JPH11129425A - Patterned sheet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a low-priced patterned sheet which permits the free and easy setting of a pattern and also the generation of no pattern irregularities. SOLUTION: A clear coat 2 is formed on one of the faces of a release sheet 1. A patterned reinforcing material 3 whose pattern is printed is laminated on the clear coat 2. The patterned reinforcing material 3 can be replaced with another reinforcing material 3 with a different pattern. Thus it is possible to set a desired pattern more freely and easily that applying plural colored coatings by a sprayer or the like to form a pattern.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a patterned sheet used for forming a fiber-reinforced plastic molded article having a pattern (including a pattern) such as marble or granite by molding.

[0002]

2. Description of the Related Art Fiber-reinforced plastic molded articles (FRP) have been conventionally used as members constituting floor pans of bathrooms, washrooms, toilets, etc., top plates of sinks, walls and ceilings of bathrooms, and the like.
Molded products) are usually used, but these F
As the RP molded product, a patterned FRP molded product having a high designability and a grain pattern such as marble or granite is used.

In forming such a patterned FRP molded product, a patterned sheet A is used in Japanese Patent Application Laid-Open No. 8-177478. As shown in FIG. 4, the patterned sheet A is formed by applying a plurality of colored paints to one surface of the release sheet 1 by spraying or the like to form a pattern layer 10, and reinforcing the reinforcing material 11 formed of a nonwoven fabric or the like with the pattern layer 10. And a stone-patterned pattern layer 10 formed of a plurality of colored paints.

In manufacturing a patterned FRP product using the patterned sheet A, a press molding method can be used, and the reinforcing material 11 of the patterned sheet A can be used.
SMC (Sheet Molding Compound) or BMC (B
(ulk Molding Compound)
Next, the laminate is subjected to heat and pressure to form a desired shape, and at the same time, the molding material is cured to integrate the patterning sheet A (the reinforcing material thereof) with the molding material. This is performed so that the release sheet 1 is released.
In this manner, a patterned FRP molded product having a stone pattern expressed by the pattern layer 10 on the surface can be formed.

[0005]

However, since the patterning sheet A has a pattern layer 10 formed by applying a plurality of colored paints, it is difficult to express a desired pattern such as a stone pattern. However, there is a problem that the degree of freedom is small and the pattern varies. Further, there is a problem that various kinds of multicolor paints are required to form the pattern layer 10, and the production cost is increased.

SUMMARY OF THE INVENTION The present invention has been made in view of the above points, and provides an inexpensive patterning sheet which can easily set a pattern freely and does not cause a variation in the pattern. It is intended for.

[0007]

According to a first aspect of the present invention, there is provided a patterned sheet A having a clear coating film 2 formed on one surface of a release sheet 1 and a patterned reinforcing material 3 patterned by printing. It is characterized by being laminated on the clear coating film 2. A patterned sheet A according to a second aspect of the present invention is characterized in that, in addition to the configuration of the first aspect, a protective material 4 having air permeability is laminated on the patterned reinforcing material 3. is there.

The patterned sheet A according to the third aspect of the present invention is characterized in that the clear coating film 2 contains at least one of an antibacterial agent and a fungicide in addition to the constitution of the first or second aspect. It is characterized by the following.

[0009]

Embodiments of the present invention will be described below. The release sheet 1 adheres to the surface of the clear coating film 2 before forming the patterned FRP molded product, and
And can be easily peeled off from the surface of the clear coating film 2 after the formation of the patterned FRP molded article, and is, for example, polypropylene (PP), polyethylene (PE), polyethylene terephthalate ( PE
T) Thickness formed of synthetic resin such as 30 to 100 μm
Sheet material can be used.

