JPH0126333B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to an FRP molded product, and more particularly to an FRP molded product having a printed pattern.

Conventionally, FRP molded products have been used for a variety of purposes, including bathtubs and ships. The present invention makes it possible to provide such an FRP molded product having a beautiful printed pattern.

The method of creating FRP molded products is conventionally known. For example, a mold is created, a synthetic resin is applied to the mold, a glass mat layer is superimposed on it, and then a synthetic resin is applied on top of that. The method of impregnating the glass mat layer, repeating the overlapping of the glass mat layer and coating and impregnating the synthetic resin to integrate the whole, and then demolding to obtain an FRP molded product of the desired thickness is as follows: The hand lay-up molding method and the spray-up molding method are well known, and these are collectively called the open mold molding method. In this case, the synthetic resin applied to the mold becomes a synthetic resin surface layer.

The FRP molded products obtained in this way are lightweight and have excellent waterproof and heat insulating properties, so they are widely used in bathtubs and the like. Especially considering that bathrooms are installed on the second floor of a house or in each room of a hotel, it is strongly desired that the bathroom be lightweight. In addition, unit baths in which the bathtub, washing area, washing area wall, etc. are integrated are also preferably made of FPR because they have excellent waterproof properties.

As mentioned above, although FRP molded products have many advantages in function as bathtubs, etc. compared to heavy products such as stainless steel or tiles, there has been no significant growth in demand. Not obtained. The reason for this is that conventionally it has not been possible to obtain FRP molded products with beautiful patterns.

In other words, when products such as bathtubs compete with stainless steel, tiles, etc. other than FPR, the appearance, in addition to functionality, has a large impact on the product value.

Some FRP molded products have pearl pigments mixed into the synthetic resin surface layer or other layers, and although the aesthetic effect is satisfactory to some extent, the overall color is plain, and beautiful patterns such as natural stone or painted tiles are used. You can't compete with what you have.

In addition, when making large items like unit baths using the open mold method, productivity is low, so the product must be of high value, but as mentioned above, when using FRP molded products, Bathrooms were not beautiful with the desired pattern, and were monotonous compared to bathrooms using tiles. For this reason, in the case of unit baths, there are some that use FRP bathtubs and walls etc. with melamine decorative boards or DAP decorative boards, and combine these to overcome the monotony. Advantages such as waterproofness and heat insulation are sacrificed.

In order to improve the monotony of FRP molded products as described above, marble patterns, stone patterns, etc. are created using methods such as transfer to the glass mat layer that is overlapped when making FRP molded products, or thermal transfer to glass cloth in advance. It is also known that there are patterns on it.

However, when a pattern is applied to the glass mat layer in this way, the pattern needs to be visible when it becomes a product, so the synthetic resin layer impregnated into the glass mat layer must be non-obscuring. Therefore, it is impossible to eliminate the artificial feeling such as the appearance of the glass cloth in the glass mat layer.

The present invention aims to improve the above-mentioned drawbacks of FRP molded products and provide FRP molded products with beautiful printed patterns.

FIG. 1 is an explanatory view of one embodiment of the FRP molded product of the present invention, which has a desired number of glass mat layers 1 impregnated with a synthetic resin and a transparent synthetic resin surface layer 2, and has a synthetic resin surface layer 2. A printed pattern 3 is applied to the back surface of the surface layer 2. In this case, the printed pattern 3 is printed on the glass mat 4 in the glass mat layer 1.
It is not applied to the synthetic resin surface layer 2.
It is placed on the back of the . Also, glass mat layer 1
A shading layer is provided for shading the glass mat therein, and this shading layer is present between the printed pattern 3 and the glass mat 4 adjacent to the printed pattern 3.
Since this shielding layer shields the glass mat in the glass mat layer 1, it can be made into a shielding layer by using an opaque resin as the synthetic resin 5 with which the glass mat 4 is impregnated. Alternatively, a shading layer can be formed by applying opaque ink, synthetic resin, etc. at the same time or after printing the printed pattern 3 on the back side of the synthetic resin surface layer 2.

