KR0159586B1 - Molded product with a pattern and method of making the same - Google Patents

Abstract

Patterned molded articles such as waterproof floor pans for bathrooms are produced by the following method. A coloring paint is apply | coated to one side of a peelable sheet | seat, and the pattern layer which has a desired pattern is formed. Before the colored paint of the pattern layer is dried and cured, a reinforcing sheet is placed on the pattern layer, and a part of the colored paint of the pattern layer is impregnated into the reinforcing sheet, and then the colored paint applied on the release type sheet is almost completely cured to obtain a pattern forming sheet. . The pattern forming sheet is set on the mold so that the release sheet is in contact with the mold surface, a resin molding material is disposed on the pattern forming sheet, and integrally molded under pressure heating conditions to obtain a pattern forming molded article. Prior to the molding process, the colored paint is almost completely cured to form a warning pattern layer, and the pattern layer is not easily softened at the time of molding by reinforcing the pattern layer with a reinforcing sheet. A pattern layer does not flow, and the pattern formation molded article which has a favorable external appearance can be manufactured. It is preferable to use polyester nonwoven fabric or glass nonwoven fabric as a reinforcement sheet. In addition, if necessary, after the coating protective material is disposed between the pattern-forming sheet and the resin molding material, the molded article can be integrally formed under pressure heating conditions.

Description

Patterned molded article and its manufacturing method

1 is a side view of a pattern-forming sheet of the present invention.

2 is a conceptual diagram showing an example of a coloring coating application step in the method for producing a pattern-forming molded article of the present invention.

3A to 3C are explanatory views showing a method of flatly fixing a release type sheet and a reinforcing sheet during a drying process of a coloring paint in the method of manufacturing a pattern-forming molded article of the present invention.

4 is an explanatory diagram showing an example arranged on a mold of a pattern forming sheet and a resin molding material.

5 is a side view of a pattern forming sheet in which a coating protective material is laminated.

6 is a side view of a pattern forming sheet in which two coating protective materials are laminated.

FIG. 7 is an explanatory view showing a method of preventing the resin molding material from invading from the side portion of the pattern forming sheet in the molding step of the method for manufacturing a pattern forming molded article of the present invention. FIG.

* Explanation of symbols for main parts of the drawings

1: release sheet 2: coloring paint

3: pattern layer 4: reinforcement sheet

10: resin forming material 13: light source

BACKGROUND OF THE INVENTION 1. Field of the Invention [0001] The present invention relates to a patterned molded article used as a waterproof floor pan or a top plate of a sink such as a bathroom or a washroom, and a manufacturing method thereof.

BACKGROUND ART As a waterproof floor fan for a bathroom, a molded article in which a Oh Young-Suk pattern or a marble pattern is formed on the surface of a fiber reinforced plastic (FRP) has been used. Such patterned molded articles are produced by, for example, the Hand Lay-up method or the Press Molding Method.

In the hand lay-up method, a plurality of colored paints are blown onto a surface of a mold by using a spray gun or the like to form a desired pattern to form a stone shape, and then the colored paints are cured. The glass fiber and the resin material overlap each other on top of each other to form a back layer or to form a gel by applying a light-transmissive resin to the surface of the mold. The granules are blown to form a stone, and the back layer is formed so that the glass fiber and the resin overlap each other after curing the translucent resin.

In the hand layup method, since the formation of the pattern is performed by the use of a spray gun, it is possible to form the pattern only on a part of the surface of the molded article. Therefore, there is an advantage in that the pattern can be freely drawn in a desired place of the molded article in preparing the design. On the other hand, there is a problem that the productivity is bad because the manufacturing process requires a large number of processes, the manufacturing price is high.

On the other hand, the press molding method is a method in which a granular material for stone shape is mixed with a molding material called SMC (Sheet Molding Compound) or BMC (Bulk Molding Compound), and the mixed molding material is placed in a mold and press-molded. The press-molding method has good productivity and is advantageous in terms of manufacturing cost, on the other hand, it is difficult to form a stone shape on a part of the surface of the molded article, and is restricted in making a design. In addition, there is a problem that the strength of the molded article is not stabilized because the granular material for the shape of stones is distributed over the entire molded article.

Hereinafter, the manufacturing method of the pattern forming molded article proposed above is demonstrated.

Japanese Patent Application Laid-open No. 5-285973 specifies a method for producing a patterned molded article by placing a nonwoven fabric or paper patterned by printing in a mold and placing a molding material thereon and press molding under a heat press condition. Doing.

However, in the above method, a printing plate for printing a pattern on a nonwoven fabric or paper must be made for each pattern, and there is a problem that the overall manufacturing price becomes expensive in consideration of the cost and time required to prepare a printing plate on which a desired pattern is drawn. .

