JPH0911257A - Resin molding having patterns and production thereof - Google Patents

Abstract

PURPOSE: To produce a resin molding having desired patterns, for example, inlaid patterns by charging a compsn. containing a curable resin in a mold to spread the same under pressure and subsequently performing mold opening to arrange pattern materials becoming patterns to the compsn. before curing the curable resin to again press the compsn. CONSTITUTION: After a predetermined amt. of a compsn. 1 is charged in a lower mold 10 being a female mold, an upper mold 11 being a male mold is allowed to fall to perform mold clamping to spread the compsn. 1 in a cavity under pressure. Next, the upper mold 11 is raised to perform mold opening and pattern materials 2... are arranged on the spread compsn. 1 at the positions corresponding to desired patterns. Thereafter, the upper mold 11 is allowed to again fall to perform mold clamping operation. By this method, the pattern materials 2... are pressed to be embedded in the compsn. 1. In this state, the compsn. 1 is subjected to thermal pressure molding, that is, press molding to be cured. Next, the upper mold 11 is raised to perform mold opening to take out a resin molding 3.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a resin molded product having a desired pattern such as an inlaid pattern, and a method for producing the resin molded product.

[0002]

2. Description of the Related Art Generally, when a pattern is formed on an article such as natural stone by an inlay, the following method is used. That is, first, a concave portion (groove) for embedding a pattern material to be a pattern in the above article is formed by cutting or the like. Next, a pattern material coated with an adhesive or the like is fitted into the concave portion.

However, according to the above method, an article having a desired pattern cannot be mass-produced at low cost.
Therefore, as a substitute for natural stone with an inlaid pattern, artificial marble (resin molded product) having a pattern such as an inlaid pattern has been conventionally proposed. As a method for producing such artificial marble, for example, in Japanese Patent Laid-Open No. 6-210648, a plate-shaped body to be patterned is placed on a mold (lower mold) and then heat-treated on the plate-shaped body. A method of arranging a compound containing a curable resin, clamping the mold, and heating / pressurizing is disclosed. That is, a method has been proposed in which the plate-shaped body and the compound are arranged in this order on a mold, and then the mold is clamped and press-molded to obtain an artificial marble having a pattern by one press.

[0004]

In the conventional manufacturing method described above, the compound is placed on the plate-shaped body placed on the mold and pressurized, and the compound is filled in the cavity. Therefore, when manufacturing an artificial marble having a pattern on the entire surface, that is, when a large pattern is formed using a relatively large plate-like body, the plate-like shape is accompanied by the spreading operation in the cavity of the compound. The body does not move in the cavity, and an artificial marble having a desired pattern is obtained.

However, for example, in the case of manufacturing artificial marble having a pattern only on a part of the surface, that is, in the case of using a relatively small plate-like body to form a scattered pattern or a fine pattern, the cavity of the compound The plate-like body moves in the cavity due to the spreading operation inside. That is, even if the plate-shaped body is arranged at a desired position on the mold,
There is a problem that the plate-like body is moved by the pressure, and only artificial marble having a pattern unevenly distributed (that is, a desired pattern is not formed) can be obtained.
In order to suppress the movement of the plate-shaped body, for example, a troublesome work such as attaching the plate-shaped body to a mold is required.

Further, in the above conventional manufacturing method, after the compound is placed on the plate-shaped body, the compound is filled in the cavity. Therefore, for example, when the mechanical strength of the plate-shaped body is small, the plate-shaped body is damaged (for example, torn) by the pressure applied when the compound is spread,
A desired pattern cannot be formed.

That is, the above-mentioned conventional manufacturing method can be applied only when manufacturing artificial marble having a pattern on the entire surface by using a plate-shaped body having a relatively large size and a predetermined mechanical strength. Is a method that cannot be done. That is, the above conventional manufacturing method uses, for example, a relatively small plate-shaped body to manufacture an artificial marble having a pattern only on a part of the surface, or uses a plate-shaped body having a relatively small mechanical strength. However, there is a problem in that it is difficult to apply it when manufacturing artificial marble having a pattern.

Therefore, there is a method for producing an artificial marble (resin molding) having a desired pattern such as an inlaid pattern by using a plate having a relatively small size or a plate having a relatively small mechanical strength. It has been demanded. In the above conventional manufacturing method, the plate-shaped body must be turned upside down and placed on the mold in order to obtain a desired pattern. Therefore, positioning and arranging the plate-shaped body is complicated.