For example, when applying the printed pattern 3 using a transfer printing method, when creating a transfer sheet, an opaque layer serving as a shading layer is formed on the base material for the transfer sheet, and a desired printed pattern is formed on the opaque layer. By simultaneously transferring the desired printed pattern and the shading layer to the synthetic resin surface layer 2 using the thus obtained transfer sheet, a shadow is created between the glass mat 4 adjacent to the printed pattern and the printed pattern 3. A covering layer can be formed.

In order to form the printed pattern 3, it is preferable to employ the transfer printing method as described above, but in addition to this, a direct printing method such as a screen printing method may also be selected and adopted as appropriate.

When a transfer printing method is adopted, there are advantages such as no need for a large screen printing machine, elaborate printed patterns can be easily formed, and the work is simple. After applying the printed pattern 3, a glass mat layer is formed, but this process is conventionally done in FRP.
This process is similar to the known process for obtaining molded products.

The method for manufacturing the printed patterned FRP molded product of the present invention will be explained as follows, taking as an example a case where a transfer printing method is adopted.

A colorless or colored transparent synthetic resin paint is applied onto the mold. This becomes the synthetic resin surface layer 2. The coating thickness is usually around 0.5mm, but
Naturally, it changes depending on the product's use, quality, etc.

Next, a transfer sheet having a desired printed pattern is brought into close contact with the synthetic resin paint so that the printed pattern surface is in contact with the synthetic resin paint to transfer the printed pattern.

The timing for bringing the transfer sheet into close contact with the paint layer, which will become the synthetic resin surface layer, can be before the paint layer completes gelation. In this case, it is necessary to transfer the printed pattern without deteriorating it while the paint layer is gelling. The transfer sheet is made of a base material such as vinylon film or polyester film, with a binder such as nitrified cotton, cellulose acetate, or polyester resin, and a large amount of extender pigment to improve the adhesion between the paint layer and the ink layer. It is preferable to use one in which a desired printed pattern is formed using mixed ink. Note that the base material for the transfer sheet is not limited to those mentioned above, and a desired material can be appropriately selected and used. With the transfer sheet in close contact with the paint layer, the paint layer is gelled, and when it reaches a predetermined hardening state, only the base material for the transfer sheet is peeled off, thereby completing the transfer.

After this, as in the usual method, the process of stacking glass mat layers such as glass cloth, applying synthetic resin on top, and impregnating the glass mat is repeated as many times as necessary, and then demolded to obtain an FRP molded product.
As already mentioned, the shading layer can be applied at the same time as or after the printed pattern is applied, or by using an opaque resin to impregnate the glass mat layer. That's right.

FIG. 2 is an explanatory diagram of another embodiment of the present invention, in which a synthetic resin surface layer 2 includes a layer 21 partially or entirely dispersed with a fine piece material having metallic luster or pearlescent luster, and It differs from the one shown in FIG. 1 in that it consists of a layer 22 that does not contain .

The fine piece materials include fine powders and pearl powders of inorganic materials such as fluorite, mica, titanium oxide, aluminum, and brass, or metals such as aluminum and chromium are vapor-deposited onto polyester films and made into minute pieces. These can be easily incorporated into the synthetic resin surface layer by kneading them into the resin for forming the synthetic resin surface layer.

Note that the layer 21 containing fine particle material and the layer 22 not containing fine particle material may be stacked in the reverse order to that shown in FIG. 2. Further, the fine piece material may be contained in a single synthetic resin surface layer as shown in FIG.

FIG. 3 is an explanatory diagram of another embodiment of the present invention, in which a transparent synthetic resin layer 6 is further formed on the back side of the printed pattern 3. In this case, the shielding layer is formed between the synthetic resin layer 6 and the glass mat 4. In this case as well, the fine piece material may be contained in the synthetic resin surface layer 2 and/or the synthetic resin layer, and furthermore, each of these layers may be two layers as in the case of FIG. good.

By containing the fine piece material in the transparent synthetic resin layer, the design effect of the FRP molded product becomes even more excellent.

As the resin used for the synthetic resin surface layer 2 of the present invention and the resin impregnated into the glass mat, those used in ordinary FRP molded products such as polyester resin may be appropriately selected and used.

Since the present invention has the above-described configuration, an FRP molded product having a beautiful printed pattern is provided, and moreover, it has an elaborate pattern in which the eyes of the glass cloth are not visible.
FRP molded products are provided.

