KR102667948B1 - Pattern material for plastic molded products, patterned plastic molded products mixed with the same, and method of manufacturing pattern materials for plastic molded products - Google Patents

Abstract

The present invention provides a pattern material for plastic molded products that has heat resistance without compromising design properties, a patterned plastic molded product combining the same, and a method for manufacturing a pattern material for plastic molded products.
It consists of a base material (2) and a colored layer (3) formed on the surface of the base material (2). The base material 2 is made of flake-shaped mica, and the colored layer 3 contains at least a pigment 4 mainly composed of titanium oxide-coated mica in which the surface of the flake-shaped mica particles is coated with titanium oxide, a resin, and a solvent. It is formed by the paint it contains. The size of mica is 0.01mm to 20mm, and the particle diameter of titanium oxide-coated mica is 0.5㎛ to 200㎛.

Description

Pattern material for plastic molded products, patterned plastic molded products mixed with the same, and method of manufacturing pattern materials for plastic molded products

The present invention relates to a pattern material for plastic molded products, a patterned plastic molded product combining the same, and a method for manufacturing a pattern material for plastic molded products. More specifically, it relates to a pattern material for plastic molded products consisting of a base material and a colored layer formed on the surface of the base material, a patterned plastic molded product combining the same, and a method of manufacturing a pattern material for plastic molded products.

Conventionally, patterned plastic molded articles have been formed by mixing a pattern material into a heat-melted thermoplastic resin. For example, a method for producing artificial marble as shown in Patent Document 1 is known. However, as shown in paragraph [0015] of the above document, it is common to use the same type of resin as the molded product for the pattern material, and a pattern material with heat resistance that can be used for molding at high temperatures has been required.

In addition, for example, a method for producing a resin molded article as shown in Patent Document 2 is also known. In this method, a capsule with the colorant covered by a film and encapsulated inside is contained in the molding material, and the film is burst by heat during press molding to cause the colorant to flow within the molding material to create various patterns. forms. In such cases, the colorant may fade or discolor due to the heat during molding, deteriorating the design of the pattern.

In addition, molding materials such as sheet molding compound (SMC) and bulk molding compound (BMC) used in housing equipment, etc. are usually heated and hardened at 100 to 180°C, so molding at high temperatures is not assumed. In many cases, discoloration or fading of the pattern material due to heat is not taken into consideration. Therefore, if it is possible to manufacture a heat-resistant patterned material that does not cause changes such as discoloration in the colored layer due to high-temperature molding and does not deteriorate design properties, a new use will arise.

Japanese Patent Publication No. 2003-95723 Japanese Patent Publication No. 2018-34333

Taking this conventional situation into consideration, the present invention aims to provide a pattern material for plastic molded products that has heat resistance without compromising design properties, a patterned plastic molded product combining the same, and a method for manufacturing a pattern material for plastic molded products.

In order to achieve the above object, the characteristic of the pattern material for plastic molded articles according to the present invention is that in the structure consisting of a base material and a colored layer formed on the surface of the base material, the base material is made of flaky mica (mica). The colored layer is formed by a paint containing at least a pigment (pearl pigment) containing titanium oxide-coated mica, in which the surface of a thin plate-shaped mica particle is coated with titanium oxide, and a resin and a solvent. The size of the mica is 0.01mm to 20mm, and the particle diameter of the titanium oxide-coated mica is 5㎛ to 200㎛.

