JPH07329091A - Manufacture of patterned thick molded product - Google Patents

Abstract

PURPOSE:To obtain a high depth sensation, by a method wherein almost a half as much as of a transparent molding material forming a transparent layer on the occasion of hardening by containing an unsaturated polyester resin and mineral fine particles is supplied, on which cloth to which a pattern is imparted is put, on which the remainder transparent molding material is supplied. CONSTITUTION:Almost a half 2 as much as of a transparent molding material which contains unsaturated polyester resin and mineral fine particles and forms a transparent layer on the occasion of hardening is supplied on a mold face of a bottom force 12 under a state of mold break. Patterned cloth 3 or a porous sheet are put on the material, on which the remainder transparent molding material 4 is supplied. Then mold clamping is performed and compression molding of a molded product 5' is performed. Then mold break and demolding are performed and a patterned thick molded product which possesses a patterned layer within a wall of a bottom wall and is provided with a transparent resin layer on the patterned layer is obtained.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a thick molded product made of a thermosetting resin having a pattern such as a bathtub, a counter and an apron.

[0002]

2. Description of the Related Art As a conventional method for molding a thermosetting resin molded product having a pattern, for example, Japanese Patent Laid-Open No. 54-113682.
In the publication, a thin paper-like transparent surface mat having a thickness of 0.1 to 0.5 mm, a tape-shaped patterned cloth (which may be impregnated with a thermosetting resin in advance), and an FRP base material are further laminated and heated and pressed. A method of molding has been proposed.

According to this method, the thermosetting resin is infiltrated into the textures or voids of the pattern cloth and the surface mat by heating and pressurizing, and a transparent layer is formed on the pattern cloth. It is said that a molded product having hot water resistance, wear resistance, and corrosion resistance and a deep pattern can be obtained.

[0004]

However, in this molding method, there is a limit to the transparent layer formed by infiltration at the time of heat and pressure molding, and a thick transparent layer cannot be obtained.
Therefore, in practice, there is a problem in that a patterned molded article having a high sense of depth cannot be manufactured.

The present invention has been made for the purpose of solving the above-mentioned problems of the prior art and providing a method for easily manufacturing a thick molded product with a pattern having a high sense of depth.

[0006]

The present invention provides approximately half of a transparent molding material containing an unsaturated polyester resin and inorganic fine particles between a pair of molds and forming a transparent layer when cured. It is supplied, and a cloth or porous sheet having a pattern is placed thereon, and the remaining transparent molding material is supplied on it, or in the approximately central portion in the thickness direction of the transparent molding material. The method is a method for producing a thick wall molded article with a pattern, in which a cloth or a porous resin sheet provided with a pattern is sandwiched and supplied, and then the mold is closed and the molding material is heated and pressed to be cured and molded.

In the present invention, the transparent molding material is generally a sheet molding compound (hereinafter referred to as S).
It is used in the form of a bulk molding compound (hereinafter referred to as MC) or a bulk molding compound (hereinafter referred to as BMC).

SMC or BMC is a resin composition obtained by adding a thickening agent, a curing accelerator, an internal release agent, a coloring agent, a low-shrinking agent, etc. to an unsaturated polyester resin in addition to inorganic fine particles. Infiltrate the reinforcing fiber material such as glass fiber,
It is made into a sheet or a bulk, covered with a release film such as a polyethylene film and aged, and usually thickened to 10,000 poise or more to be a semi-solid. Aging is usually performed by placing the material under a temperature condition of 30 to 50 ° C. for half a day to 2 days.

The unsaturated polyester resin is a mixture of an unsaturated polyester obtained by polycondensing an unsaturated dibasic acid, a glycol, and optionally a saturated dibasic acid, and a copolymerizable monomer. As the resin component contained in the unsaturated polyester resin, in addition to the unsaturated polyester, a thermoplastic resin added for reducing the shrinkage is used.

As the unsaturated dibasic acid, for example, maleic anhydride, fumaric acid, itaconic acid, citraconic acid and the like are used. Examples of the glycol include ethylene glycol, diethylene glycol, triethylene glycol, propylene glycol, 1,3-butanediol,
1,4-butanediol, 16-hexanediol, bisphenol A, ethylene oxide adduct of bisphenol A, neopentyl glycol and the like are used.

Examples of the saturated dibasic acid include phthalic anhydride, orthophthalic acid, isophthalic acid, terephthalic acid,
Adipic acid, succinic acid, tetrachlorophthalic acid, het acid, etc. are used.

Examples of the copolymerizable monomer include styrene, dichlorostyrene, vinyltoluene, vinyl acetate,
Methacrylic acid, methacrylic acid ester, acrylic acid, acrylic acid ester, diallyl phthalate and the like are used, and among them, styrene is preferably used. Usually, the amount of the copolymerizable monomer contained in the unsaturated polyester resin is 20 to 50% by weight.

