JPH091765A - Patterned sheet and manufacture thereof - Google Patents

Abstract

PURPOSE: To prevent generation of defective appearance on a molding by forming a coat having uniform thickness at the time of molding and preventing color coatings from mixing with each other. CONSTITUTION: A surface of a sheet 1 is coated with plain color or multicolor color coatings 2 and cured completely so as to form a coat 3. On the surface of the coat 3, a coat reinforcing material 4 to be formed of an unwoven cloth is provided. The color coatings 2 are cured completely so as to form a firm coat 3 and the coat 3 is reinforced by a coat reinforcing material 4, so that the coat 3 can be prevented from being excessively softened by heat pressure at the time of molding and can be prevented from flowing which occurs due to pressure at the time of molding. Even when the coat 3 is formed by the multicolor color coatings 2, the color coatings 2 can be prevented from mixing with each other.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a patterning sheet used for molding a patterned molded article used for floor pans, walls, ceilings, and sink tops of bathrooms, washrooms, toilets, etc. The present invention relates to a manufacturing method.

[0002]

2. Description of the Related Art Conventionally, waterproof floor pans for bathroom units and the like have been formed of patterned products made of fiber reinforced plastic (FRP) with a stone pattern such as granite or marble. For example, Japanese Patent Application No.
A patent application has been filed as No. 320410.

As described above, the method for producing a patterned molded article for which a patent has been applied is such that a colored coating material is applied to one side of a polyester sheet, and a coating film is formed on one side of the sheet with a glass cloth or a glass surface mat. A reinforcing material is laminated, and a resin-impregnated non-woven fabric or a coating-film protective material formed of a resin-impregnated non-woven fabric and a resin-impregnated glass cloth is laminated on the surface of the coating film reinforcing material, and this is heated to semi-cure the colored paint. To form a coating film to create a patterning sheet, set this patterning sheet in the mold, and stack the molding material on the patterning sheet and set it in the mold, and heat and press the molding material in the mold. A molded article is formed by molding, and a coating film is cast on the surface of the molded article by this pressure heating molding to form a pattern, and after demolding, the sheet is peeled off from the surface of the molded article.

In the patterning sheet of this application, the colored paint is semi-cured to form a coating film, so that the coating film is very easy to flow, and even a little resin of the molding material reaches the coating film during molding. Then, the coating film will collapse. Therefore, by providing a resin-impregnated non-woven fabric or resin-impregnated glass cloth coating protective material on the surface side of the coating film, the molding material does not flow into the coating film due to heat and pressure during molding. In this way, the coating film is prevented from collapsing and the resin of the molding material is prevented from seeping out onto the surface of the molded product.

[0005]

However, in the above-mentioned conventional patterning sheet, since the coating film is formed by semi-curing the colored coating material, the coating film is excessively softened by heat and pressure during molding, There is a problem that the coating film will flow due to the pressure applied during molding and it will not be possible to form a coating film with a uniform thickness.If a coating film is formed with colored paints of multiple colors, the coating film will not be formed due to the molding pressure. There is a problem in that the colored coating materials are mixed with each other by flowing, and a beautiful pattern cannot be formed on the molded product, resulting in defective appearance of the molded product.

Further, in the above-mentioned conventional patterning sheet, since the coating film protective material formed of the resin-impregnated nonwoven fabric or the resin-impregnated glass cloth is provided on the surface side of the coating film, the resin contained in the coating film protective material at the time of molding. However, there is a problem in that the particles flow into the coating film and pass therethrough, and ooze out onto the surface of the molded product, in particular, the corners and convex portions of the irregularities of the molded product, where the molding pressure is applied. Further, there is a problem that it is difficult to match the color of the resin contained in the coating film protective material with the color of the resin contained in the molding material, and the difference in color generated thereby impairs the appearance of the molded product. Further, when a plurality of coating film protective materials are laminated on the coating film, there is a problem that air does not escape between the coating film protective materials during molding and the surface of the molded product swells. In addition, a non-woven fabric or glass cloth must be impregnated with a resin to form a coating film protective material, which has a problem that the number of steps is increased, the cost is increased, and the lead time is lengthened.

Further, in the above-mentioned conventional patterning sheet, it is not possible to easily confirm the coating amount when the coloring paint is applied to the sheet, and variations in the coating amount cause defects such as see-through of the pattern in the molded product. There was a problem of doing. In addition, if the coating film reinforcing material is formed of glass cloth or glass surface mat, it is not possible to completely impregnate the coating film reinforcing material with the colored coating material before curing, resulting in an unimpregnated portion of the colored coating material during cutting or storage. However, there is a problem that a coating film is damaged during transportation. Further, when the colored coating material is dried and cured by heating, there are problems that wrinkles occur in the sheet due to heat shrinkage of the sheet, the coating film peels from the sheet, and the coating film peels from the coating film reinforcing material. It was

The present invention has been made in view of the above points, and it is possible to form a coating film having a uniform thickness at the time of molding, and prevent color paints from being mixed with each other to cause a defective appearance of a molded product. The resin can be prevented from seeping out onto the surface of the molded product, and the appearance of the molded product is not spoiled by different colors. It is possible to prevent it from occurring, and it is possible to prevent the number of processes from increasing, the cost to increase, the lead time to increase, and the occurrence of a see-through pattern on the molded product. In addition, it is possible to prevent the coating film from being damaged during cutting, storage, and transportation, and to cause wrinkles on the sheet, the coating film to peel from the sheet, and the coating film to peel from the coating film reinforcement material. What to do It is an object to provide a texturing sheet and a manufacturing method thereof can be made to have no.

