KR100936730B1 - Moulding compound for compressive and injection moulding and the method of manufacturing it - Google Patents

Abstract

PURPOSE: A molding compound is provided to express beautiful marbling patterns on the surface of final product or parts through pressure molding or injection molding without use of a film in which pattern is transferred, and to produce molded products having marbling patterns and excellent mechanical strength. CONSTITUTION: A molding compound comprises a phenol resin as a base material, a melamine resin forming partterns, and an inorganic filler. The melamine resin is the resin showing patterns in molding, has a color difference with a phenol resin as a base material, and mixes a resin as a base material with the inorganic filler after incompletely curing it by heat treatment of 110~150 °C.

Description

Molding material for compression and injection molding and its manufacturing method {MOULDING COMPOUND FOR COMPRESSIVE AND INJECTION MOULDING AND THE METHOD OF MANUFACTURING IT}

The present invention relates to a molding material for compression and injection molding, and more particularly, to a molding material and a method of manufacturing the same, which exhibits a marbling pattern during molding.

Compression and injection thermoforming materials consist of a resin that acts as a binder and an inorganic filler that acts as a filler. And a small amount of a plasticizer, a hardening | curing agent, a mold release agent, etc. are added. The compression and injection thermoforming process heats the molding material in the temperature range of about 100 ~ 200 ℃ near the softening point of the binder resin to make it flowable, and then pushes it into a certain shape to fill every corner with strong pressure by compression or injection method. The final product is manufactured by curing the molding material by heating the mold temperature to a temperature range of 150 ~ 250 ℃. When a product is manufactured by thermoforming a molding material including a resin binder to complete curing, it is possible to mass-produce complex shapes easily, so the application range is very wide.

Products or parts that have been cured by thermoforming molding materials containing resin binders by compression or injection method are monochromatic in color and are determined by the characteristics of the resin binder. At this time, to adjust to the desired color is added a colorant. In addition, in order to meet various consumer's tastes and to enhance the merchandise, a beautiful pattern is added in addition to the desired color, which has a beautiful color and a beautiful pattern by coating with a patterned film additionally on the finished product or component. You can manufacture products and parts.

As a method of coating a patterned film, a technology of manufacturing a product or a part with a pattern by attaching the film to a product or a part that has been fully cured by thermoforming and then heat-compressing it with a thermoforming machine is disclosed in Korea. It is described in the issue. In order to prevent the coating layer on the surface of the product or part finally manufactured from being damaged by abrasion during use, the patterned surface formed by transfer in the film surface is directed to the coated object to be heat-pressed to prevent wear. The method of preventing the loss of the patterned surface by means of Korean Patent Laid-Open No. 2002-0080302 has also been presented. In Korea Utility Model Registration No. 244430, the sheet impregnated with melamine resin is first adhered to the surface of the coating material to express various patterns on the surface of products or parts made of various materials such as plywood, wood, stone, and metal. The present invention describes a method of manufacturing a final product or a component in which various patterns are expressed by temporarily bonding a plurality of films to be temporarily bonded.

The coating method using the conventional pattern transfer film as described above is a process of heat-pressing the film after the temporary adhesion to the coating material, which is useful for the manufacture of large or flat products or parts, but has a small shape, a curved shape, or an elaborate shape. It is difficult to apply three-dimensional compression of a precise shape to apply to the manufacture of parts or products, and also difficult to effectively remove pores generated in the film during the compression process. In addition, since the additional coating process must be performed on the final product or component that is hardened, it has a problem in that productivity is difficult and mass production is difficult and economical.

In the present invention to solve the problems of the prior art as described above, when the pattern is expressed and compression molding or injection molding is made to be cured as it is without using a separate film coating method to obtain a final finished product having a beautiful pattern It is intended to provide a material and a method of manufacturing the same.

To this end, in the present invention,

Resin which becomes a base material; Resin which shows a pattern at the time of shaping | molding; Including inorganic filler,

The resin showing the pattern has a color difference from the resin serving as the substrate, and after being incompletely cured, is mixed with the resin serving as the substrate together with the inorganic filler,

The present invention provides a molding material in which a marbling pattern is expressed by differences in color and fluidity between resins during molding.