The clear coating film 2 is a gel coat obtained by drying and curing a clear coating material (clear gel coat resin), and is for protecting the surface of a patterned FRP molded product, and is provided with a transparent or patterned reinforcing material 3. Should just be transparent enough to show through. The clear paint is a thermosetting resin composition, for example, a composition obtained by blending 1 to 5 parts by weight of a curing agent and 20 to 40 parts by weight of a filler with respect to 100 parts by weight of an unsaturated polyester resin can be used. . It is preferable that the clear coating film 2 contains at least one or both of an antibacterial agent and a fungicide in order to impart antibacterial performance and fungicide performance. As the antibacterial agent, a silver-based antibacterial agent or the like can be used, and it is preferable to add 0.3 to 1.0% by weight based on the total amount of the clear paint. In addition, as an antifungal agent, organic thiabendazole (TBZ) or the like can be used, and can be incorporated in an amount of 0.02 to 0.2% by weight based on the total amount of the clear paint. If the amount of the antibacterial agent is less than 0.3% by weight or the amount of the fungicide is less than 0.02% by weight,
There is a possibility that sufficient antibacterial performance and antifungal performance cannot be imparted to the clear coating film 2, and the compounding amount of the antibacterial agent is 1.0
Even if the amount exceeds 0.2% by weight or the amount of the fungicide exceeds 0.2% by weight, the antibacterial and antifungal properties of the clear coating film 2 are not significantly improved, and However, there is a risk that the cost will be increased, and the cost will be disadvantageous.

The patterned reinforcing material 3 is formed by printing a pattern such as a stone pattern on a base material such as a polyester nonwoven fabric or a glass nonwoven fabric by printing. It also has a reinforcing effect for preventing cracks and cracks. The basis weight (weight per unit area) of the patterned reinforcing material 3 is 20
１２０120 g / m ² can be set. If the basis weight of the patterned reinforcing material 3 is less than 20 g / m ² , the clear coating film 2 may not be sufficiently reinforced,
If the basis weight of the patterned reinforcing material 3 exceeds 120 g / m ² , the bendability of the patterned sheet A is reduced, and it may be difficult to form a patterned FRP molded product having a desired shape.

In forming the patterned sheet A, first, a clear paint is applied uniformly on one side of the release sheet 1 to a thickness of 0.3 to 0.5 mm. Next, the reinforcing material 3 with a pattern is placed on the surface of the clear paint layer, and this is heated and dried at 100 to 120 ° C. for 60 to 90 minutes by a hot air drier. By hardening the clear paint in this way to form the clear coating film 2 and integrally laminating the clear coating film 2 and the patterned reinforcing material 3,
A patterned sheet A as shown in FIG. 1 can be formed. The above-mentioned clear coating film 2 is preferably formed by completely curing a clear coating material. When the clear coating film 2 is in a semi-cured state, the clear coating film 2 is softened by heat during molding of the patterned FRP molded product and the fluidity is increased, and the clear coating film 2 softened by the molding pressure flows out and has a pattern. Clear coating film 2 of uniform thickness on the surface of FRP molded product
May not be able to be formed.

In forming a patterned FRP molded article using the patterned sheet A as described above, first, the molding material 5 is superimposed on the surface of the patterned reinforcing material 3 of the patterned sheet A. Next, the laminate is subjected to heat and pressure to impregnate the resin component of the molding material 5 into the patterned reinforcing material 3, form the laminate into a desired shape, and further cure the resin component of the molding material 5. Thus, the patterned reinforcing material 3 and the molding material 5 are integrated. Next, by peeling the release sheet 1 from the surface of the clear coating film 2, a patterned FRP molded product having a stone pattern represented by the patterned reinforcing material 3 on the surface can be formed.

In forming a floor pan of a bathroom unit using the above-mentioned patterning sheet A, FIG.
As shown in (1), first, the patterning sheet A is set with the other surface of the release sheet 1 (the surface on which the clear coating film 2 is not formed) facing the molding surface of the lower mold 13 of the mold, and the patterned reinforcement is set. The molding material 5 is placed on the surface of the material 3, and then the upper mold (not shown) and the lower mold 13 are clamped so that the patterned reinforcing material 3 and the molding material 5 are brought into close contact with each other and heated and pressed to form the molding material 5. 5
Is impregnated into the patterned reinforcing material 3, the laminate is formed into a desired shape, and the resin component of the molding material 5 is cured to integrate the patterned reinforcing material 3 with the molding material 5. The release sheet 1 is released from the surface of the clear coating film 2 while removing the molded product.