[0009]

A patterning sheet A according to claim 1 of the present invention forms a coating film 3 by applying a single color or a plurality of colors of a color paint 2 on the surface of the sheet 1 and completely curing it. The coating sheet 3 is provided with a coating film reinforcing material 4 formed of a non-woven fabric on the surface of the coating film 3. Further, the patterning sheet A according to claim 2 of the present invention is the patterning sheet A according to claim 1. In addition to the constitution, one of the polyester non-woven fabric 6 and the glass non-woven fabric 7 is provided on the surface of the coating film reinforcing material 4 as the coating film protecting material 5.

Further, in addition to the constitution of claim 1, the patterned sheet A according to claim 3 of the present invention comprises both the polyester non-woven fabric 6 and the glass non-woven fabric 7 as the coating film protective material 5 of the coating film reinforcing material 4. It is characterized by being provided on the surface. The method for producing a patterned sheet according to claim 4 of the present invention comprises: applying a single color or a plurality of colors of color paint 2 to the surface of the sheet 1, and then laminating a coating film reinforcing material 4 on the surface of the sheet 1. Then, the colored paint 2 is dried and completely cured to form the coating film 3.
Is formed.

According to a fifth aspect of the present invention, in addition to the configuration of the fourth aspect, the patterning sheet manufacturing method further includes the sheet 1
When the colored paint 2 is applied to the surface of the sheet 1, light is applied to the sheet 1 from the surface side opposite to the coated surface of the sheet 1. The method for producing a patterned sheet according to claim 6 of the present invention, in addition to the configuration of claim 4 or 5, cures the colored paint 2 while fixing at least two sides of the sheet 1 and the coating film reinforcing material 4. It is characterized by that.

[0012]

[Function] Single-color or multi-color coloring paint 2 on the surface of the sheet 1
Is coated and completely cured to form the coating film 3, and the coating film reinforcing member 4 formed of a nonwoven fabric is provided on the surface of the coating film 3.
By completely curing the colored paint 2 to form a strong coating film 3 and reinforcing the coating film 3 with a coating film reinforcing material 4,
It is possible to prevent the coating film 3 from being excessively softened by heat and pressure during molding, to prevent the coating film 3 from flowing due to pressure during molding, and to apply the colored coating material 2 of multiple colors. Even when the film 3 is formed, the colored paint 2 can be prevented from being mixed.

Since one of the polyester non-woven fabric 6 and the glass non-woven fabric 7 is provided as the coating film protective material 5 on the surface of the coating film reinforcing material 4, the molding material 10 is supplied to the surface of the coating film protective material 5 to apply the coating material. Molding material 10 at the time of molding with the film protective material 5
Can be appropriately weakened so that the resin contained in the molding material 10 does not pass through the coating film 3. Further, the coating film protective material 5 can be sufficiently impregnated with the molding material 10,
The adhesion between the coating film 3, the coating film reinforcing material 4, and the molding material 10 can be increased. Further, since the coating film 3 is firmly formed as described above, it does not collapse even if a little pressure is applied by the flow of the molding material 10, and therefore the resin of the molding material 10 does not pass through the coating film protective material 5 at all. Since it is not necessary to provide such a function, the coating film protective material 5 can be formed of a non-woven fabric containing no resin, and the resin of the coating film protective material 5 can be prevented from seeping out to the surface of the molded product. In addition, it is possible to prevent a color difference between the resin of the coating film protective material 5 and the resin of the molding material 10, and the coating film protective material 5 has air permeability, so that a plurality of sheets can be formed. Coating protective material 5
It is possible to prevent air from being accumulated between the coating film-protecting materials 5 even if the above-mentioned structure is provided, and it is not necessary to form the coating film-protecting material 5 by impregnating a non-woven fabric with a resin.

Since the coating film protective material 5 is formed of both the polyester nonwoven fabric 6 and the glass nonwoven fabric 7, the coating film protective material 5
The flow of the molding material 10 at the time of molding can be sufficiently weakened so that the resin contained in the molding material 10 does not pass through the coating film 3 and the pressure due to the flow of the molding material 10 does not exert a large amount on the coating film 3. Can be In addition, a single color or a plurality of colors of colored paint 2 are applied to the surface of the sheet 1,
Next, the coating film reinforcing material 4 formed of a non-woven fabric was laminated on the above-mentioned surface of the sheet 1, and then the colored coating material 2 was dried and completely cured to form the coating film 3. By providing the film reinforcing material 4 on the surface of the colored coating material 2 before curing, it is possible to sufficiently impregnate the coating material reinforcing material 4 with the colored coating material 2 and increase the adhesion between the coating film 3 and the coating material reinforcing material 4. it can.

