WO2010092760A1 - 樹脂成形体の製造方法、樹脂成形体 - Google Patents
樹脂成形体の製造方法、樹脂成形体 Download PDFInfo
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- WO2010092760A1 WO2010092760A1 PCT/JP2010/000494 JP2010000494W WO2010092760A1 WO 2010092760 A1 WO2010092760 A1 WO 2010092760A1 JP 2010000494 W JP2010000494 W JP 2010000494W WO 2010092760 A1 WO2010092760 A1 WO 2010092760A1
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- Prior art keywords
- resin
- insert
- pressing member
- insert body
- base
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Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C39/00—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
- B29C39/02—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles
- B29C39/10—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor for making articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. casting around inserts or for coating articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C33/00—Moulds or cores; Details thereof or accessories therefor
- B29C33/12—Moulds or cores; Details thereof or accessories therefor with incorporated means for positioning inserts, e.g. labels
- B29C33/123—Moulds or cores; Details thereof or accessories therefor with incorporated means for positioning inserts, e.g. labels for centering the inserts
- B29C33/126—Moulds or cores; Details thereof or accessories therefor with incorporated means for positioning inserts, e.g. labels for centering the inserts using centering means forming part of the insert
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C39/00—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
- B29C39/003—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor characterised by the choice of material
- B29C39/006—Monomers or prepolymers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C39/00—Shaping by casting, i.e. introducing the moulding material into a mould or between confining surfaces without significant moulding pressure; Apparatus therefor
- B29C39/22—Component parts, details or accessories; Auxiliary operations
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C43/00—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor
- B29C43/02—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles
- B29C43/18—Compression moulding, i.e. applying external pressure to flow the moulding material; Apparatus therefor of articles of definite length, i.e. discrete articles incorporating preformed parts or layers, e.g. compression moulding around inserts or for coating articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
- B29C45/17—Component parts, details or accessories; Auxiliary operations
- B29C45/46—Means for plasticising or homogenising the moulding material or forcing it into the mould
- B29C45/56—Means for plasticising or homogenising the moulding material or forcing it into the mould using mould parts movable during or after injection, e.g. injection-compression moulding
- B29C45/561—Injection-compression moulding
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
- B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
- B29C70/72—Encapsulating inserts having non-encapsulated projections, e.g. extremities or terminal portions of electrical components
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
- B29K2033/00—Use of polymers of unsaturated acids or derivatives thereof as moulding material
- B29K2033/04—Polymers of esters
- B29K2033/08—Polymers of acrylic acid esters, e.g. PMA, i.e. polymethylacrylate
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/44—Furniture or parts thereof
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/44—Furniture or parts thereof
- B29L2031/441—Countertops
Definitions
- the present invention relates to a method for producing a resin molded body having a pattern to be applied to counters, wall surfaces and the like of kitchens and furniture, and a resin molded body.
- resin counters commonly called artificial marble are used as counter materials for kitchens and furniture.
- artificial marble which is obtained by injecting or charging a liquid acrylic resin containing an inorganic filler, polyester resin, epoxy resin, or the like into a mold and press-curing, is often used.
- a liquid acrylic resin containing an inorganic filler, polyester resin, epoxy resin, or the like is often used.
- JP 2002-361668 A Japanese Patent Laid-Open No. 06-210648 JP 09-11257 JP 2002-321232 A JP 2008-296398 A
- the support member since the support member has no gap, hole, or internal space, the support member is an inclusion having different physical properties in the base resin as the base material. Further, the presence of the support member divides the base resins as the base materials from each other. As a result, the product in which such a support member is dispersed in the base material has a problem that the impact resistance is lowered.
- the base resin as a base material is filled inside, the base resin flows, but when the base resin flows, the support member is placed around the support member in order to inhibit the flow of the base resin. There was a problem that the base resin was not easily filled.
- the support member is exposed to a mold temperature and a high temperature due to heat generated by curing the resin during molding of the base resin, but in the case of a resin support member, the repulsive force is reduced due to softening by heating.
- the pressing force to the insert body is reduced, and the insert body and the mold contact surface cannot be brought into contact with no gap.
- the base resin enters between the insert body and the mold contact surface.
- the insert body will not be exposed.
- the insert body moves due to the flow pressure of the base resin due to a decrease in repulsive force. For this reason, it has been necessary to prevent the supporting member from being softened by heating by specifying the physical property parameters such as the heat resistance of the supporting member to some extent.
- a piece of decorative material can be easily set at a desired position, and a plate-like body is cut for the purpose of easily forming a pattern or pattern into a desired form.
- a piece of decorative material formed in this manner is attached to a sheet-like holding body, and then the holding body in which the piece is stuck in the cavity of the mold 20 is set, and then the mold is closed, and then the resin material A technique for injecting and curing is disclosed.
- Patent Documents 2 to 4 are disclosed, but none of the Patent Documents discloses a specific means for solving the above-described problem.
- the present invention has been devised in view of the above-mentioned problems, and the object of the present invention is to solve the problems that could not be solved by the above-described prior art and to display a specific pattern on the surface.
- the object of the present invention is to solve the problems that could not be solved by the above-described prior art and to display a specific pattern on the surface.
- a reduction in impact resistance due to the dispersion of the supporting member in the base resin is prevented, and the occurrence of voids in the curing process of the base resin is prevented by preventing the base resin from being unfilled.