Although the clear coating film 2 of the patterned sheet A is completely cured as described above, it will be appropriately softened by heating and pressurizing during molding, and therefore, the FRP molded article with a pattern will be softened. Even if the surface is uneven (lower die 13
(Even if the molding surface has an uneven shape), the clear coating film 2 can be deformed along the unevenness, and even if the surface is an FRP molded product with a pattern having an uneven shape, it can be finely patterned.

The above-mentioned patterned sheet A uses the patterned reinforcing material 3 which is patterned by printing, so that the patterned reinforcing material 3 can be replaced with another patterned reinforcing material 3 having a different pattern. A desired pattern can be set more freely and easily than forming a pattern by applying a plurality of colored paints by spraying or the like. In addition, the reinforcement material 3 with a pattern
Since the pattern is formed by printing, variation in the pattern can be reduced as compared with the case where the pattern is formed by applying a plurality of colored paints by spraying or the like. Further, there is no need for a variety of multicolor paints or a step of applying these paints, and the production cost can be kept low.

In the above-mentioned patterned sheet A, since the clear coating film 2 contains an antibacterial agent and a fungicide, even if a small amount of the antibacterial agent and the fungicide are used, a pattern having high antibacterial and fungicidal properties is provided. FRP molded articles can be formed. In other words, a normal FRP molded product contains an antibacterial agent and a fungicide in the molding material 5 in order to obtain antibacterial performance and antifungal performance. A large amount of antibacterial agents and fungicides must be added to spread the antimicrobial agent and fungicides even if a large amount of antibacterial agents and fungicides are incorporated in the FRP molded product. Since there are few antibacterial agents and fungicides that exhibit antifungal properties, FRP molded articles having high antibacterial and antifungal properties could not be formed. However, since the patterned sheet A of the present invention contains an antibacterial agent and a fungicide in the clear coating film 2 having a small volume, a small amount of the antibacterial agent and the fungicide can be used. Since it does not spread over the entire surface and is concentrated on the clear coating film 2 formed on its surface, the antibacterial performance and the antifungal performance of the patterned FRP molded product can be enhanced.

FIG. 3 shows another embodiment. This patterned sheet A is formed by laminating the protective material 4 on the surface of the patterned reinforcing material 3 on the laminate composed of the release sheet 1, the clear coating film 2 and the patterned reinforcing material 3 as described above. I have. The protective material 4 has air permeability, has a good surface appearance, and adheres to the clear coating film 2 and the molding material 5, and may be a nonwoven fabric such as a polyester nonwoven fabric or a glass nonwoven fabric. When a plurality of protective materials 4 are used, different types of nonwoven fabrics can be used together. Protective material 4
The basis weight and the number of sheets to be used are appropriately set in accordance with conditions such as the uneven shape and depth of the molding surface of the lower mold 13 and the like of the molding die, the presence or absence of joints, the combination of flat and irregular surfaces, and the type of molding material 5. However, the basis weight of the protective material 4 is 30 to 240 g.
/ M ² , and the number of used protective materials 4 can be set to 1 to 3 respectively. In addition, the protective material 4 may be larger than the laminate composed of the release sheet 1, the clear coating film 2, and the patterned reinforcing material 3, or may be the same size. The protective material 4 is laminated on the surface of the patterned reinforcing material 3 before the molding material 5 is superimposed on the patterned sheet A (the patterned F).
(Before RP molding)
After setting a laminate composed of the release sheet 1, the clear coating film 2, and the patterned reinforcing material 3 in the lower mold 13, the protective material 4 may be laminated.