Further, when the colored paint 2 is applied to the surface of the sheet 1, since the sheet 1 is irradiated with light from the surface side opposite to the coated surface of the sheet 1, the light passing through the sheet 1 passes to the sheet 1. It is possible to easily check the application amount of the colored paint. Further, since the coloring paint 2 is cured while fixing at least two sides of the sheet 1 and the coating film reinforcing material 4,
The sheet 1 and the coating film reinforcing material 4 can be constrained so as not to shrink due to heat.

The present invention will be described in detail below. The sheet 1 is a transfer sheet that transfers the coating film 3 formed of the colored coating material 2 on the surface of the molded product, has a releasability with respect to the coating film 3, and allows the molding material 10 to penetrate during molding. However, it may be formed of any material as long as it can be easily peeled from the molded product without being broken after molding. For example, the thickness is 30 to 100 μm.
A thermoplastic resin sheet such as a polypropylene resin (PP) sheet, a polyethylene resin (PE) sheet, or a polyethylene terephthalate resin (PET) sheet can be used.

The colored paint 2 is a colored gel coat resin, and for example, a thermosetting resin composition colored with a toner or the like can be used. Further, as a specific example, 100 parts by weight of the unsaturated polyester resin will be used. Curing agent 1 to 5 parts by weight, filler 20 to 40 parts by weight, coloring toner 2 to 10
It is possible to use, as the coloring paint 2, a mixture containing parts by weight. This colored paint 2 may be blended with DAP resin (diallyl phthalate resin, DAP resin) if necessary, and the adhesive force of the colored paint 2 to the sheet 1 may be slightly lowered by blending this DUP resin. It is possible to prevent the colored coating material 2 from sticking to the coating material 1.

The coating film reinforcing material 4 can be formed of a non-woven fabric such as a glass non-woven fabric 7 or a polyester non-woven fabric 6 (with a basis weight of 30 g / m ² or less). The quality items required for the coating film reinforcing material 4 include good compatibility with the coating film 3 formed by the colored coating material 2 when the colored coating material 2 is sufficiently and completely impregnated,
In addition, the workability is high, the drying (curing) of the impregnated colored coating material 2 is high, and the cutability (workability to a predetermined size) is high.
And the moldability is high with no swelling during molding, but these quality items can be sufficiently satisfied by forming the coating film reinforcing material 4 from a non-woven fabric. If a glass mat or a glass surface mat is used as the membrane reinforcing material 4, the above quality items cannot be sufficiently satisfied.

Next, a method of manufacturing a patterned sheet using the above member will be described. First, a single color or a plurality of colors of colored paint 2 is applied to one surface of a sheet 1 cut into a predetermined size with a spray gun 11 or the like so as to have a thickness of about 0.2 to 0.6 mm to form a pattern, The coating film reinforcing material 4 is allowed to stand so that the surface of the colored coating material 2 does not lose its pattern, and the coating material reinforcing material 4 is impregnated with the colored coating material 2. After that, it is dried at 100 to 120 ° C. for 20 to 20 ° C. with a hot air dryer. By heating for 90 minutes and evaporating the solvent contained in the colored coating material 2 through the coating film reinforcing material 4, the colored coating material 2 is dried and completely cured to form the coating film 3. A patterned sheet A as shown in FIG. 1 is created. When the coating material 3 is formed by completely curing the colored coating material 2 as described above, the coating material 3 does not have stickiness (stickiness) and does not flow or stick to another object, and is molded. It is softened by the heat and pressure of time, but it does not cause pattern flow or pattern breakage.

As described above, in the above-described embodiment, the coloring paint 2 is completely cured to form the coating film 3 and the coating film reinforcing material 4 is provided on the surface of the coating film 3. Therefore, the coloring paint 2 is completely cured. To strongly form the coating film 3 and to reinforce the coating film 3 with the coating film reinforcing material 4, so that the coating film 3 can be heated and pressed during molding.
Can be prevented from softening too much, the coating film 3 can be prevented from flowing due to the pressure applied during molding, and even when the coating film 3 is formed with the colored coating materials 2 of a plurality of colors, the colored coating material 2 Can be prevented from becoming a mixed state.

In the above-mentioned method for producing a patterned sheet,
The colored paint 2 can be applied to the sheet 1 by irradiating it with light from the surface side opposite to the coated surface of the sheet 1. That is, as shown in FIG. 2, the pedestal 12 is formed of a transparent or translucent glass plate, a wire mesh, a perforated plate or the like that transmits light, and an illumination formed by a fluorescent lamp or an incandescent lamp under the pedestal 12. The fixture 1 is installed and the light source 13 is provided.
A transparent or semi-transparent sheet 1 that transmits light from the light source 13 is placed on top of the light source 2, and the light from the light source 13 is mounted on the pedestal 1
The colored paint 2 can be applied to the upper surface of the sheet 1 with the spray gun 11 while looking through the sheet 2 and the sheet 1.

By irradiating the light from the lower side of the sheet 1 and applying the colored paint 2 while observing the light through the sheet 1, the amount of the colored paint 2 attached to the surface of the sheet 1 is reduced. When the amount is large, the light is not transmitted, and when the amount is small, the amount of the transmitted light is large. Therefore, the application amount of the colored coating material 2 can be easily judged by the light and shade of the light, and the application amount of the colored coating material 2 ( The coloring paint 2 can be applied while adjusting the film thickness) to be uniform without variation.