- Another object of the present invention is to provide a method for producing a resin molded body and a resin molded body that can produce a molded article having a stable quality without causing any bending and can further improve the reproducibility of a specific pattern.
- the inventor makes a pressing member in which a gap leading to the inside is formed in advance abuts on the insert body, and penetrates the inside base resin through the pressing gap of the pressing member. And then curing the base resin to prevent a decrease in impact resistance and to obtain a molded product having a stable quality without generating voids or bending during the curing process of the base resin. Invented the manufacturing method.
- the method for producing a resin molded body according to claim 1 is a method for producing a resin molded body in which a base resin is cured in a pair of molds. While placing on the mold body, preventing the insert body from moving on the mold body and contacting the insert body with a pressing member in which a gap leading to the inside is formed in advance, the one mold body The pressing member that is in contact with the insert body is pressed by bringing the opposite mold body close to the mold body, and the base resin enters the inside through the gap of the pressed pressing member. And then curing the base resin.
- the method for producing a resin molded body according to claim 2 is characterized in that, in the invention according to claim 1, the pressing member made of a spring is brought into contact with the insert body.
- the method for producing a resin molded body according to claim 3 is characterized in that, in the invention according to claim 2, a spring formed of a resin having a heat resistant temperature of 70 ° C. or more is brought into contact with the insert body.
- a pressing member made of a metal spring having at least a mold contact portion with respect to the other mold body covered with resin is brought into contact with the insert body. It is characterized by making it.
- a method for producing a resin molded body according to any one of the first to fourth aspects wherein a plurality of insert bodies formed integrally with each other are placed on the mold body.
- a method for producing a resin molded body according to the fifth aspect of the present invention wherein the plurality of insert bodies formed integrally with each other by machining, resin molding with a mold, or punching are formed into one mold body. It is mounted on the top.
- a seventh aspect of the present invention there is provided a method for producing a resin molded body according to the fifth or sixth aspect, wherein the injection guide is used for pouring the resin injected from the other shape side to the one shape side when the mold body is in proximity. An insert body provided with a portion is placed.
- the method for producing a resin molded body according to claim 8 is the invention according to claim 7, wherein the insert body provided with an opening penetrating vertically or a notch formed in the periphery is placed as the inflow guide portion. It is characterized by.
- the method for producing a resin molded body according to claim 9 is the insert body according to any one of claims 1 to 8, wherein the pressing member is previously joined instead of contacting the pressing member with the insert body. Is placed on one mold body.
- a method for producing a resin molded body wherein an insert body made of a material having the same physical properties as the base resin according to any one of the first to ninth aspects is placed on one mold body.
- the resin molded body according to claim 11 is manufactured by the method for manufacturing a resin molded body according to any one of claims 1 to 10.
- the resin molded body according to claim 12 includes a base resin, an insert body embedded in the base resin, and a pressing member, and the insert body exposes the exposed surface formed on the top to the base resin surface, and presses the base resin.
- the member is abutted against the bottom of the insert body, and further, a base resin is infiltrated into the pressing member.
- the heat resistance of the pressing member can be suppressed by increasing the heat resistance of the pressing member as compared with the mold temperature during resin molding or the curing heat generation temperature of the resin.
- the force does not decrease, and it is possible to prevent the resin from entering the contact surface between the insert body and the mold and the displacement of the insert body due to the resin flow pressure.
- the pressing material is made of resin or a metal covered with resin, so that the surface of the mold body is wrinkled when it comes into contact with the pressing material. Can be prevented.
- the insert body and the connecting part by cutting or resin molding, it is not necessary to attach a plurality of exposed parts to the connected part, and the insert body to be exposed may be fine. It is possible to prevent the displacement of the insert body. Further, by integrating the insert body and the connecting portion, the pressing member is not required for each insert body, the cost of the pressing member can be reduced, and the setting time of the pressing member can be shortened.
- the linear expansion coefficient and hardness are similar by using an insert body of the same physical property material and the base resin, the linear expansion coefficient can be reduced through a heating / cooling process at the time of resin filling and a temperature change during use. Cracks due to differences are less likely to occur.
- FIG. 1 is a configuration example of a work top of a counter 2 made of artificial marble manufactured through a method for manufacturing a resin molded body to which the present invention is applied.
- Counter 2 as a resin molded body is placed on a cabinet and fixed when applied to a system kitchen.
- the counter 2 includes a front edge 26a, a water return, and a back guard.
- the size of the counter 2 is usually about 60 to 98 cm in depth and about 180 to 300 cm in width, and the size is determined according to customer requests.
- the counter 2 has an insert body 11 constituting a specific pattern such as a petal exposed on the surface.
- the counter 2 and the insert body 11 are made of acrylic artificial marble.
- This artificial marble is a so-called acrylic artificial marble obtained by blending an acrylic resin with an inorganic filler such as aluminum hydroxide or silicon dioxide.
- the insert body 11 is not limited to the case of being made of such a material, and may be made of a resin material such as polyester, epoxy, or FRP (Fiber Reinforced Plastics), and the material is not limited.
- FIG. 2 shows a cross-sectional configuration diagram of the counter 2.
- the counter 2 is integrated so as to fix the insert body to be a pattern in the process of curing the base resin constituting the base material 12.
- the base resin that forms the base 12 of the counter 2 is obtained by injecting an acrylic resin as a base resin into a mold and curing it.
- FIG. 11 is embedded in the base material 12 so that the lower surface thereof is directly exposed on the surface 21a of the counter 2.