Examples of the thermoplastic resin contained in the unsaturated polyester resin for reducing the shrinkage include polystyrene, polyvinyl acetate, polymethyl methacrylate, polyethylene, poly ε-caprolactone, saturated polyester and polyvinyl chloride. , Polybutadiene, polystyrene-acrylic acid copolymer, polystyrene-polyvinyl acetate copolymer, ethylene-vinyl acetate copolymer, vinyl chloride-vinyl acetate copolymer, acrylonitrile-styrene copolymer and the like are used.

As the inorganic fine particles, aluminum hydroxide or glass powder, which has a refractive index close to that of the unsaturated polyester resin and can ensure higher transparency, is preferably used. These may be used alone or in combination.

Aluminum hydroxide usually has an average particle size of 2
Those having a range of -40 μm, preferably 3-20 μm are used. The glass powder usually has an average particle size of 2 to 50 μm.
m, preferably 3 to 30 μm. If the average particle size of the aluminum hydroxide or glass powder is too small, the transparency will be extremely reduced.

The amount of the fine inorganic particles added is preferably 50 to 350 parts by weight, more preferably 100 to 300 parts by weight, based on 100 parts by weight of the unsaturated polyester resin. If it is less than 50 parts by weight, the viscosity of the molding material is too low and the moldability becomes poor. If it exceeds 350 parts by weight,
The dispersibility of the resin component becomes insufficient, the resin does not reach the inorganic fine particles, or the viscosity rises abnormally and the moldability deteriorates.

When aluminum hydroxide and glass powder are used in combination, the mixing ratio of both is preferably 30 to 95% by weight of aluminum hydroxide and 5 to 70% by weight of glass powder. As other inorganic fine particles, calcium carbonate, calcium sulfate or the like is used.

The glass fiber preferably has a length of 1 to 80 mm. When the length is shorter than 1 mm, the reinforcing effect is small, and when the length is longer than 80 mm, the viscosity increases and the moldability deteriorates. Especially for artificial marble, those having a diameter of 1 to 20 mm are preferable, and those having a diameter of 1.2 to 15 mm are more preferable. Two
If it is longer than 0 mm, the appearance of the molded product will be impaired.

The amount of glass fiber added is preferably in the range of 1 to 40% by weight based on the entire transparent molding material. If the amount added is less than 1% by weight, the reinforcing effect is small, and if it exceeds 40% by weight, the viscosity increases and the moldability deteriorates.

Particularly in the case of artificial marble, the amount of glass fiber added is 1 to 20% by weight based on the whole transparent molding material.
Is preferable, and 3 to 15% by weight is more preferable. 1
When it is less than 20% by weight, the reinforcing effect is small, and when it is more than 20% by weight, the transparency decreases.

As the curing agent, for example, a polymerization initiator such as tertiary butyl perbenzoate, benzoyl peroxide, methyl ethyl ketone peroxide, cumene hydroperoxide, etc. is used. As the release agent, for example, zinc stearate, calcium stearate or the like is used. As the thickener, for example, magnesium oxide, magnesium hydroxide, calcium oxide, calcium hydroxide or the like is used.

As the cloth, it is preferable to use a non-woven fabric made of glass fiber, which has a pattern, a pattern, a color or the like previously applied thereto and into which a thermosetting resin can easily penetrate. In addition, organic fibers such as nylon and vinylon, and those woven using natural fibers such as cotton are used. A perforated sheet or film made of polyester, polyethylene, polypropylene or the like and having a thickness of 200 to 800 μm may be used so that the thermosetting resin can be easily impregnated.

As a method of patterning the cloth, a method of pouring a pigment between BMCs can be adopted. According to this method, it is possible to impart a beautiful and interesting pattern with a sense of flow.

In the present invention, as a method of supplying the molding material between the pair of molds, approximately half of the transparent molding material is supplied, and a cloth or porous sheet having a pattern is placed thereon. , The rest of the transparent molding material may be supplied thereon, or a pattern-applied cloth or porous resin sheet may be sandwiched between the transparent molding material and the substantially central portion in the thickness direction. It may be supplied at.

Hereinafter, an example of the method for producing a patterned thick molded product of the present invention will be described with reference to the drawings. FIG. 1 is a sectional view showing a part of a mold used in the present invention. The mold 1 includes an upper mold 11 and a lower mold 12. Between the upper mold 11 and the lower mold 12, a cavity 13 having an inner surface shape corresponding to the outer surface shape of a bath as a molded product to be molded when the mold is clamped.
Are formed.

First, as shown in FIG. 2, in the open mold state, half of the total amount of SMC as the transparent molding material, that is, the first BMC 2 is supplied onto the mold surface of the lower mold 12, and then the first BMC 2 is supplied thereon. The patterned cloth 3 is placed, and the other half of the second BMC 4 is supplied onto the patterned cloth 3. At this time, the first BMC2 and the second BMC4
It does not matter even if the pattern cloth 3 is inserted between the dies while the pattern cloth 3 is sandwiched substantially in the center in the thickness direction.