Japanese Patent Publication Hei 3-38092 and Japanese Patent Laid-Open Publication Hei 5-116163 apply a light-transmissive resin to the surface of a sheet to form a stone-form particle formation on the light-transmissive resin, and apply a colorant to the surface to form a stone-patterned sheet. A stone pattern sheet is placed on the mold so that the surface on which the stone pattern granular material is not formed is in contact with the mold surface, and then a molding material is set on the stone pattern sheet to be integrally molded under pressure heating conditions. It describes how to make shaped molded articles. However, in the above method, it is difficult to produce a pattern other than a stone pattern, and there is a problem that the degree of freedom in selecting a pattern is small. Moreover, it can also be listed as a problem that a difference arises in a stone pattern for each molded article.

In Japanese Patent Laid-Open No. 3-227300, a soft colored gel coat resin is applied to the surface of a peelable film, and after changing the colored gel coat resin, a colored gel coat resin surface is applied by using an adhesive on various substrates. A method of forming a patterned layer of colored gel coat resin on a substrate by adhering and peeling off a release film after drying the adhesive is specified. However, in the said method, since the colored gel coat resin surface is adhere | attached on a board | substrate using an adhesive agent, there exists a problem that it is difficult to adhere to the board | substrate which becomes uneven | corrugated. Japanese Patent Application Laid-Open No. 5-318468 forms a desired pattern by applying a transparent or colored gel coat resin to which a curing agent and a chain transfer agent are added to the surface of a base film to form a desired pattern, and semi-curing the gel coat resin After obtaining the coat sheet, peeling the base film from the gel coat sheet and placing the gel coat sheet on the mold, and overlapping the molding material thereon, it is specified a method for producing a molded article formed by integral molding under heat and press conditions. . However, the method requires precise control of the curing reaction of the gel coat resin in order to obtain the semi-cured state of the gel coat resin, resulting in an increase in the difficulty of the operation. In addition, when integrally molding under the heat and press condition, since the gel coat sheet is in a semi-cured state, there is a possibility that breakage of the gel coat sheet (flow of a pattern, etc.) occurs due to the flow of the molding material.

SUMMARY OF THE INVENTION An object of the present invention is to provide a method capable of producing a patterned molded article efficiently and at a low price while solving or improving the problems included in the prior art. That is, the manufacturing method of the pattern formation molded article of this invention includes the following processes. First, in order to draw a desired pattern on a 1st surface of a peelable sheet | seat, a coloring paint is apply | coated and a patterned layer is obtained. The peelable sheet used here has peelability with respect to a coloring paint, and has a 2nd surface in which the coloring paint is not apply | coated.

Subsequently, a breathable reinforcing sheet is placed on the pattern layer before the color coating of the pattern layer is lightly dried, and a part of the coloring paint of the pattern layer is impregnated into the reinforcing sheet, and then the color coatings are almost completely cured to obtain a pattern forming sheet. The obtained pattern forming sheet is placed on the mold such that the second surface of the release sheet is in contact with the mold surface, the molded resin material is disposed on the pattern forming sheet, and integrally molded under pressure heating conditions to obtain a pattern forming molded article. In addition, the peelable sheet is peeled off from the patterned molded article as necessary after the patterned molded article is discharged from the mold. In the production method of the present invention, before drying and curing the colored paint of the pattern layer, a breathable reinforcing sheet is disposed on the pattern layer, and a part of the colored paint of the pattern layer is impregnated into the reinforcement sheet, and then the colored paint is almost completely cured. Since the sheet forming sheet is formed, the following effects are acquired compared with the case where the coloring paint is welcomed.

(1) The workability can be improved without paying attention to the control of the curing reaction of the coloring paint in order to obtain the semi-cured state of the coloring paint, and as a result, the manufacturing cost of the patterned molded article can be lowered.

(2) At the time of pressurized heating molding, the pattern layer can be prevented from being damaged by the softening and flow of the pattern layer generated when the colored coating of the pattern layer is in a semi-cured state. In particular, in the case of a pattern layer prepared by using a multicolored coloring paint, it is possible to prevent the coloring paint from being mixed due to softening of the pattern layer at the time of pressure molding, resulting in poor appearance.

(3) The pattern layer is damaged by the pressure of the molding material, and leakage of the molding material between the pattern layer and the peelable sheet can be prevented.

In the manufacturing method, the reinforcing sheet is preferably any one of a polyester nonwoven fabric and a glass nonwoven fabric.

Moreover, in the said manufacturing method, it is also preferable to arrange | position a coating protective material on the pattern formation sheet set to the mold, and to arrange | position a resin molding material on a coating protective material, and to integrally shape under pressure heating conditions. By the use of the coating protective material, the flow of the resin material pressurized at the time of molding to the pattern layer can be weakened, and the damage of the pattern layer due to the molding material can be prevented more effectively. As a coating protective material, it is preferable to use at least 1 of a polyester nonwoven fabric or a glass nonwoven fabric. In particular, when manufacturing a pattern forming molded article having irregularities on the surface by using both a polyester nonwoven fabric and a glass nonwoven fabric as the coating protective material, the pattern forming sheet, the polyester nonwoven fabric, and the glass nonwoven fabric are placed on the mold surface in the order of loading of the resin material. It is preferable. By adopting the lamination order as described above, since the heat shrinkage of the polyester nonwoven fabric generated at the time of molding is alleviated by the presence of the glass nonwoven fabric, it is possible to more reliably prevent the occurrence of wrinkles in the uneven attention on the surface of the molded article. Moreover, it is preferable that the coating protective material is formed larger than the pattern formation sheet. In the case of disposing a plurality of coating protective materials on the pattern forming sheet, at least one of the coating protective materials may be formed larger than the pattern forming sheet.