According to the above configuration, since the base material is mica in the form of flakes, thermal deformation of the mica as the base material is suppressed even at high temperatures of, for example, 300°C or higher, and designability does not deteriorate. Furthermore, the colored layer is formed by a paint containing a pigment containing titanium oxide-coated mica as a main component, in which the surface of the thin plate-shaped mica particles is coated with titanium oxide. The coloring of pigments is usually due to the absorption and scattering of light by the pigment particles themselves, but the coloring of pearl pigments is due to multiple reflections of light in the titanium oxide layer on the surface of the mica particles and the resulting interference. Therefore, it is difficult to be influenced by external environments such as light and heat, and titanium oxide-coated mica is physically and chemically stable. Therefore, it is believed that by forming a colored layer on the surface of a flaky mica base material with a paint containing a pearl pigment as a main component, discoloration and fading of the pattern material are suppressed even at high temperatures of 300°C or higher. Furthermore, the present inventors confirmed that the colored layer containing the pearl pigment did not peel off from the surface of the mica substrate and adhered firmly. This is thought to be because the main component (material) of the base material and the colored layer is mica, so the shrinkage and expansion rates are the same, and the adhesion of the contact surface is maintained even when a large temperature environment change occurs during molding. . Additionally, the size of the mica is 0.01 mm to 20 mm. If it is within this numerical range, it can be used without deteriorating its function as a pattern material. Additionally, the particle diameter of the titanium oxide-coated mica is 5 μm to 200 μm. If it is within this numerical range, it is possible to ensure heat resistance without deteriorating the function (designability) as a pattern material. In this way, it is possible to use it as a pattern material even at high temperatures without its function (designability) deteriorating.

In addition, in order to achieve the above object, the characteristic of the patterned plastic molded article obtained by mixing the pattern material for plastic molded articles according to the present invention is that the pattern material for plastic molded articles according to any of the above structures is mixed with a thermoplastic resin. . In this case, for example, the thermoplastic resin may be ABS resin or polycarbonate resin. As described above, since the pattern material for plastic molded products has heat resistance, it can be used for thermoplastic resins such as ABS resin and polycarbonate resin that require processing such as molding at high temperatures.

In addition, in order to achieve the above object, a feature of the method for producing a pattern material for plastic molded articles according to the present invention is that it comprises flaky mica and titanium oxide-coated mica in which the surface of the thin-plate shaped mica particles is coated with titanium oxide as the main component. The method involves stirring and mixing a paint containing at least a pigment as a main component, a resin, and a solvent, and forming the colored layer using the paint on the surface of the mica.

According to the characteristics of the pattern material for plastic molded products according to the present invention, the patterned plastic molded product containing the same and the method for manufacturing the pattern material for plastic molded products, it has become possible to improve heat resistance without compromising design properties.

Other objects, configurations and effects of the present invention will become clear from the following description of the embodiments of the present invention.

1 is an enlarged photograph of a patterned plastic molded product mixed with a pattern material for plastic molded products according to the present invention.
Figure 2 is a cross-sectional view schematically showing a pattern material for plastic molded products.
Figure 3 is a diagram explaining the coloring process of the pattern material for plastic molded products according to the present invention.
Figure 4a is a partial enlarged photograph of the pattern material before the test in Example 1.
Figure 4b is a partial enlarged photograph of the pattern material before the test of Comparative Example 1.
Figure 4c is a partial enlarged photograph of the pattern material before the test of Comparative Example 2.
Figure 4d is a partial enlarged photograph of the pattern material before the test of Comparative Example 3.
Figure 5a is a partial enlarged photograph showing the state of the pattern material after the heat resistance test in Example 1.
Figure 5b is a partial enlarged photograph showing the state of the pattern material after the heat resistance test of Comparative Example 1.
Figure 5c is a partial enlarged photograph showing the state of the pattern material after the heat resistance test of Comparative Example 2.
Figure 5d is a partial enlarged photograph showing the state of the pattern material after the heat resistance test of Comparative Example 3.
Figure 6a is a partial enlarged photograph showing the state of the pattern material after the discoloration durability test in Example 1.
Figure 6b is a partial enlarged photograph showing the state of the pattern material after the discoloration durability test of Comparative Example 1.
Figure 6c is a partial enlarged photograph showing the state of the pattern material after the discoloration durability test of Comparative Example 2.
Figure 6d is a partial enlarged photograph showing the state of the pattern material after the discoloration durability test of Comparative Example 3.
Figure 7 is a partial enlarged photograph showing the state of the pattern material after the additional discoloration durability test in Example 1.

Next, the present invention will be described in more detail with appropriate reference to the attached drawings.