Such FRP molded products can be applied to all kinds of products in which FRP molded products are generally used, such as ships and bathtubs. This is particularly effective for products that require beautiful printed patterns, such as unit baths.

Further, when forming the synthetic resin surface layer 2, it is possible to transfer the synthetic resin paint by closely contacting the transfer sheet before it hardens, so that the manufacturing time is not prolonged.

Next, examples of the present invention will be shown.

<Example 1> A transfer sheet was prepared by gravure printing a pebble pattern on a vinylon matte film having a thickness of 25 μm. The printing ink in this case used a binder consisting of nitrified cotton, an alkyd resin, a plasticizer, etc., and the pigments used were extender pigments such as silica and barium sulfate, and organic pigments as coloring pigments. Transparency can be achieved by using organic pigments.

Separately, a mold for FRP molding was made from the master mold for the unit bath, and after releasing the mold with polyvinyl alcohol, 0.3 mm of colorless polyester resin was applied.
It was coated to a film thickness of mm. In this case, spray coating was applied to ensure uniform thickness. Immediately after coating was completed, the transfer sheet was cut into a desired size and brought into close contact with the ink side facing the coating layer. If the area to be painted corresponds to a washing area, there may be some unevenness, so hand roll work was performed to ensure complete contact. When the adhesion was completed, the coating layer was left to stand until it gelled. The gelation time was 30 minutes. After gelation was completed, only the vinylon pine film was peeled off to complete the transfer.

Next, after stacking the glass mat layer, an opaque polyester resin is applied and impregnated, and then the intermediate layer lamination process and the backing layer lamination process are carried out using the hand lay-up method in exactly the same way as obtaining ordinary FRP molded products. Completed. Finally, the mold was removed to obtain a unit bath made of FRP molded product. This product had a beautiful stone grain pattern printed on it, and the glass pine was invisible, making it a highly valuable product.

<Example 2> An abstract pattern was gravure printed on a polyester matte film having a thickness of 25 μm under the same printing conditions as in Example 1 to obtain a transfer sheet. Further, a unit bath mold similar to that in Example 1 was subjected to mold release treatment using wax. Next, a polyester resin mixed with 1% by weight of mica powder having a particle size of about 30 μm to 60 μm was spray coated. The coating thickness in this case was 0.5 mm. Immediately after spraying was completed, transfer was carried out in the same manner as in Example 1 using the transfer sheet, and a glass mat layer was further formed in the same manner as in Example 1. The mold was then demolded to obtain a unit bath. This product had an excellent design effect due to the synergistic effect of the beautiful abstract pattern and the mica powder in the synthetic resin surface layer, and had a high commercial value.

[Brief explanation of drawings]

Figure 1 is an explanatory diagram of one embodiment of the FRP molded product of the present invention, and Figures 2 and 3 are FRP molded products of the present invention.
It is an explanatory view of other embodiments of a molded product. 1...Glass mat layer, 2...Synthetic resin surface layer, 3
...Printed pattern, 4...Glass mat, 5...Synthetic resin,
6... Synthetic resin layer, 21... Layer containing fine piece material, 22... Layer not containing fine piece material.

Claims (1)

[Scope of Claims] 1. In an FRP molded product having a glass mat layer impregnated with a synthetic resin and a transparent synthetic resin surface layer, a printed pattern is provided on the back side of the transparent synthetic resin surface layer. An FRP molded product with a printed pattern, characterized in that a shading layer for shading the glass mat in the glass mat layer exists between the glass mat close to the printed pattern and the printed pattern. 2 In the transparent synthetic resin surface layer,
The printed pattern according to claim 1, characterized in that opaque fine pieces made of an inorganic or organic material or fine piece materials having metallic luster or pearlescent luster are partially or entirely dispersed. FRP molded product. 3. The synthetic resin surface layer having transparency shall consist of two layers: a layer in which metal powder or pigment having metallic luster or pearlescent luster is partially or fully dispersed and a layer in which it is not contained. With a printed pattern according to claim 1, characterized in that
FRP molded product. 4. The FRP molded product with a printed pattern according to claim 1, wherein the FRP molded product is a unit bath. 5. Claim 1, characterized in that the printed pattern is applied by a transfer method.
FRP molded product with printed pattern as described in section.