Further, in the above-described method for producing a patterned sheet, the colored coating material 2 can be dried and cured while fixing the two sides of the sheet 1 and the coating film reinforcing material 4. Before the sheet 1 is cut into a predetermined size, it is in a rolled-up state. Therefore, the sheet 1 is greatly shrunk in the winding direction by heating to dry and cure the colored coating material 2. Then, the coating film 3 peels from the sheet 1 or wrinkles occur in the coating film 3 due to the difference in heat shrinkage between the sheet 1 and the coating film reinforcing material 4. Moreover, when the coating film reinforcing material 4 is formed of a glass non-woven fabric, the glass non-woven fabric does not significantly shrink due to heating, so that the difference in the heat shrinkage rate from the sheet 1 becomes very large, and the peeling of the coating film 3 or the coating film 3 occurs. The wrinkles of No. 3 are particularly remarkable.

Then, as shown in FIG. 3 (b), a laminate comprising the sheet 1, the colored paint 2 and the coating film reinforcing material 4 is placed on the drying frame 15 formed of an iron plate, and the coating film reinforcing material is placed. 4A and 4B, the strip steel 16 is disposed along the upper surfaces of both ends in the winding direction, and a vise 17 sandwiching the lower surface of the drying rack 15 and the upper surface of the strip steel 16 is shown in FIG. The sheet 1 and the coating film reinforcing material 4 are fixed at a plurality of positions on both ends of the coating film reinforcing material 4 in the winding direction, and the colored coating material 2 is dried and cured by heating in this state. .

By fixing the two sides of the end portion of the sheet 1 in the winding direction with the vise 17 in this manner, the sheet 1 can be restrained so as not to be thermally shrunk, and the sheet 1 and the coating film reinforcing material 4 can be restrained. Of coating film 3 due to the difference in heat shrinkage of
It is possible to prevent the occurrence of wrinkles, and it is particularly effective when the coating film reinforcing material 4 is formed of a glass nonwoven fabric. Even when the coating film reinforcing material 4 is formed of a polyester non-woven fabric, it is possible to prevent both the sheet 1 and the coating film reinforcing material 4 from shrinking and prevent peeling of the coating film 3 and wrinkling of the coating film 3. can do. Further, the sheet 1 may shrink in a direction other than the winding direction due to heating, so that the sheet 1 shown in FIG.
As shown in Fig. 3, by fixing the two sides of the sheet 1 other than the ends in the winding direction in the same manner as in the configuration shown in Fig. 3 (b), the sheet 1 is restrained so as not to contract in directions other than the winding direction. As a result, peeling of the coating film 3 and generation of wrinkles on the coating film 3 can be prevented more effectively.

Next, a method for manufacturing a patterned molded article using the above embodiment will be described. First, the patterning sheet A is set on the molding die with the other surface of the sheet 1 (the surface on which the coating film 3 is not formed) facing the inner surface of the molding die, and SMC (Sheet Molding) is set on the surface of the coating film reinforcing material 4. Compoud) and BMC
A molding material 10 such as (Bulk Molding Compoud) is placed on top of it, and then the mold is clamped to heat the coating material reinforcing material 4 and the molding material 10 while heating and pressurizing the molding material 10 to form a molding product. Remove the molded product from the surface of the molded product from the sheet 1
A patterned molded article is formed by peeling off only the sheet, and leaving the coating film 3 and the coating film protective material 4 from the sheet 1 on the surface of the molded article and transferring them. Patterned sheet A as described above
Although the coating film 3 is completely hardened, it is softened by heat and pressure during molding, and therefore the coating film 3 can be deformed along the uneven shape of the molded product (the uneven shape of the molding die). Even if the molded product has an uneven shape, it can be beautifully patterned. In addition, the sheet 1 of the above-mentioned forming die
It is preferable that the surface contacting with is recessed by the thickness of the sheet 1, and this can prevent the recess from being formed in the molded product by the thickness of the sheet 1.

FIG. 4 shows another embodiment. In this embodiment, a coating film protective material 5 is further provided on the surface of the coating film reinforcing material 4 of the embodiment shown in FIG. The coating film protective material 5 has adhesion to the coating film 3 and the molding material 10, weakens the flow of the molding material 10 at the time of molding, and the mold (pattern) of the coating film protective material 5 is formed on the surface of the coating film 3. It must be formed with something that does not come out. Therefore, a polyester non-woven fabric 6 or a glass non-woven fabric 7 can be used as the coating film protective material 5, and preferably a polyester non-woven fabric 6 or a glass non-woven fabric 7 containing no resin can be used. The weight per unit area (weight per unit area) of the coating film protective material 5 may be appropriately set depending on the uneven shape of the molding die used, the depth, the presence or absence of joints, the combination of the flat portion and the uneven portion, and the like.
The size of the coating film protective material 5 may be the same as the sheet 1 or larger than the sheet 1. A plurality of coating film protective materials 5 may be used.