- 3 (a) is a perspective view of the insert body 11
- FIGS. 3 (b) and 3 (c) are plan views of the insert body 11.
- a fine specific pattern can be displayed on the surface 21a of the counter 2 through the pattern surface 82a.
- the convex portion 82 is provided on the substrate 81 so that the pattern surface 82a corresponding to the petal pattern having a size of about 5 to 20 mm is formed. Since the pattern surface 82a is directly exposed on the surface 21a of the counter 2, the pattern surface 82a is configured in parallel with each other and with high smoothness. Needless to say, the pattern formed by the convex portions 82 may be any shape.
- the convex portion 82 is not limited to a material for design purposes, and may be a material for adding a function or a material for adding a shape, and is not limited to the material or the purpose of use.
- the substrate 81 is provided with an opening 83 at the center.
- the pressing member 14 made of, for example, a coil spring is joined to the opening 83 on the back surface 81 b side of the substrate 81.
- the pressing member 14 may be non-detachably bonded to the substrate 81 with an adhesive or the like, or may be simply mechanically detachably fitted to the opening 83.
- the coil springs here include conical coil springs, compression coil springs, circular coil springs (conical coil springs in that category), deformed coil springs, etc. as defined in JIS B0103. Any object that can be elastically deformed by being rolled up into a shape or the like is included. Further, this coil spring corresponds to a generally called helical spring.
- the coil spring may be an elastic body in which a gap leading to the inside is formed, and it is necessary that a gap leading to the inside is formed even when pressed. Through this gap, the base resin as a base material can be filled into the coil spring.
- the pressing member 14 is made of a synthetic resin material.
- 4A is a plan view of the coil spring of the pressing member 14, and FIG. 4B shows a side view thereof.
- the pressing member 14 is formed with an abutting portion 214 with which the pressing member abuts at the uppermost portion, and is provided with a bottom surface 213, and the diameter thereof is reduced downward from the abutting portion 214 to the bottom surface 213.
- a space 211 is also formed. Then, the resin can be poured into the inside (the open space above the bottom surface in FIG. 4A) through the gap 211, and the resin is discharged from the inside through the gap 211 to the outside. It is configured so that it can be poured.
- the spring constant of the pressing member 14 may be less than the strength that hinders compression during molding, and may be more than the strength sufficient to fix the design plate when the substrate is poured. There is a case where at least the upper end of the pressing member 14 contacts the back surface 81b of the substrate 81 constituting the insert body 11, and at least the lower end thereof is directly exposed from the back surface 21b of the counter 2.
- this insert body 11 is regularly or randomly arrange
- the insert body 11 may omit the configuration of the convex portion 82. In such a case, the substrate 81 in the insert body 11 is directly exposed on the surface.
- the pressing member 14 is joined to the insert body 11 at the back surface 81b, and the insert body 11 is not exposed from the back surface 21b of the counter 2.
- the insert body 11 is made of a resin having substantially the same properties as the base resin constituting the base member 12, but the present invention is not limited to this, and different resins are used. You may make it do. Moreover, you may make it comprise the material which comprises this insert body 11 with a metal other than resin, for example.
- the thermal expansion coefficient of the acrylic artificial marble constituting the substrate 12 is, for example, 5 ⁇ 10 ⁇ 5 .
- the acrylic artificial marble, which is the same material, or a polypropylene resin having a thermal expansion coefficient of 5 ⁇ 10 ⁇ 5 was finished beautifully. .
- the reason for this is that by making the material of the insert body 11 and the base resin constituting the base material 12 have the same thermal expansion coefficient, the same thermal expansion behavior is exhibited even with respect to the temperature applied at the time of manufacture.
- the plate thickness t 12 of the substrate 12 is about 7 to 10 mm, and the plate thickness t 13 of the insert body 11 is about 5 to 8 mm.
- the difference between the plate thickness t 12 of the base 12 and the plate thickness t 13 of the insert body 11, in other words, the thickness from the back surface 81 b of the substrate 21 constituting the insert body 11 to the back surface 21 b of the counter 2 is About 2 mm.
- FIG. 5 is a flow showing a method for producing a resin molded body.
- step S ⁇ b> 11 the above-described insert body 11 is disposed between the upper mold body 51 and the lower mold body 52 that are vertically opposed to each other.
- a gasket 33 is interposed between the upper mold body 51 and the lower mold body 52 on both sides to prevent leakage of resin to be injected in the subsequent stage.
- a sealing material made of any material may be used.
- Heaters 35 and 36 are mounted on the upper mold body 51 and the lower mold body 52, respectively, so that they can be heated.
- step S11 the arrangement of the insert body 11 will affect the pattern finally formed on the surface 21a of the counter 2, so that it is placed so as to become a desired pattern. Become.
- the insert body 11 is placed as such.
- the upper mold body 51 is pushed up to some extent with respect to the lower mold body 52, and a wide internal space is formed. For this reason, it becomes possible to improve workability
- the insert body 11 is placed on the upper surface 52a of the lower mold body 52, and this placement is determined according to the pattern of the surface 21a of the counter 2 finally obtained.
- step S11 the pressing member 14 is brought into contact with the insert body 11 to arrange it.
- the pressing member 14 may be arranged such that the pressing member 14 made of, for example, a coil spring is joined to the substrate 81 constituting the insert body 11 and the opening 83 provided in the center.
- the insert material 11 with the pressing member 14 bonded thereto may be prepared in advance and placed on the upper surface 52a of the lower mold body 52 in step S11.