The pattern material 1 for plastic molded articles according to the present invention (hereinafter simply referred to as "pattern material") is formed on the base material 2 and the surface of the base material 2, as shown in FIGS. 1 and 2. It consists of a colored layer (3). This pattern material 1 is mixed with a thermoplastic resin and processed into a plastic molded product with a pattern. Additionally, the horizontal width of the patterned plastic molded product (plate-shaped body) illustrated in FIG. 1 is about 10 cm.

Since the pattern material 1 according to the present invention has a heat resistance of about 300°C as will be described later, it can be molded by mixing it with a thermoplastic resin with a relatively high molding temperature, such as ABS resin or polycarbonate resin, for example. do. The function (designability) as a pattern material is not lost due to the heat during molding, and the pattern is clearly expressed in the plastic molded product. Of course, it is not limited to thermoplastic resins such as the above-described ABS resin or polycarbonate resin, and it is possible to apply the pattern material 1 to thermoplastic resins that can be molded at lower temperatures than these resin materials.

(Substrate)

As shown in FIG. 2, the substrate 2 has a flaky shape and is made of natural mica (mica) or synthetic mica. The size of the flaky mica 2 (hereinafter referred to as flaky mica 2) used as this substrate is, for example, about 0.01 mm to 20 mm in length (the length of the longest part) of one piece. Alternatively, the flaky mica (2) may have a particle size of about 4 mesh to 166 mesh in terms of JIS test strainer mesh. If it is less than this lower limit, it is difficult to clearly express the pattern when mixed into a plastic molded article. On the other hand, if this upper limit is exceeded, when mixed with a thermoplastic resin and molded, they are not sufficiently mixed with each other, and the finish of the molded product deteriorates.

(Colored layer)

The colored layer 3 is formed of a pigment (hereinafter also referred to as a “pearl pigment”) 4 whose main component is titanium oxide-coated mica in which the surface of a thin plate-shaped mica particle is coated with titanium oxide. The particle diameter of this pearl pigment 4 is approximately 5 μm to 200 μm. If it is less than this lower limit, it is difficult to clearly express the pattern when mixed into a plastic molded article. On the other hand, if this upper limit is exceeded, when mixed with a thermoplastic resin and molded, they are not sufficiently mixed with each other, and the finish of the molded product deteriorates.

Here, since the color development (coloring) of a general pigment is due to the absorption and scattering of light by the pigment particles themselves, the pigment itself is affected by the external environment, and discoloration or fading is likely to occur. On the other hand, since the above-described pearl pigment develops color due to multiple reflections of light and interference thereof from the titanium oxide layer on the surface of the mica particles, it is difficult to be affected by external environments such as light and heat. Additionally, titanium oxide-coated mica is physically and chemically stable. Therefore, it is thought that pearl pigments are unlikely to discolor or fade due to heat.

(manufacturing method)

The pattern material (1) according to the present invention is made by coloring flaky mica (2) graded into the sizes described above with a pearl pigment (4).

In the coloring process, the flaky mica (2) and the paint are put into the drum (11) of the stirrer (tumbler) (10), and the mixture is rotated and stirred by the blades (12) and the drum (11). Here, the paint contains at least a resin, a pearl pigment (4) as the main component, and a solvent, and is blended in a ratio of 2% by weight or more and 20% by weight or less with respect to the flaky mica (2). If it is less than the lower limit, there will be less paint compared to the flake mica 2, and the paint will not spread widely on each flake mica 2 and cannot be sufficiently colored, causing stains. On the other hand, if the upper limit is exceeded, too much paint is used, time is required to form (especially drying) the colored layer 3, and production efficiency decreases. In addition, the thin mica 2 tends to stick together to form cores (blocks), and the particle diameter becomes non-uniform. In addition, the paint is made by dispersing the pearl pigment 4 with a disper, further dispersing it by adding glass beads, mixing the pearl pigment 4 with a resin and solvent, and dispersing it with a disper. It is manufactured by stirring.