Next, a method for manufacturing a patterned molded article using this embodiment will be described. First, the patterning sheet A is set on the molding die with the other surface of the sheet 1 (the surface on which the coating film 3 is not formed) facing the inner surface side of the molding die, and SMC, BMC, etc. on the surface of the coating film protective material 5. The molding material 10 is placed on top of it, and then the mold is clamped to impregnate the coating material protective material 5 with the molding material 10 so that the coating material reinforcing material 4 and the molding material 10 are brought into close contact with each other and heated and pressed to form the molding material 10. After forming the product, the molded product is released from the mold, only the sheet 1 is peeled from the surface of the molded product, and the coating film 3, the coating film protective material 4, and the coating film protective material 5 remain on the surface of the molded product from the sheet 1. Then, a patterned molded article is formed by transferring.

As described above, in this embodiment, by providing the coating film protective material 5 on the surface side of the coating film 3, the flow of the molding material 10 at the time of molding by the coating film protective material 5 is appropriately weakened and the molding material is formed. It is possible to prevent the resin contained in 10 from reaching the coating film 3 and passing therethrough, and to prevent the resin of the molding material 10 from seeping out onto the surface of the molded product, and in particular a molded product to which a large molding pressure is applied. It is possible to prevent the resin of the molding material 10 from oozing out into the corners and convexes of the uneven portion. Further, as described above, the coating film 3 is completely cured and is protected by the coating film reinforcing material 4, so that the coating film 3 is firmly formed, and some pressure is applied by the flow of the molding material 10. Therefore, the coating film protective material 5 does not need to have a function of preventing the resin of the molding material 10 from passing through at all. Therefore, the coating film protective material 5 can be formed of the polyester non-woven fabric 6 or the glass non-woven fabric 7 containing no resin, and the resin of the coating film protective material 5 does not ooze out on the surface of the molded product unlike the conventional example. In addition, no color difference occurs between the resin of the coating film protective material 5 and the resin of the molding material 10, and the coating film protective material 5 has air permeability, so that a plurality of coating film protective materials are provided. 5 and between the coating film protective material 5 and the coating film reinforcing material 4 can be removed through the coating film protective material 5 to prevent air from being accumulated. In addition, the nonwoven fabric is impregnated with resin. By doing so, it is not necessary to form the coating film protective material 5.

In the above embodiment, when set in the molding die, it may be punched with a Thomson die to form a predetermined size. At this time, as shown in FIG. 5, the sheet 1 and the coating film reinforcing material 4 are formed. The four corners of the coating film protective material 5 can be cut at 45 ° to each side to form the C chamfered shape 20. In this way, the corners of the sheet 1, the coating film reinforcing material 4, and the coating film protective material 5 are C
By forming the chamfered shape 20, the patterning sheet A
The corners of the shape have a two-dimensional drawing shape, and it is possible to prevent wrinkles from being generated at the corners of the molded product.

FIG. 6 shows another embodiment. In this embodiment, a polyester non-woven fabric 6 and a glass non-woven fabric 7 are further provided as a coating film protective material 5 on the surface of the coating film reinforcing material 4 of the embodiment shown in FIG. The order of the polyester non-woven fabric 6 and the glass non-woven fabric 7 is arbitrarily set depending on the shape of the molding die and the like. It is also preferable that the polyester non-woven fabric 6 and the glass non-woven fabric 7 are not impregnated with resin.

This example is used in the manufacture of a patterned molded article in the same manner as the example shown in FIG. 4, but the example shown in FIG. 6 is better than the example shown in FIG. 6, the resin contained in the molding material 10 can reach the coating film 3 and hardly pass through in the embodiment shown in FIG. 6, and the resin of the molding material 10 exudes to the surface of the molded article. The coating film 3 can be sufficiently protected so as not to exist.

[0033]

The present invention will be described below in detail with reference to examples. Example 1 As the sheet 1, a 100 μm-thick polyester sheet (E5000 manufactured by Toyobo Co., Ltd.) was used. Unsaturated polyester resin (GC manufactured by Dainippon Ink and Chemicals, Inc.
-505) 100 parts by weight, curing agent (PB manufactured by NOF CORPORATION)
Z) 4 parts by weight, filler (Heidilite manufactured by Showa Denko KK) 2
5 parts by weight were mixed, and white toner 4PHR and black toner 4PHR were mixed with the mixture 100 and stirred to prepare a two-color coloring paint 2. Then, the sheet 1 is set on a frame made of a wire mesh, and the weight ratio of the white colored paint 2 is 30 to 40% by weight and the black colored paint 2 is 60 to 70% by weight on the surface of the sheet 1 by using a multicolor gel coat gun. Then, it was granularly applied with a thickness of 0.5 mm to form a granite pattern.

Next, a polyester non-woven fabric (R-011 basis weight 23 g / m ² manufactured by Mitsui Petrochemical Industry Co., Ltd.) as a coating film reinforcing material 4 was allowed to stand on the side of the sheet 1 on which the coloring paint 2 was applied, and then 110 ° C. Was dried for 60 to 90 minutes in the hot air drying oven, the coloring paint 2 was completely cured to form the coating film 3, and the patterned sheet A shown in FIG. 1 was prepared. (Example 2) The coating film reinforcing material 4 of the above-mentioned Example 1 was made of a glass nonwoven fabric (Mitsubishi Paper Mills GFC-3000 basis weight 30 g /
A patterned sheet A was prepared in the same manner as in Example 1 except that m ² ) was used. (Comparative Example 1) The coating film reinforcing material 4 of the above-described Example 1 was used as a glass mat (chopped strand mat MC30 manufactured by Nitto Boseki Co., Ltd.).
A patterning sheet A was prepared in the same manner as in Example 1 except that it was changed to 0). (Comparative Example 2) A glass surface mat (3600E manufactured by Asahi Fiber Glass,
A patterned sheet A was prepared in the same manner as in Example 1 except that the three types (3601E and 3603E) were used.