- the upper mold body 51 and the lower mold body 52 are heated.
- the upper mold body 51 and the lower mold body 52 are heated via the heaters 35 and 36 mounted thereon.
- the heating temperature at this time is a temperature at which neither the upper mold body 51 nor the lower mold body 52 is cooled and solidified, and is held at such temperature for about 10 minutes.
- This step eliminates the temperature difference at the start of heating and compression of the insert body 11 and the base material 12, prevents the occurrence of gaps and the like, and contributes to reliable molding.
- the heating step in step S11 may be omitted as necessary, and heating may be started after step S15.
- step S12 the process proceeds to step S12, and the upper die 51 is pushed down.
- the lower surface 51 a of the upper mold body 51 comes into contact with the pressing member 14.
- the upper mold body 51 is at least in contact with the pressing member 14, and as a result, the pressing member 14 and the insert body 11 are in close contact with each other and can be fixed so as not to be displaced.
- the pressing member 14 is pressed to the extent that the pressing member 14 is elastically deformed vertically by pressing the upper mold body 51 downward. Also in this step S12, the above-described heating temperature is maintained.
- step S12 it is only necessary that the insert body 11 can be pressed via the pressing member 14 by bringing the upper mold body 51 facing the lower mold body 52 close to each other, and the upper mold body 51 is not necessarily pushed down. However, the lower mold body 52 may be pushed upward.
- step S13 the process proceeds to step S13, and the base material 12 made of a thermosetting resin such as an acrylic resin, a polyester resin, or an epoxy resin is injected into the gap between the lower mold body 52 and the upper mold body 51.
- a thermosetting resin such as an acrylic resin, a polyester resin, or an epoxy resin
- the method of introducing the resin into the mold by injection has been described.
- the method is not limited to the method of introducing the resin, and a bulk or sheet-shaped resin 301 may be charged in advance.
- the upper mold body 51 first reaches the pressing member 14, and then reaches the resin 301 charged in the lower mold body 52, respectively. What is necessary is just to arrange.
- the insert body 11 can be pressed against the lower mold body 52, and the resin wraps around the product surface or the insert body 11. The deviation can be prevented.
- the base 12 in order to maintain the above-described heating temperature, the base 12 can be spread throughout the gap between the lower mold body 52 and the upper mold body 51 in a liquefied state without being cured. It becomes possible. Also in this step S13, the pressing of the insert body 11 through the pressing member 14 by causing the lower mold body 52 and the upper mold body 51 to approach each other is continued. Thereby, since the insert body 11 is supported via the pressing member 14 when the base material 12 made of a thermosetting resin is injected, the insert body 11 is designated without being affected by the flow in the base material 12. It is possible to prevent movement from the position.
- the gap between the substrate 81 and the upper mold body 51 in the insert body 11 when the upper mold body 51 is pushed down is 1 mm or more. The reason is that if the gap between the insert body 11 and the upper mold body 51 is less than 1 mm, it becomes difficult to fill the base resin constituting the base material 12 in the gap.
- step S14 the lower mold body 52 is pushed up to press it to a pressure suitable for thermosetting.
- the base material 12 is heated to a temperature suitable for thermosetting.
- the amount of pressing deformation in step S14 varies depending on the elastic modulus, cross-sectional area, cross-sectional shape, and installation density of the pressing member 14.
- the distance between the upper mold body 51 and the lower mold body 52 is about 9 mm.
- the interval is further reduced by about 1 mm. Thereby, the insert body 11 and the base material 12 will be integrated.
- step S15 the process proceeds to step S15, and the upper mold body 51 and the lower mold body 52 that have been maintained at the heating temperature described above are naturally cooled to near room temperature.
- the upper mold body 51 and the lower mold body 52 are separated from each other, and the patterned panel body 1 in which the base material 12 and the insert body 11 are integrated with each other is taken out.
- the manufacturing of the patterned panel body 1 is completed through the processes from step S11 to step S15.
- Step S13 after injecting the base material 12 made of a thermosetting resin, as shown in Step S14, the base material 12 is further added.
- the upper mold body 51 and the lower mold body 52 are pressurized.
- the insert body 11 is simply supported via the pressing member 14, thereby preventing the base material 12 from being influenced by the flow during injection.
- the insert member 11 is appropriately pressed on the upper surface 52a of the lower mold body 52 by pressurizing the pressing member 14 so as to be elastically deformed, and the insert body 11 and the lower mold body 52 can be pressed. It is possible to prevent the base material 12 from entering with more close contact with the upper surface 52a. As a result, it is possible to prevent the surface of the insert body 11 from being partially covered with the base material 12 at the end of molding.
- the insert member 11 is appropriately pressed on the upper surface 52a of the lower mold body 52 by pressurizing the pressing member 14 until it is elastically deformed. As a result, the insert body 11 and the lower mold body are pressed.
- the upper surface 11a and the substrate surface 21a from which the base material 12 and the insert body 11 are exposed can be finished more flatly, and the smoothness can be improved. It becomes possible.
- the insert body 11 is not configured only by the convex portion 82, but one or a plurality of convex portions 82 are configured on the substrate 81 and pressed by the pressing member 14 via the substrate 81.
- the base material 12 made of the thermosetting resin that has flowed in can prevent the fine protrusions 82 constituting the specific pattern from being displaced, and ensure the reproducibility of the pattern to be expressed. It becomes possible.