That is, the present invention has been made in view of the above conventional problems, and its object is not limited by the size and mechanical strength of a pattern material to be a pattern, and for example, an inlaid pattern or the like. Another object of the present invention is to provide a manufacturing method capable of manufacturing a resin molded product having the desired pattern of 1. Another object of the present invention is to provide a resin molded product having a desired pattern such as an inlaid pattern.

[0010]

In order to achieve the above-mentioned object, the inventors of the present invention are not limited by the size and mechanical strength of a pattern material to be a pattern, and have a resin pattern having a desired pattern. The inventors have made earnest studies on a method capable of manufacturing. As a result, the composition containing the curable resin is put in a mold such as a mold, pressurized and spread, and then the mold is opened, and thereafter, a pattern is formed on the composition before the curable resin is cured. It has been found that a resin molded product having a desired pattern can be manufactured by arranging a pattern material to be formed and pressing it again, and completed the present invention.

That is, in the method for producing a resin molded product having a pattern according to the invention of claim 1, in order to solve the above-mentioned problems, a composition containing a curable resin is put into a mold and spread under pressure. After that, the mold is opened, and before the curable resin is cured, a pattern material to be a pattern is arranged on the composition and the pressure is applied again.

A method for producing a resin molded product having a pattern according to a second aspect of the present invention is the method for producing a resin molded product having a pattern according to claim 1 in order to solve the above problems. Is characterized in that the above pattern material is harder.

In order to solve the above-mentioned problems, a resin molded product having a pattern according to a third aspect of the present invention is a resin molded product having a pattern material to be patterned on a molded product containing a curable resin. It is characterized in that the pattern material is glass and / or wood.

Hereinafter, the present invention will be described in detail. The composition used in the method for producing a resin molded product having a pattern according to the present invention (hereinafter, simply referred to as a resin molded product) is not particularly limited as long as it contains a curable resin. The composition is, in addition to the curable resin, a filler, a curing agent, a curing accelerator, an ultraviolet absorber, a shrinking agent, a coupling agent, a thickener, an internal mold release agent, a polymerization inhibitor, and a pigment. If necessary, additives such as colorants such as dyes and dyes are included.
In addition, the composition is a fiber reinforced resin (FMC) such as sheet molding compound (SMC) or bulk molding compound (BMC) generally used for press molding.
RP). The method for mixing the curable resin and the additive in the composition, the order of mixing, and the like, that is, the method for producing the composition are not particularly limited.

The curable resin is not particularly limited as long as it can be pressure-molded. Examples of the curable resin include acrylic resins, unsaturated polyester resins, vinyl ester resins, urethane resins, phenol resins and the like. Only one kind of these curable resins may be used, or two or more kinds thereof may be appropriately mixed and used. Among the above-exemplified curable resins, acrylic resins and unsaturated polyester resins are particularly suitable, but the curable resin may be appropriately selected depending on, for example, the use of the resin molded product.

Examples of the filler include aluminum hydroxide, calcium carbonate, silica, crushed glass, glass powder, glass frit, ceramics, crushed natural stone, and sand, but are not particularly limited. . Further, glass fiber, carbon fiber or the like which improves the mechanical strength of the resin molded product may be used as a filler. That is, to the above composition, any commonly used filler can be added. When the above-mentioned aluminum hydroxide or glass powder is used as a filler, flame retardancy and transparency can be imparted to the resin molded product. In addition, the form of the various fillers, such as the shape and particle diameter, and the amount added are not particularly limited.

As the above-mentioned colorant, a colorant generally used for curable resins can be used, and it is not particularly limited. The color of the colorant may be any color according to the desired resin molded product.

The above composition is a so-called monochromatic system when it does not contain silica, glass, ceramics, crushed natural stone, sand, etc. On the other hand, when the composition contains these fillers, the composition, that is, the resin molded product (molded product) has a so-called granite-like or marble-like ground pattern. That is, by adding silica, glass, ceramic, crushed natural stone, sand, etc. to the composition,
It is possible to obtain an artificial stone (resin molding) having a granite-like or marble-like ground pattern.