The above-mentioned Examples 1 and 2 and Comparative Examples 1 and 2 are set on the molding surface of the lower mold of the waterproof floor pan for a bathroom unit, and then a plurality of molding materials 10 such as SMC are piled up. After that, the temperature was set so that the molding surface side of the molding die was 145 ° C. and the back surface side was 130 ° C., and heating and pressure molding was performed under the conditions of a pressing force of 1200 tons and a pressing time of 4 minutes. After this, the molded product was removed from the mold, post-processing such as deburring was performed, and the sheet 1 was peeled off from the surface of the molded product to obtain a patterned molded product.

With respect to Examples 1 and 2 and Comparative Examples 1 and 2 described above, the manufacturability (impregnating property of colored paint, dry curability of colored paint), workability (cutability to a predetermined size), and moldability were evaluated. Then, comprehensive evaluation was carried out from these. The results are shown in Table 1. In Table 1, ∘ indicates no problem, Δ indicates some problems, and × indicates problems and cannot be used.

[0037]

[Table 1]

When Examples 1 and 2 and Comparative Examples 1 and 2 are compared, Examples 1 and 2 have higher impregnation of the coating material 4 with the colored coating material 2 than those of Comparative Examples 1 and 2 so that the coating material 4 is completely impregnated. Can be done
It can be seen that the adhesion between the coating film 3 and the coating film reinforcing material 4 in Examples 1 and 2 is high. Further, in Examples 1 and 2, wrinkles are less likely to occur on the sheet 1 even when the colored coating material 2 is dried and cured, and the coating film 3 is less likely to peel off from the sheet 1. However, in Comparative Example 1, wrinkles are produced on the sheet 1 and the coating film 3 is peeled off from the sheet 1, and it can be seen that the colored coating material 2 in Examples 1 and 2 has high dry curability. Further, in Examples 1 and 2, the coating film 3 was not chipped even if it was cut with the Thomson type, but in Comparative Examples 1 and 2, the coating film 3 was formed.
It can be seen that chipping occurs in the resin and the cutting properties of Examples 1 and 2 are high. Further, in Examples 1 and 2, the molded product does not swell, but in Comparative Example 1, the molded product swells.
It can be seen that the moldability of is high. (Example 3) A glass nonwoven fabric (GF manufactured by Mitsubishi Paper Mills Co., Ltd.) was further applied as a coating film protective material 5 on the surface of the coating film reinforcing material 4 of Example 1 above.
Two sheets of C-3000 basis weight 30 g / m ² ) 7 were provided to prepare a patterned sheet A. (Example 4) One polyester nonwoven fabric (R-470 manufactured by Mitsui Petrochemical Co., Ltd.) 6 was further provided as a coating film protective material 5 on the surface of the coating film reinforcing material 4 of the above-mentioned Example 1 and patterned as shown in FIG. Sheet A was created. (Example 5) One piece of polyester nonwoven fabric (R-470 manufactured by Mitsui Petrochemical Industry Co., Ltd.) 6 as a coating film protective material 5 on the surface of the coating film reinforcing material 4 of the above-mentioned Example 1, and a glass nonwoven fabric (Mitsubishi Paper Mills). One sheet of GFC-3000 manufactured by GFC-3000 Co., Ltd. was provided in this order to prepare a patterned sheet A shown in FIG. (Comparative Example 3) A glass mat similar to Comparative Example 2 was further provided as a coating film protective material 5 on the surface of the coating film reinforcing material 4 of Example 1 to prepare a patterning sheet. (Comparative Example 4) A glass cloth (WE manufactured by Nitto Boseki Co., Ltd.) was used as a coating film protective material 5 on the surface of the coating film reinforcing material 4 of Example 1 above.
-18K) was provided to prepare a patterning sheet. (Comparative Example 5) A glass sheet mat similar to that of Comparative Example 2 was further provided as a coating film protective material 5 on the surface of the coating film reinforcing material 4 of Example 1 to prepare a patterning sheet.

Using the above Examples 3 to 5 and Comparative Examples 3 to 5 in the same manner as in Examples 1 and 2, patterned molded articles were obtained.
In each of the patterned molded articles thus obtained, the adhesion between the coating film protective material 4 and the molding material 10, the presence or absence of the resin of the molding material 10 exuding to the surface of the molded article, and the appearance of the molded article were examined. It was The results are shown in Tables 2 and 3. In Tables 2 and 3, ∘ indicates that there is no problem, Δ indicates that there is a problem, and x indicates that there is a problem and it cannot be used.