- the pressing member 14 is pressed through the substrate 12 to the last, so the pressing member 14 is extremely small because the convex portion 82 is small. It becomes possible to prevent the pressing member 14 from falling down when it is unstable or pressed from above.
- the plurality of protrusions 82 may be formed together on one substrate 81. The number of points can be reduced, and the manufacturing cost can be suppressed and the work efficiency can be improved.
- the opening 83 is formed in the center of the insert body 11, when the base resin constituting the base material 12 is poured in step S13, air is released through the opening 83. As a result, it is possible to prevent air from remaining after the base material 12 is filled, and the periphery of the insert body 11 from being dented at the time of finishing, and further, causing molding defects and quality deterioration. It is possible to prevent as much as possible. Moreover, when filling the base material 12 in step S13, the base material 12 can be poured through the opening 83, and it becomes possible to prevent unfilling more firmly.
- the heating temperature described above is used in steps S14 to S15.
- the heat shrinkage of the insert body 11 and the base material 12 is approximately the same. That is, in the cooling process in step S15, almost the same amount of distortion is generated in the insert body 11 and the base material 12 due to thermal contraction, and as a result, warpage and deflection occur between the insert body 11 and the base material 12. In other words, no gaps or the like are generated between the insert body 11 and the base material 12.
- heating is started from the stage where the insert body 11 is placed between the upper mold body 51 and the lower mold body 52 in step S11. Thereby, it becomes possible to raise the temperature of the insert body 11 in advance. After that, since the base material 12 injected in step S12 is already warmed, it is possible to eliminate the temperature difference from the insert body 11 warmed in advance. As a result, it is possible to suppress the occurrence of warping due to the low temperature insert body 11 touching the high temperature base material 12.
- the pressing member 14 when the pressing member 14 having a circular cross-sectional shape, an elliptical shape, or a chamfered corner portion is disposed on the insert body 11, the pressing member 14 is configured to have a square cross-sectional shape. Compared with the case where it exists, it can prevent that stress concentrates on the corner
- the base material 12 as a base resin can be infiltrated into the pressed pressing member 14.
- the base material 12 is also filled inside the spring, it is possible to prevent the generation of a cavity due to the presence of the elastic material, and hence the generation of a dent around the insert body.
- the base 12 as the base resin can be infiltrated into the inside, so that the coil spring itself can be covered with the base resin (base 12).
- Impact resistance can be prevented from decreasing. This is because the base material 12 can be integrated with the pressing member 14 as a coil spring, and the impact resistance is almost such that the material of the base material 12 becomes a dominant factor in the base material 12 in the pressing member 14. Is meant to enter.
- the base material 12 it becomes possible to allow the base material 12 to enter the inside through the gap, and thereby the inside and the outside of the pressing material 14 are connected by the base resin through the gap.
- the base resin is not divided and the impact resistance after curing is improved.
- the resin enters the gap and flows out of the pressing member during the resin flow, so that the resin flow is not hindered and the resin is not filled.
- a conical coil spring (conical coil spring) is desirable. This is because if the conical hem side is placed toward the design plate, the possibility of falling down during the heat compression process is lower than that of a cylindrical spring, and it is possible to perform reliable molding. Further, it is possible to prevent a gap from being formed between the substrate 12 in the process of elastic deformation of the spring and the subsequent release of the pressing force, and the impact resistance performance and mechanical strength of the patterned panel body 1 can be reduced. It is possible to prevent the deterioration. Further, when the pressing member 14 is formed of a block-like elastic synthetic resin material or the like, the pressing material falls off after molding, and as a result, a part of the insert body 11 is not covered with the base material 12. Although the impact resistance is reduced, such a problem can be solved by using a spring as the pressing member 14.
- a heat-resistant safety temperature such as polycarbonate (PC), polyoxymethylene (POM), polymethyl methacrylate (PMMA), acrylonitrile-butadiene-styrene (ABS), or the like is used.
- PC polycarbonate
- POM polyoxymethylene
- PMMA polymethyl methacrylate
- ABS acrylonitrile-butadiene-styrene
- the one having a temperature of 70 ° C. or higher, desirably 110 ° C. or higher is used.
- the heat-resistant safety temperature of 70 ° C. means that the deflection temperature under load measured by 1.8 MPa exceeds 70 ° C. That is, the heat-resistant safety temperature is premised on maintaining a predetermined repulsive force (pressing force) during heating.
- the heat resistance of the pressing member 14 can be suppressed by increasing the heat resistance of the pressing member as compared with the mold temperature during resin molding or the curing heat generation temperature of the resin, the repulsive force does not decrease and the insert It is possible to prevent the resin from entering the body and the mold contact surface and the displacement of the insert body due to the resin flow pressure.
- the pressing member 14 is composed of a metal spring covered with any of polycarbonate (PC), polyoxymethylene (POM), polymethyl methacrylate (PMMA), and acrylonitrile-butadiene-styrene (ABS). Also good. This also makes it possible to exert a function as a normal metal spring, and by covering with these resins, it is possible to prevent wrinkles on the upper mold body 51 as a mold. It becomes.
- PC polycarbonate
- POM polyoxymethylene
- PMMA polymethyl methacrylate
- ABS acrylonitrile-butadiene-styrene
- the pressing member 14 is not simply brought into contact with the insert body 11 but is bonded in a non-detachable manner through, for example, an adhesive, so that the upper mold body 51 and the lower mold body 52 are brought close to each other. Even when pressed, the pressing member can be prevented from coming off the insert body 11.