The paint contains 20% by weight or more and 49.5% by weight or less of resin. If it is less than the lower limit, it does not function sufficiently as a binder, it becomes difficult to fix and maintain the pigment in the thin mica 2, solvent resistance decreases, and discoloration becomes easy. On the other hand, if the upper limit is exceeded, the resin will bond the thin mica 2 together to form a block (lump), making it difficult to disperse and color the thin mica 2 individually. In addition, examples of the resin contained in the paint include polyester resin, epoxy resin, acrylic resin, urethane resin, silicone resin, acrylic silicone resin, and acrylic urethane resin. However, these resin materials are only examples and are not limited to the above resins. The resin contained in the paint mainly functions as the binder described above and does not significantly affect the effect of the present invention.

Additionally, the paint contains pearl pigment (4) in an amount of 0.5% by weight or more and 20% by weight or less. If it is less than the lower limit, sufficient color development cannot be ensured. On the other hand, if the upper limit is exceeded, the amount of pigment increases too much, and the pigment that could not be fixed to the surface of the thin mica 2 by the resin elutes (color falls out).

Additionally, the paint contains 30% by weight or more and 75% by weight or less of a solvent. If it is less than the lower limit, it becomes difficult to sufficiently disperse the pearl pigment 4 and the resin to exist in the paint, coloring the flaky mica 2 becomes difficult, and stains are likely to occur. On the other hand, if the upper limit is exceeded, a part of the paint accumulates at the bottom of the tumbler, making it difficult to fix the pearl pigment 4 on the flaky mica 2. In addition, the formation (especially drying) of the colored layer 3 takes time, which reduces production efficiency. Additionally, as solvents, ethyl acetate, toluene, acetone, ethanol, butanol, ethyl acetate, butyl acetate, etc. are used.

According to this coloring process, sufficient heating is performed to promote the fixation (curing) of the pearl pigment 4 in the paint on the surface of the outer peripheral surface of the thin mica 2. Here, the flaky mica (2) and pearl pigment (4) have heat resistance.

Additionally, since the flaky mica 2 is colored while moving (stirring) within the drum 11, the flaky mica 2 is prevented from sticking together and forming a lump. Moreover, by rotational stirring mixing, it is possible to pass the paint containing the pearl pigment 4 on all the outer surfaces of the flaky mica 2, and coloring with the pearl pigment 4 on all the outer surfaces of the flaky mica 2. Layer 3 (coat film) is formed and colored. Afterwards, it is taken out from the stirrer (10), dried, and the solvent is volatilized to become the pattern material (1).

Here, in order to confirm the effectiveness of the present invention, the inventors conducted an experiment to confirm heat resistance and discoloration durability with respect to the following Examples and Comparative Examples 1 to 3.

The example is a pattern material colored with a paint containing flaky mica (2) as a main component and a pearl pigment (4), and is shown in Fig. 4A. Additionally, Comparative Example 1 is a pattern material in which flaky mica (2) was colored with a paint containing a disazo pigment, which is one of the organic pigments, as a main component, and is shown in FIG. 4B. Comparative Example 2 is a pattern material colored with a paint containing pearl pigment 4 using a base material made of PET (polyethylene terephthalate) resin as a main component, and is shown in FIG. 4C. Comparative Example 3 is a pattern material in which a substrate made of PET resin was colored with a disazo pigment, one of the organic pigments, and is shown in Figure 4d. Examples and Comparative Examples 1 to 3 were all colored by the above coloring process. Additionally, the magnification ratio of each photo shown in FIGS. 4A to 4D is approximately 280 times.

First, the inventors measured the surface temperature of the pattern material in real time with a radiation thermometer, heated the produced Example 1 and Comparative Examples 1 to 3 from room temperature to 250°C on an iron plate, and observed the subsequent state with the naked eye. . The observation results (photos) are shown in FIGS. 5A to 5D. As shown in these drawings (photos), in Comparative Examples 2 and 3 in which PET resin was used as the substrate, the substrate itself melted and shrank, and did not function as a pattern material. On the other hand, Example 1 and Comparative Example 1, which used thin mica (2) as the base material, showed almost no change in state before heating and functioned as a pattern material. The magnification ratio of each photo shown in FIGS. 5A to 5D is approximately 280 times.

