JPH11129268A - Method for molding decorative molding - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for molding a decorative molding having a beautiful decorative pattern without mixing of two-layered molding materials. SOLUTION: In a method for molding a decorative molding in which a material for decorative molding in which 3-30 pts.wt. of a pattern material of a flaky substance 0.1-2.5 mm in particle size is mixed into 100 pts.wt. of a thermosetting resin molding material and a material for molding a main body made of a thermosetting resin molding material are placed in multilayer in a mold and press-molded integrally, the area charge ratio of the material for decorative molding into the mold is made 50-95%, and the area charge ratio of the material for molding a main body is made equal/smaller by 20% or below to/than that of the material for decorative molding.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for forming a decorative molded product suitably used for a bathroom floor material (waterproof pan), a wall material, a bathtub and the like made of patterned fiber reinforced resin (FRP).

[0002]

2. Description of the Related Art Conventionally, as a method of forming a decorative molded product,
For example, as described in JP-A-63-4915,
By setting a sheet molding compound (SMC) with a stone pattern in a mold, covering this SMC with a glass mat, and molding with another SMC placed on the glass mat, There has been proposed a method for preventing the resin component of another SMC from exuding and impairing the appearance.

However, in the case of the above-described three-layer structure, three types of materials must be supplied to the mold. If the positioning is not performed accurately, a pattern shift occurs, and the appearance deteriorates. If the material to be supplied increases, it takes a lot of man-hours and there is a problem that productivity is hindered.

[0004]

SUMMARY OF THE INVENTION The present invention solves the above-mentioned conventional problems and provides a method for forming a decorative molded product having a beautiful decorative pattern without mixing of two layers of molding materials. It was made for the purpose of providing.

[0005]

The invention according to claim 1 of the present application (Invention 1) is characterized in that a thermosetting resin molding material has a particle size of 0.1 to 100 parts by weight based on 100 parts by weight of the resin component. 2.5m
A decorative molding material in which 3 to 30 parts by weight of a pattern material composed of a flaky material having a thickness of m is mixed, and a body molding material composed of a thermosetting resin molding material are laminated in a mold. The method for molding a decorative molded article which is integrally hot-pressed, wherein the area charge ratio of the decorative molding material to a mold is 5
A decorative molded product in which the area charge rate of the body molding material to the mold is set to 0 to 95% and is equal to or smaller than the area charge rate of the decorative molding material by 20% or less. This is a molding method.

[0006] The invention described in claim 2 of the present application (Invention 2)
Is a method for molding a decorative molded product according to the first aspect of the present invention, wherein the press speed of the mold is 0.5 to 2 mm / sec.

In the present invention, the area charge rate to the mold refers to the percentage of the charge area of the molding material relative to the area of the mold surface of the mold.

In the present invention, the pattern material constituting the decorative molding material is required not to be decomposed or deteriorated in the hot-press molding step. Flaky materials are used. Inorganic materials include finely pulverized mineral and metallic coloring materials such as colored mica and colored aluminum foil. For organic ones, colored polyethylene, polyvinyl chloride,
Examples thereof include cut films of polyamide, polycarbonate, polyethylene terephthalate (PET), and the like.

[0009] The size of the pattern material is 0.1-2.
It must be 5 mm, preferably 0.2 to 2.0 mm. If the particle size is less than 0.1 mm, the pattern material is inconspicuous,
If the thickness exceeds 2.5 mm, the dispersibility in the impregnated resin solution is deteriorated, and the resin is not impregnated. Therefore, peeling from the substrate occurs in the product, and the impression that the design is unclean. give. The thickness of the flakes of the handle made of flaky material is 1
It is preferably from 0 to 500 μm.

The amount of the pattern material added must be 3 to 30 parts by weight, preferably 10 to 25 parts by weight, based on 100 parts by weight of the resin component in the thermosetting resin molding material. If the addition amount is less than 3 parts by weight, the pattern material becomes sparse and inconspicuous, which is not preferable in terms of design. If it exceeds 30 parts by weight, the dispersibility of the pattern material deteriorates, which is not preferable in terms of design. Since the material is hardened, it is not economically preferable.