In the process of apply | coating a coloring paint on a peelable sheet, it is preferable to apply a coloring paint on the 1st surface of a peelable sheet, irradiating light from the 2nd surface side of a peelable sheet. In this way, a pattern layer having a uniform thickness can be obtained by visually observing the state (transmittance) of light passing through the colored paint applied on the peelable sheet and checking the coating thickness of the colored paint. It can form on a peelable sheet efficiently. In addition, it is possible to economically use colored paints from the viewpoint of preventing excessive application of the paints to the release type sheet.

In the manufacturing method of the pattern forming molded article of this invention, it is also preferable to form a translucent resin film by spreading translucent resin on the 1st surface of a peelable sheet before apply | coating a coloring paint to a peelable sheet. When the light-transmissive resin film is provided, not only the quality of the finally obtained patterned molded article, that is, the added value can be increased, but also the prevention of grooves on the surface of the molded article and the surface finishing treatment of the molded article after the molding step can be omitted.

The patterned molded article produced by the production method of the present invention has the following configuration. The pattern-formed molded article is composed of a molded resin layer and a pattern-formed sheet integrally molded with the molded resin layer under heating and pressing conditions. The pattern forming sheet is composed of a peelable sheet, a pattern layer having a desired pattern drawn with colored paint on one side of the peelable sheet, and a reinforcing sheet impregnated with a part of the colored paint.

These objects, structures, advantages, and features of the present invention will be more clearly understood by the following detailed description and examples of the present invention with reference to the accompanying drawings.

Hereinafter, a method of manufacturing a patterned sheet molded article of the present invention will be described in detail.

[1] application process of a peelable sheet of a coloring paint

As shown in FIG. 1, the coloring paint 2 is apply | coated to one side (henceforth a 1st surface) of the peelable sheet 1, and the patterned layer 3 which has a desired pattern is formed. For example, it is preferable to apply a coloring paint to a release type sheet so that thickness may be about 0.2-0.6 mm by use of a spray gun etc. Thus, by forming a pattern layer, a desired pattern can be drawn in arbitrary positions of a peelable type sheet, without using a printing plate. When using a multi-color coloring paint, you may apply | coat with a spray gun for every color, but from a viewpoint of productivity, it is preferable to apply at a time using a multi-color spray gun. Although there is no restriction | limiting in the shape of a peelable type sheet, since a long one can apply a coloring paint continuously, it is possible to perform an application | coating process efficiently. Application of the coloring paint to the release type sheet can be carried out by the same method as the pattern formation by the conventional hand lay-up method.

The peeling sheet 1 used for this invention has peelability with respect to a coloring paint and a translucent resin, For example, peeling type paper, a polypropylene resin sheet of 30-100 micrometers in thickness, polyethylene Thermoplastic resin sheets, such as a resin sheet and a polyethylene terephthalate resin sheet, or a polyester sheet, a nylon sheet, etc. can be used. The peelable sheet may be peeled off from the molded article at the completion stage of the patterned molded article (for example, a bath waterproofing fan or the like) which is the final product. In order to prevent the formation of flaws or contaminants in the pattern layer during the storage and transportation of the pattern-formed molded article, it may be left as it is without peeling off.

The colored paint 2 used in the present invention is a colored gel coat resin, and a thermosetting resin composition colored with a toner or the like can be used. More specifically, it can use what mix | blended 1-5 weight% of hardening | curing agents, 20-40 weight% of fillers, and 2-10 weight% of coloring toners with respect to 100 weight% of unsaturated polyester resins. To the coloring paint, a daph resin (diallyl phthalate resin, DAP resin) is added as necessary. By the addition of the dap resin, the forming force of the coloring paint to the peelable sheet can be slightly lowered to prevent sticking of the coloring paint to the peelable sheet.

It is also preferable to apply a light-transmissive resin to the first surface of the release-type sheet and to form a light-transmissive resin film (not shown) on the release-type sheet before applying the coloring paint on the release-type sheet. For example, the translucent resin film can be obtained by heating and drying the coated translucent resin in a heating furnace at a temperature of 80 to 120 ° C. for 20 to 60 minutes. Therefore, in this case, the pattern layer of the coloring paint is formed on the light-transmissive resin film. As the translucent resin, a transparent gel coat resin can be used. For example, a mixture of an unsaturated polyester resin, a curing agent, and a filler (no coloring agent is added) similar to the coloring paint can be exemplified. As mentioned above, the high quality of the molded article finally obtained by formation of a translucent resin film, ie, an added value, can be improved, and the flaw prevention of a molded article and the surface finish of the molded article in the molding process can be skipped.

