JPH09262853A - Production of decorative molded product - Google Patents

Abstract

PROBLEM TO BE SOLVED: To efficiently produce a thermosetting molded product good in appearance without breaking a pattern sheet becoming a surface. SOLUTION: A thermosetting molding material 4 is arranged to the lower mold 3 of a hot press mold and the pattern surface of a pattern sheet 1 impregnated with a thermosetting resin is sucked to the suction surface of a vacuum suction plate 2 to supply the pattern sheet 1 to the region above the thermosetting molding material 4 and suction is released to place the pattern sheet 1 on the surface of the thermosetting molding material 4. Thereafter, an upper mold is allowed to fall and, after the press surface of the upper mold comes into contact with the pattern sheet, the upper mold is allowed to fall at a falling speed of 0.5-3mm/sec to perfectly perform mold clamping up to a predetermined position.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a decorated molded article such as a bathroom floor material (waterproof pan) made of FRP with a handle, a wall material and a bathtub.

[0002]

2. Description of the Related Art Heretofore, as a method for molding a patterned FRP molded article, a method using printed thermosetting resin-impregnated paper or the like has been known (for example, JP-A-2-279313). This method sets the surface sheet side of the pattern sheet impregnated with the thermosetting resin in contact with the lower mold for molding,
The molding material is set on the pattern sheet, and then the upper molding die is clamped in the lower molding die and heated under pressure.

[0003]

According to the above conventional method, when the pattern sheet is placed on the surface of the mold heated to a high temperature, the impregnated thermosetting resin is directly subjected to heat. Here, the time (touch time) from the heat of the pattern sheet to the placement of the molding material and the closing of the mold and the start of pressurization (touch time) usually takes about 1 to 2 minutes. When the touch time is longer than the minimum time (gel time) until the curing reaction of the impregnated resin starts, the curing reaction of the impregnated resin starts without pressure, resulting in poor fluidity of the resin and so-called pre-gel Deteriorate. As a result, the surface sheet may be torn, the appearance of the product may be deteriorated, and dirt may not be easily removed.

It is possible to avoid the above problems by adjusting the impregnating resin composition so that the gel time becomes longer, but if the gel time is made longer, the pressure holding time (cure time) required for curing the resin becomes longer. Therefore, there is a problem that the molding cycle becomes long as a result.

The present invention solves the above-mentioned conventional problems and provides a method for producing a decorative molded article, which enables efficient production of a thermosetting molded article having a good appearance without tearing the pattern sheet as the surface. The purpose is to do.

[0006]

The method for producing a decorative molded article according to the present invention comprises a pattern sheet impregnated with a thermosetting resin in which a thermosetting molding material is placed in a lower die of a hot press molding die. The pattern surface is sucked onto the suction surface of the vacuum suction plate, the pattern sheet is supplied onto the thermosetting molding material, the suction is released, and the pattern sheet is placed on the surface of the thermosetting molding material, and then the pattern sheet is placed on the surface. After lowering the die and bringing the press surface of the upper die into contact with the pattern sheet, lower the upper die at a lowering rate of 0.5 to 3 mm / sec and completely clamp the die to a predetermined position. It is characterized by.

As the thermosetting molding material, various thermosetting molding materials such as SMC and BMC which have been conventionally used can be used. Specific examples include thermosetting resins such as unsaturated polyester resins, epoxy acrylate resins, and urethane acrylate resins. If necessary, various fillers, reinforcing materials, additives, etc. may be added. Can be used as a composition such as known SMC or BMC.

As the pattern sheet, there is used a prepreg sheet which is semi-cured or thickened after impregnating a base sheet with a thermosetting resin. As the base sheet, for example, paper on which a pattern is printed, non-woven fabric, woven fabric, glass mat or the like is used.

In the present invention, examples of the thermosetting resin composition to be impregnated into the pattern sheet include compositions comprising various thermosetting resins such as unsaturated polyester resin, epoxy acrylate resin, urethane acrylate resin and diallyl phthalate resin. be able to.

The pattern sheet can be impregnated with the resin by a conventionally known method. For example, a method of immersing a sheet base material in a tank containing resin to impregnate it and squeezing it with a roll to remove excess resin, or placing the resin on the sheet base material while transporting the sheet base material on the belt. There are a method of impregnation by squeezing with a roll or a blade, and a method of placing a resin on a release sheet and stacking sheet base materials and squeezing with a roll or blade.

In the present invention, a hot press molding machine conventionally used as a molding machine can be used, and the molding die is a conventional die,
A casting mold or the like can be used. The molding die generally comprises an upper die and a lower die, and usually the upper die is used as a movable die and the lower die as a fixed die. The molding die is attached to the molding machine, and a required amount of the molding material is placed on the lower mold in the molding die heated to 80 to 180 ° C.

A pattern sheet is placed on the thermosetting molding material. At this time, the pattern surface of the pattern sheet is adsorbed by the vacuum adsorption plate and transferred onto the thermosetting molding material, and the adsorption is released to place the pattern sheet on the thermosetting molding material.
In this way, the pattern sheet can be supplied in a flat state, and can be accurately and efficiently arranged at a fixed position. The size of the pattern sheet may cover the entire surface of the molded product, may be a small size that partially decorates, and may be any size or shape.