The pattern material to be used as a pattern (hereinafter simply referred to as a pattern material) used in the method for producing a resin molded product according to the present invention can form a desired pattern such as an inlaid pattern on the above composition. Further, it is not particularly limited as long as it does not cause melting, deterioration, shrinkage, etc. when the composition is cured. As the above pattern material, for example, having the same composition as the above composition, and
A resin composition having a hue or tone different from that of the composition, that is, a resin composition obtained by adding a colorant to the composition; the resin composition is increased with a thickener such as magnesium oxide (MgO) or isocyanate. Resin composition formed by viscous; resin cured product obtained by curing (molding) each of the above resin compositions; natural stones such as granite and marble; various minerals; metals such as stainless steel and copper; wood; shells; ceramics; glass; Examples include slag. The wood, shells, glass and the like may be colored in any color. Further, the glass may have a pattern.

The shape of the pattern material may be, for example, a rod shape, a spherical shape, a plate shape or the like, but is not particularly limited and may be appropriately selected according to the desired pattern. The size and amount of the pattern material are not particularly limited and may be appropriately selected according to the desired pattern. That is, since there is no restriction due to the shape, size, etc., it is possible to form any pattern with the pattern material. As the colorant, a colorant generally used for curable resins can be used, and the colorant is not particularly limited. Further, the color of the colorant may be different from the composition in terms of hue and color tone, and may be a color suitable for forming a desired pattern. Furthermore, when the pattern material is made of, for example, a resin composition or a resin cured product, the method for producing the pattern material is not particularly limited.

The hardness of the pattern material, that is, the relationship between the hardness of the composition and the hardness of the pattern material is not particularly limited. For example, in the case of forming a pattern having a clear (so-called clear) contour, that is, a so-called sharp pattern, the pattern material is preferably harder than the composition. Further, for example, when forming a pattern having an unclear (so-called vague) contour, that is, a so-called blurred pattern, is the pattern material softer than the composition, or the hardness of the composition and the pattern material? Is preferably equal to the hardness of the.

The thickness of the pattern material, that is, the depth to be embedded in the composition is not particularly limited,
It does not detach from the composition, and the resulting pattern has an appearance
0.5 mm or more is preferable so that so-called depth can be felt. In addition, in order to completely prevent the pattern material from detaching from the composition, the inner portion is larger than the inner portion (so-called undercut) of the resin molded article (molded article). State) is more preferable. Thereby, the pattern material can be fixed to the composition without using an adhesive or the like. When the pattern material is made of, for example, a resin composition or a cured resin, the pattern material and the composition adhere to each other, so that the pattern material is detached from the composition without the so-called undercut state. There is no such thing.

Next, an example of a method for producing a resin molded product will be described below with reference to FIG. First, FIG.
As shown in (a), after charging a predetermined amount of the composition 1 into a lower mold (hereinafter, referred to as a lower mold) 10 which is a female mold, an upper mold (hereinafter, an upper mold) which is a male mold is charged. Called the mold) 11
Lower and perform the mold clamping operation. Thereby, the composition 1
Is pressurized and spread into the cavity. The above mold clamping operation may be performed until the composition 1 is spread over almost the entire cavity, and the upper mold 10 and the lower mold 1 are not necessarily required.
It is not necessary to clamp 1 completely. Both molds 10.1
1 is attached to, for example, a press machine and is heated to a predetermined temperature. Further, the thickness of the spread composition 1, that is, the thickness of the resin molded product to be produced is not particularly limited.

Next, when the composition 1 is spread, the upper mold 11 is raised to open the mold as shown in FIG. At this time, the composition 1, that is, the curable resin is hardly cured. Next, as shown in FIG. 3C, the pattern material 2 is arranged on the spread composition 1, that is, at a position corresponding to a desired pattern. The arrangement method of the pattern materials 2 ... Is not particularly limited. For example, when the pattern material 2 is solid, it may be placed on the composition 1. When the pattern material 2 is, for example, in the form of a paste, the pattern material 2 is put in an appropriate bag or the like, and then the composition 1 is added.
Just squeeze it out. Further, different types of pattern materials, that is, two or more types of pattern materials may be used.

The composition used for press molding usually contains various additives. Further, the curable resin is cured to some extent from the viewpoint of molding processability and the like. Therefore, the composition 1 has a predetermined hardness. Therefore, the pattern material 2 ... Arranged on the composition 1 does not sink into the composition 1 by its own weight.

After that, as shown in FIG.
1 is lowered again and the mold clamping operation is performed. As a result, the pattern materials 2 ... Are pressurized and embedded in the composition 1. In this state, the composition 1 is heated and pressed, that is, press-molded to cure the composition 1. The mold clamping operation of embedding the pattern materials 2 in the composition 1 may be performed until the curable resin is completely cured.