At this time, in order to further increase the fluidity difference between the resins, the resin showing the pattern may be used by classifying the particle size in the range of 10 ~ 10,000㎛ by grinding after incomplete curing.

In the present invention,

(a) heat treating the melamine resin at 110 to 150 ° C. in a kneader to incompletely cure and then grind to obtain an incompletely cured powdered melamine resin;

(b) blending the powdered phenolic resin with the incompletely cured powdered melamine resin of (a) at 90-40 wt% vs. 10-60 wt%, and adding an inorganic filler, a plasticizer, a curing agent and a release agent thereto. Uniformly mixing to obtain a resin mixture;

(c) a method of producing a melamine-phenolic resin molding material in which a marbling pattern is expressed during molding, which comprises the step of heat-treating the resin mixture of (b) in a kneader at a temperature of 130 to 180 ° C. and then cooling the mixture to room temperature. Is provided.

In the molding material of the present invention, a beautiful marbling pattern is expressed on the surface of the final product or part while compression molding or injection molding is performed without the use of the transfer film. According to the present invention, it is possible to mass-produce a molded article having a beautiful marbling pattern through compression molding or injection molding, and at the same time, it is economical and has excellent mechanical strength of the produced molded article. In particular, unlike the conventional method, since it is not necessary to coat the pattern-transferred film one by one in order to implement a pattern on the surface, a compact or complex shape product can be manufactured by compression molding or injection molding that can be mass-produced. In addition, the molding material of the present invention can implement various functions depending on the characteristics of the resin or inorganic filler used. In particular, the melamine-phenolic resin (MPMC) molding material of the present invention using a phenolic resin and melamine resin is combined with the advantages of each resin, economical and functional, it can be utilized in various applications in various fields.

The molding material of the present invention comprises a resin serving as a base material; A resin exhibiting a pattern during molding; Inorganic fillers are included.

As used herein, "molding" includes compression molding and injection molding. As used herein, the term "molding material" refers to a molding material that is molded by compression molding or injection molding to manufacture a molded article.

As the resin serving as the base material and the resin showing the pattern, all of the usual resins used in the compression or injection thermoforming material can be used. For example, Phenol resin; Melamine resins; Novolac resins; Epoxy resins can be used. Resin as a base material and a resin showing a pattern can be the same type of resin or different types of resins, and can be composed of one or more types of resins, respectively. Preferably, a phenol resin may be used as the base resin, and a melamine resin having a beautiful color upon curing may be used as the resin having a pattern. Phenolic resin has the advantage of easy production and high mechanical strength, melamine resin is expensive but beautiful color, hard, electrically stable and flame retardant.

Resin which shows the said pattern uses what has a color difference with resin used as a base material. Moreover, resin which shows the said pattern is used after incomplete hardening so that the difference of fluidity with resin used as a base material can be shown. Therefore, the marbling pattern is expressed by the difference in color and fluidity between the resin that is the base material and the resin that represents the pattern during molding. Preferably, in order to further increase the fluidity difference between the resins, the resin showing the pattern is used by classifying the particle size in the range of 10 to 10,000 μm. If the particle size of the pulverized resin is 10 μm or less, the pattern to be expressed is too small to express the marbling pattern. If the particle size is 10,000 μm or more, the fluidity is difficult due to poor fluidity in the final thermoforming process. Can be drastically lowered.

Preferably, melamine resin having a beautiful color after heat curing is used as a resin having a pattern. When using melamine resin as a resin showing a pattern, it is incompletely hardened by heat treatment at 110 to 150 ° C. in a kneader to control fluidity. At this time, if the heat treatment temperature is 110 ℃ or less, there is no change in fluidity because the curing reaction does not progress. If the heat treatment temperature is 150 ℃ or more, excessive curing reaction proceeds during heat treatment, resulting in no fluidity, and thus the final molding process such as compression molding and injection molding. The marbling pattern may not be expressed.

