JP3461713B2 - Manufacturing method of patterned panel - Google Patents
Manufacturing method of patterned panelInfo
- Publication number
- JP3461713B2 JP3461713B2 JP05334898A JP5334898A JP3461713B2 JP 3461713 B2 JP3461713 B2 JP 3461713B2 JP 05334898 A JP05334898 A JP 05334898A JP 5334898 A JP5334898 A JP 5334898A JP 3461713 B2 JP3461713 B2 JP 3461713B2
- Authority
- JP
- Japan
- Prior art keywords
- resin
- layer
- surface resin
- mold
- pattern
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Expired - Fee Related
Links
Landscapes
- Laminated Bodies (AREA)
- Moulding By Coating Moulds (AREA)
Description
【0001】[0001]
【発明の属する技術分野】本発明は、高級バスユニット
等の設備ユニットの壁パネル等に用いられる模様入りパ
ネルの製造法に関するものである。BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a patterned pad used for wall panels of equipment units such as high-end bus units.
It relates to the manufacturing method of flannel .
【0002】[0002]
【従来の技術】従来の高級バスユニットの壁材として
は、タイル貼付壁や天然石貼付壁等があり、これらは基
板にタイルや板状天然石を貼り付けて製造されている。
しかし、これらは、重く、割れやすく、目地部分が汚れ
やすく、高価である等の理由から、近年、これに代わる
ものとして、繊維強化プラスチック(FRP)成形品に
絵付を施して、商品価値を向上させた模様入り壁材が開
発されている。製造法の多くは、インキで模様付けした
転写フィルムを用いて、ベースフィルム上の表面樹脂に
転写フィルムの模様を転写する方法が採用されている。
転写フィルムを用いて模様入り壁材を製造する方法とし
ては、図2に示すような工程からなる方法が知られてい
る(特開平2−223449号公報等)。2. Description of the Related Art As a wall material for a conventional high-class bus unit, there is a wall to which tiles are attached, a wall to which natural stones are attached, and these are manufactured by attaching tiles or plate-like natural stones to a substrate.
However, these are heavy, fragile, easy to stain the joints, and expensive, and in recent years, as an alternative to them, fiber reinforced plastic (FRP) molded products are painted to improve the commercial value. A wall material with a patterned pattern is being developed. Most of the manufacturing methods employ a method of transferring the pattern of the transfer film to the surface resin on the base film using a transfer film patterned with ink.
As a method for producing a patterned wall material using a transfer film, a method including steps shown in FIG. 2 is known (Japanese Patent Laid-Open No. 2-223449, etc.).
【0003】すなわち、
(1)離型剤102を塗布した型101表面の一端部
に、透明又は半透明の未硬化の表面樹脂103を塊状に
載置する工程。
(2)ベースフィルム104の片面に表面樹脂に可溶な
インキで模様付けした転写フィルム107の模様付け面
の端部側を塊状の表面樹脂103に押しつけ、次いで、
転写フィルム107をローラ108により型表面の一端
部側から押圧して塊状の表面樹脂103を均一に延伸す
ると同時に表面樹脂上に重ね合わせる工程。
(3)延伸した表面樹脂103を硬化させた後、ベース
フィルム104を剥離して上記表面樹脂上に模様106
を転写する工程。
(4)模様106を転写した表面樹脂103上に、透明
樹脂層105を積層させる工程。
(5)透明樹脂層が硬化後、有色不透明樹脂109を積
層させる工程。
(6)有色不透明樹脂109が硬化後、その上に、充填
材、強化材及び低収縮材を含有する樹脂補強層(A)1
10を積層させる工程。
(7)前記樹脂補強層(A)110が硬化後、その上
に、ガラス繊維を含有する樹脂補強層(B)111を積
層硬化させる工程。上記方法により得られる模様入り壁
材は、軽く、模様が鮮明で立体感があり、より安価に製
造できる。That is, (1) a step of placing uncured transparent or translucent uncured surface resin 103 in a lump form on one end of the surface of the mold 101 coated with the release agent 102. (2) The end portion side of the patterning surface of the transfer film 107, which is patterned on one surface of the base film 104 with the ink soluble in the surface resin, is pressed against the massive surface resin 103, and then,
A step of pressing the transfer film 107 from one end side of the mold surface by the roller 108 to uniformly stretch the lumpy surface resin 103 and at the same time superposing it on the surface resin. (3) After the stretched surface resin 103 is cured, the base film 104 is peeled off and the pattern 106 is formed on the surface resin.
Process of transferring. (4) A step of laminating the transparent resin layer 105 on the surface resin 103 on which the pattern 106 is transferred. (5) A step of laminating the colored opaque resin 109 after the transparent resin layer is cured. (6) After the colored opaque resin 109 is cured, a resin reinforcing layer (A) 1 containing a filler, a reinforcing material, and a low shrinkage material thereon.
A step of stacking 10. (7) A step of, after the resin reinforcing layer (A) 110 is cured, laminating and curing a resin reinforcing layer (B) 111 containing glass fiber thereon. The patterned wall material obtained by the above method is light, has a clear pattern, has a three-dimensional effect, and can be manufactured at a lower cost.
