JPH0410907A - Molding method for synthetic resin laminate structure - Google Patents

Abstract

PURPOSE:To impart an excellent pattern and enhance the durability by spraying a colored resin liquid in the form of spots after gelation of a gelcoat layer formed on a mold surface, to thereby provide a colored spot layer, and providing a different-colored layer and a reinforcement layer. CONSTITUTION:A mold release agent is applied to the surface of a male mold 7, and a resin liquid consisting mainly of a transparent unsaturated polyester resin is applied thereto by a spray-up method to form a gelcoat layer 1, which is then gelled. Next, a uniform dispersion of a gold powder or the like in a transparent unsaturated polyester resin is sprayed to form a colored spot layer 2. On the outside of the colored spot layer 2, an admixture of a transparent unsaturated polyester resin with a pigment or the like is applied uniformly by a spray-up method to form a colored layer 3. A back reinforcement layer 5 comprising an ortho unsaturated polyester resin, which is loaded heavily with a white pigment, and glass fibers is formed on a female mold 6. The male mold 7 and female mold 6 are mated, and a mixture of an iso unsaturated polyester resin with colored pieces or the like is poured into the resulting mold, and is hardened to form a molding compound layer 4.

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) The present invention relates to a method for producing a one-component resin laminated structure that can be used as a material for bathtubs, bathroom wall materials, counters, waterproof pans, etc. be.

(Prior Art) Conventionally, fiber-reinforced plastics using unsaturated polyester resin have been used as synthetic resin laminate structures for the purpose of increasing mechanical strength in bathtubs, ships, tanks, and the like. However, in recent years, synthetic resin laminated structures with patterned patterns have been studied in order to design structures suitable for aesthetic purposes and various other uses.

For example, a laminated structure has been proposed that uses transparent resin concrete hardened with unsaturated polyester resin to prevent warping and cracking at corners (Japanese Patent Publication No. 60-49426). issue). In addition, a mica layer is provided on the surface layer and colored (Special Publication No. 61-2554)
No. 2, No. 25543) and a structure made of resin concrete in which a pattern layer and a gel coat layer are successively laminated on the surface side of the surface reinforcement layer have been proposed (Utility Model Application No. 63-12).
No. 5530).

(Problem to be solved by the invention) However, in the case of adding a pattern with excellent surface design as in the latter case, it is necessary to add an inorganic substance or metal of a certain size other than powder as a filler. However, there is a problem that the pattern is limited and the filler is not uniformly dispersed in the unsaturated polyester resin, but settles and becomes non-uniform. Furthermore, if the weight of the filler is reduced too much, there is a problem in that it floats on the unsaturated polyester resin.

There is a method of forming the sides and patterns by painting, but there are problems in that it requires a large amount of work and has poor heat resistance and abrasion resistance. Therefore, the challenge is how to easily impart excellent patterns and the like to synthetic resin molded articles and make them durable without impairing their aesthetic appearance.

(Means for Solving the Problems) In order to solve the above-mentioned problems, the present invention, as a result of intensive research, not only provides an excellent three-dimensional effect when the pattern is seen below the surface transparent layer. This study focused on the fact that patterns can be varied in a variety of ways depending on the conditions set by carefully distributing the material by spraying it on the surface.
The process includes a step of forming a transparent gel coat layer on the surface of a mold having a product surface shape, a step of spraying a colored resin liquid in spots after this gel coat layer has at least gelled, and then spraying the colored spot layer. and forming a reinforcing layer and a colored layer different in hue, lightness, or saturation.

In the present invention, the surface layer is formed as a transparent resin or a gel coat layer made of a lightly colored transparent resin.

Here, the gel coat layer is a thin synthetic resin layer that forms the surface of the product, and is transparent or almost transparent.It is usually made only of resin, and no filler is mixed in, giving the product gloss, heat resistance, stain resistance, and water resistance. , a layer that provides scratch prevention function. As the above-mentioned transparent resin, unsaturated polyester resins may be used, particularly bisphenol-based or isophthalic acid-based unsaturated polyester resins which have been used conventionally and have various properties such as hot water resistance, depending on the purpose. This formation method is
This is usually done by applying a mold release agent to a mold (wooden mold, FRP mold, metal mold, etc.) that has the surface shape of the product and spraying it. The thickness is suitably in the range of about 0.3 to 0.6 mm, and the viscosity of 1800 to 3000 cps is excellent in workability, and silica, styrene monomer, and organic thixotropic agent are used to adjust the viscosity.