In forming a patterned FRP molded product using such a patterned sheet A, first, a molding material 5 is superimposed on the surface of the protective material 4 of the patterned sheet A. Next, the laminate is subjected to heat and pressure to form a molding material 5.
The resin component is impregnated into the patterned reinforcing material 3 and the protective material 4 and the laminate is formed into a desired shape.
By curing the resin, the patterned reinforcing material 3, the protective material 4, and the molding material 5 are integrated. Next, by peeling the release sheet 1 from the surface of the clear coating film 2,
A patterned FRP molded product having a stone pattern expressed by the patterned reinforcing material 3 on the surface can be formed.

When a floor pan of a bathroom unit is formed using the patterning sheet A as described above, FIG.
As shown in (1), first, the patterning sheet A is set with the other surface (the surface on which the clear coating film 2 is not formed) of the release sheet 1 facing the molding surface of the lower mold 13 of the molding die.
The molding material 5 is placed on the surface of the mold, and the upper mold (not shown) and the lower mold 13 are clamped, and the molding material 5 is heated and pressed while the patterned reinforcing material 3 and the protective material 4 are in close contact with the molding material 5. The patterned reinforcing material 3 and the protective material 4 are impregnated with the resin of the molding material 5, the laminate is formed into a desired shape, and the resin of the molding material 5 is further cured to form the patterned reinforcing material 3.
Then, the protective material 4 and the molding material 5 are integrated, after which the molded product is released from the mold and the release sheet 1 is removed from the surface of the clear coating film 2.
Is carried out so as to be peeled off.

In the patterned sheet A, since the protective material 4 is laminated on the patterned reinforcing material 3, the flow of the molding material 5 at the time of molding can be appropriately reduced by the protective material 4, and the molding material 5 (resin ) Can be prevented from passing through the patterned reinforcing material 3 and reaching the clear coating film 2 or from passing through the clear coating film 2 and reaching the surface of the molded product. When molding a patterned FRP molded product having an uneven surface with a molding die, the molding pressure is not evenly applied to the entire molding surface of the molding die, and the entire corner or convex portion of the concave portion or convex portion is formed. A strong pressure is applied to the molding material 5, and the strong pressure causes the flow of the molding material 5 to increase at the corners of the concave portions and convex portions or the convex portions, and the molding material 5 (resin component) reaches the clear coating film 2 and is broken. In some cases, molding failure may occur, such as the appearance of the molded article, or the appearance of the molded article may be deteriorated. By intervening, it is possible to prevent these molding defects from occurring.

[0022]

The present invention will be described below in detail with reference to examples. Example 1 A release sheet 1 was formed by cutting a 100 μm-thick polyethylene sheet (product number “E500” manufactured by Toyobo) into a predetermined size. Next, a clear paint was applied to one side of the release sheet 1 with a thickness of 0.4 mm using a coating gun. As the clear paint, 100 parts by weight of an unsaturated polyester resin (GC-505 manufactured by Dainippon Ink and Chemicals), 4 parts by weight of a curing agent (PBZ manufactured by Nippon Oil & Fats), and a filler (product number “Heidilite” manufactured by Showa Denko) ") And 25 parts by weight. Next, on the surface of the clear paint layer, a reinforcing material 3 with a pattern (a patterned polyester non-woven fabric manufactured by Kureha Tech Co., Ltd., and having a product number of “PK95-182A”).
C)), and then heating the laminate in a hot air drying oven at 115 ° C. for 75 minutes to completely cure the clear paint to form a clear coat 2 and a clear coat 2
The patterned sheeting A as shown in FIG.

(Example 2) In the laminate of the release sheet 1, the clear coating film 2 and the patterned reinforcing material 3 of Example 1, a protective material 4 (Mitsubishi Paper Glass nonwoven fabric) was further applied to the surface of the patterned reinforcing material 3. Then, one sheet of the product number "GFC-3000") was laminated to form a patterned sheet A as shown in FIG.

(Example 3) In the laminate of the release sheet 1, the clear coating film 2, and the patterned reinforcing material 3 of Example 1, a protective material 4 (manufactured by Mitsui Petrochemical Industries, Ltd.) was further applied to the surface of the patterned reinforcing material 3. It is a polyester nonwoven fabric and has a product number "R-47".
0 ") were laminated to form a patterned sheet A as shown in FIG.