The material of the vacuum suction board is metal, wood, synthetic resin,
Although a material such as glass can be used, aluminum is preferable because it does not damage the mold or the pattern sheet and the suction cup can be easily operated manually. The vacuum suction board is a hollow box-shaped one, and the inside of the box can be depressurized to about -300 to -760 mmHg, and suction holes are opened on the surface that adsorbs the pattern sheet according to the shape of the pattern sheet. It is what Further, it is preferable to provide a middle crosspiece or have a honeycomb structure so that the suction plate is not deformed when the pressure is reduced.

The size and arrangement of the suction holes may be adjusted depending on the rigidity of the pattern sheet and the degree of pressure reduction so that the pattern sheet can be supplied without wrinkles, but the diameter is 0.1 to 0.1 mm.
It is preferably 5 mm, more preferably 0.5 to 2 mm. The distance between the holes is preferably 5 to 200 mm, more preferably 30 to 70 mm. It is not necessary to make the distance between the holes narrower than 5 mm, but if it exceeds 200 mm, the pattern sheet will not be sufficiently adhered to the suction plate.

The pressure reduction by the suction plate is -300 to -650 m.
mHg is preferred. Pressure due to decompression is -300 mmHg
If it is higher than the above, the adsorption of the pattern sheet is insufficient, and -65
When it is lower than 0 mmHg, the pattern sheet is locally strongly adsorbed when the pattern sheet is set on the suction cup, and wrinkles may occur.
Further, it is preferable that the suction plate is provided with a mechanism capable of being aligned with the mold, and for example, a fitting portion for positioning is provided between the suction plate and the lower mold, or by adjusting the position of the lower mold. For example, the suction cup is equipped with a position sensor function that can position the suction cup and an automatic stop function.

After the pattern sheet is placed on the thermosetting molding material, the upper mold is lowered, and after the upper mold comes into contact with the pattern sheet, the upper mold is lowered at a rate of 0.5 to 3 mm / sec. Is lowered to a predetermined position to complete the mold clamping. The descending speed is preferably between 0.8 and 2 mm / sec. It is preferable that the time from the time when the thermosetting molding material is placed on the lower mold to the completion of the mold clamping is shorter, so it is preferable to lower the mold as quickly as possible until the upper mold comes into contact with the pattern sheet. The descending speed until the mold clamping is completed is 3 mm /
If it is faster than seconds, defective states such as tears and wrinkles will occur in the pattern sheet during molding, and if it is slower than 0.5 mm / second, the fluidity of the thermosetting molding material will deteriorate and molding will be defective.

After the mold clamping is completed, 10 to 150 kg /
It is cured under a pressure of cm ² for 30 seconds to 15 minutes, and then the upper mold is lifted to take out the product to obtain a decorative molded product in which pattern sheets are laminated.

(Operation) When the pattern sheet is placed on the thermosetting molding material placed on the lower mold, the pattern surface of the pattern sheet is adsorbed on the vacuum suction board and transferred to the thermosetting molding material. , The pattern sheet is placed on the thermosetting molding material by releasing the adsorption. As a result, the pattern sheet can be supplied in a flat state and can be accurately and efficiently arranged at a fixed position. Since the pattern sheet does not directly touch the lower mold, it does not receive the heat of the mold directly.

After the pattern sheet is placed on the thermosetting molding material, the upper mold is lowered, and after the upper mold comes into contact with the pattern sheet, the upper mold is lowered at a rate of 0.5 to 3 mm / sec. The mold sheet is lowered to a predetermined position to complete the mold clamping, so that the pattern sheet does not suffer from defective conditions such as tears and wrinkles, and good molding can be performed without impairing the fluidity of the thermosetting molding material. You can

[0020]

BEST MODE FOR CARRYING OUT THE INVENTION Next, an embodiment of the method for producing a decorative molded product of the present invention will be described for the case where a pattern is attached to the washing part of the FRP waterproof pan of the bathroom unit. (Example) A pattern sheet obtained by gravure-printing a stone-tone pattern on the surface of titanium paper (manufactured by Kojin Co., Ltd.) having a basis weight of 80 g / m ² was used as a base sheet for impregnation. As the thermosetting resin to be impregnated, the following composition was added to the above-mentioned base sheet for impregnation at 120 g / m ^2.
It was impregnated and dried to obtain a patterned sheet. Mixing of thermosetting resin for impregnation Unsaturated polyester resin liquid 100 parts by weight Diallyl phthalate resin liquid 100 parts by weight Curing agent (benzoyl peroxide) 2 parts by weight

1 to 5 are sectional views showing an embodiment of a method for manufacturing a decorative molded product according to the present invention. The upper mold 5 (product front side) and the lower mold 3 (product back side) of the hot press mold shown in FIG. 5 are heated to 140 ° C. and 130 ° C., respectively, and correspond to the decorative portion of the waterproof pan washing area. SM on the lower die 3 part
The required amount of C4 (manufactured by Takeda Pharmaceutical Co., Ltd.) was set.