- the pressing member 14 smaller than the surface area of the insert body 11 is disposed.
- steps S13 and S14 it is possible to form a path of the thermosetting resin constituting the base material 12 between the pressing members 14, and the thermosetting property in the gap between the upper mold body 51 and the lower mold body 52. It is possible to prevent unfilling of the resin from occurring.
- the arrangement interval of the insert body 11, or adjacent interval t 11 between projections 82 which are, if between the adjacent lines and circles were adjusted to open 1mm above, a complicated shape such that there is a continuous sharp Even if it exists, it is possible to ensure the passage of the thermosetting resin along the insert body 11 by adjusting so that a gap of 2 mm or more can be opened.
- the base material 12 can be filled without a gap in the gap between the upper mold body 51 and the lower mold body 52, impact resistance and other mechanical strength can be further improved. It should be noted that not only the interval t 11 but also the interval between the insert body 11 or the convex portion 82 and the end of the work top 21 is similarly 1 mm or more to prevent the thermosetting resin from being unfilled. Can do.
- the dimensions of the female portion provided on the base material and the design plate are required to be the same in order to prevent a gap from being formed, while the clearance dimension is required for fitting. It is difficult to find a molded product with no gap due to the problem that it is necessary and cannot be made the same, and even if trying to produce such dimensions, there will be some error due to temperature change and compression during resin molding
- the pressing member 14 made of the above-mentioned block-like elastic synthetic resin
- the pressing member 14 is elastically deformed outward in the horizontal direction, and the base member is in that state.
- the material 12 is cured.
- the pressing member 14 is released from the up and down pressing, the one elastically deformed outward in the horizontal direction contracts, and a gap is formed between the base material 12 and the pressing member 14.
- This gap is equivalent to a locally reduced plate thickness, and may act as an obstructing factor that lowers the impact resistance performance and mechanical strength of the patterned panel body 1.
- the pressing member 14 made of a block-like elastic synthetic resin As an alternative to the pressing member 14 made of a block-like elastic synthetic resin, the pressing member 14 made of the above-mentioned conical spring or a metal winding spring is arranged on the insert body 11. You may do it. Similarly, it is possible to prevent a gap from being formed with the base material 12 in the process of elastic deformation of the spring and subsequent release of the pressing force, and impact resistance performance and mechanical strength in the obtained counter 2 can be prevented. Can be prevented from being lowered by the gap.
- a backing material 121 may be further provided on the pressing member 14.
- the spring may protrude from the back surface 21b.
- irregularities are formed on the back surface 21b. Smoothness decreases.
- the adhesiveness with the other members on the back surface 21b is lowered, and the workability is hindered.
- the material of the backing material 121 may be made of metal, wood, resin, fiber, or the like.
- FIG. 7 shows the step S14 in the case where a pattern is formed on the front and back of the patterned panel body 1 by providing the insert body 11 on both the front surface and the back surface.
- the pressing member 14 is further placed on the upper part of the pressing member 14, and the upper mold body 51 facing the lower mold body 52 is pushed down until it comes into contact with the insert body 11 placed on the upper part of the pressing member 14. Is possible.
- the present invention is not limited to the above-described embodiment, and may be configured by integrating a plurality of insert bodies 11 with each other.
- FIG. 8 to 11 show examples in which a plurality of insert bodies 11 are integrated with each other.
- FIG. 8 (a) is a perspective view of a state in which the plurality of insert bodies 11 are integrally formed of the same material with respect to the base 85
- FIG. 8 (b) is a perspective view of this from the back side. is there.
- the plurality of insert bodies 11 are integrally formed on the base 85 with a space therebetween, for example, by cutting, resin molding through pressing with a mold, or punching.
- the pressing member 14 made of, for example, a coil spring is brought into contact with the back surface of the base 85 at least at the time of manufacture. Further, the pressing member 14 may be attached to the base 85 in advance.
- FIG. 9 shows an example in which adjacent insert bodies 11 are cross-linked with a cross-linked body 88.
- FIG. 9 (a) is a perspective view of a state in which the bridge body 88 is integrated with the insert body 11 as if it were installed
- FIG. 9 (b) is a perspective view of the same when viewed from the back side.
- the pressing member 14 is brought into contact with or joined in advance to the back surface of the bridging body 88 or the insert body 11.
- an opening 86 is formed at the center, and when the base resin constituting the substrate 12 is poured, air can be extracted through the opening 86.
- the base resin can be poured through the opening 86. If the opening 86 is not provided, as shown in FIG. 9 (c), the resin does not flow well in the gap G between the adjacent insert bodies 11, which may cause unfilling. If 86 is provided, the resin can be poured through the opening 86 as shown in FIG. 9 (d), and unfilling can be prevented.
- the opening 86 is injected from the other mold body side (the upper mold body 51 side in FIG. 9 (d)) to one mold body side (the lower mold body 52 side in FIG. 9 (d)) when the mold body is in proximity. What is necessary is just to be comprised as an inflow guide part for pouring the made resin. That is, the configuration is not limited to the opening 86, and any configuration may be used as long as it guides the flow of resin from the upper mold body 51 side to the lower mold body 52 side.
- FIG. 10 shows an example in which the insert bodies 11 are joined to each other via a base 85 provided at the center.
- the pressing member 14 is brought into contact with or joined to the back surface of the base 85 at least during manufacture.