【0004】[0004]
【発明が解決しようとする課題】しかし、上記方法は次
のような問題もある。模様入り壁材の表面(化粧面)の
樹脂層103とガラス繊維入り樹脂補強層(B)111
の熱線膨張係数の違いからか、模様入り壁材が反り変形
を起こしやすい。However, the above method also has the following problems. Resin layer 103 on the surface (decorative surface) of the patterned wall material and resin reinforcing layer (B) 111 containing glass fiber
Due to the difference in the coefficient of linear thermal expansion, the patterned wall material tends to warp and deform.
【0005】また、型表面の一端部に未硬化の表面樹脂
を塊状に載置する場合、必要な塗布量の表面樹脂を一箇
所(一端部)に一度に載置することになる。延伸を始め
るとローラの前方にある表面樹脂が延伸方向だけでなく
その直角方向にも移動し、この移動は表面樹脂の延伸と
共に型端部から型外へと逸脱し、(ローラが型表面の他
端部に到達する前に)表面樹脂が不足して欠陥部が発生
する。そのため、欠陥部の修正も必要となる。Further, when the uncured surface resin is placed in a lump form on one end of the mold surface, the required amount of the surface resin is placed at one location (one end) at a time. When the stretching is started, the surface resin in front of the roller moves not only in the stretching direction but also in the direction perpendicular to the stretching direction, and this movement deviates from the mold end part to the outside of the mold as the surface resin stretches. A shortage of surface resin (before reaching the other end) causes defects. Therefore, it is necessary to correct the defective portion.
【0006】本発明は、上記の従来方法の欠点に鑑みて
なされたものであり、壁材の反り変形が起こりにくく、
また、表面樹脂の材料歩留りの良い模様入り壁材の製造
法を提供することを目的とする。The present invention has been made in view of the above-mentioned drawbacks of the conventional method, and it is difficult for warping deformation of the wall material to occur.
Another object of the present invention is to provide a method for producing a patterned wall material having a good surface resin material yield.
【0007】[0007]
【課題を解決するための手段】本発明は、
(a)型表面に、未硬化の透明な表面樹脂を載置し、
(b)ベースフィルムの片面に前記表面樹脂に可溶のイ
ンキで模様付けした転写フィルムの模様付け面の端部を
型表面上の表面樹脂に押しつけながら、転写フィルムを
型表面の一端部側から他端部側へ押圧して表面樹脂を均
一に延伸すると共に表面樹脂上に重ね合わせ、
(c)延伸した表面樹脂を半硬化させ、ベースフィルム
を剥離して前記表面樹脂上に前記模様を転写し、
(d1)模様が転写された表面樹脂上に、ガラス繊維及
び樹脂を含有する中間層を形成させ、
(d2)前記中間層上に充填材、低収縮剤及び樹脂を含
有する混和物層を形成させ、
(d3)前記混和物層中の充填材の沈降を促進させ、
(d4)その後、前記混和物層上に、ガラス繊維及び樹
脂を含有するバック層を積層し、硬化させ、
(e)脱型する、ことを特徴とする模様入りパネルの製
造法である。According to the present invention, (a) an uncured transparent surface resin is placed on a mold surface, and (b) a pattern is formed on one surface of a base film with an ink soluble in the surface resin. While pressing the end of the patterned surface of the attached transfer film against the surface resin on the mold surface, the transfer film is pressed from one end side to the other end side of the mold surface to uniformly stretch the surface resin and the surface resin Overlaid on top, (c) the stretched surface resin is semi-cured, the base film is peeled off to transfer the pattern onto the surface resin, and (d1) the surface resin onto which the pattern has been transferred, glass fiber and Forming an intermediate layer containing a resin, (d2) forming an admixture layer containing a filler, a low-shrinking agent and a resin on the intermediate layer, and (d3) allowing sedimentation of the filler in the admixture layer. (D4) then on the admixture layer A laminated backing layer containing a glass fiber and a resin, and cured, and (e) demolding the patterned panel.
【0008】前記手順(d3)における充填材の沈降を
促進させる手段は、好ましくは、全体を揺動して行うも
のである。The means for promoting the sedimentation of the filler in the step (d3) is preferably performed by rocking the whole.
【0009】前記手順(b)における転写フィルムとし
ては、好ましくは、ベースフィルムの片面に表面樹脂に
可溶なインキの単色層とその単色層上に配された模様と
が形成されている転写フィルムを用いる。The transfer film in the step (b) is preferably a transfer film in which a single color layer of an ink soluble in a surface resin and a pattern arranged on the single color layer are formed on one surface of a base film. To use.
【0010】また、前記手順(a)における表面樹脂の
載置は、型表面の一端から他端に向かって帯状ジグザク
に配置することが好ましい。Further, the surface resin is preferably placed in the step (a) in a zigzag band shape from one end to the other end of the mold surface.