(Example 4) The clear paint of Example 1
Further, a patterned sheet A was formed in the same manner as in Example 1 except that a clear paint was obtained by adding 0.5% by weight of a silver-based antibacterial agent (product number “P01” manufactured by Shinto V Cerax Co., Ltd.). did. (Example 5) Except that 0.1% by weight of an organic fungicide containing thiabendazole (product number "Hoxter HP" manufactured by Hokuko Chemical Co., Ltd.) was added to the clear paint of Example 1 to obtain a clear paint. A patterned sheet A was formed in the same manner as in Example 1.

Patterned sheet A of Examples 1 to 5
Is easy to set the pattern freely, can prevent the pattern from varying, and is inexpensive. Next, floor pans of the bathroom unit were formed using the above-described Examples 1 to 5. First, as shown in FIG. 2, the patterning sheet A is set with the other surface (the surface on which the clear coating film 2 is not formed) of the release sheet 1 facing the molding surface of the lower mold 13 of the molding die. The surface of the reinforcing member 3 (Example 4,
Molding material 5 (SMC) for surface 5 of protective material 4)
The upper mold (not shown) and the lower mold 13 are then clamped, heated and pressed to form a desired shape.
The molded product was released from the mold and the release sheet 1 was released from the surface of the clear coating film 2. The molding conditions were set such that the upper mold and the lower mold had a temperature of 145 ° C. on the molding surface side (the release sheet 1 side) and 130 ° C. on the opposite surface side (the molding material 5 side). The pressurization time was set to 4 minutes.

The floor pan (patterned FRP molded product) of the bathroom unit thus formed has good moldability without swelling or the like during molding, and has no peeling or wrinkling of the clear coating film 2. The adhesion between the patterned reinforcing material 3 and the protective material 4 and the molding material 5 was high, so that the pattern did not fall off, and the molding material 5 did not exude on the surface.

[0028]

As described above, according to the first aspect of the present invention, a clear coating film is formed on one surface of a release sheet, and a patterned reinforcing material patterned by printing is laminated on the clear coating film. Therefore, it is possible to replace the patterned reinforcing material with another patterned reinforcing material having a different pattern, and to set a desired pattern more freely and easily than forming a pattern by applying a plurality of colored paints by spraying or the like. Is what you can do. Further, since the pattern of the patterned reinforcing material is formed by printing, it is possible to reduce the variation of the pattern as compared with the case where the pattern is formed by applying a plurality of colored paints by spraying or the like. Further, there is no need for a variety of multicolor paints or a step of applying these paints, and the production cost can be kept low and the cost can be reduced. A patterning sheet, comprising:

In the invention according to claim 2 of the present invention, since a protective material having air permeability is laminated on the patterned reinforcing material,
The protective material can make it difficult for the molding material to reach the clear coating film or the release sheet at the time of molding, and can reduce molding defects. In the invention according to claim 3 of the present invention, since at least one of an antibacterial agent and a fungicide is contained in the clear coating film, the antibacterial agent and the antibacterial agent are concentrated on the clear coating film formed on the surface of the molded article. A fungicide can be present, and even a small amount of an antibacterial agent or a fungicide can form a patterned FRP having high antibacterial performance and antifungal performance.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view illustrating an example of an embodiment of the present invention.

FIG. 2 is a schematic diagram showing a method of using the same.

FIG. 3 is a sectional view showing an example of another embodiment of the present invention.

FIG. 4 is a sectional view showing a conventional example.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Release sheet 2 Clear coating film 3 Patterned reinforcing material 4 Protective material

Claims (3)

[Claims] 1. A patterned sheet formed by forming a clear coating film on one surface of a release sheet and laminating a patterned reinforcing material patterned by printing on the clear coating film. 2. The patterned sheet according to claim 1, wherein a patterned reinforcing material is laminated with a protective material having air permeability. 3. A clear coating film comprising at least one of an antibacterial agent and a fungicide.
Or the patterning sheet of 2.