In the application | coating process of a coloring paint to a peeling type sheet | seat, a coloring paint is apply | coated on the 1st surface of a peeling sheet, irradiating light from the surface (henceforth a 2nd surface) side opposite to the 1st surface of a peeling type sheet. It is preferable. That is, as shown in FIG. 2, the release type sheet 1 is provided on a temporary light guide 12 having a light transmitting property, for example, a glass plate, a wire mesh, a perforated plate, and the like. 13) For example, a fluorescent lamp or an incandescent lamp is provided, and the light source is applied to the second surface of the peelable sheet while irradiating light with the spray gun 11 to apply the coloring paint. By adopting the above structure, the coating operation is carried out while visually confirming the state (transmittance) of the light passing through the release type sheet coated with the coloring paint, so that the pattern layer 3 having a uniform thickness can be efficiently It becomes possible to form on a peeling type sheet. In other words, it is possible to prevent the irrationality caused by the application of the non-uniform coloring paint, for example, the permeation of the pattern layer caused by the application of only a small amount of the coloring paint. In addition, it is economical because application of an excess amount of colored paint is also prevented.

[2] impregnation with reinforcing sheets for coloring paints

Before the colored coating 2 of the patterned layer 3 formed on the release sheet 1 is cured, the breathable reinforcing sheet 4 is placed on the surface of the patterned layer before the patterned layer is collapsed. Is impregnated into the reinforcing sheet. At this time, when the pressure of the degree which the pattern of a pattern layer does not go up is added to the reinforcement sheet put on the pattern layer, since it is accelerated the impregnation of a coloring paint with the reinforcement sheet, it is preferable. Thereafter, the applied coloring paint 2 is dried and almost completely cured to obtain the pattern forming sheet A of the present invention. As shown in FIG. 1, the pattern forming sheet A has a laminated structure composed of a peelable sheet 1, a pattern layer 3, and a reinforcing sheet 4. As shown in FIG. The following effects are mentioned as a role which a reinforcement sheet in the structure of the said pattern formation sheet plays. When the reinforcing sheet is not included in the pattern forming sheet, the cured pattern layer is easily broken or cut by torsion of the peeling sheet, but when the reinforcing sheet is reinforced, the cracking or cutting of the pattern layer as described above Is hardly generated and can provide particularly improved workability in handling the patterned sheet.

The reinforcing sheet 4 used in the present invention has a plurality of holes having air permeability. For example, glass cloth (weaving 60 g / m 2, mesh # 30 to # 60) woven glass long fiber, glass nonwoven fabric or polyester nonwoven fabric (weaving 30 g / m 2 or less) can be exemplified. In particular, it is preferable to use glass nonwoven fabric or polyester nonwoven fabric. The weaving amount (weight per unit area) of the reinforcing sheet is set in consideration of the uneven shape of the mold used in the molding process, the depth, the presence or absence of lines, the combination of the flat portion and the uneven portion, and the like. In order to harden | cure a coloring paint almost completely, it is preferable to dry in a heating furnace at 100-120 degreeC for 20 to 90 minutes.

By the way, in the dry-hardening process of the apply | coated coloring paint 2, the pattern formation sheet A which prevents generation | occurrence | production of the wrinkles of the pattern layer 3 resulting from the curvature of the peeling sheet 1 was dried on the temporary stand 15 It is preferable to fix on the top. In particular, when the peelable sheet is cut and supplied in a predetermined shape while being rolled and mounted in a roll shape, there is a possibility that large warpage of the peelable sheet occurs in the wound direction during drying, so that the patterned sheet is placed on the drying rack. It is preferable to fix it. For example, as shown in FIGS. 3A to 3C, the spherical pattern forming sheet A is placed on the dry temporary stand 15 of the iron plate, and at least two sides of the pattern forming sheet A (FIG. 3A), Preferably, the edge 16 is installed along four sides (FIG. 3c), and the pattern forming sheet A is fixed to the dry temporary placing table 15 by the screws 17 installed at several places on one side at equal intervals. It is preferable to dry in a hot air drying furnace.

[3] molding processes for resin molding materials and pattern forming sheets

The pattern forming sheet A produced by the above [1] and [2] is integrally molded with the resin forming material 10 to produce a pattern forming molded article such as a waterproof floor fan for a bathroom. As shown in Fig. 4, the pattern forming sheet A is disposed so that the second surface of the release sheet is in contact with the surface of the mold 30, and the resin molding material is disposed on the pattern forming sheet. Thereafter, the pattern forming sheet and the resin molding material are integrally molded under the heat and press conditions. In addition, in FIG. 4, although the coating protective material 5 is arrange | positioned between the pattern formation sheet A and the resin molding material 10, the detailed description of the coating protective material 5 is mentioned later. Since the pattern layer of the pattern forming sheet is softened to a degree deformable according to the shape of the unevenness of the mold under the heat and press condition at the time of molding, the patterned layer can be transferred to the patterned shaped article to make the uneven shape of the mold beautiful. Moreover, it is preferable to make the mold surface which contact | connects a peelable sheet | seat concave only by the thickness of a peeling sheet. By carrying out the mold design as described above, it is possible to prevent the thickness difference per minute of the peeling sheet generated when the peeling sheet is peeled from the molded article so as not to remain on the surface of the molded article. As a resin molding material 10 used in the manufacturing method of the pattern formation molded article of this invention, thermosetting resins, such as unsaturated polyester resin, an epoxy resin, a phenol resin, a melamine resin, a urea resin, a silicone resin, etc. The sheet molding compound (SMC) which mixed glass fiber etc. and shape | molded in the sheet form, and the BMC (bulk molding compound) which mixed the reinforcing fiber shorter than SMC and shape | molded the lump shape with the above-mentioned thermosetting resin can be mentioned.