Examples of the thermosetting resin composition constituting the decorative molding material include conventionally known materials such as bulk molding compound (BMC) and conventionally known SMC. As a BMC, a uniform paste obtained by mixing a resin component such as an unsaturated polyester resin or vinyl ester resin with a low-shrinkage agent, a thickener, a filler, a curing agent, a release agent, etc., as a reinforcing material And the like, in which the above glass fibers are uniformly dispersed to form a bulk.

As the SMC, a mixture of a resin component such as an unsaturated polyester resin or a vinyl ester resin and a low-shrinkage agent, a thickener, a filler, a curing agent, a release agent, etc., dispersed uniformly, and a thickener (necessary) Is dispersed in an appropriate solvent) and quickly mixed to form an admixture, which is immediately applied to a glass fiber at a predetermined ratio, and covered on both sides with a film of polyethylene or the like. Pressurization is used to promote the impregnation of the admixture into the glass fibers, sufficiently defoaming, winding up to a predetermined length, storing at an appropriate temperature and aging.

In the present invention, as a material for molding a main body made of a thermosetting molding material, a conventionally known B
Materials such as MC and conventionally known SMC similar to the above can be used. However, in order to form a high-strength main body layer, S
MC is preferred.

As a molding machine for producing a decorative molded article in the present invention, a conventionally known press molding machine can be used, and as a mold, a conventionally known mold, casting mold, or the like can be used. In general, the upper and lower molds are preferable as the form of the mold.
In this case, usually, the upper mold is used as a movable mold and the lower mold is used as a fixed mold.

The process for producing the decorative molded article of the present invention is, for example, as follows. First, as shown in FIG. 1, the upper and lower molds 1 including the upper mold 11 and the lower mold 12 are attached to a molding machine (not shown), and heated to 80 to 180 ° C.
The decorative molding material 2 and the main body molding material 3 are charged on the lower mold 12 so as to be laminated in this order, and the mold is closed.
~120kg / cm ² of heat and pressure molded 30 seconds to 20 minutes at a pressure, after curing the resin, opening the mold, by demolding, decorative moldings beautiful decorative pattern on the surface layer was formed Is obtained.

Here, the area charge rate of the decorative molding material to the mold must be 50 to 95%.
Preferably it is 0-85%. If it is less than 50%, when the mold is closed and the molding material flows therein, the pattern material tends to be oriented in the flow direction, and the pattern material tends to be sparse and dense. 95
%, The air in the mold and the air contained in the molding material do not escape during the molding flow, so that pinholes and blisters are likely to be generated on the surface of the molded product.

The area charge rate of the main body molding material to the mold must be equal to or smaller than the area charge rate of the decorative molding material by 20% or less. When the area charge rate of the decorative molding material is exceeded, the body molding material easily wraps around the surface of the decorative molding material, and the appearance tends to be poor. When the area charge rate of the decorative molding material is less than 20%, when the mold is closed, pressure is applied to the main body molding material first, and the main body molding material is decorated rather than the partial pressure flowing in the horizontal direction. The partial pressure applied to the molding material becomes strong and large, so that the body molding material penetrates the decorative molding material, and the body molding material comes out to the surface and the appearance is deteriorated.

In the present invention, the pressing speed of the mold is
It is preferable to set it to 0.5 to 2 mm / sec. If the speed is less than 0.5 mm / sec, the surface of the decorative molding material hardens in a state where no pressure is applied while flowing in the mold, so that a surface on which the mirror surface of the mold is not transferred is formed, and the surface is rough. It tends to be a molded article having an unsatisfactory glossy appearance. 2m
If m / sec is exceeded, the decorative molding material or the main body molding material will flow quickly, and when the decorative molding material flows quickly, the decorative molding material will break during the flow, The body molding material tends to flow out of the cuts, resulting in poor appearance. When the body molding material flows quickly, it wraps around the decorative molding material, and in this case, the appearance also tends to be poor. The speed at which these two materials flow in a balanced manner is 0.5 to 2 mm / sec.