[0040]

[Table 2]

[0041]

[Table 3]

When Examples 3 to 5 in Table 2 and Comparative Examples 3 to 5 in Table 3 are compared, in Comparative Examples 3 and 4, the resin of the molding material does not impregnate the coating film protective material 5 and the adhesion is low, and molding is performed. Swelling occurs on the surface of the molded product, and a glass pattern or a cross pattern appears on the surface of the molded product to impair the appearance. In Comparative Example 5, the resin of the molding material oozes out on the surface of the molded product, However, in Examples 3 to 5, there is no problem in all the evaluated performances, and Examples 3 to 5 have higher performance than Comparative Examples 3 to 5. (Embodiment 6) A sheet 1 similar to that of the above-described Embodiment 1 is placed on a pedestal 14 formed of stainless steel wire mesh, and the pedestal 12 is placed.
A fluorescent lamp was set as the light source 13 on the lower side, and suction was applied from the back surface of the pedestal 12 to fix the sheet 1. Thereafter, in the same manner as in Example 1, the coloring paint 2 was applied, the coating film reinforcing material 4 was allowed to stand, the coloring paint 2 was completely cured to form the coating film 3, and the patterning sheet shown in FIG. A was created.

In this embodiment, when the colored coating material 2 is applied to the sheet 1, the thickness of the colored coating material 2 can be visually judged by the degree of transmission of the light transmitted through the sheet 1, and the coating material having a uniform thickness can be obtained. The film 3 could be formed. (Embodiment 7) A sheet 1 similar to that of the above-described Embodiment 1 is placed on a base 14 formed of stainless steel wire mesh, and the base 12 is mounted.
A fluorescent lamp was set as the light source 13 on the lower side, and suction was applied from the back surface of the pedestal 12 to fix the sheet 1. Thereafter, in the same manner as in Example 2, the colored coating material 2 was applied and the coating film reinforcing material 4 was allowed to stand. After this, a laminate of the sheet 1 and the coating film reinforcing material 4 is placed on the iron plate drying frame 15, 5 × 30 mm strip steel 14 is set along the four sides of the stack, and five points per side are evenly spaced. Place vise 17 on each and
The sheet 1 and the coating film reinforcing material 4 are fixed and constrained by the above, and the colored coating material 2 is completely cured in the same manner as in Example 1 above to form the coating film 3
Was formed and cooled until the temperature of the sheet 1 became the same as the ambient temperature, and the patterned sheet A shown in FIG. 1 was prepared.

In this embodiment, the sheet 1 and the coating film reinforcing member 4 are fixed and constrained by the vise 17 so as not to shrink due to heat, so that the coating film 3 is not separated from the sheet 1 and the coating film 3 is not peeled off. Three
No wrinkles were formed on the sheet 1, the coating film reinforcing material 4, or the like.

[0045]

As described above, the invention according to claim 1 of the present invention forms a coating film by coating the surface of a sheet with a single color or a plurality of colors of coloring paint and completely curing the coating film. Since a coating film reinforcement made of non-woven fabric is provided on the base, the colored paint is completely cured to form a strong coating film and the coating film is reinforced with the coating film reinforcement material, so that heat and pressure during molding can be applied. It is possible to prevent the coating film from softening too much, to prevent the coating film from flowing due to pressure during molding, and to form a coating film having a uniform thickness during molding. . In addition, even when a coating film is formed with colored paints of multiple colors, it is possible to prevent the colored paints from mixing with each other, and prevent the colored paints from mixing with each other to prevent appearance defects in the molded product. Is something that can be done.

According to the second aspect of the present invention, since one of the polyester nonwoven fabric and the glass nonwoven fabric is provided on the surface of the coating film reinforcing material as the coating film protective material, the molding material is supplied to the surface of the coating film protective material. By doing so, it is possible to appropriately weaken the flow of the molding material during molding with the coating film protective material so that the resin contained in the molding material does not pass through the coating film, and the resin exudes to the surface of the molded product. Can be prevented. Further, the coating film protective material can be sufficiently impregnated with the molding material, and the adhesion between the coating film, the coating film reinforcing material and the molding material can be enhanced.

Further, since the coating film is firmly formed as described above, it does not collapse even if a slight pressure is applied by the flow of the molding material, so that the resin of the molding material should not pass through the coating material protective material at all. It is possible to form the coating film protective material with a resin-free nonwoven fabric so that the resin of the coating film protective material does not seep out onto the surface of the molded product. In addition, it is possible to prevent color difference between the resin of the coating film protective material and the resin of the molding material, and to prevent the appearance of the molded product from being impaired. Since the protective material has air permeability, it is possible to prevent air from accumulating between the plurality of coating film protective materials and prevent swelling on the surface of the molded article. In addition to non-woven resin Impregnated to be able to avoid having to form a coating film protective member, the number of processes or increased,
The cost will not increase and the lead time will not increase.