In addition, as shown in FIG. 4 or FIG. 5, it is preferable to insert the coating protective material 5 between the pattern forming sheet A and the resin molding material 10 before performing pressure heating molding. The coating protective material 5 is sandwiched between the pattern forming sheet A and the molding resin material 10 to weaken the flow of the pressurized molding material 10 to the pattern layer 3 during molding. The damage of the pattern layer by the molding material can be prevented more reliably. As the coating protective material 5, it is preferable to use at least one of a polyester nonwoven fabric and a glass nonwoven fabric. In particular, as shown in FIG. 6, the polyester nonwoven fabric 6 is disposed on the pattern forming sheet A as the first coating protective material, and the glass nonwoven fabric 7 is disposed on the polyester nonwoven fabric as the second coating protective material. After arrange | positioning the resin molding material 10 on a glass nonwoven fabric, it is preferable to integrally shape under pressurized heating conditions. By adopting the stacking procedure as described above, even when producing a waterproof floor fan for the bathroom having unevenness on the surface, for example, a drainage V groove on the surface, a good waterproof fan without wrinkles can be produced around the V groove. Can be.

Moreover, as shown in FIG. 5, it is preferable to form the coating protective material 5 larger than the pattern formation sheet A. FIG. When several coating protective material is used, at least 1 coating protective material should just be formed larger than the pattern formation sheet in it. In FIG. 6, only the glass nonwoven fabric 7 as a coating protective material is formed larger than the pattern formation sheet A. In FIG. Specifically, it is preferable that the outer circumferential portion of the coating protective material is made about 5 mm to 10 mm larger than the outer circumferential portion of the pattern forming sheet. With such a shape as described above, the deviation can be corrected by the outer circumferential portion of the coating protective material even if the coating protective material slightly deviates by the flow of the resin molding material during the press molding. In addition, as shown in FIG. 7, when the outer periphery of the coating protective material 5 is cut to cover the side portion of the pattern forming sheet A and curvature, resin molding is performed through the side portion of the pattern forming sheet A during molding. It is possible to prevent the material 10 from directly invading the patterned layer 3.

By the way, before a pattern formation sheet is set to a mold surface, it may be punched out using a Thomson mold in a predetermined shape. As shown in Fig. 8, when the pattern forming sheet A has a spherical shape, it is preferable to form the trimmed portion 20 by cutting and removing four corners of the pattern forming sheet at 45 degrees with respect to each side. By forming the trimmed part 20 as mentioned above, wrinkles can be prevented from occurring in the corner part of a final molded article.

Example 1

As the peelable sheet, a polyester sheet having a thickness of 100 μm (Oriental Yarn E5000) was used. On the other hand, as a coloring paint, the coloring paint of two colors of white and black was produced by the following method. That is, 100% by weight of an unsaturated polyester resin (GC-505 manufactured by Nippon Ink Chemical Co., Ltd.), 4% by weight of a curing agent (PBZ, manufactured by Nippon Oil Industries, Ltd.), and 25% by weight of a filler (made by Digestion Electric Works) are mixed with the mixture 100. White toner 4PHR and black toner 4PHR were stirred and mixed, respectively, to obtain a white and black two-color coloring paint. A white and black colored paint was applied onto a peelable sheet set on a temporary frame of a wire mesh product using a multi-color gel coat gun to prepare a patterned layer. The coating amount of the coloring paint was 30-40 wt% of the white coloring paint and 60-70 wt% of the black coloring paint of the pattern layer. The thickness of the pattern layer was 0.5 mm, and the pattern of the fish stone was drawn.

As the reinforcing sheet, a polyester nonwoven fabric (A) (Mitsui Petrochemical Co., Ltd. R-001, weaving 23 g / m 2) was used. The reinforcing sheet (A) is placed on the pattern layer before the coloring paint of the pattern layer is cured, and a part of the coloring paint is impregnated in the reinforcing sheet, followed by drying in a condition of 60 to 90 minutes at 110 ° C. by a hot air drying furnace. Was completely cured. What was obtained as mentioned above was punched out to predetermined size using the Thompson mold, and the pattern formation sheet of Example 1 was obtained.