【0011】<作用>型表面の一端部から透明な未硬化
の表面樹脂を帯状ジグザグに載置しながら、型及び表面
樹脂上に転写フィルムを押しつけ、転写フィルムをロー
ラ等により一方向に押圧すると、延伸方向に直角な方向
の表面樹脂の移動が抑えられると共に、脱泡されながら
表面樹脂が均一に延伸される。したがって、材料の無駄
が少ない。転写フィルムとしてベースフィルムの片面に
単色インキ層と模様(インキ)とが形成された転写フィ
ルムを用いた場合の、模様が転写された表面樹脂上で
は、型の方から順に、表面樹脂層、模様(インキ)及び
単色インキ層が構成され、単色インキ層が隠蔽層の役割
を担う。そのため、本発明の製造法で製造された模様入
り壁材は、従来技術におけるような透明樹脂層105
(図2)や有色不透明樹脂層109(図2)を積層する
ことなく、模様の色相が再現される。<Operation> While the transparent uncured surface resin is placed on the belt-shaped zigzag from one end of the mold surface, the transfer film is pressed onto the mold and the surface resin, and the transfer film is pressed in one direction by a roller or the like. The movement of the surface resin in the direction perpendicular to the stretching direction is suppressed, and the surface resin is uniformly stretched while defoaming. Therefore, there is little waste of material. When a transfer film in which a single color ink layer and a pattern (ink) are formed on one surface of a base film is used as the transfer film, on the surface resin on which the pattern is transferred, the surface resin layer and the pattern are sequentially arranged from the mold side. An (ink) and a monochromatic ink layer are formed, and the monochromatic ink layer plays the role of a hiding layer. Therefore, the patterned wall material manufactured by the manufacturing method of the present invention has the transparent resin layer 105 as in the prior art.
The hue of the pattern is reproduced without laminating (FIG. 2) or the colored opaque resin layer 109 (FIG. 2).
【0012】また、中間層を積層した後に混和物層を積
層する際、混和物層が未硬化(液状)のうちに揺動等に
よって充填材の沈降を促進させる。これにより、混和物
層内の充填材が沈降分離し、樹脂含有率の低い層と樹脂
含有率の高い層が形成される。樹脂含有率の高い層は、
充填材が沈降分離した樹脂含有量の低い層をあいだに挟
んで表面樹脂層と均衡を保つため、熱線膨張係数の差に
より生じる成形物の反り変形を緩和することになる。In addition, when the mixture layer is laminated after the intermediate layer is laminated, the sedimentation of the filler is promoted by shaking or the like while the mixture layer is uncured (liquid state). This causes the filler in the mixture layer to settle and separate, forming a layer with a low resin content and a layer with a high resin content. The layer with high resin content is
Since the filler is sandwiched between layers having a low resin content separated by sedimentation to maintain balance with the surface resin layer, the warp deformation of the molded product caused by the difference in the coefficient of linear thermal expansion is reduced.
【0013】[0013]
【発明の実施の形態】以下に、発明の実施の形態を説明
する。図1は、本発明の模様入り壁材の製造の手順を示
す説明図である。離型剤2を塗布した型1表面の一端部
側から透明(本明細書では、半透明を含む意味で用い
る)な未硬化の表面樹脂3を帯状ジグザグ状に載置し
(手順a)、ベースフィルム4の片面に表面樹脂3に可
溶なインキで単色層5を形成した後にその上に模様6を
配した転写フィルム7の模様付け面の端部側を型1表面
上の表面樹脂3に押しつけ、転写フィルム7をローラ8
等の押圧・延伸手段で型1表面の一端部側から押圧して
表面樹脂3を均一に延伸すると共に表面樹脂3上に重ね
合わせる(手順b)。この際、型表面への表面樹脂の載
置(手順a)と、転写フィルムの表面樹脂上への重ね合
わせ(手順b)の作業を別々に行うこともできるが、好
ましくは、図1(b)に示すように同調させて行う。BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of the present invention will be described below. FIG. 1 is an explanatory view showing the procedure of manufacturing the patterned wall material of the present invention. An uncured surface resin 3 that is transparent (used in this specification to include translucence) is placed in a zigzag band shape from one end of the surface of the mold 1 coated with the release agent 2 (procedure a), The monochromatic layer 5 is formed on one surface of the base film 4 with an ink soluble in the surface resin 3 and then the pattern 6 is arranged on the surface of the transfer film 7. The transfer film 7 onto the roller 8
The surface resin 3 is uniformly stretched by pressing from one end side of the surface of the mold 1 by a pressing / stretching means such as the above and is superposed on the surface resin 3 (procedure b). At this time, the work of placing the surface resin on the mold surface (procedure a) and the superposition of the transfer film on the surface resin (procedure b) can be carried out separately, but preferably, as shown in FIG. ) Synchronize as shown in ().
【0014】次に、延伸した表面樹脂3を半硬化させ
る。半硬化させる方法は、樹脂の種類等によって異なる
が、加熱や紫外線照射等である。その後、ベースフィル
ム4を剥離して上記表面樹脂3上に単色インキ層5と模
様(インキ)6を転写させる(手順c)。Next, the stretched surface resin 3 is semi-cured. The method of semi-curing varies depending on the type of resin and the like, but is heating, irradiation of ultraviolet rays, or the like. Then, the base film 4 is peeled off and the single color ink layer 5 and the pattern (ink) 6 are transferred onto the surface resin 3 (procedure c).
