is used, it is preferably 50 to 120 kg / cm ^2, and when a molding material for low pressure molding, which is so-called low pressure SMC, is used. , 5-25
It is preferably set to kg / cm ² . If the molding pressure is too low, the molding material has a drawback that it is difficult to obtain sufficient fluidity. On the contrary, if it is too high, the mold is likely to deteriorate during mass production, which is not preferable in any case.

[0036]

In the manufacturing method of the present invention, the upper surface of the lower mold is
A gap is created between the decorative sheet and the concave / convex part of the lower mold by providing a smooth part located on the outer periphery of the uneven part for forming the product embossed surface and placing the end of the decorative sheet on this smooth part. Therefore, it becomes difficult to cause defects such as the resin component of the molding material flowing into the decorative sheet.

[0037]

Embodiments of the present invention will be described below with reference to the drawings.

In this example, as shown in FIG. 1, the embossed partition formed by narrow joints (13) was formed on the bottom of the molded product of the waterproof pan (11) obtained by the method of the present invention. A surface (12) and a smooth portion (14) around these surfaces were formed.

1. Preparation of Molding Machine and Mold Next, in FIG. 2, an 800-ton press molding machine manufactured by Kawasaki Yuko Co., Ltd. was used as the molding machine. 117 for the mold
An upper mold (5) and a lower mold (6) for molding a cm × 87 cm waterproof pan (11) (see FIG. 1) were prepared. Upper mold (5), lower mold
Steam piping (not shown) was embedded in both (6).

On the upper surface of the lower mold (6), a height of 0.2
An uneven portion (2) for forming a product embossed surface and a flat portion (3) for forming a joint are provided vertically and horizontally. A smooth portion (4) having a width of 8 mm was provided on the outer periphery of the uneven portion (2).

This mold was attached to the above press molding machine. The upper mold (5) was a movable mold and the lower mold (6) was a fixed mold.
On the side edge of the lower die (6), a guide pin for positioning
(9) is provided to project upward, and the upper mold (5) is correspondingly provided.
Is provided with a guide hole (10).

2. Adjustment of decorative sheet The decorative sheet (8) was adjusted as follows.

1) Preparation of impregnating resin liquid (1) Unsaturated polyester resin liquid (number average molecular weight of about 830
100 parts by weight of 0: isophthalic acid type unsaturated polyester resin dissolved in acetone: toluene mixed solvent (1: 1), solvent 35% by weight (2) Polymerization initiator (tertiary butyl peroxybenzoate) 1 part by weight Parts (1) and (2) above were mixed and stirred to obtain a resin solution for impregnation.

2) Adjustment of the decorative sheet (8) Decorative sheet 1: titanium paper (thickness 0.1 mm, 80 g / m
² , PM11P: manufactured by Kojin Co., Ltd., which has a stone pattern printed on it, is cut into a size of 78 cm × 108 cm, and this cut piece is immersed in the above resin liquid to impregnate the resin, and then the cut piece is rolled. Pressed with to remove excess resin, and decorative sheet 1 was obtained. The weight ratio of the base material (paper) in this decorative sheet is 50.
% By weight.

Decorative sheet 2: cloth (made of nylon, thickness: 0.
A decorative sheet 2 was obtained in the same manner as the decorative sheet 1 except that a stone pattern was printed on 1 mm, 90 g / m ² , manufactured by Toyobo Co., Ltd.). The weight ratio of the base material in this decorative sheet is 4
It was 5% by weight.

Decorative sheet 3: non-woven fabric (made of polyester,
Thickness 0.36 mm, 40.7 g / m ^Two, Sontara # 80
00: Made by Toray-Dupont) with a stone pattern printed
A decorative sheet 3 is obtained in the same manner as the decorative sheet 1 except that it is used.
Was. The weight ratio of the base material in this decorative sheet is 50% by weight.
Met.

Decorative sheet 4: glass cloth (thickness 0.2
5mm, 200g / m ² , plain weave, WF230100B
S6: Nitto Boseki Co., Ltd.), a decorative sheet 4 was obtained in the same manner as the decorative sheet 1 except that a stone pattern was printed. The weight ratio of the base material in this decorative sheet was 35% by weight.

Decorative sheet 5: glass mat (thickness 0.3
A decorative sheet 5 was obtained in the same manner as the decorative sheet 1 except that a stone pattern was printed on 0 mm, 300 g / m ² , MC300A104: manufactured by Nitto Boseki Co., Ltd. The weight ratio of the base material in this decorative sheet was 35% by weight.

Decorative sheet 6: overlay paper (thickness: 0.
A decorative sheet 6 was obtained in the same manner as the sheet 1 except that a stone pattern was printed on 12 mm, 100 g / m ² (manufactured by Kojin Co., Ltd.). The base material (paper) content of the obtained decorative sheet was 45% by weight.