Next, the colored spot layer formed on this gel coat layer is formed after the gel coat layer is at least gelatinized (cured to the extent that the next spray does not blend). Therefore, it is preferable to perform heating at 50° C. for 30 minutes, for example.

For this colored spot layer, it is preferable to use a resin composition made of a transparent resin that is the same as or of the same type as the matrix resin of the gel coat layer and colored more strongly than the gel coat layer, and is usually based on a resin composition with a viscosity of 500 to 4000 cps. Pressure 0.5~
l Okg/cm” range, atomization pressure 0.2~2,0
It is preferable to spray at a discharge rate of 5 to 500 kg/cm.The lower the atomization pressure and the higher the discharge rate, the larger the spotted particles will become. The density (percentage of spots) can be varied by spraying time.

The back of the pattern is a continuous layer to the above surface layer and colored spot layer.
It requires a colored layer to form the appearance and a reinforcing layer to ensure the structural strength of the product. This colored layer must not have the same hue, lightness, or saturation as the spotted layer, but must differ in any one of them. For this clear color, it is preferable to use a resin composition obtained by applying a color different from that of the colored spot layer to a transparent resin that is the same as or of the same type as the matrix resin of the gel coat layer.

The above-mentioned back reinforcing layer is usually formed from fiber-reinforced plastic such as glass fiber impregnated with unsaturated polyester resin, but it is not limited to such a reinforcing layer.
Other reinforcing layers may be used, such as fiber-free thermosets, wood, metal plates, etc.

A compound layer may be formed in place of the colored layer or between the colored layer and the reinforcing layer. In order to provide strength, this compound layer contains a large amount of filler in a transparent resin, forms a fairly thick layer, and is adjusted to be opaque or slightly transparent. As the transparent resin, unsaturated polyester resin may be used as in the surface layer. Glass frit, aluminum hydroxide, and other materials can be used as fillers. When the colored layer is omitted, it is preferable to color this compound layer.

As mentioned above, the embodiments of the present invention include the following embodiments.

1-, G/colored speckled layer/colored G/C/FRP (Figure 2) 2, G/colored speckled layer/colored G/FRP or C (
(Fig. 4) 3. G/Colored Spot Layer/Row Color C/FRP (Fig. 5) Here, G means a gel coat layer, C means a compound layer, and FRP means fiber reinforced plastic.

(Operations and Effects of the Invention) According to the present invention, a colored spot layer is formed on the back side of the transparent gel coat layer, and a colored layer is formed thereon, so that when viewed from the surface, a sense of perspective is created and the color is deep. You can create patterns.

Furthermore, the size and proportion of the pattern can be changed arbitrarily by setting various spray conditions, so it is easy to produce patterns with various designs.

In particular, the gel coat layer on the surface can impart heat resistance and abrasion resistance to the pattern.

Hereinafter, embodiments according to the present invention will be described in detail.

(Example 1) As shown in FIG.
Pearl pigment made by coloring fine mica powder with titanium oxide (average diameter 20-200μ, thickness 1μ or less, 1
0.1 part by weight of 4% by weight coat) was added and uniformly dispersed by stirring. A predetermined amount of a curing agent and a curing accelerator are added to this, and silica, styrene monomer, and an organic thixotropic agent are added to adjust the viscosity.
Adjust it to a range of 0 cps and apply it uniformly to the male mold 7 to a thickness of 0.3 mm using a spray-up method to form a gel coat layer l.
was formed. Thereafter, it is heated at 50°C for 130 minutes to form a gel. Next, as shown in FIG. 14% by weight
0.5 parts by weight of Coat) was added and uniformly dispersed by stirring to give a viscosity of 2000 cps. Using Iwata Seisakusho W-77, the original pressure was 3 kg/CJ, and the atomization pressure was 0.5.
kg/am2 and a coating amount (discharge amount) of 200 g/min for 20 seconds (in the case of a bathtub size) to form a colored spot layer 2.