The pattern forming sheet was placed on the surface of the mold for the waterproof floor fan for the bathroom so that the reinforcing sheet was placed upwards, and then 10 sheets of SMC molding materials were placed on the reinforcing sheet, and then integrally formed under heating and pressing conditions. The molding temperature was set so that the molding surface side (product surface side) of the molding die was 145 ° C and the inner surface side was 130 ° C. The molding pressure was 1200 tons and the pressurization time was 4 minutes.

Thereafter, the pattern-forming molded article was removed from the mold, and post-processing such as a finishing process was carried out to peel off the release type sheet from the surface of the molded article, thereby manufacturing a waterproof floor fan for a bathroom of Example 1 having a fish-eye pattern.

In addition, in the manufacturing process of the waterproof fan of Example 1, three steps of evaluation (circle) (no problem), (triangle | delta) (with some problem), and x (not used for problem) were performed about the following items. The evaluation results are shown in Table 1.

Evaluation item 1: manufacturability (impregnation of colored paint, dry curability of colored paint)

Evaluation Item 2: Workability (Cutability to Predetermined Size)

Evaluation Item 3: Formability

Example 2

In the same manner as in Example 1 except that a glass nonwoven fabric (GFC-3000 weave 30g / m 2 manufactured by Mitsubishi Paper Co., Ltd.) was used instead of the reinforcing sheet of Example 1, a waterproof floor fan for a bathroom of Example 2 was prepared. Evaluation similar to Example 1 was performed to the waterproof bottom fan of Example 2. The evaluation results are shown in Table 1.

Comparative Example 1

Instead of using the pattern forming sheet which semi-cured the coloring coating instead of the pattern forming sheet which completely hardened the coloring coating produced in Example 1, the waterproofing floor fan for the bathroom of Comparative Example 1 was prepared by the same manufacturing method as in Example 1. Produced. Evaluation similar to Example 1 was performed to the waterproof bottom fan of the comparative example 1. The evaluation results are shown in Table 2.

Comparative Example 2

In the manufacturing method of Example 1, the glass nonwoven fabric (GFC-3000 weave 30g / m <2> manufactured by Mitsubishi Paper Co., Ltd.) was used instead of the polyester nonwoven fabric (A), and the pattern formation sheet which changed the coloring paint of the pattern layer was used. A water-resistant floor fan for bathrooms of Comparative Example (2) was produced in the same manner as in Example 1 except that it was used. Evaluation similar to Example 1 was performed to the waterproof bottom fan of the comparative example 2. The evaluation results are shown in Table 2.

From the results of Tables 1 and 2, (1) impregnation of the coloring paint on the reinforcing sheet, (2) presence or absence of wrinkles or peeling of the pattern layer during drying, and (3) pattern formation by a Thompson mold Regarding the evaluation of the presence or absence of the fracture of the pattern layer during punching of the sheet, the difference was not confirmed and confirmed by completely curing or semi-curing the coloring paint during the creation of the pattern forming sheet.

However, in the molding process for manufacturing the waterproof floor fan, when the pattern forming sheet with semi-finish colored paint is used, the pattern layer flows during molding, resulting in poor appearance and poor quality of the product. . On the other hand, when the pattern formation sheet which completely hardened the coloring paint of this invention was used, it was possible to maintain favorable external appearance, without generating the flow of the pattern layer as mentioned above. As mentioned above, the manufacturing method of this invention showed the outstanding result in all the evaluations in the manufacturing process of a patterned molded article.

Example 3

In the molding process of Example 1, two glass nonwoven fabrics (30 g / m2 of GFC-3000 weave manufactured by Mitsubishi Paper Co., Ltd.) were disposed between the pattern forming sheet and the resin molding material as a coating protective material, and then the molded article was integrally formed. Except for the same as in Example 1 to prepare a waterproof floor fan for the bathroom of Example 3.

In the waterproof floor fan manufactured as described above, three steps of evaluation (○ (no problem), Δ (some problems), × (not available for problem)) were performed on the following items. Table 3 shows the results of the evaluation.

Evaluation item 1: adhesiveness of coating protective material and resin molding material

Evaluation item 2: presence or absence of the leakage of the resin molding material on the surface of a waterproof bottom fan

Evaluation Item 3: Appearance Evaluation of Waterproof Floor Fan

Example 4

In the molding process of Example 1, one polyester nonwoven fabric (B) (R-470 manufactured by Mitsui Petrochemical Co., Ltd.) was disposed between the pattern forming sheet and the resin molding material as a coating protective material, and these were integrally molded. Except for the same as in Example 1 to prepare a waterproof floor fan for the bathroom of Example 4. Evaluation similar to Example 3 was performed to the waterproof bottom fan of Example 4. Table 3 shows the results of the evaluation.

Example 5

In the molding process of Example 1, each of a polyester nonwoven fabric (B) (R-470 manufactured by Mitsui Petrochemical Co., Ltd.) and a glass nonwoven fabric (GFC-3000 manufactured by Mitsubishi Paper Co., Ltd.) was formed as a coating protective material. A waterproof floor fan for the bathroom of Example 5 was prepared in the same manner as in Example 1 except that the molded material was placed between the molding materials and then integrally molded. As a lamination | stacking procedure, the polyester nonwoven fabric (B) was laminated | stacked on the pattern formation sheet of Example 1, and the glass nonwoven fabric was piled up on the above. Evaluation similar to Example 3 was performed to the waterproof bottom fan of Example 5. The evaluation results are shown in Table 3.