- a notch 89 having a rectangular cross-section surrounded by the adjacent insert body 11 and the base 85 is formed at four locations as the inflow guide portion, and when the base resin constituting the base material 12 is poured, the notch 89 is formed. The air can be extracted through the resin, and the resin can be poured.
- FIG. 11 shows an example of a base 85 formed of a single plastic base plate in which openings 86 as flow guides are regularly arranged.
- FIG. FIG. 11B is a perspective view of the insert plate 11 integrally formed
- FIG. 11B is a perspective view of the insert plate 11 viewed from the back side.
- the pressing member 14 is brought into contact with or attached to the back surface of the base 85 at least at the time of manufacture.
- the base 85 is configured with a large area so that a large number of insert plates 11 can be attached to the base 85.
- air can be removed through the opening 86 and the resin can be poured.
- the opening 86 may be provided as the inflow guide portion in the base 85, or the opening 83 may be provided in the insert body 11.
- the opening 83 is provided in the insert body 11, air can be extracted by providing an opening at a position on the base 83 corresponding to the opening 83.
- the insert body 11 is integrally configured via the base 85
- the connected insert body 11 is placed on the lower mold body 52, for example, as shown in FIG.
- a pressing member 14 for preventing the insert body 11 from moving on the lower mold body 52 is brought into contact with or attached in advance to the back surface of the base 85.
- the base resin constituting the base material 12 is injected while pressing the pressing member 14 brought into contact with the base 85 by bringing the lower mold body 52 and the upper mold body 51 close to each other. Curing will be performed.
- the plurality of insert bodies 11 are integrated with the base 85 described above, it is possible to firmly prevent the positional deviation between the plurality of insert bodies 11 in particular. That is, since the plurality of insert bodies 11 are connected to the single base 85, even when the base material 12 is filled, the insert bodies 11 are not misaligned, and the design can be further improved. Further, by adopting a unit configuration in which the insert body 11 is integrated with the base 85, the work is completed by setting the unit without setting the insert bodies 11 one by one in the lower mold body 52. Therefore, manufacturing labor can be reduced.
- the plurality of insert bodies 11 by cutting or resin molding, it is not necessary to attach the plurality of exposed parts to the connecting parts, and the insert body to be exposed may be fine. It is possible to prevent the displacement of the insert body. Further, by integrating the insert body and the connecting portion, the pressing member is not required for each insert body, the cost of the pressing member can be reduced, and the set time of the pressing member can be shortened.
- the present invention is not limited to the case where the insert body 11 is integrated with the base 85, and may be configured by joining the insert body 11 and the substrate 85 separately manufactured.
- FIG. 12B shows a cross-sectional configuration of the counter 2 manufactured based on the manufacturing method described above.
- the pattern surface 82 a of the convex portion 82 is exposed, and in addition to the convex portion 82, the insert body 11, the base 85, and the pressing member 14 are embedded inside the base material 12.
- the base 85 is integrated with each other with respect to the plurality of insert bodies 11, and the pressing member 14 is in contact with the bottom of the base 85.
- FIG. 13 shows an example in which the insert body 11 is connected via a base 122 composed of a net-like body.
- the material of the base 122 may be made of metal, but may be made of resin.
- the base 122 is configured with a larger area than the insert body 11.
- FIG. 14 is an example in which the base 123 has a function as the pressing member 14 described above.
- the base 123 is configured as an elastic body such as a coil spring. According to this configuration, it is possible to make the base 123 play the role without separately disposing the pressing member 14, thereby reducing the component cost.
- the present invention may be applied to any building structure such as a panel or a mirror cabinet.
- FIG. 16 shows a cross-sectional view of the top plate structure of the counter 2 when illuminated by the light bulb 151.
- FIG. 16 is an upside-down view of FIG. 2 described above, with the front surface 21a of the counter 2 on the upper side and the back surface 21b of the counter 2 on the lower side. Note that the same components and members as those in FIG. 2 are denoted by the same reference numerals, and the description thereof will be omitted.
- the light bulb 151 is attached almost directly below the insert body 11.
- the light bulbs 151 are arranged directly under the randomly placed insert bodies 11, but even in such a case, the space 156 is formed. It becomes possible to cope with this.
- the bulb 151 is, for example, a so-called incandescent bulb, LED (Light Emitting Diode), halogen lamp, HID (High Intensity Discharge) lamp, or the like.
- a fluorescent lamp or any other illumination means may be used.
- the light bulb 151 is connected to the switching control unit 152.
- the switching control unit 152 supplies power to the light bulb 151.
- the switching control unit 152 is connected to the operation unit 154.
- the operation unit 154 includes buttons that can be operated by the user. Information input from the user via the operation unit 154 is notified to the switching control unit 152, and the switching control unit 152 receives the input information. On the basis of the. It will control lighting by the light bulb.
- the command is notified to the switching control unit 152, and the switching control unit 152 turns on the light bulb 151 based on the command. / OFF.
- the command is notified to the switching control unit 152, and the switching control unit 152, based on this, notifies the illumination intensity of the light bulb 151. Adjust.
- the switching control unit 152 may automatically control the light bulb 151 other than the manual operation by the user. Such automatic control of the light bulb 151 may be executed through a program stored in a memory stored in the switching control unit 152. In the program, for example, the illumination intensity of the light bulb 151 is changed at a constant cycle or at a random cycle.
- the above-described illumination function may be implemented.