【0015】単色インキ層5と模様6を転写した表面樹
脂3上に、ガラス繊維及び樹脂を含有する中間層9を形
成させ(手順d1)、中間層9が液状から固体状化(ゲ
ル化)した状態で、その上に充填材、低収縮剤及び樹脂
を含有する混和物層10を形成させ(手順d2)、前記
混和物層10が未硬化(液状)の状態のうちに、充填材
の沈降を促進させる(手順d3)。充填材の沈降を促進
させる手段としては、好ましくは、揺動や振動を与える
ことであり、揺動や振動を与える条件は混和物層の組成
や成形物(壁材)の大きさ等によって変動するので、適
宜、最適な条件を定める。充填材を沈降させた後、その
混和物層10の上に、ガラス繊維及び樹脂を含有するバ
ック層11を積層し、硬化させる(手順d4)。このと
きの硬化の条件は、樹脂が完全に硬化する条件で行う。
完全に硬化させる方法は、樹脂の種類等によって異なる
が、加熱や紫外線照射等である。最後に、脱型して目的
の模様入り壁材が得られる(手順e)。An intermediate layer 9 containing glass fibers and a resin is formed on the surface resin 3 on which the monochrome ink layer 5 and the pattern 6 have been transferred (procedure d1), and the intermediate layer 9 is changed from a liquid state to a solid state (gelation). In this state, the admixture layer 10 containing the filler, the low-shrinking agent and the resin is formed thereon (procedure d2), and while the admixture layer 10 is in an uncured (liquid) state, Accelerate sedimentation (procedure d3). The means for accelerating the sedimentation of the filler is preferably to give shaking or vibration, and the conditions for giving the shaking or vibration vary depending on the composition of the admixture layer and the size of the molded product (wall material). Therefore, the optimum conditions are appropriately determined. After the filler is settled, the back layer 11 containing the glass fiber and the resin is laminated on the mixture layer 10 and cured (procedure d4). The curing conditions at this time are such that the resin is completely cured.
The method of completely curing it depends on the type of resin and the like, but it is heating, irradiation with ultraviolet rays, or the like. Finally, demolding is performed to obtain the desired patterned wall material (procedure e).
【0016】本発明で使用される表面樹脂は特に制限す
るものではないが、不飽和ポリエステル樹脂、アクリル
樹脂、エポキシ樹脂等の透明な熱硬化性樹脂が好まし
い。これに硬化剤、充填材、顔料等を適宜、混合しても
よい。透明樹脂層の厚さは、好ましくは100〜300
μmの範囲とする。The surface resin used in the present invention is not particularly limited, but a transparent thermosetting resin such as unsaturated polyester resin, acrylic resin or epoxy resin is preferable. A curing agent, a filler, a pigment and the like may be appropriately mixed therewith. The thickness of the transparent resin layer is preferably 100 to 300.
The range is μm.
【0017】型は模様入り壁材に合わせた形状の型を用
いる。通常は表面が滑らかな平板状の型である。型の表
面には、成形物(模様入り壁材)の剥離を容易にするた
めに好ましくは離型剤を用いる。離型剤には、ポリビニ
ルアルコールを主成分とするフィルム形やワックス等が
あり、特に制限するものではない。As the mold, a mold having a shape adapted to the patterned wall material is used. Usually, it is a flat plate type with a smooth surface. A mold release agent is preferably used on the surface of the mold in order to facilitate peeling of the molded product (patterned wall material). The release agent includes a film type containing polyvinyl alcohol as a main component, wax, and the like, and is not particularly limited.
【0018】転写フィルムを構成するベースフィルムと
しては、耐熱性、剥離性を有し、かつ表面樹脂に不溶で
あれば特に制限はない。ポリエチレン、ポリプロピレ
ン、ナイロン、ポリエステル、フッ素系フィルム等のプ
ラスチックフィルム、アルミ箔等の金属箔を単体又は他
のフィルムと貼り合わせたもの、紙又はプラスチックフ
ィルムの表面に離型性のある樹脂を塗布したもの等が使
用できる。ここで、フィルムの厚さは、表面樹脂を均一
に延伸するために10μm〜100μm程度であること
が好ましい。The base film constituting the transfer film is not particularly limited as long as it has heat resistance and peelability and is insoluble in the surface resin. Plastic film such as polyethylene, polypropylene, nylon, polyester, fluorine film, metal foil such as aluminum foil alone or laminated with other film, paper or plastic film coated with releasable resin Things etc. can be used. Here, the thickness of the film is preferably about 10 μm to 100 μm in order to uniformly stretch the surface resin.