[0019]

According to the method for molding a decorative molded article of the present invention, the area charge rate of the decorative molding material to the mold is set to 50 to 95%, so that the decorative molding material is flowed into the body molding material to be patterned. Is not oriented or the density of the pattern material does not occur, and conversely, there is little flowability, air does not easily escape and pinholes and swelling do not occur on the surface, The area charge rate of the material into the mold is equal to or greater than the area charge rate of the decorative molding material.
By reducing the size to 0% as a limit, the body forming material does not wrap around the decorative molding material, and the body forming material does not penetrate the decorative molding material,
A decorative molded product having a beautiful decorative pattern can be obtained.

In the method for molding a decorative molded product according to the second aspect of the present invention, the mold is pressed at a speed of 0.5 to 2 mm / sec. It has a beautiful decorative pattern without mixing of materials.

[0021]

The present invention will be described below with reference to examples. Example 1 A decorative molded product used as a kitchen counter was molded. As a molding machine, an 800-ton press molding machine manufactured by Kawasaki Yuko Co., Ltd. was used. For the mold, 1600m on the long side
An upper and lower mold 1 shown in FIG. 1 for forming a rectangular plate of mx short side 400 mm was prepared, in which an electric heater and a cooling pipe were embedded in both the upper mold 11 and the lower mold 12. The mold 1 was attached to a press molding machine. The upper mold 11 was a movable mold, and the lower mold 12 was a fixed mold.

As a material for decorative molding, a material obtained by kneading a pattern material into the following SMC was used. SMC: To 100 parts by weight of the unsaturated polyester resin, 1 part by weight of t-butyl perbenzoate (TBPB) as a curing agent, 140 parts by weight of aluminum hydroxide (average particle size: 12 μm) as a filler, and various additives are added in necessary amounts. After kneading, the mixture was impregnated so as to contain 10% by weight of glass fiber (fiber length 1 inch).

Pattern material: 15 parts by weight of a colored PET film [(white) particle size 0.2 mm: 1 part by weight, particle size 1.5 m
m: 2 parts by weight, particle size 2.0 mm: 1 part by weight, (black) particle size 0.2 mm: 1 part by weight, particle size 1.0 mm: 1 part by weight,
Particle size 2.0 mm: 1 part by weight, (gray) particle size 0.5 mm:
1 part by weight, particle size 1.0 mm: 1 part by weight, particle size 2.0 m
m: 1 part by weight].

As the material for forming the main body, 100 parts by weight of an unsaturated polyester resin, 1 part by weight of TBPB as a curing agent, and aluminum hydroxide as a filler (average particle diameter of 1 part) were used.
After kneading with 140 parts by weight of 2 μm), SMC impregnated with 1-inch long glass fiber (25% by weight of the whole) in an impregnation line was used.

The temperature of the mold was adjusted to 145 ° C. for the lower mold and 125 ° C. for the upper mold, and the material for decorative molding (area charge rate: 9) was placed on the lower mold.
0%), the material for body molding (area charge rate 80%), and the mold is closed at a press speed of 1 mm / sec.
After holding the pressure at a pressure of 5 kg / cm ² for about 10 minutes, the mold was opened to obtain a decorative molded product. The appearance of the obtained decorative molded product is
There were no cracks or portions without patterns, etc., and the stones had a beautiful decorative pattern of stone tone.

Example 2 The area charge rate of the decorative molding material was set to 75%.
A decorative molded product was obtained in the same manner as in Example 1, except that the area charge rate of the body forming material was 75% and the pressing speed was 0.8 mm / sec. The appearance of the obtained decorative molded article had no cracks, no pattern, and the like, and had a beautiful decorative pattern with a stone-grain tone.