Next, as shown in FIG.
And mold opening is performed to cure the cured composition 1, that is,
The resin molded product 3 is taken out. The resin molded product 3 is obtained through the above steps. The surface of the resin molded product 3, that is, the surface having a pattern may be polished as necessary.

In the above description, both molds 10 and
Although the case where 11 is preheated to a predetermined temperature has been illustrated, both molds 10 and 11 are heated to a predetermined temperature in the step of press-molding the composition 1 (that is, the step shown in FIG. It should be. Further, in the above description, the lower mold 1
Although the case where 0 is a female mold and the upper mold 11 is a male mold is illustrated, the lower mold may be a male mold and the upper mold may be a female mold. However, it is preferable that the lower mold is a female mold. Furthermore, in the above description, the case where both molds 10 and 11 are used is illustrated, but the mold used for molding the composition 1 may be made of FRP or the like. That is, the composition 1 may be molded by a so-called cold press method.
In this case, the composition 1 in which the pattern materials 2 are embedded may be carried into the curing furnace or the like together with the mold without performing mold opening, and may be heat-molded. When a mold made of FRP or the like is used, it may be pressurized using a press machine or may be pressurized manually (for example, applying pressure to the mold by applying weight).

The method for producing a resin molded product according to the present invention is
As described above, a composition containing a curable resin is put into a mold, pressurized and spread, then the mold is opened, and a pattern material to be a pattern is formed on the composition before the curable resin is cured. This is a method of arranging and pressurizing again.

Thus, after the composition is pressed and spread, the pattern material is placed on the composition and pressed again, so that the pattern material is only embedded in the composition,
It does not move within the cavity and is not damaged (eg, shredded). Therefore, by arranging the pattern material at an arbitrary position on the composition, a resin molded product having a desired pattern can be easily and easily manufactured. That is, a resin molded product having a desired pattern can be produced even when the pattern material is relatively small or the mechanical strength is relatively small. Further, it is not necessary to pre-mold the pattern material into a shape corresponding to the pattern, and it is only necessary to dispose the pattern material according to the desired pattern, and thus the positioning and disposing work of the pattern material are easy, and A resin molded product can be manufactured at low cost. Furthermore, since no gap is formed at the boundary between the composition and the pattern material, the appearance of the resin molded product is beautiful.

As a result, a resin molded product having a desired pattern such as an inlaid pattern can be manufactured in large quantities and at low cost without being restricted by the size and mechanical strength of the pattern material to be the pattern. Further, by appropriately selecting the additive and the pattern material contained in the composition, a resin molded product having excellent design properties, for example, an artificial stone having a ground pattern of granite or marble and having an inlaid pattern It is possible to easily and easily obtain a resin molded product such as.

As described above, the method for producing a resin molded product according to the present invention is a method in which the pattern material is harder than the composition. This makes it possible to produce a resin molded product having a pattern having a clear (so-called clear) contour, that is, a so-called sharp pattern.

Furthermore, the resin molded product according to the present invention is a resin molded product having a pattern material on a molded product containing a curable resin as described above, and the pattern material is glass and / or wood. It is a composition. As a result, it is possible to obtain a resin molded product having a beautiful pattern and having an excellent design, such as a molded product inlaid with glass and / or wood.

The resin molded product is used, for example, as follows.
Decorative materials for construction such as tiles and wall panels; housing equipment such as bathtubs, bathroom panels, kitchen counters, vanities, and table tops; various decorative items, nameplates, etc., but not particularly limited Absent.

[0035]

According to the above method, the resin molded product is obtained by placing the composition containing the curable resin in a mold, applying pressure to spread the composition, and then opening the mold to obtain the composition before curing the curable resin. It is manufactured by arranging a pattern material to be a pattern on an object and pressing it again.

As a result, a resin molded product having a desired pattern such as an inlaid pattern can be manufactured in large quantities and at low cost without being restricted by the size of the pattern material to be the pattern and the mechanical strength. Further, by appropriately selecting the composition and the pattern material, it is possible to easily form a resin molded product having an excellent design property, for example, a resin molded product such as an artificial stone having an inlaid pattern and having a ground pattern of granite or marble. And can be easily obtained.

According to the above method, a resin molded product having a pattern having a clear (so-called clear) contour, that is, a so-called sharp pattern is manufactured by using a pattern material harder than the composition. be able to.

Further, according to the above constitution, it is possible to obtain a resin molded product having a beautiful pattern and having a beautiful design, such as a molded product inlaid with glass and / or wood.