【0019】単色インキ層及び模様に使用するインキ
は、表面樹脂に可溶であるものから選ぶ。不飽和ポリエ
ステル樹脂、アクリル樹脂、エポキシ樹脂、硝化綿(ニ
トロセルロース)系樹脂等に顔料又は染料を混合したも
の等が好ましい。模様は、木目、石調、抽象柄等いずれ
でもよく、特に制限するものではない。The ink used for the monochrome ink layer and the pattern is selected from those soluble in the surface resin. An unsaturated polyester resin, an acrylic resin, an epoxy resin, a nitrified cotton (nitrocellulose) resin, or the like mixed with a pigment or a dye is preferable. The pattern may be any of wood grain, stone tone, abstract pattern, etc., and is not particularly limited.
【0020】転写フィルムを押圧する方法は、表面樹脂
を型全面にわたって均一に延伸できればよく、特に制限
はない。例えば、ローラ等が用いられる。表面樹脂の厚
みは、好ましくは100μm〜300μmで延伸され
る。The method of pressing the transfer film is not particularly limited as long as the surface resin can be uniformly stretched over the entire surface of the mold. For example, a roller or the like is used. The thickness of the surface resin is preferably 100 μm to 300 μm.
【0021】ガラス繊維及び樹脂を含有する中間層に使
用する樹脂も特に制限するものではないが、不飽和ポリ
エステル樹脂、アクリル樹脂、エポキシ樹脂等の熱硬化
性樹脂に硬化剤等を適宜、混合したものが好ましい。こ
の中間層には、後述の混和物層に使用される充填材と同
様の充填材(層の弾性率の向上、成形品の表面平滑性の
向上、増量等の目的)や顔料等を適宜、混合することが
できる。用いるガラス繊維としては、ガラスマット、ガ
ラスクロス、ガラスペーパー等がある。The resin used for the intermediate layer containing the glass fiber and the resin is not particularly limited, but a thermosetting resin such as an unsaturated polyester resin, an acrylic resin or an epoxy resin is mixed with a curing agent or the like as appropriate. Those are preferable. In this intermediate layer, a filler similar to the filler used for the later-described admixture layer (improvement of elastic modulus of the layer, improvement of surface smoothness of the molded product, purpose of increasing amount, etc.), pigment or the like is appropriately added. Can be mixed. Examples of the glass fiber used include glass mat, glass cloth, glass paper and the like.
【0022】混和物層及びバック層に使用される樹脂も
特に制限するものではないが、不飽和ポリエステル樹
脂、アクリル樹脂、エポキシ樹脂等の熱硬化性樹脂に硬
化剤を適宜、混合したものが好ましい。The resin used in the admixture layer and the back layer is not particularly limited, but a resin obtained by appropriately mixing a thermosetting resin such as an unsaturated polyester resin, an acrylic resin or an epoxy resin with a curing agent is preferable. .
【0023】混和物層に使用される充填材としては、水
酸化アルミニウム、炭酸カルシウム、硫酸カルシウム、
ガラス粉末、プラスチック粉末、結晶性シリカ粉末、溶
融シリカ粉末、硫酸バリウム、珪酸マグネシウム(タル
ク)、クレー、カオリン、酸化マグネシウム、又は珪藻
土がある。充填材の使用量は、樹脂100重量部に対し
て通常50〜700重量部である。As the filler used in the mixture layer, aluminum hydroxide, calcium carbonate, calcium sulfate,
Glass powder, plastic powder, crystalline silica powder, fused silica powder, barium sulfate, magnesium silicate (talc), clay, kaolin, magnesium oxide, or diatom
There is soil . The amount of the filler used is usually 50 to 700 parts by weight with respect to 100 parts by weight of the resin.
【0024】混和物層に強化材を使用する場合、その強
化材としては、ガラス短繊維、炭素短繊維、ビニロン短
繊維、ナイロン短繊維等があり、繊維の長さは1〜50
mmが好ましい。強化材の使用量は、樹脂100重量部
に対して通常1〜10重量部である。When a reinforcing material is used in the mixture layer, the reinforcing material includes glass short fibers, carbon short fibers, vinylon short fibers, nylon short fibers, etc., and the fiber length is 1 ~ 50
mm is preferred. The amount of the reinforcing material used is usually 1 to 10 parts by weight with respect to 100 parts by weight of the resin.
【0025】混和物層に使用される低収縮剤としては、
ポリスチレン、ポリ酢酸ビニル、ポリアクリレート、ポ
リエチレンテレフタレート、スチレン−酢酸ビニルブロ
ック共重合体、又はスチレン−メタクリル酸メチルブロ
ック共重合体がある。低収縮剤の使用量は、樹脂100
重量部に対して通常10〜40重量部である。混和物層
の厚さは通常3〜10mmの範囲とする。バック層に使
用するガラス繊維としては、先と同様、ガラスマット、
ガラスクロス、ガラスペーパー等がある。透明な表面樹
脂層に、中間層、混和物層及びバック層を積層する方法
は、樹脂溶液の塗布、流し込み法、ハンドレイアップ法
等の公知の方法で行うことができる。As the low-shrinking agent used in the admixture layer,
Polystyrene, polyvinyl acetate, polyacrylate, polyethylene terephthalate, styrene-vinyl acetate block copolymer, or styrene-methyl methacrylate block
Block copolymers . The amount of low shrinkage agent used is 100
It is usually 10 to 40 parts by weight with respect to parts by weight. The thickness of the admixture layer is usually in the range of 3 to 10 mm. As the glass fiber used for the back layer , a glass mat,
There are glass cloth, glass paper, etc. The intermediate layer, the admixture layer and the back layer may be laminated on the transparent surface resin layer by a known method such as application of a resin solution, pouring method or hand layup method.