As shown in FIG. 2, these colored spots range in diameter from 1 to 5 degrees - 1 to 0.5 to 3 degrees in depth, depending on the dispersion conditions.

From above this colored spot layer, 15 parts by weight of pigment (dark green) was added to 100 parts by weight of transparent unsaturated polyester resin (gel coat resin), as shown in Figure 1 (■).
Uniform dispersion was achieved by stirring. A predetermined amount of a curing agent and a curing accelerator were added thereto, and in order to adjust the viscosity, silica and styrene monocou 1 organic thixotropic agent were added to adjust the viscosity to a range of 1800 to 3000 cps. The colored layer 3 was formed by uniformly applying the coating to a thickness of 3 eaves.

On the other hand, as shown in Fig. 1 (■), a back reinforcing layer 5 made of ortho-unsaturated polyester resin containing a large amount of white pigment and glass fiber (mixed with 30% by weight) was applied to the female mold 6 by a hand lay-up method. Laminated at 0.8 m.

Here, the male mold 7 and the female mold 6 are fitted with a gap of about 10 mm, and then 100 parts by weight of iso-unsaturated polyester resin, 180 parts by weight of glass frit h, and a colored piece (white spherical unsaturated polyester resin ( Injection lower 1 by mixing 10 parts by weight (average particle size 1 nn) with predetermined amounts of curing agent and curing accelerator.
The molding compound layer 4 was formed by injecting and curing the molding compound.

The above synthetic resin laminate molded product shown in Fig. 2 has an appearance in which the colored spot layer existing in the middle can be seen through the pearly layer, making it possible to obtain a molded product with a very deep patterned design. Ta. Furthermore, the appearance differs depending on the viewing angle as described above, and a molded article with a very high-class appearance is obtained.

(Example 2) A gel coat layer is formed in the same manner as in Example 1.

A colored speckled layer is then formed as in Example 1 by dispersing under the same conditions as in Example 1, this colored speckled layer being not covered by the second gelcoat layer here.

On the other hand, as shown in FIG. Laminated at .8+m+.

Here, the male star 7 and the female mold 6 are fitted with a gap of about 10 ra, and then 100 parts by weight of iso-unsaturated polyester resin, 180 parts by weight of glass 7 lift, 10 parts by weight of pigment and a predetermined amount of curing are applied. The casting agent and the curing accelerator were mixed, injected, and cured to form a casting compound layer.

The synthetic resin laminate molded product has the cross-sectional shape shown in Figure 5, and the colored spot layer in the middle can be seen through the pearly layer, and the molded product has a very deep patterned design. I was able to get Furthermore, the appearance differs from Kamikita depending on the viewing angle, and a molded product with a very high-class appearance is obtained.

(Example 3) The composition and formation method of the surface gel coat layer, colored spot layer, and second gel coat layer were the same as in Example 1, but the second gel coat layer was made of ortho-unsaturated polyester resin containing a large amount of white pigment. The back reinforcement layer made of glass fiber (30% by weight) was made to a thickness of 0.8++ by hand lay-up method.
Laminated at o.

A laminate molded product having the cross-sectional shape shown in Section 4 is obtained.

[Brief explanation of the drawing]

Figures 1 - ■ are cross-sectional views showing the structural steps of a bathtub laminate molded body produced by the method of the present invention, Figure 2 is a cross-sectional view of a laminate molded body produced by the method of the present invention, and Figure 3 is a partially enlarged view of the same. figure,
Figure 4, 5I3! :l is a sectional view of another example of a laminate molded product produced by the method of the present invention. ■...Surface gel coat layer, 2...Colored spot layer, 3.
...Colored layer, 4...Compound layer, 5...Reinforcing layer Fig. 1■ Fig. 1■

Claims (1)

[Claims] 1. A step of forming a transparent gel coat layer on the surface of a mold having a product surface shape, and a step of spraying a colored resin liquid in spots after the gel coat layer has at least gelled. A method for molding a synthetic resin laminate structure, comprising the steps of: thereafter forming a colored layer and a reinforcing layer that are different in hue, lightness, or saturation from the colored spot layer.