Example 3 As a decorative molding material, the following SMC was used in which a pattern material was kneaded. SMC: 100 parts by weight of unsaturated polyester resin, 1 part by weight of t-butyl perbenzoate (TBPB) as a curing agent, 140 parts by weight of aluminum hydroxide (average particle size: 12 μm) as a filler, and 7 parts by weight of pigment (beige) And a mixture obtained by adding necessary amounts of various additives and then impregnated so as to contain 25% by weight of glass fiber (fiber length 1 inch).

Pattern material: white colored mica (particle size: 1.0 mm)
3 parts by weight, 2 parts by weight of black colored mica (particle size: 1.0 mm).

As a material for forming the main body, 100 parts by weight of an unsaturated polyester resin, 1 part by weight of TBPB as a curing agent, and aluminum hydroxide as a filler (average particle diameter of 1 part) were used.
2 μm) 140 parts by weight, 7 parts by weight of a pigment (beige), and a necessary amount of various additives are kneaded, and then a glass fiber having a length of 1 inch is impregnated with 25% by weight of the total in an impregnation line.
SMC impregnated to contain was used.

A decorative molded product was obtained in the same manner as in Example 1 except for the above. The appearance of the obtained decorative molded product had no cracks or portions without patterns, the whole was beige, and had a beautiful decorative pattern with a stone-grain tone.

Comparative Example 1 A decorative molded product was obtained in the same manner as in Example 1 except that the area charge rate of the body molding material was 60% and the pressing speed was 0.8 mm / sec. The appearance of the obtained decorative molded article had a decorative pattern in which spots were observed at the center.

Comparative Example 2 A decorative molded product was obtained in the same manner as in Example 1 except that the area charge rate of the body molding material was 80% and the pressing speed was 3 mm / sec. The appearance of the obtained decorative molded product is
It had a decorative pattern in which pattern breakage was observed.

Comparative Example 3 A decorative molded product was obtained in the same manner as in Example 3 except that the area charge rate of the body molding material was 60% and the pressing speed was 0.8 mm / sec. The appearance of the obtained decorative molded article had a decorative pattern in which spots were observed at the center.

[0034]

[Table 1]

[0035]

The method for forming a decorative molded article of the present invention, as described above, has no pinholes or blisters on its surface, and is beautifully decorated without mixing of two layers of molding material. A decorative molded article having a pattern can be obtained.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view illustrating a process for manufacturing a decorative molded product of the present invention.

[Description of Signs] 1 mold 2 decorative molding material 3 thermosetting molding material 11 upper mold 12 lower mold

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[Procedure amendment]

[Submission date] January 8, 1998

[Procedure amendment 1]

[Document name to be amended] Statement

[Correction target item name] 0010

[Correction method] Change

[Correction contents]

The amount of the pattern material added must be 3 to 30 parts by weight, preferably 10 to 25 parts by weight, based on 100 parts by weight of the resin component in the thermosetting resin molding material. If the addition amount is less than 3 parts by weight, the pattern material becomes sparse and inconspicuous, which is not preferable in terms of design. If it exceeds 30 parts by weight, the dispersibility of the pattern material deteriorates, which is not preferable in terms of design. Since the material is expensive , it is not economically preferable.

Claims (2)

[Claims] In a thermosetting resin molding material, 3 to 30 parts by weight of a flaky material having a particle size of 0.1 to 2.5 mm is mixed with 100 parts by weight of the resin component. In a molding method of a decorative molded product, a decorative molding material and a main body molding material made of a thermosetting resin molding material are integrally hot-press molded in a mold in a laminated state. In addition, the area charge rate of the decorative molding material to the mold is 50 to 95.
%, And the area charge rate of the body molding material to the mold is equal to or smaller than the area charge rate of the decoration molding material by 20% or less. Molding method of molded article. 2. The press speed of the mold is 0.5 to 2 m.
The method for molding a decorative molded product according to claim 1, wherein the molding speed is m / sec.