【0026】[0026]
【実施例】実施例1
図1に示した手順で、模様入り壁材を作製した。
手順a:型の表面上に、予め離型剤をスプレーガンで均
一に塗布した。用いた表面樹脂の組成は、次の通り。不
飽和ポリエステル樹脂(日立化成工業株式会社製、商品
名PS−3717):100重量部、スチレンモノマ
ー:10重量部、メチルエチルケトンパーオキサイド
(日本油脂株式会社製、商品名パーメックN):1重量
部、ナフテン酸コバルト: 0.5重量部。なお、型へ
の離型剤の塗布は、成形5回ごとに行った。EXAMPLES Example 1 A patterned wall material was produced by the procedure shown in FIG. Procedure a: A mold release agent was previously applied uniformly on the surface of the mold with a spray gun. The composition of the surface resin used is as follows. Unsaturated polyester resin (manufactured by Hitachi Chemical Co., Ltd., trade name PS-3717): 100 parts by weight, styrene monomer: 10 parts by weight, methyl ethyl ketone peroxide (manufactured by NOF Corporation, trade name Permek N): 1 part by weight, Cobalt naphthenate: 0.5 part by weight. The mold release agent was applied to the mold every 5 moldings.
【0027】手順b:ベースフィルム(ポリエステルフ
ィルム;厚み50μm)の片面に、硝化綿(ニトロセル
ロース)系樹脂に顔料及び染料を混合したインキで単色
インキ層と模様インキ層を形成させた転写フィルムの模
様付け面の端部側を帯状ジグザグの表面樹脂に押付け、
転写フィルムをローラにより型表面の一端部側から押圧
して表面樹脂を200μm厚さ程度に均一に延伸すると
共に表面樹脂上に重ね合わせた。なお、表面樹脂3は延
伸と同時に、ローラ8で押圧する延伸方向前方に載置す
る。
手順c:延伸した表面樹脂を、温風炉(70℃)中で3
0分間処理して半硬化させた後、ベースフィルムを剥離
し、模様(インキ)及び単色インキ層を表面樹脂上に転
写した。Step b: A transfer film in which a single color ink layer and a pattern ink layer are formed on one surface of a base film (polyester film; thickness 50 μm) with an ink prepared by mixing pigment and dye in a nitrified cotton (nitrocellulose) resin. Press the end side of the patterning surface against the surface resin of the band zigzag,
The transfer film was pressed by a roller from one end side of the mold surface to uniformly stretch the surface resin to a thickness of about 200 μm, and was superposed on the surface resin. At the same time as the stretching, the surface resin 3 is placed in front of the stretching direction in which the roller 8 presses. Step c: The stretched surface resin is placed in a warm air oven (70 ° C.) for 3
After treating for 0 minutes and semi-curing, the base film was peeled off, and the pattern (ink) and the monochrome ink layer were transferred onto the surface resin.
【0028】手順d1:模様及び単色インキ層が転写さ
れた表面樹脂に、ガラス繊維及び樹脂を含有する中間層
を積層させた。上記中間層の成分・組成は、ガラス繊維
チョップドストランドマット:230g/m2、有色不
飽和ポリエステル樹脂(東京インキ株式会社製、商品名
カラードレジン):100重量部、スチレンモノマー:
10重量部、メチルエチルケトンパーオキシド(日本油
脂株式会社製、商品名パーメックN):1重量部、ナフ
テン酸コバルト:0.5重量部。Step d1: An intermediate layer containing glass fiber and resin was laminated on the surface resin on which the pattern and the monochrome ink layer were transferred. The components and composition of the intermediate layer are as follows: glass fiber chopped strand mat: 230 g / m 2 , colored unsaturated polyester resin (manufactured by Tokyo Ink Co., Ltd., trade name Color Dresin): 100 parts by weight, styrene monomer:
10 parts by weight, methyl ethyl ketone peroxide (manufactured by NOF CORPORATION, trade name Permec N): 1 part by weight, cobalt naphthenate: 0.5 part by weight.