[0039]

The present invention will be described in more detail with reference to the following Examples and Comparative Examples, but the present invention is not limited thereto. In addition, "part" described in Examples and Comparative Examples means "part by weight".

[Example 1] First, an acrylic syrup as a raw material of a composition was synthesized. That is, methylmethacrylate 190 was placed in a separable flask which is a reaction vessel equipped with a thermometer, a gas blowing tube, a reflux condenser and a stirrer.
And 10 parts of methacrylic acid were charged. Next, the reaction solution was heated to 80 ° C. under a nitrogen gas atmosphere while stirring the reaction solution. Then, while stirring the reaction solution, 0.01 part of 2,2′-azobisisobutyronitrile which is a polymerization initiator and 0.6 part of n-dodecyl mercaptan which is a chain transfer agent were added to the reaction solution. The polymerization reaction was started. And
When the viscosity of the reaction liquid at 25 ° C. reached about 300 poise, the flask was cooled to terminate the polymerization reaction. As a result, an acrylic syrup having a solid content of 40% by weight was obtained.

A composition was prepared using this acrylic syrup. That is, 90 parts of the acrylic syrup as a curable resin, 10 parts of trimethylolpropane trimethacrylate, and 5 parts of styrene, and finely powdered aluminum hydroxide as a filler (manufactured by Showa Denko KK; trade name: Hijilite H) -320) 100 parts, natural white granite halves 550 parts, glass powder (Nitto Boseki Co., Ltd .; trade name Konak FMB-5W-001) 150 parts, and reinforced glass fiber (Nippon Electric Glass Co., Ltd .; products 35 parts of excellent chopped strand ECSO6B-144 / P) was added,
Further, 1 part of a curing agent (manufactured by NOF Corporation; trade name Perhexa TMH) and 2 parts of a coupling agent (manufactured by Shin-Etsu Chemical Co., Ltd .; trade name KBM-503) were added. Then, this mixture was kneaded with a kneader to obtain BMC, that is, a composition.

Next, a pattern material was prepared. That is, 90 parts of the acrylic syrup, 10 parts of trimethylolpropane trimethacrylate, and 5 parts of styrene, which are raw materials of the above composition, 100 parts of the above-mentioned aluminum hydroxide and 1 part of glass powder.
50 parts, 35 parts tempered glass fiber, 1 part hardening agent, and 2 parts coupling agent were added, and further natural tea granite quarts
550 parts and 2 parts of a thickener magnesium oxide (Kyowa Chemical Industry Co., Ltd .; trade name Kyowamag 20) were added. Then, this mixture was kneaded with a kneader to obtain a kneaded product. That is, a kneaded product was obtained in the same manner as the composition except that the natural granite used as the raw material of the composition was changed as described above and the thickener was further added. Next, this kneaded product was preformed into a rod having a predetermined size and then thickened to obtain a pattern material.

A resin molded product was produced using the composition and the pattern material prepared as described above. First, the lower mold attached to the press was heated to 110 ° C, and the upper mold was heated to 115 ° C. Next, after charging the lower mold with a predetermined amount of the composition, the upper mold is lowered, and the press pressure is 50 kgf / cm ²
The mold clamping operation was performed at ~ 85 kgf / cm ² . Thereafter, the upper mold was immediately lifted to open the mold. The composition was then pressurized and spread over almost the entire cavity. At this time, the composition was hardly cured.

Next, a pattern material is appropriately arranged on the spread composition so that a striped pattern and a checkered pattern are formed, then the upper mold is lowered again, and the mold is pressed at a pressure of 85 kgf / cm ² . The tightening operation was performed. Then, in this state, the composition was cured by press molding for 10 minutes. Then, the upper mold was lifted to open the mold, and a resin molded product, which was a cured composition, was taken out. Then, the surface of the obtained resin molded product, that is, the surface having a pattern was polished using a wet polishing machine. The pattern material was embedded in the composition.

The obtained resin molded product had an appearance such that the surface thereof had a striped pattern and a checkered pattern formed by combining two kinds of natural stones. That is, by the above-mentioned manufacturing method, an artificial stone as a resin molded product having a beautiful striped pattern and a lattice-striped pattern, which is excellent in design, is obtained, as one natural stone is inlaid with the other natural stone. .