3. Preparation of molding material The following was used as the molding material (7).

(1) Unsaturated polyester resin liquid (40% by weight of styrene, even if an isophthalic acid-based unsaturated polyester resin having a number average molecular weight of about 2000 is dissolved in styrene) 70 parts by weight (2) Polystyrene resin liquid ( Weight average molecular weight about 95,000
Polystyrene resin dissolved in styrene, styrene concentration 65% by weight) 30 parts by weight (3) Polymerization initiator (tertiary butyl peroxybenzoate) 1 part by weight (4) Calcium carbonate powder (NS-100: Nitto powder) Chemical Co., Ltd.) 120 parts by weight (5) Coloring pigment (titanium oxide powder, SR-1: Sakai Chemical Industry Co., Ltd.) 6 parts by weight (6) Thickener (magnesium oxide powder, average particle size about 3 μ)
m, Kyowamag 150: Kyowa Chemical Industry Co., Ltd.) 1 part by weight (7) Internal mold release agent (zinc stearate: Sakai Chemical Industry Co., Ltd.)
3 parts by weight (8) Glass fiber (Roving made by Asahi Fiber Glass Co., Ltd .: ER4630LBD166W cut into a length of 25 mm, hereinafter abbreviated as GF) 70 parts by weight Compounds (1) to (7) of the above compounding materials After the materials are mixed and sufficiently kneaded, the resulting kneaded product is impregnated into the glass fiber of (8) by an SMC manufacturing device, and the mixture is heated at 40 ° C for 24 hours.
After aging for a time, a colored (white) SMC molding material having a thickness of about 2 mm was obtained.

4. Molding method The SMC molding material (7) and the decorative sheet (8) thus obtained were molded as follows.

(Example 1) As shown in FIG. 2, the upper die
After heating (5) to 140 ° C and lower mold (6) to 150 ° C, the above decorative sheet 1 is used as the decorative sheet (8), and the end portion (8a) of the decorative sheet 1 is on the smooth portion (4). It was placed on the upper surface of the lower mold (6). 70 cm x 1 of the above SMC molding material (7)
Five pieces cut into a size of 00 cm were charged. 30m from the position where the upper mold (5) contacts the SMC molding material
m up to 50 mm / sec, 30 mm above the position to contact the SMC molding material (7) to 10 mm / sec until it contacts the SMC molding material (7), and then to the SMC molding material (7) until the deadline The upper mold (5) was clamped at a speed of 2 mm / sec, and after closing, pressure molding was performed at a pressure of 70 kg / cm ² for 240 sec. After that, open the upper mold (5) and remove the mold, and as shown in Fig. 1, embossed surface (12) on the bottom.
And narrow joints (13) and a smooth part (14) on the outer circumference.
A decorative molded article of the waterproof pan (11) in which the above was formed was obtained. This molding was repeated 10 times to obtain 10 molded products.

(Examples 2 to 6) Molding was performed in the same manner as in Example 1 except that the decorative sheet (8) shown in the table below was used.

(Comparative Examples 1 to 6) A decorative sheet of 77 cm ×
Molding was performed in the same manner as in Example 1 except that the decorative sheet was cut into 107 cm, and the decorative sheet was placed on the lower mold so that the end portion of the decorative sheet was on the embossed surface.

In each of the examples and comparative examples, as in Example 1, molding was repeated 10 times to obtain 10 molded products.

5. Evaluation Method In each of the above Examples and Comparative Examples, the molded articles obtained were visually evaluated for the presence or absence of SMC inflow.

[0058]

[Table 1]

[Table 2] As is clear from the results of Table 1 and Table 2 above, in each of the examples of the present invention, there was no defect, but in the comparative example, the defect rate was high.

[0059]

EFFECTS OF THE INVENTION Since the method for producing a decorated molded product according to the present invention is configured as described above, it is possible to prevent defective products from occurring and to easily form a beautifully decorated molded product with high molding efficiency. The effect that it can manufacture is produced.

[Brief description of the drawings]

FIG. 1 is a schematic plan view of a waterproof pan manufactured by the method of the present invention.

FIG. 2 is a schematic vertical sectional view of an apparatus for carrying out the method of the present invention, showing a state before molding by a mold.

[Explanation of Codes] 2: Concavo-convex part for forming product embossed surface 3: Flat part for forming joints 4: Smooth part 5: Upper mold 6: Lower mold 7: Molding material (SMC) 8: Decorative sheet 8a: Edge of sheet Part 11: Waterproof pan (molded product) 12: Product embossed surface 13: Joint part 14: Smooth part

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁶ Identification code Agency reference number FI Technical display location B29L 9:00

Claims (1)

[Claims] 1. A decorative sheet is placed on a lower mold having an uneven portion for forming a product embossed surface on its upper surface, and a thermosetting molding material is placed on the decorative sheet. A method for producing a decorative molded product by heating and compressing in a state of sandwiching between a lower mold and an upper mold, wherein a smooth part located on the outer periphery of the uneven portion is provided on the upper surface of the lower mold. A method for producing a decorative molded article, characterized in that the end of the decorative sheet is placed on.