Comparative Example 3

Instead of the pattern forming sheet which completely hardened the coloring coating of Example 1, the pattern forming sheet which semi-cured the coloring coating was used, and two glass nonwoven fabrics (30 g / m2 of CFC-3000 by Mitsubishi Paper Co., Ltd.) as a coating protective material. Is placed between the pattern forming sheet and the resin molding material. Except having integrally molded these, it carried out similarly to Example 1, and produced the waterproof floor fan for bathroom of the comparative example 3. Evaluation similar to Example 3 was performed to the waterproof bottom fan of the comparative example 3. The evaluation results are shown in Table 4.

[Comparative Example 4]

Instead of the pattern forming sheet which completely hardened the coloring coating of Example 1, the pattern forming sheet which semi-hardened the coloring coating was used, and one polyester nonwoven fabric (B) as a coating protection material (R-470 by Mitsui Petrochemical Industries, Ltd.) ) Was disposed between the pattern-forming sheet and the resin molding material, and the waterproof floor fan for the bathroom of Comparative Example 4 was produced in the same manner as in Example 1 except that these were integrally molded. Evaluation similar to Example 3 was performed with the waterproof bottom fan of the comparative example 4. The evaluation results are shown in Table 4.

[Comparative Example 5]

Instead of the pattern forming sheet which completely hardened the coloring coating of Example 1, the pattern forming sheet which semi-hardened the coloring coating was used, and polyester nonwoven fabric (B) (R-470 by Mitsui Petrochemical Co., Ltd.) and glass as a coating protective material. Each of the nonwoven fabrics (CFC-3000 manufactured by Mitsubishi Paper Co., Ltd.) was disposed between the pattern forming sheet and the resin molding material, and was then molded and molded in the same manner as in Example 1, except that the waterproofing for the bathroom of Comparative Example 5 was performed. A bottom pan was produced. In addition, as a lamination procedure, the polyester nonwoven fabric (B) was also made to overlap a glass nonwoven fabric on the pattern formation sheet of Example 1 on it. Evaluation similar to Example 3 was performed to the waterproof bottom fan of the comparative example 5. The evaluation results are shown in Table 4.

As shown in Table 4, in the case of using a pattern forming sheet in which the colored layer of the pattern layer is semi-cured, the molding resin material leaks through the pattern layer to the side of the release type sheet while heating and molding, and the colored layer of the pattern layer is softened. This resulted in a flow phenomenon of the paint (phenomena in which a plurality of color paints were mixed and the pattern broke). On the other hand, in Examples 4 to 6 using a pattern forming sheet in which the colored paint was completely cured, a waterproof bottom fan having a good appearance could be produced without causing a flow of the paint.

Example 6

Hereinafter, the water-proof fan of Example 6 was produced like Example 1 except having apply | coated the coloring paint on the peelable sheet | seat by the method shown. That is, the coloring sheet was applied onto the peeling sheet while irradiating light from a light source (fluorescent lamp) disposed on the lower part of the mounting table by placing the peelable sheet on a temporary table formed of a wire mesh made of stainless steel. During the application step, the release type sheet was fixed by being sucked by the suction means through a temporary mesh wire rod.

According to the method of the above embodiment, since the coating operation of the coloring paint can be continued while visually confirming the light transmittance in the light source passing through the peeling type sheet coated with the coloring paint, a uniform thickness is applied to the whole of the peeling sheet. The patterned layer of the coloring paint which had was able to be formed.

Example 7

As a spherical release type sheet, a polyester sheet having a thickness of 100 μm (Oriental Spinning Products E5000) was used. On the other hand, as a coloring paint, the coloring paint of two colors of white and black was produced by the following method. That is, 100% by weight of an unsaturated polyester resin (GC-505 manufactured by Nippon Ink Chemical Co., Ltd.), 4% by weight of a curing agent (PBZ, manufactured by Nippon Oil Industries, Ltd.), and 25% by weight of a filler (made by Digestion Electric Works) are mixed with the mixture 100. The white toner 4PHR and the black toner 4PHR were stirred and mixed, respectively, to prepare colored paints of white and black two colors. A white and black colored paint was applied onto a peelable sheet set on a temporary frame of a wire mesh product using a multi-color gel coat gun to prepare a patterned layer. Since the light source (fluorescent lamp) disposed under the temporary base of the wire mesh while irradiating the coloring paint was irradiated toward the peelable sheet, the transmittance of the light passing through the peelable sheet coated with the coloring paint was visually confirmed. As a result, the pattern layer of uniform thickness can be manufactured on a peeling type sheet. The peelable sheet is fixed to the suctioned by the suction means through the temporary stand of the wire mesh. The coating amount was determined so that the white colored paint was 30 to 40% by weight of the patterned layer, and the black colored paint was 60 to 70% by weight of the patterned layer. The thickness of the pattern layer was 0.5 mm, and the pattern of the fish stone was drawn.