Example 2 First, a composition was prepared. That is, unsaturated polyester resin (manufactured by Nippon Shokubai Co., Ltd .; trade name Epolak NH-111) as a curable resin 85
Fine powder aluminum hydroxide as a filler (Showa Denko KK; trade name Heidilite H-320)
250 parts, 550 parts of natural white granite quarts, and 35 parts of tempered glass fiber (Nippon Electric Glass Co., Ltd .; trade name Chopped Strand ECSO6B-144 / P) are added,
Further, 1 part of a curing agent (manufactured by Kayaku Akzo Co., Ltd .; trade name Kayacarbon BIC-75), 15 parts of a shrinkage reducing agent (manufactured by Nippon Shokubai Co., Ltd .; trade name AT-600), and a coupling agent (Shin-Etsu Chemical). Kogyo Co., Ltd .; trade name KBM
-503) 2 parts were added. Then, this mixture was kneaded with a kneader to obtain BMC, that is, a composition.

Next, a pattern material was prepared. That is, 250 parts of the above-mentioned aluminum hydroxide, 35 parts of reinforced glass fiber, 1 part of curing agent, 15 parts of shrinkage reducing agent, and 2 parts of coupling agent are added to 85 parts of unsaturated polyester resin which is a raw material of the above composition.
In addition, 550 parts of natural tea granite dichotomite and 2 parts of magnesium oxide (Kyowa Chemical Co., Ltd .; trade name: Kyowamag 20) as a thickener were added. Then, this mixture was kneaded with a kneader to obtain a kneaded product. That is, a kneaded product was obtained in the same manner as the composition except that the natural granite used as the raw material of the composition was changed as described above and the thickener was further added. Next, this kneaded product was preformed into a rod having a predetermined size and then thickened to obtain a pattern material.

Using the composition thus prepared and the pattern material, press molding and polishing were carried out in the same manner as in Example 1 to produce a resin molded product.

The obtained resin molded product had an appearance such that the surface thereof had a striped pattern and a lattice striped pattern formed by combining two types of natural stones. That is, by the above-mentioned manufacturing method, an artificial stone as a resin molded product having a beautiful striped pattern and a lattice-striped pattern, which is excellent in design, is obtained, as one natural stone is inlaid with the other natural stone. .

Example 3 A composition was prepared by performing the same operation as in Example 2. Further, a kneaded product was obtained by performing the same operation as in Example 2 except that 550 parts of natural black granite dichroic stone was used in place of 550 parts of natural tea granite dichroic stone in Example 2. Then, after preforming this kneaded product into an appropriate figure or character shape,
By increasing the viscosity, a pattern material was obtained.

Using the composition and pattern material prepared as described above, a resin molded product was manufactured by performing press molding and polishing in the same manner as in Example 1.

The obtained resin molded product had an appearance such that a pattern of figures and characters was formed on the surface by combining two kinds of natural stones. That is, FIG.
As shown in FIG. 3, the resin molded product 3 had a pattern of figures and characters (“M” in the figure) formed on the surface 3a by the pattern material 2. Incidentally, as shown in FIG. 3, the back surface 3b of the resin molded product 3 had a natural stone appearance.

That is, according to the above-mentioned manufacturing method, an artificial stone as a resin molded product having a beautiful design having a beautiful figure or character pattern, such as one natural stone inlaid with the other natural stone, is obtained. Was given.

Example 4 A composition was prepared by performing the same operation as in Example 2. Further, instead of the pattern material in Example 2, a rod, chain and net made of stainless steel of a predetermined size were used as the pattern material.

Using the composition and pattern material prepared as described above, a resin molded product was produced by performing press molding and polishing in the same manner as in Example 1.

The obtained resin molded product had an appearance such that chains, nets, etc. were formed of stainless on the surface of natural stone. That is, by the above-described manufacturing method, an artificial stone as a resin molded product having a beautiful pattern and having a beautiful pattern, such as natural stone inlaid with stainless steel, was obtained. The bending strength of this artificial stone is 4.7kgf / mm ²
Met. Further, the bending strength of the resin molded product obtained by press molding only the above composition, that is, the resin molded product in which stainless steel was not embedded was 3.7 kgf / mm ² .

Example 5 A composition was prepared by performing the same operation as in Example 2. Further, instead of the pattern material in Example 2, a rod of a predetermined size made of teak which is wood, a colored glass ball (marble), a glass rod of a predetermined size, and the above composition are molded. Then, the processed product processed into a rod having a predetermined size was used as a pattern material.