The vacuum suction disk 2 shown in FIG. 1 sucks the pattern surface of the pattern sheet 1 upside down as shown in FIG. 2 and transfers it onto the SMC 4, and the lower mold as shown in FIG. The positioning pins 31 and 31 of No. 3 were inserted into the positioning holes 22 and 22 of the vacuum suction disk 2, the suction was released, and the vacuum suction disk 2 was removed by mounting it on the SMC 4 as shown in FIG. Thereafter, as shown in FIG. 5, the upper mold 5 is lowered while inserting the positioning pin 31 into the pin hole 51 of the upper mold 5, and 5 mm before the lower surface of the upper mold 5 contacts the pattern sheet 1,
The mold was clamped at a descending speed of 1.5 mm / sec until it was completely clamped to a predetermined molding position, and the upper mold 5 was closed, followed by press molding at 100 kg / cm ² for 3 minutes. The touch time at this time was 20 seconds, and the total time required for one molding was 5 minutes.

FIG. 6 is a perspective view of the vacuum suction plate 2,
A large number of suction holes 24, 24, ...
Is provided, and one side surface of the main body 20 is connected to the vacuum pump P via the suction hose 6. A plurality of reinforcing plates 23, 23 are provided in the main body 20, and protrusions 21, 21 having positioning holes 22, 22 are provided on both side surfaces of the main body 20.

The surface of the obtained molded product was beautiful without the generation of pregel and without any defects in the appearance such as tears and wrinkles of the pattern sheet.

(Comparative Example 1) The same pattern sheet and SMC as those used in the examples were used. The upper mold and the lower mold of the hot press molding machine used in the examples are reversed, that is, the upper mold is set to the lower side, the lower mold is set to the upper side, and the upper mold is set to 130.
C., the lower mold was heated to 140.degree. Place the pattern sheet with the pattern side facing the lower mold, and place the required amount of SMC on it.
(Takeda Pharmaceutical Co., Ltd.) is placed and the upper mold is lowered, and the lowering speed is from 5 mm before the lower surface of the upper mold comes into contact with the pattern sheet to the time when the upper mold is completely closed to the predetermined molding position.
After closing the mold at 5 mm / sec and closing the mold, 1
Press molding was performed at 00 kg / cm ² for 3 minutes. The touch time at this time was 90 seconds, and the total time required for one molding was 5 minutes. The surface of the molded product was not smooth, stains did not easily come off, and there was no commercial value.

(Comparative Example 2) The lowering time of the mold clamping is 6 mm /
A waterproof pan was molded in the same manner as in the example except that the seconds were set. This product had no commercial value because it was torn from the edge of the pattern sheet.

[0027]

EFFECT OF THE INVENTION The method for producing a decorative molded product of the present invention is configured as described above, and when the pattern sheet is placed on the thermosetting molding material placed on the lower mold, the pattern of the pattern sheet is formed on the vacuum suction plate. The surface is adsorbed and transferred onto the thermosetting molding material, and the pattern sheet is placed on the thermosetting molding material by releasing the adsorption, so that the pattern sheet can be supplied in a flat state.
It can be accurately and efficiently placed at a fixed position.
Further, after the press surface of the upper die comes into contact with the pattern sheet, the mold is completely clamped to a predetermined position at a descending speed of 0.5 to 3 mm / sec. A thermosetting molded product having a good appearance can be efficiently manufactured.

[0028]

[Brief description of drawings]

FIG. 1 is a cross-sectional view showing a state in which a pattern sheet is adsorbed on an adsorption disc in the method for producing a decorative molded product of the present invention.

FIG. 2 is a cross-sectional view showing a state in which FIG. 1 is turned upside down.

FIG. 3 is a cross-sectional view showing a state where the suction disk of FIG. 2 is set in a lower mold.

[Fig. 4] SMC in the lower mold

FIG. 5 is a cross-sectional view showing a state of hot pressing.

FIG. 6 is a perspective view showing a vacuum suction disk.

[Explanation of symbols]

 1: Pattern sheet 2: Vacuum suction board 3: Lower mold 4: SMC 5: Upper mold 6: Suction hose 22: Positioning hole 31: Positioning pin

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification code Office reference number FI Technical display location E03C 1/20 E03C 1/20 Z // B29K 101: 10 105: 06 B29L 31:10

Claims (1)

[Claims] 1. A thermosetting molding material is placed in a lower die of a hot press molding die, and the pattern surface of a pattern sheet impregnated with a thermosetting resin is adsorbed on an adsorption surface of a vacuum adsorption disk to form the pattern. The sheet is supplied onto the thermosetting molding material, the adsorption is released, the pattern sheet is placed on the surface of the thermosetting molding material, and then the upper mold is lowered so that the pressing surface of the upper mold is the above pattern. A method for producing a decorative molded product, which comprises lowering the upper mold at a descending speed of 0.5 to 3 mm / sec after the contact with the sheet and completely clamping the mold to a predetermined position.