As a spherical reinforcing sheet, a glass nonwoven fabric (GFC-3000 weave 30 g / m 2 manufactured by Mitsubishi Paper Co., Ltd.) was used. The reinforcing sheet was placed on the pattern layer before the colored paint of the pattern layer was cured, and a part of the colored paint was impregnated into the reinforcing sheet to obtain a laminate. The laminate was placed on a drying rack of an iron plate, and a strip network of 5 × 30 mm was set along four sides of the laminate, and the biscued laminates provided at five locations on one side at equal intervals were fixed and placed in a hot air drying furnace. Drying by a hot air drying furnace was carried out at 110 ° C. for 60 to 90 minutes, and the pattern layer was almost completely cured. What was obtained as mentioned above was punched in predetermined size using the Thompson mold, and the pattern sheet of Example 7 was produced. After the same as in Example 1 after the waterproof floor fan for the bathroom of Example 7 was prepared.

In the above embodiment, since the peelable sheet and the reinforcing sheet are fixed and dried with a bisque, the warp does not occur in the peelable sheet or the reinforcing sheet, and no wrinkles or peeling occurs in the pattern layer, and a smooth pattern forming sheet can be produced. It was confirmed.

Claims (14)

In order to draw a desired pattern on the first surface of the peelable sheet, a coloring paint is applied to obtain a patterned layer, wherein the peelable sheet has peelability to the colored paint, and the peelable sheet has a second coating not coated with the coloring paint. A process having a surface, a step of placing a breathable reinforcing sheet on the pattern layer before the colored paint of the pattern layer is dried and hardened, impregnating a part of the colored paint of the pattern layer into the reinforcing sheet, A process of obtaining a pattern forming sheet by almost completely curing the coloring paint, placing the pattern forming sheet on the mold so that the second surface of the peelable type projecting contact with the mold surface, and placing a molding resin material on the pattern forming sheet, A method of manufacturing a pattern-forming press-formed product, comprising the step of integrally molding under a pressure heating condition. The pattern-forming molded article is composed of a molded resin layer and a pattern-forming sheet integrally molded to the molded resin layer under heating and pressurization conditions, and is formed on a peelable sheet and a desired pattern layer and a pattern layer drawn with colored paint on one side of the peelable sheet. A reinforcement sheet disposed and impregnated with a part of the coloring paint, and the colored paint in the pattern forming sheet is almost completely cured before being integrally molded with the molding resin material. The method according to claim 1, wherein the reinforcing sheet is any one of a polyester nonwoven fabric and a glass nonwoven fabric. The method of manufacturing a pattern-forming press-formed product according to claim 1, further comprising a step of inserting a coating protective material between the pattern-forming sheet and the resin molding material and then integrally molding it under pressurized heating conditions. The pattern forming molded article according to claim 2, further comprising a coating protective material inserted between the molded resin layer of the pattern forming molded article and the pattern forming sheet. The method of manufacturing a pattern forming press-formed product according to claim 4, wherein the coating protective material is any one of a polyester nonwoven fabric and a glass nonwoven fabric. The nonwoven fabric of claim 1, further comprising a polyester nonwoven fabric as a first coating protective material on the patterned sheet set in the mold, a glass nonwoven fabric as a second coating protective material on the polyester nonwoven fabric, and a molded resin material on the glass nonwoven fabric. Method of manufacturing a pattern-forming press-formed article comprising the step of integrally molding under pressure heating conditions after arranging. 3. A first coating protective material made of a polyester nonwoven fabric formed on a pattern forming sheet between a pattern forming sheet and a molded resin layer, and a second coating protective material made of a glass nonwoven fabric formed on the first coating protective material. Patterned moldings made. The method of manufacturing a pattern-forming press-formed product according to claim 4, wherein the coating protective material includes a step formed larger than the pattern-forming sheet. The method of claim 1, wherein the pretreatment is performed on the release sheet before the coloring paint is applied to the release sheet, wherein the pretreatment includes applying a light-transmissive resin to the first surface of the release sheet. Method for producing a formed press-molded article. The method of manufacturing a pattern-forming press-formed product according to claim 1, further comprising a step of applying a coloring paint onto the first surface of the release type sheet while irradiating light from the second surface side of the release type sheet. The method of claim 1, wherein the peelable sheet and the reinforcing sheet is a spherical, the colored paint applied on the peelable sheet while keeping the peelable sheet and the reinforcing sheet flat with at least two sides of the spherical peelable sheet and the reinforcing sheet fixed at least on both sides thereof. Method of producing a pattern-forming press-formed product comprising the step of dry curing. The pattern forming molded article according to claim 2, wherein the reinforcing sheet is any one of a polyester nonwoven fabric and a glass nonwoven fabric. The pattern forming molded article according to claim 5, wherein the coating protective material is any one of a polyester nonwoven fabric and a glass nonwoven fabric.