Next, as shown in FIG. 3, the mold is clamped to perform compression molding of the molded product 5 '. After that, the mold is opened and demolded, and as shown in FIG. 4, a patterned thick-walled molded product having a pattern layer 52 in the wall of the bottom wall 51 and a transparent resin layer provided on the pattern layer. Get 5.

[0028]

The method for producing a thick molded article with a pattern of the present invention is a transparent molding material containing an unsaturated polyester resin and inorganic fine particles between a pair of molds, and forming a transparent layer when cured. Of about half of the above, a cloth or porous sheet having a pattern is placed thereon, and the remaining transparent molding material is supplied on it, or in the thickness direction of the transparent molding material. After feeding a cloth or porous resin sheet with a pattern sandwiched in the approximate center, close the mold and heat and pressurize the molding material to cure and mold it, resulting in a thick transparent layer on the pattern layer. Since the layers can be formed, it is possible to produce a beautiful patterned thick molded product having a high sense of depth.

Further, since the thickness of the transparent layer formed on the pattern layer can be adjusted by adjusting the amount of the transparent molding material, the feeling of depth of the pattern can be variously changed. . Further, the depth feeling of the thick molded product can be easily changed by changing the light transmittance of the transparent molding material.

[0030]

EXAMPLES The present invention will be described below with reference to examples. 100 parts by weight of unsaturated polyester resin, 125 parts by weight of glass powder (average particle size 5 μm), 125 parts by weight of aluminum hydroxide (average particle size 8 μm), 13 parts by weight of glass fiber (cut length 1.5 mm), 1 part by weight of a curing agent (tertiary butyl peroxy compound), 3 parts by weight of a release agent (zinc stearate), and a thickener (magnesium oxide) 1
After weighing out parts by weight, these were kneaded in a Henschel mixer and then aged at 40 ° C. for 40 hours to prepare BMC.

On the other hand, as the pattern cloth, a non-woven fabric made of polyester resin of 80 g / m ² was used, on one side of which a flow pattern was printed with a cobalt blue pigment. This patterned cloth was cut along the bottom of the molding bath to be molded.

A bath mold was set in a 300-ton press and the temperature of the upper mold was set to 130 ° C and the temperature of the lower mold was set to 105 ° C. The mold was opened and 70% of the area of the lower mold surface was charged with half the total amount of BMC. The cut pattern cloth was placed on it. Furthermore, the other half of BMC was charged on the pattern cloth.

Then, the mold is closed and the compression pressure is 100 k.
Compression molding took place under the conditions of gf / mm ² and a pressing time of 12 minutes. After compression molding, open the mold, bottom wall thickness is about 9mm
Then, a patterned artificial marble bath having a transparent resin layer of about 4.5 mm provided on the pattern was obtained.

When the transparency of this bath was evaluated, it was about 25.7%. In addition, the evaluation of transparency is
According to JIS K7105 A method, total light transmittance is measured by a haze meter (manufactured by Tokyo Denshoku Co., Ltd., trade name “TC-H3D”).
P ”).

[0035]

EFFECT OF THE INVENTION The method for producing a thick-walled molded product with a pattern according to the present invention, having the above-mentioned constitution, can produce a beautiful thick-walled molded product with a high sense of depth. By changing the amount of the transparent molding material or the light transmittance, the depth feeling of the thick molded product can be easily changed.

[0036]

[Brief description of drawings]

FIG. 1 is a cross-sectional view showing an example of a mold used in the present invention.

FIG. 2 is a cross-sectional view illustrating the first half of the steps of the example of the method for manufacturing a thick molded product with a pattern according to the present invention.

FIG. 3 is a cross-sectional view illustrating the latter half of the steps of the example of the method for manufacturing a thick molded product with a pattern according to the present invention.

FIG. 4 is a cross-sectional view showing a thick-walled molded product with a pattern obtained by the method of the present invention.

[Explanation of symbols]

 1 Mold 2 1st BMC 3 Patterned cloth 4 2nd BMC 5 Molded product 11 Upper mold 12 Lower mold 13 Cavity

Continuation of front page (51) Int.Cl. ⁶ Identification code Office reference number FI technical display location B32B 27/06 8413-4F 27/12 8413-4F 27/20 Z 8413-4F // B29K 67:00 101: 10 105: 16 B29L 9:00 31:44

Claims (1)

[Claims] 1. A half of a transparent molding material containing an unsaturated polyester resin and inorganic fine particles, which forms a transparent layer when cured, is supplied between a pair of molds, and a pattern is formed on the transparent molding material. The applied cloth or porous sheet is placed, and the remaining transparent molding material is supplied on it, or the pattern-applied cloth or cloth is provided in the approximately central portion in the thickness direction of the transparent molding material. After supplying with the porous resin sheet sandwiched,
A method for producing a thick molded product with a pattern, characterized in that a mold is closed and a molding material is heated and pressed to be cured and molded.