Using the composition thus prepared and the pattern material, press molding and polishing were carried out in the same manner as in Example 1 to produce a resin molded product.

The obtained resin molded product had an appearance such that a complicated pattern was formed on the surface of a natural stone by the rod made of teak, the glass ball, the glass rod and the processed product. In other words, by the above manufacturing method, like inlaid natural stone with a plurality of pattern materials such as wood and glass,
An artificial stone was obtained as a resin molded product having a beautiful pattern and excellent design.

Example 6 A composition was prepared by performing the same operation as in Example 2. Further, the same operation as in Example 2 is carried out except that 550 parts of natural black granite dichotomite is used instead of 550 parts of natural tea granite dichotomite in Example 2 and that 2 parts of a thickener is not added. Thus, a kneaded product was obtained. Then, this kneaded product was preformed so as to have an appropriate figure or character shape, thereby obtaining a pattern material. The hardness of the composition and the hardness of the pattern material were almost equal.

Using the composition and the pattern material prepared as described above, a resin molding was produced by carrying out the press molding in the same manner as in Example 1.

The obtained resin molded product had an appearance such that a pattern of a figure or a character was formed with a vague contour on the surface by combining two kinds of natural stones. That is, the above-mentioned manufacturing method provided a resin molded product having a bleeding pattern and excellent in designability, which could not be formed by the conventional inlay.

Example 7 A composition was prepared by performing the same operation as in Example 2. Further, instead of the pattern material in Example 2, a cube and a cylinder made of stainless steel and having a height equal to the desired thickness of the resin molded product were used as the pattern material.

Using the composition and the pattern material prepared as described above, a resin molded product was manufactured by performing press molding and polishing in the same manner as in Example 1.

The obtained resin molded product had an appearance such that a square or circular pattern was formed of stainless steel on the surface and the back surface of a natural stone tone. That is, by the above-described manufacturing method, an artificial stone as a resin molded product having a beautiful pattern and having a beautiful pattern, such as a surface of a natural stone inlaid with stainless steel, was obtained.

Example 8 First, copolymerized polymer beads as a raw material of the composition were synthesized. That is, a partially saponified polyvinyl alcohol (manufactured by Nippon Synthetic Chemical Industry Co., Ltd .; trade name Gohsenol GH-20) is placed in a separable flask which is a reaction vessel equipped with a thermometer, a gas blowing tube, a reflux condenser and a stirrer. 2000 g of completely demineralized water dissolved to a concentration of 0.5% by weight was charged. on the other hand,
In a separate container, a mixture of 85 parts of styrene, 15 parts of 2-hydroxypropyl methacrylate, 1 part of benzoyl peroxide as a polymerization initiator, and 0.1 part of n-dodecyl mercaptan as a chain transfer agent was prepared.

Next, while stirring the above aqueous solution under a nitrogen gas atmosphere, the aqueous solution was heated to 80 ° C., and then 1000 g of the above mixture was added to the aqueous solution. Then, after about 4 hours, the reaction solution started to generate heat, so the flask was cooled,
The temperature of the reaction was maintained below 85 ° C. Then, after the above exotherm was completed, the reaction solution was heated to 90 ° C. and stirred for about 1 hour. Then, the flask was cooled to room temperature to terminate the reaction.

After the reaction was completed, the above reaction solution was suction-filtered using a nylon gauze having a mesh size of 60 μm to obtain a granular polymer. Then, the obtained polymer was washed with completely demineralized water and then dried at 60 ° C. in a vacuum dryer. As a result, copolymerized polymer beads were obtained.

A composition was prepared using the copolymerized polymer beads. That is, 50 parts of the copolymerized polymer beads as a curable resin, 5 parts of maleic anhydride, 15 parts of trimethylolpropane trimethacrylate, and 40 parts of styrene are added to a filler of fine powder aluminum hydroxide (Showa Denko K.K. Company name; product name Heidilite H-32
0) 300 parts and tempered glass fiber (Nippon Electric Glass Co., Ltd .; trade name Chopped Strand ECSO6B-14)
4 / P) 30 parts, and a curing agent (manufactured by Kayaku Akzo Co., Ltd .; trade name Kayacarbon BIC-75) 1
Part, a coupling agent (manufactured by Shin-Etsu Chemical Co., Ltd .; trade name KBM-503), and 2 parts of zinc stearate as an internal mold release agent were added. Also, in this mixture,
A polymerization inhibitor was added so that the concentration would be 100 ppm.