Abstract
Description
2 カウンター
11 意匠板
12 基材
14 弾性部材
21 ワークトップ
26a 水返し
26 前垂れ
27 バックガード
31 上型体
32 下型体
33 ガスケット
35、36 ヒータ
41 樹脂
51 上型体
52 下型体
Claims (12)
- 一対の型内でベース樹脂を硬化させる樹脂成形体の製造方法において、当該樹脂成形体の表面に表出させるためのインサート体を一方の型体上に載置するとともに、上記インサート体が上記型体上で動くことを防止するとともに内部へ通じる空隙が予め形成された押さえ部材を当該インサート体に当接させ、
上記一方の型体に対向する他方の型体を当該一方の型体に対して近接させることにより上記インサート体に当接させた押さえ部材を押圧し、上記押圧した当該押さえ部材の上記空隙を通じて内部へ上記ベース樹脂を浸入させ、その後上記ベース樹脂を硬化させることを特徴とする樹脂成形体の製造方法。 - バネからなる上記押さえ部材をインサート体に当接させること
を特徴とする請求項1記載の樹脂成形体の製造方法。 - 耐熱温度が70℃以上の樹脂によって形成されたバネをインサート体に当接させること
を特徴とする請求項2記載の樹脂成形体の製造方法。 - 少なくとも上記他方の型体に対する型接触部を樹脂で覆った金属製のバネからなる押さえ部材をインサート体に当接させること
を特徴とする請求項2記載の樹脂成形体の製造方法。 - 互いに一体に形成された複数のインサート体を型体上に載置すること
を特徴とする請求項1~4のうち何れか1項記載の樹脂成形体の製造方法。 - 削り出し加工、型による樹脂成形、又は打ち抜き加工により互いに一体に形成された複数の上記インサート体を一方の型体上に載置すること
を特徴とする請求項5記載の樹脂成形体の製造方法。 - 型体の近接時において他方の型体側から一方の型体側へ注入された樹脂を流し込むための流込案内部が設けられたインサート体を載置することを特徴とする請求項5又は6記載の樹脂成形体の製造方法。
- 上記流込案内部として、上下に貫通する開口又は周囲に形成された切欠が設けられたインサート体を載置することを特徴とする請求項7記載の樹脂成形体の製造方法。
- 上記押さえ部材をインサート体に当接させる代わりに、予め上記押さえ部材が接合されたインサート体を一方の型体上に載置することを特徴とする請求項1~8のうち何れか1項記載の樹脂成形体の製造方法。
- 上記ベース樹脂と同一物性からなる材料で構成されたインサート体を一方の型体上に載置することを特徴とする請求項1~9のうち何れか1項記載の樹脂成形体の製造方法。
- 請求項1~10のうち何れか1項記載の樹脂成形体の製造方法により製造されたことを特徴とする樹脂成形体。
- ベース樹脂と、ベース樹脂に埋設されてなるインサート体並びに押さえ部材とを備え、インサート体は、頂部に形成させた表出面をベース樹脂表面に露出させ、押さえ部材は、インサート体の底部に当接させてなり、更に当該押さえ部材内部にベース樹脂が浸入されていること
を特徴とする樹脂成形体。
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KR1020117016200A KR101671198B1 (ko) | 2009-02-12 | 2010-01-28 | 수지 성형체의 제조방법, 수지 성형체 |
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JP (1) | JP5441936B2 (ja) |
KR (1) | KR101671198B1 (ja) |
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JPH06210648A (ja) | 1993-01-18 | 1994-08-02 | Okura Ind Co Ltd | 象嵌調人工大理石の製造方法 |
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JP2002321232A (ja) | 2001-04-24 | 2002-11-05 | Matsushita Electric Works Ltd | 人造大理石の製造方法 |
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2010
- 2010-01-28 KR KR1020117016200A patent/KR101671198B1/ko active IP Right Grant
- 2010-01-28 CN CN201080005518.4A patent/CN102292202B/zh active Active
- 2010-01-28 JP JP2010550434A patent/JP5441936B2/ja active Active
- 2010-01-28 WO PCT/JP2010/000494 patent/WO2010092760A1/ja active Application Filing
- 2010-02-10 TW TW099104174A patent/TWI533990B/zh active
Patent Citations (4)
Publication number | Priority date | Publication date | Assignee | Title |
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JPH0428533A (ja) * | 1990-05-24 | 1992-01-31 | Fuji Rubber Co Ltd | 表示板一体成型法 |
JPH04298309A (ja) * | 1991-03-27 | 1992-10-22 | Ikeda Bussan Co Ltd | ウレタンバッキングカ−ペットの製造方法 |
JP2001001373A (ja) * | 1999-06-23 | 2001-01-09 | Teikoku Tsushin Kogyo Co Ltd | 部材のモールド樹脂内へのインサート成形方法 |
JP2002361668A (ja) * | 2001-06-13 | 2002-12-18 | Yamaha Livingtec Corp | 成形品の加飾方法 |
Also Published As
Publication number | Publication date |
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KR20110128798A (ko) | 2011-11-30 |
TW201029821A (en) | 2010-08-16 |
CN102292202B (zh) | 2014-03-19 |
CN102292202A (zh) | 2011-12-21 |
JPWO2010092760A1 (ja) | 2012-08-16 |
JP5441936B2 (ja) | 2014-03-12 |
KR101671198B1 (ko) | 2016-11-01 |
TWI533990B (zh) | 2016-05-21 |
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