In addition, the resin (melamine resin) exhibiting the pattern is incompletely cured and then coated with an amine-based silane solution to ensure compatibility with the heterogeneous resin serving as a substrate and to improve interfacial bonding force. That is, when the amine silane solution is evenly applied by spraying, the resin powder is soaked and dried, the amine silane solution is converted into silanol form by hydrolysis reaction, and the -OH group of silanol reacts with -OH group on the surface of melamine resin. _As O is released, it forms a strong bond of -O- and is coated on the melamine resin mixture particles. The silanol strongly bound to the surface of the melamine resin mixture particles enhances the bonding strength with heterogeneous resins such as phenolic resins and improves the compatibility between resins. It is possible to prevent the weakening of the binding force. It is preferable that the amine silane solution is evenly wetted by spraying. In the present specification, "coating" means that the resin powder is evenly wetted with an amine silane solution. Preferably, an amine silane solution is used at about 0.2 to 3 wt% of the weight of the resin showing a pattern. If the amine-based silane solution is 0.2 wt% or less, it does not affect compatibility with heterogeneous resins and improves the interfacial bonding force. If the amine-based silane solution is 3 wt% or more, the amine-based silane solution is converted to silanol through a hydrolysis reaction. The coating may sharply drop the fluidity so that the marbling pattern may not be expressed, and at the same time, the thermoforming may be difficult.

The mixing ratio between the resin serving as the base material and the resin showing the pattern is preferably adjusted to be 90 to 40 wt% to 10 to 60 wt% for the expression of the marbling pattern. If the mixing ratio of the resin showing the pattern is 10 wt% or less, the marbling effect is insignificant and not beautiful, and if it is 60 wt% or more, the pattern may not be expressed.

The molding material of the present invention contains an inorganic filler in addition to the resin as in the conventional compression or injection thermoforming material. As the inorganic filler, any conventional inorganic filler used for compression or injection thermoforming materials can be used, for example, glass fibers; CaCO ₃ ; Talc; Wood; Feldspar; One or more kinds of clays may be used. The inorganic filler is used in the usual amount of the inorganic filler used for the resin in the usual compression or injection thermoforming material, wherein the resin is calculated as the total resin in which the resin which is the above-mentioned resin and the resin showing the pattern are added together. Preferably, the inorganic filler is used in an amount of 50 to 150 parts by weight based on 100 parts by weight of the total resin of the molding material of the present invention.

In addition, the molding material of the present invention may further include a known additive used in conventional thermoforming materials such as a plasticizer, a curing agent, a release agent, etc. in addition to the inorganic filler to improve moldability, promote curing, and release property.

Hereinafter, the method for producing a melamine-phenolic resin molding material according to the present invention using phenol resin as the base resin and melamine resin as the resin showing the pattern will be described step by step.

Obtaining Incomplete Cured Melamine Resin

After curing, the melamine resin with beautiful color is heat treated at 110 ~ 150 ℃ for 3 minutes in the kneader alone, incompletely cured, and then cooled to room temperature and pulverized to a certain size. Preferably, the pulverized particles are classified into 10 to 10,000 μm, more preferably 100 to 5,000 μm, depending on the particle size.

In addition, preferably, the incompletely cured powdery melamine resin thus obtained is spray-coated with an amine silane solution corresponding to 0.2 to 3 wt% of the weight of the resin, and the interface generated by the difference in fluidity with the dissimilar resin in the next step. Prevents a decrease in bonding strength. In this case, preferably, the wet melamine resin powder is dried to completely volatilize the wet alcohol solvent.

In this case, additives such as an inorganic filler, a plasticizer, a curing agent, a releasing agent, and the like may be added to the melamine resin in a conventional range as in the manufacture of a conventional compression or injection thermoforming material.

Obtaining Resin Mixture Mixed Evenly

90 to 40 wt% of the powdered phenol resin is blended with 10 to 60 wt% of the incompletely cured powdered melamine resin obtained in the above step. Preferably, the incompletely cured powdered melamine resin is classified according to particle size to increase the difference in fluidity with the phenolic resin so that the marbling pattern appears more clearly during thermoforming. An inorganic filler such as glass fiber, CaCO ₃ , talc, wood, feldspar, clay, and the like is blended with 50 to 150 parts by weight based on 100 parts by weight of the total resin, and a plasticizer is added thereto. Known additives such as hardeners, mold release agents and the like are added in small proportions at known proportions. Then use a high speed mixer or the like to mix uniformly, preferably put in a high speed mixer at a rotational speed of 980 ~ 1,100rpm for about 30 minutes to achieve a uniform mixing.