Then, a compound was obtained by kneading this mixture with a kneader. Furthermore, after aging this compound at 40 ° C. for 24 hours, the compound was
550 parts of natural white granite halves were added. By kneading this mixture with a kneader, BMC, that is,
A composition was obtained.

A cube and a cylinder made of stainless steel having a height equal to the desired thickness of the resin molded product were used as the pattern material.

Using the composition thus prepared and the pattern material, press molding and polishing were carried out in the same manner as in Example 1 to produce a resin molded product.

The obtained resin molded product had an appearance such that a square or circular pattern was formed of stainless on the front and back surfaces of natural stone. That is, by the above-described manufacturing method, an artificial stone as a resin molded product having a beautiful pattern and having a beautiful pattern, such as a surface of a natural stone inlaid with stainless steel, was obtained.

Comparative Example 1 A composition and a pattern material were prepared by performing the same operation as in Example 3. Then, a resin molded product for comparison was manufactured using these compositions and pattern materials. First, the lower mold attached to the press was heated to 130 ° C, and the upper mold was heated to 135 ° C. Next, after placing the pattern material at a desired position on the lower mold, a predetermined amount of the composition was charged on the pattern material. afterwards,
The upper mold was lowered, and the mold clamping operation was performed at a press pressure of 85 kgf / cm ² . Then, in this state, the composition was cured by press molding for 10 minutes. Thereafter, the upper mold was lifted to open the mold, and a cured resin composition for comparison was taken out. Then, the surface of the obtained comparative resin molded product, that is, the surface having the pattern was polished using a wet polishing machine.

In the obtained comparative resin molded product, the pattern material was crushed as the pattern material moved due to pressure.
The patterns were unevenly distributed and unclear. That is, the desired pattern was not formed on the comparative resin molded product.

As is clear from the results of Examples 1 to 8 and Comparative Example 1 described above, by the manufacturing method according to the present invention, a resin molded article having a desired pattern such as an inlaid pattern and having an excellent design property is simple. And it turns out that it can be easily obtained.

[0077]

EFFECTS OF THE INVENTION According to the above method, a resin molded product is obtained by placing a composition containing a curable resin in a mold, pressing and spreading the composition, and then opening the mold, before curing the curable resin. It is manufactured by disposing a pattern material to be patterned on the composition and pressing again.

Thus, it is possible to mass-produce inexpensively a resin molded product having a desired pattern such as an inlaid pattern, without being restricted by the size and mechanical strength of the pattern material to be the pattern. Produce an effect. Further, by appropriately selecting the composition and the pattern material,
It is possible to easily and easily obtain a resin molded product having an excellent design property, for example, a resin molded product such as an artificial stone having an inlaid pattern and having a ground pattern of granite or marble.

Further, according to the above method, a resin molded product having a pattern having a clear (so-called clear) contour, that is, a so-called sharp pattern is produced by using a pattern material harder than the composition. There is an effect that can be.

Further, according to the above constitution, it is possible to obtain a resin molded product having a beautiful pattern and a beautiful design, such as a molded product inlaid with glass and / or wood. .

[Brief description of the drawings]

FIG. 1 is an explanatory view illustrating steps of a method for producing a resin molded product in one embodiment of the present invention, (a) shows a state where a mold is charged with the composition, and (b) shows a composition. After the object is spread, the mold is opened, (c) shows the pattern material placed on the spread composition, and (d).
Shows a state where the mold is clamped, and (e) shows a state where the mold is opened.

FIG. 2 is a schematic perspective view showing an example of a resin molded product obtained by the above manufacturing method.

FIG. 3 is a schematic perspective view showing the resin molded product.

[Explanation of symbols]

 1 Composition 2 Pattern Material 3 Resin Molded Product 10 Lower Mold (Mold) 11 Upper Mold (Mold)

──────────────────────────────────────────────────続 き Continued on the front page (51) Int.Cl. ⁶ Identification code Agency reference number FI Technical display location B29K 105: 16

Claims (3)

[Claims] 1. A composition containing a curable resin is placed in a mold, pressurized and spread, and then the mold is opened to form a pattern material on the composition before the curable resin is cured. A method for producing a resin molded product having a pattern, which comprises arranging and pressing again. 2. The method for producing a resin molded product having a pattern according to claim 1, wherein the pattern material is harder than the composition. 3. A resin molded product having a pattern material to be patterned on a molded product containing a curable resin, wherein the pattern material is glass and / or wood. Stuff.