Next, the inventors heated the produced Example 1 and Comparative Examples 1 to 3 from room temperature to 300°C on an iron plate while measuring the surface temperature of the pattern material in real time with a radiation thermometer, and observed the subsequent state with the naked eye. did. The observation results (photos) are shown in FIGS. 6A to 6D. As shown in these drawings (photographs), in Comparative Examples 1 and 3 using organic pigments, the pigment itself discolored or faded, and the function (designability) of the pattern material deteriorated. Since the color development (coloring) of such ordinary organic pigments is due to the absorption and scattering of light by the pigment particles themselves, it is thought that the pigment itself is affected by heat, resulting in changes in light absorption and scattering. Additionally, in Comparative Example 2 using a pearl pigment, discoloration of the pigment could not be confirmed, but the PET resin substrate itself was discolored to yellow, and the function (designability) of the pattern material was deteriorating. On the other hand, in the examples colored with pearl pigment, there was no discoloration of the pigment and it functioned as a pattern material. Since the color development of the pearl pigment is due to multiple reflections of light in the titanium oxide layer on the surface of the mica particles and the resulting interference, it is thought that it is less susceptible to the influence of external environments such as heat and does not fade. Additionally, for the examples, heating was performed in the same manner as above for 5 minutes at 320°C, but as shown in FIG. 7, it was confirmed that both the base material and the pigment remained almost unchanged from before heating and functioned as a pattern material. Additionally, the magnification ratio of each photo shown in FIGS. 6A to 6C is approximately 280 times. The magnification ratio of each photo shown in FIGS. 6D and 7 is approximately 70 times.

In this way, by constructing the base material 2 from thin mica 2 and coloring its surface with the pearl pigment 4, it is possible to improve heat resistance without impairing designability. Moreover, since mica has high transmittance (light transmittance) and pearl pigment has high reflectance, it is also possible to improve designability compared to combinations of other base materials and pigments. In addition, since the flaky mica (2) (base material) and the pearl pigment (4) (colored layer) have the same main component of mica, the shrinkage and expansion rates are the same, and even if a large temperature environment change occurs during molding, etc. Adhesion is maintained and designability does not deteriorate.

The present invention is not limited to, for example, sheet-like materials such as interior materials such as wallpaper, flooring, cosmetics, and cloth, or building materials, but is used as a pattern material for plastic molded products such as artificial marble and various daily necessities and electrical appliances. It is possible.

1: pattern material
2: Base material (mica)
3: colored layer
4: Pearl mica (pearl pigment)
10: Stirrer (tumbler)
11: drum
12: wings

Claims (4)

In the pattern material for plastic molded products consisting of a base material and a colored layer formed on the surface of the base material,
The substrate is made of flaky mica,
The colored layer is formed by a paint containing at least a pigment and a resin and a solvent containing titanium oxide-coated mica in which the surface of a thin plate-shaped mica particle is coated with titanium oxide,
The length of the longest part of the flake-shaped mica is 0.01 mm to 20 mm,
A pattern material for plastic molded products, characterized in that the length of the longest part of the titanium oxide-coated mica particles is 0.5 μm to 200 μm. A patterned plastic molded product, characterized in that the pattern material for plastic molded products according to claim 1 is mixed with a thermoplastic resin. According to paragraph 2,
A plastic molded product with a pattern, characterized in that the thermoplastic resin is ABS resin or polycarbonate resin. In the method for producing a pattern material for plastic molded articles according to claim 1,
A paint containing at least a pigment, a resin, and a solvent containing flaky mica and titanium oxide-coated mica in which the surface of the flaky mica particles is coated with titanium oxide is stirred and mixed, and the above-described coating is applied to the surface of the flaky mica. A method of manufacturing a pattern material for plastic molded products, characterized in that the colored layer is formed using a paint.