Preparation of Melamine-Phenol Resin (MPMC) Molding Materials

The resin mixture obtained in the above step is heat-treated in a kneader at 130 ~ 180 ℃ to prepare a molding material of the present invention capable of compression molding and injection molding. In this case, the heat treatment temperature and time vary depending on the amount of the mixture to be injected. Since the amount of volatilization generated from the molding material in the mold due to heat during compression and injection molding, there is a possibility that the final heat-molded product or parts may be damaged. By controlling the temperature, the volatile content of the molding material is sufficiently removed and at the same time, the fluidity is controlled to facilitate injection. After heat treatment, the mixture is cooled to room temperature and coarsely ground to form a melamine-phenol resin material capable of compression and injection molding.

In the molding material of the present invention thus obtained, a beautiful marbling pattern is expressed at the time of molding due to color difference and fluidity difference between different resins. That is, due to the difference in fluidity and color difference between the resin showing the pattern and the resin serving as the base material, the marbling pattern is expressed by the per-point or disordered filling in the mold during compression molding and injection molding. In the present invention, the marbling effect is enhanced by incomplete curing of the resin showing the pattern, and preferably, the resin having the pattern is classified and used for each particle size to induce fluidity difference according to the particle size to further strengthen the marbling effect. Let's do it.

EXAMPLE

Hereinafter, the present invention will be described in more detail with reference to specific examples. However, these examples are only for illustrating the present invention in more detail, the scope of the present invention is not limited by these examples.

Example 1

Preparation of molding material expressing marbling pattern

(1) After curing, melamine resin with beautiful color is put into kneader alone and heat treated for 3 minutes at different temperatures in the range of 110 ~ 150 ℃, then cooled to room temperature to obtain incompletely cured melamine resin, and then crushed Powdered. 2 is a result of the fluidity change of the melamine resin according to the heat treatment temperature.

(2) The incompletely cured powdered melamine resin and powdered phenol resin prepared in (1) were mixed at a weight of 1: 1, and the glass fibers were mixed at a weight of 1: 1 as an inorganic filler with respect to the total weight of the resin thus added. Thereafter, a plasticizer, a curing agent, and a releasing agent were added thereto at 0.7 wt%, 0.8 wt%, and 0.7 wt% of the total weight of the mixture, respectively, and uniformly mixed using a high speed mixer. Then, the resin mixture uniformly mixed was added to the kneader to remove the volatiles while performing heat treatment in the range of 130 ~ 180 ℃ to have a suitable thermal fluidity. After the heat treatment was cooled to room temperature and coarsely pulverized to obtain a melamine-phenolic resin molding material (MPMC) of the present invention capable of compression and injection molding while expressing a marbling pattern.

When the molding material of this embodiment thus obtained is compression molded or injection molded, a desired final product or part can be produced. Figures 3a and 3b is a result showing the change in the marbling pattern according to the fluidity change of the melamine resin in the molded final part.

Example 2

Preparation of molding material expressing marbling pattern

(1) The incompletely cured melamine resin was pulverized and then subjected to the same procedure as in Example 1 (1), except that 100 to 5000 µm was classified according to the particle size to obtain an incompletely cured melamine resin.

(2) The melamine-phenolic resin of the present invention which can be pressed and injection molded while expressing a marbling pattern by performing the same procedure as in Example (2) except that the incompletely cured melamine resin is classified and used for each particle size. Molding material (MPMC) was obtained.

Figures 4a to 4d is a result showing the change in the marbling pattern according to the particle size of the melamine resin fluidity control by heat treatment in the final part obtained by compression molding the molding material of this embodiment.

Example 3

Preparation of Melamine-Phenol Resin (MPMC) Molding Material through Amine Silanol Coating

(1) After obtaining the incompletely cured melamine resin powder in the same manner as in Example 2, the amine-based silane solution corresponding to 1.6 wt% of the melamine resin powder was spray coated on the melamine resin powder. The wet melamine resin powder was kept in a 60 ° C. dryer for 12 hours so that the alcohol solvent was completely volatilized to obtain a melamine resin powder coated with silanol.