Further, in the invention according to claim 3 of the present invention, since the coating film protective material is formed of both the polyester nonwoven fabric and the glass nonwoven fabric, the flow of the molding material at the time of molding is sufficiently weakened in the molding with the coating film protective material. It is possible to prevent the resin contained in the material from passing through the coating film, prevent the pressure due to the flow of the molding material from being applied to the coating film, and make the thickness of the coating film uniform. Effect,
The effect of preventing mixing of colored paints to prevent the appearance of defective molded products and the effect of preventing resin exudation on the surface of molded products are even more effective. The invention according to claim 4 of the present invention is to apply a single-color or multi-color coloring paint to the surface of the sheet, and then apply a non-woven fabric to the surface of the sheet. Since the film reinforcing material was laminated, and then the colored coating material was dried and completely cured to form a coating film, by coating the surface of the colored coating material with a coating material reinforcing material formed of a non-woven fabric before curing, The coating film reinforcing material can be sufficiently impregnated with the paint to enhance the adhesion between the coating film and the coating film reinforcing material, and it is possible to prevent the coating film from being damaged during cutting, storage and transportation. In addition, in claim 5 of the present invention According to the invention, when the colored paint is applied to the surface of the sheet, the sheet is irradiated with light from the surface side opposite to the coated surface of the sheet. Therefore, the amount of the colored paint applied to the sheet depends on how light passes through the sheet. Can be easily checked, the colored paint will not be used wastefully due to the large coating amount, and the pattern will not appear on the molded product due to the coating amount of the colored coating being too small. Is what you can do.

In the invention according to claim 6 of the present invention, since the coloring paint is cured while fixing at least two sides of the sheet and the coating film reinforcing material, the sheet and the coating film reinforcing material are restrained so as not to be thermally contracted. It is possible to prevent the sheet from wrinkling, the coating film from peeling from the sheet, and the coating film from peeling from the coating film reinforcing material.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view showing an embodiment of a patterning sheet of the present invention.

FIG. 2 is a cross-sectional view showing an example of a state in which a colored paint is applied to the above sheet.

3A is a plan view showing an embodiment of a dry-curing process for a colored coating material, FIG. 3B is a cross-sectional view of FIG. 3A, and FIG. It is a top view which shows an example.

FIG. 4 is a cross-sectional view showing another embodiment of the above patterning sheet.

FIG. 5 is a cross-sectional view showing still another embodiment of the above patterning sheet.

FIG. 6 is a cross-sectional view showing still another embodiment of the above patterning sheet.

[Explanation of symbols]

 1 sheet 2 colored paint 3 coating film 4 coating film reinforcing material 5 coating film protective material 6 polyester non-woven fabric 7 glass non-woven fabric

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[Procedure amendment]

[Submission date] July 31, 1995

[Procedure amendment 1]

[Document name to be amended] Statement

[Correction target item name] 0003

[Correction method] Change

[Correction contents]

As described above, the method for producing a patterned molded article for which a patent has been applied is such that a colored coating material is applied to one side of a polyester sheet, and a coating film is formed on one side of the sheet with a glass cloth or a glass surface mat. A reinforcing material is laminated, and a resin-impregnated non-woven fabric or a coating-film protective material formed of a resin-impregnated non-woven fabric and a resin-impregnated glass cloth is laminated on the surface of the coating film reinforcing material, and this is heated to semi-cure the colored paint. To form a coating film to create a patterning sheet, set this patterning sheet in the mold, and stack the molding material on the patterning sheet and set it in the mold, and heat and press the molding material in the mold. molded to a pattern-like form on the surface of the molded article in this pressure heating molding to form a molded article, after demolding is obtained so as to peel the sheet from the surface of the molded article.

[Procedure amendment 2]

[Document name to be amended] Statement

[Correction target item name] 0004

[Correction method] Change

[Correction contents]

In the patterning sheet of this application, the colored paint is semi-cured to form a coating film, so that the coating film is very easy to flow, and even a little resin of the molding material reaches the coating film during molding. Then, the coating film will collapse. Therefore by providing a resin-impregnated nonwoven fabric or a resin-impregnated glass cloth coating protective material on the surface of the coating film is impervious to resin molding material, so as not written molding material is fluid in the coating film heating and pressure during molding To prevent the coating film from collapsing and prevent the resin of the molding material from seeping out onto the surface of the molded product.

Claims (6)

[Claims] 1. A coating film is formed by coating a monochromatic or multicolored coloring paint on the surface of a sheet and completely curing it, and a coating film reinforcing material formed of a non-woven fabric is provided on the surface of the coating film. A patterned sheet characterized by. 2. The patterning sheet according to claim 1, wherein one of a polyester non-woven fabric and a glass non-woven fabric is provided on the surface of the coating film reinforcing material as a coating film protecting material. 3. The patterning sheet according to claim 1, wherein both the polyester nonwoven fabric and the glass nonwoven fabric are provided on the surface of the coating film reinforcing material as coating film protecting materials. 4. The surface of the sheet is coated with a single color or a plurality of colors of colored paint, and then a coating film reinforcing material formed of a non-woven fabric is laminated on the surface of the sheet, and then the colored paint is dried to completeness. A method for producing a patterned sheet, which comprises curing to form a coating film. 5. The method for producing a patterned sheet according to claim 4, wherein in applying the colored paint to the surface of the sheet, the sheet is irradiated with light from the surface side opposite to the coated surface of the sheet. 6. The method for producing a patterned sheet according to claim 4, wherein the colored paint is cured while fixing at least two sides of the sheet and the coating film reinforcing material.