【0029】手順d2:
上記中間層上に、混和物層を積層し、未硬化(液状)の
うちに、系全体を、1分間揺動させた。揺動の条件:水
平方向に1往復/秒で60秒間、ストローク長さ100
mm。なお、混和物層の成分・組成は、不飽和ポリエス
テル樹脂(日立化成工業株式会社製、商品名PS−51
81PT):100重量部、低収縮剤のスチレン−酢酸
ビニルブロック共重合体(日本油脂株式会社製、商品名
モディパーSV30):15重量部、炭酸カルシウム粗
粒(日東粉化工業株式会社製、商品名寒水石#40):
300重量部、炭酸カルシウム細粒(日東粉化工業株式
会社製、商品名炭カルTS−70):200重量部、メ
チルエチルケトンパーオキシド(日本油脂株式会社製、
商品名パーメックN):4重量部、ナフテン酸コバルト
2重量部。Step d2: The mixture layer was laminated on the above intermediate layer, and the whole system was shaken for 1 minute while it was uncured (liquid state). Oscillation conditions: 1 reciprocation / sec in the horizontal direction for 60 seconds, stroke length 100
mm. The components and composition of the mixture layer are unsaturated polyester resin (Hitachi Chemical Co., Ltd., trade name PS-51
81PT): 100 parts by weight , styrene-acetic acid as a low-shrinking agent
Vinyl block copolymer (manufactured by NOF CORPORATION, trade name: Modiper SV30): 15 parts by weight, calcium carbonate coarse particles (manufactured by Nitto Koka Kogyo Co., Ltd., trade name Kansui stone # 40):
300 parts by weight, calcium carbonate fine particles (manufactured by Nitto Koka Kogyo Co., Ltd., product name Cal TS-70): 200 parts by weight, methyl ethyl ketone peroxide (manufactured by NOF Corporation,
Product name Permek N): 4 parts by weight, cobalt naphthenate 2 parts by weight.
【0030】手順d3:充填材を沈降分離させた上記混
和物層の上にガラス繊維及び樹脂を含有するバック層を
積層した。バック層の成分・組成は、ガラス繊維チョッ
プドストランドマット:230g/m2、不飽和ポリエ
ステル樹脂(日立化成工業株式会社製、商品名PS−5
182APT):100重量部、スチレンモノマー:1
0重量部、メチルエチルケトンパーオキシド(日本油脂
株式会社製、商品名パーメックN):1重量部、ナフテ
ン酸コバルト:0.5重量部。ついで、温風炉(70
℃)中で40分間処理し、樹脂を完全硬化させた。
手順d4:脱型し成形品(模様入り壁材)を得た。Step d3: A back layer containing a glass fiber and a resin was laminated on the mixture layer obtained by separating the filler by sedimentation. Components and composition of the back layer are glass fiber chopped strand mat: 230 g / m 2 , unsaturated polyester resin (Hitachi Chemical Co., Ltd., trade name PS-5
182APT): 100 parts by weight, styrene monomer: 1
0 parts by weight, methyl ethyl ketone peroxide (manufactured by NOF CORPORATION, trade name Permec N): 1 part by weight, cobalt naphthenate: 0.5 parts by weight. Then, the hot air oven (70
(° C) for 40 minutes to completely cure the resin. Step d4: Mold release was performed to obtain a molded product (patterned wall material).
【0031】[0031]
【発明の効果】本発明の製造法により得られる模様入り
壁材は、反り変形が起こりにくい。また、鮮明で、立体
感があり、高級感もある。本発明の製造法では、表面樹
脂に模様(インキ)に加え単色インキ層を転写させると
単色インキ層が隠蔽層の役割を担うので、従来のように
透明樹脂層や有色不透明樹脂層を積層することなく表面
模様の色相を再現できる。それゆえ、従来よりも積層工
程が少ない。また、押圧、延伸時に表面樹脂が枠外に逸
脱せず、修正する必要も少ない。INDUSTRIAL APPLICABILITY The patterned wall material obtained by the manufacturing method of the present invention is less likely to warp. In addition, it is clear, has a three-dimensional appearance, and has a luxurious feel. In the production method of the present invention, when a monochromatic ink layer is transferred to the surface resin in addition to the pattern (ink), the monochromatic ink layer plays a role of a masking layer, so that a transparent resin layer or a colored opaque resin layer is laminated as in the conventional case. The hue of the surface pattern can be reproduced without any. Therefore, the number of stacking steps is smaller than in the past. Further, the surface resin does not move out of the frame during pressing and stretching, and it is not necessary to correct it.
【図1】本発明の模様入り壁材の製造法の一実施例を示
す工程説明図である。FIG. 1 is a process explanatory view showing an example of a method for producing a patterned wall material of the present invention.
【図2】従来の模様入り壁材の製造法を示す工程説明図
である。FIG. 2 is a process explanatory view showing a conventional method for producing a patterned wall material.