(2) Melamine-phenolic resin molding of the present invention that can be compressed and injection molded while expressing a marbling pattern by performing the same method as in Example (2) except that the melamine resin powder coated with silanol is used. Material (MPMC) was obtained.

Figure 5 shows the change in flexural strength when the fluidity is controlled and the melamine resin with the particle size classification is completed with an amine-based silane solution.

 The molding material of the present invention can produce a large amount of molded articles having a beautiful marbling pattern through compression molding or injection molding, so it is economical and excellent in mechanical strength of the produced molded articles, and thus can be used in various applications in various industrial fields. In particular, unlike the conventional film coating method, since it is possible to mass-produce small or complex shaped products, it is also useful for the production of small products, parts, and the like having beautiful patterns. The molding material of the present invention has a variety of uses according to the resin used, and the melamine-phenolic resin (MPMC) molding material of the present invention using phenol resin and melamine resin can be applied to all fields in which the resin can be used. In particular, the handle may be used for cooking utensils and other kitchen utensils such as a frying pan having a marble pattern.

1 is a surface optical photograph of a component having a complex shape in which a beautiful pattern is expressed on a surface thermoformed with a melamine-phenol molding material.

2 is a result of the fluidity change of the melamine resin mixture according to the heat treatment temperature.

Figure 3 is a result of the change in the marbling pattern of the cured final part according to the fluidity change of the melamine resin mixture, Figure 3a is a surface photograph of the final part of flow rate 142mm, Figure 3b is a final part of flow rate 116.5mm The surface photograph of.

Figure 4 shows the change in the marbling pattern of the cured final part according to the particle size of the melamine resin mixture is controlled by the heat treatment, Figure 4a particle size 180㎛, Figure 4b particle size 159㎛, Figure 4c particles Size 141 μm, FIG. 4D shows the result of particle size 127 μm.

5 is a result showing the change in flexural strength when the flow control and the melamine resin mixture of the particle size classification according to the embodiment of the present invention by the weight ratio (wt%) of the amine-based silane solution.

Claims (12)

Phenol resin which becomes a base material; Melamine resin to form a pattern; Including inorganic filler, The melamine resin has a color difference with the phenolic resin, which is a base material, when molded, and is incompletely cured by heat treatment at 110 to 150 ° C., and then mixed with the base resin together with the inorganic filler. Molding material characterized in that the marbling pattern is expressed by the difference in color and fluidity between the resin during molding. The molding material according to claim 1, wherein in order to further increase the fluidity difference between the resins, the melamine resin is incompletely cured and pulverized to classify the particle size in the range of 10 to 10,000 µm. The molding material as set forth in claim 2, wherein the melamine resin is coated with an amine-based silane solution corresponding to 0.2 to 3 wt% of the weight of the pulverized powder after incomplete curing, and then mixed with the phenol resin. The molding material according to any one of claims 1 to 3, wherein the mixing ratio between the phenol resin and the melamine resin is 90 to 40 wt% to 10 to 60 wt%. delete delete delete delete The method according to claim 4, wherein the inorganic filler is glass fiber; CaCO ₃ ; Talc; Wood flour; Feldspar; And at least one member selected from the group consisting of clays. The method of claim 9, further comprising: a plasticizer; Curing agent; And at least one additive selected from the group consisting of release agents. (a) heat treating the melamine resin at 110 to 150 ° C. in a kneader to incompletely cure and then grind to obtain an incompletely cured powdered melamine resin; (b) blending the powdered phenolic resin with the incompletely cured powdered melamine resin of (a) at 90-40 wt% vs. 10-60 wt%, and adding an inorganic filler, a plasticizer, a curing agent and a release agent thereto. Uniformly mixing to obtain a resin mixture; (C) a method of producing a molding material that is expressed in a marbling pattern during molding comprising the step of heat-treating the resin mixture of (b) in the kneader in the range of 130 ~ 180 ℃ and then cooled to room temperature. The method of claim 11, further comprising spray coating an amine-based silane solution corresponding to 0.2 to 3 wt% of the weight of the incompletely cured powdered melamine resin of (a).

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