1.型 2.離型剤
3.表面樹脂 4.ベースフィル
ム
5.単色インキ層 6.模様(イン
キ)
7.転写フィルム 8.ローラ
9.ガラス繊維及び樹脂を含有する中間層
10.充填材、低収縮剤及び樹脂を含有する混和物層
11.ガラス繊維及び樹脂を含有するバック層
12.充填材量が高い層(樹脂含有量の低い層)
13.充填材量が低い層(樹脂含有量の高い層)
101.型 102.離型剤
103.表面樹脂 104.ベースフィ
ルム
105.透明樹脂層 106.模様(イン
キ)
107.転写フィルム
108.ローラ 109.有色不透明
樹脂層
110.樹脂補強層A 111.樹脂補強層
B1. Type 2. Release agent 3. Surface resin 4. Base film 5. Monochromatic ink layer 6. Pattern (ink) 7. Transfer film 8. Laura 9. Intermediate layer containing glass fiber and resin 10. Admixture layer containing filler, low shrinkage agent and resin 11. Back layer containing glass fiber and resin 12. 13. Layer with high filler content (layer with low resin content) 13. Layer with low filler amount (layer with high resin content) 101. Mold 102. Release agent 103. Surface resin 104. Base film 105. Transparent resin layer 106. Pattern (ink) 107. Transfer film 108. Laura 109. Colored opaque resin layer 110. Resin reinforcement layer A 111. Resin reinforcement layer B
───────────────────────────────────────────────────── フロントページの続き (72)発明者 笠木 久義 富山県富山市一本木1010番地 日立化成 ユニット株式会社内 (56)参考文献 特開 平5−318469(JP,A) 特開 昭62−97833(JP,A) (58)調査した分野(Int.Cl.7,DB名) B32B 1/00 - 35/00 B29C 41/00 - 41/52 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Hisagi Kasagi, 1010 Ippongi, Toyama City, Toyama Prefecture, Hitachi Chemical Unit Co., Ltd. (56) Reference JP-A-5-318469 (JP, A) JP-A-62-97833 ( (58) Fields surveyed (Int.Cl. 7 , DB name) B32B 1/00-35/00 B29C 41/00-41/52
Claims (4)
を載置し、 (b)ベースフィルムの片面に前記表面樹脂に可溶のイ
ンキで模様付けした転写フィルムの模様付け面の端部を
型表面上の表面樹脂に押しつけながら、転写フィルムを
型表面の一端部側から他端部側へ押圧して表面樹脂を均
一に延伸すると共に表面樹脂上に重ね合わせ、(c)延
伸した表面樹脂を半硬化させ、ベースフィルムを剥離し
て前記表面樹脂上に前記模様を転写し、 (d1)模様が転写された表面樹脂上に、ガラス繊維及
び樹脂を含有する中間層を形成させ、 (d2)前記中間層上に充填材、低収縮剤及び樹脂を含
有する混和物層を形成させ、 (d3)前記混和物層中の充填材の沈降を促進させ、 (d4)その後、前記混和物層上に、ガラス繊維及び樹
脂を含有するバック層を積層し、硬化させ、 (e)脱型する、ことを特徴とする模様入りパネルの製
造法。1. A patterning surface of a transfer film, comprising: (a) an uncured transparent surface resin placed on a mold surface, and (b) one surface of a base film patterned with an ink soluble in the surface resin. While pressing the end part of the mold against the surface resin on the mold surface, the transfer film is pressed from one end side to the other end side of the mold surface to uniformly stretch the surface resin and superimpose it on the surface resin (c). The stretched surface resin is semi-cured, the base film is peeled off, and the pattern is transferred onto the surface resin. (D1) An intermediate layer containing glass fiber and resin is formed on the surface resin onto which the pattern is transferred. And (d2) forming an admixture layer containing a filler, a low-shrinking agent and a resin on the intermediate layer, (d3) promoting the sedimentation of the filler in the admixture layer, (d4) Contains glass fiber and resin on the mixture layer That the back layer are laminated, cured, (e) demolding method for producing a patterned containing panel, characterized in that.
させる手段が全体を揺動させるものである、請求項1の
製造法。2. The production method according to claim 1, wherein the means for promoting the sedimentation of the filler in step (d3) is to rock the whole.
スフィルムの片面に表面樹脂に可溶なインキの単色層と
その単色層上に配された模様とが形成されている転写フ
ィルムであることを特徴とする、請求項1又は2の製造
法。3. The transfer film in step (b) is a transfer film having a monochromatic layer of ink soluble in a surface resin and a pattern arranged on the monochromatic layer formed on one surface of a base film. The manufacturing method according to claim 1 or 2, characterized in that.
表面の一端から他端に向かって帯状ジグザクに配置する
ことを特徴とする、請求項1〜3のいずれかの製造法。4. The method according to any one of claims 1 to 3, characterized in that the surface resin is placed in step (a) in a band-shaped zigzag from one end to the other end of the mold surface.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP05334898A JP3461713B2 (en) | 1998-03-05 | 1998-03-05 | Manufacturing method of patterned panel |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
JP05334898A JP3461713B2 (en) | 1998-03-05 | 1998-03-05 | Manufacturing method of patterned panel |
Publications (2)
Publication Number | Publication Date |
---|---|
JPH11245361A JPH11245361A (en) | 1999-09-14 |
JP3461713B2 true JP3461713B2 (en) | 2003-10-27 |
Family
ID=12940280
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
JP05334898A Expired - Fee Related JP3461713B2 (en) | 1998-03-05 | 1998-03-05 | Manufacturing method of patterned panel |
Country Status (1)
Country | Link |
---|---|
JP (1) | JP3461713B2 (en) |
-
1998
- 1998-03-05 JP JP05334898A patent/JP3461713B2/en not_active Expired - Fee Related
Also Published As
Publication number | Publication date |
---|---|
JPH11245361A (en) | 1999-09-14 |
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